Manitou Telehandler MVT 1130 L MVT 1340 L Comfort Line Repair Manual 547296 - PDF DOWNLOAD

REF : 547296 (EN)

COSTRUZIONI INDUSTRIALI VIA ENRICO FERMI 5 41013 CASTELFRANCO EMILIA MODENA ☎ +39 (0)59/950511

YOUR DEALER :

REPAIR MANUAL

e n i L t r o Comf

MVT 1130 L MVT 1340 L

04/1997

1a DATA DI PUBBLICAZIONE 1st DAT PUBLICATION INFORMAZIONI CATALOGO INFORMATION CATALOGUE CATALOGUE INFORMATION KATALOG AUSKUNFT

1ére DATE D'EDITION 04/97 1st DATUM AUSGABE

DATA DI PUBBLICAZIONE DATE D'EDITION DATE PUBLICATION DATUM AUSGABE

OSSERVAZIONI OBSERVATION OBSERVATION BEMERKUNG

Text and illustrations herewith enclosed may not be reproducet, not even in part and by any means.

Because of the possible time lag beween the introduction of technical modifications (an on-going process the aim of which is to offer products which are being continually improved) and the latest up date of the manual, we must point out, for the sake of correctness, that the data contained in this edition are liable to change at any time and are therefore not biding.

MVT

R E PA I R M A N U A L

INDEX CHAPTER

PAGE

Specification

4

Oils - greases - fluids - fluel - filters

10

Scheduled maintenance

11

Electrical system MVT 1130 L - MVT 1340 L

17

Electrical system MVT 1130 L

27

Electrical system MVT 1340 L

36

Hydraulic manouvering system

45

Hydraulic steering - brake system

49

Transmission hidraulic system

51

Hidraulics -

Pressure testing Safety valve Removing the suction screen and return Faults, causes, cures

52 55 56 57

Transmission inspection and adjustements

59

Page

1

MVT

R E PA I R M A N U A L

INDEX CHAPTER

PAGE

Brake system - Draining procedure - Parking brake

68 69

The disassembly and assembly of the booms recommendations

73

-

74 78 79 81 82 83

Boom hose Removal of Removal of Removal of Removal of Removal of

replacement tilting cylider the cylinder from the small telescope the small telescope the intermediate telescope cylinder intermediate telescope

Removing the telescopic boom

84

Removing the lifting cylinder

87

Removing the compensation cylinders

88

Removing the rear axle lock cylinder

89

Lifting cylinder dismantling

90

Tilting cylinder dismantling

91

1° Telescope cylinder dismantling

92

2° Telescope cylinder dismantling

93

Page

2

MVT

R E PA I R M A N U A L

INDEX CHAPTER

PAGE

Compensating cylinder dismantling

94

Leveling cylinder dismantling

95

Rear axle lock cylinder dismantling MVT 1340 L

96

Engine dismantling

97

Removing the wheels

105

Removing the front and rear differential axle - Removing the front differential axle and hydrostatic motor - Removing the hydrostatic motor only - Removing the rear differential axle

106 109 110

Removing the water and oil radiator

112

Removing the control valve

115

Removing the cab

116

Parking brake and speed change lever Hydraulic (transmission hydrostatic) Hydraulic (hidraulic controls) Hydraulic (telescope circuit tilting) Hydraulic (lifting, compensation circuit) Hydraulic (leveling system) Hydraulic (fan circuit) Hydraulic (steering circuit) Pedals linkage (brake and accelerator) Hydraulic (lock rear oscillation) MVT 1340 L

120 121 122 123 124 125 126 127 128 129

Page

3

MVT 1130 L

R E PA I R M A N U A L

SPECIFICATIONS ENGINE : Type Injection system Firing order Valve clearance Intake Exhaust Displacement Bore and stroke Compression Nominal speed Idle speed Power Maximum torque at 1400 rpm

PERKINS 1004.4 4 cylinders - 4 cycles Direct 1-3-4-2 0,008 in.

0,018 in.

3990 cm3 - 236 C.I. 100 x 127 mm 3.9 x 5.0 in.

16.5 : 1 2300 rpm 750 rpm 91 cv / 77 kw-DIN 70020 289 Nm - 391,8 Lbf ft

COOLING SYSTEM: Type

Water cooled-closed circuit with bypass.

Fan N°. of blades Diameter

8 500 mm - 19.1 in

Thermostat Start to open

82° C

(180°F)

ELECTRICAL CIRCUIT : Ground Battery Alternator

Negative 12 V - 125 AH 12 V - 55 AH with voltage regulator incorporated.

BRAKES: Type

Disc brakes in oil bath

Page

4

MVT 1130 L

R E PA I R M A N U A L

TRANSMISSION : Type Type N° of forward speeds N° of reverse speeds Forward / reverse N° Wheel drive

Rexroth Hydrostatic Pump and motor with variable displacement 2 2 Electrohydraulic 4

HIDRAULIC CIRCUIT : Main circuit Type of pump Flow rate Nominal pressure

Gear type 80 L/min - 21,1 US GPM 270 bars - 3857 psi

Cooling and frame leveling circuit Type of pump Flow rate Nominal pressure

Gear type 38 L/min - 10 US GPM 120/80 bars - 1714/1142 psi

Power steering circuit Type of pump Flow rate Nominal pressure

Gear type 38 L/min - 10 US GPM 140 bars - 2000 psi

Max. Travel Speed Forward and reverse-unloaded: Forward and reverse - loaded:

25 Km/h - 15,5 mph 5 Km/h - 3,1 mph

Tire sizes Front and rear

15 - 19,5 NHS SGL

Tire Pressures Front and rear

4,2 bars - 60 psi

Page

5

MVT 1130 L

R E PA I R M A N U A L

Lifting Speed unloaded boom retracted

118 ft / min (10 sec)

Lowering Speed unladed boom retracted

147 ft / min (8 sec)

Telescopic Speed unloaded - Extension

59 ft / min (20 sec)

Telescopic Speed unloaded - Retract

85 ft / min (14 sec)

Fork Dimensions (lenght x width x thickness)

1200 x 125 x 45 mm 48 x 4,9 x 1,8 in

Fork Spread

1220 mm - 48 in

Load Center

600 mm - 24 in

Rated Capacity and std equipement.

2720 kg - 6000 Ibs

Weigth with std carriage and forks

8780 kg - 19356 Ibs

Axle Ground Weight Front axle - unloaded Rear axle - unloaded

Loaded weight with std carriage and forks

3180 kg - 6996 Ibs 5600 kg - 12320 Ibs

11500 kg - 25369 Ibs

Loaded with telescopic arm retracted and forks at 20 cm up (8 in) - Front axle - Rear axle

8850 kg - 19510 Ibs 2650 kg - 5842 Ibs

Tow Bar Pull - unloaded - loaded

6300 kg - 13890 Ibs 8020 kg - 17700 Ibs

Page

6

MVT 1340 L

R E PA I R M A N U A L

SPECIFICATIONS ENGINE : Type Injection system Firing order Valve clearance Intake Exhaust Displacement Bore and stroke Compression Nominal speed Idle speed Power Maximum torque at 1400 rpm

PERKINS 1004.4 4 cylinders - 4 cycles Direct 1-3-4-2 0,008 in.

0,018 in.

3990 cm3 - 236 C.I. 100 x 127 mm 3.9 x 5.0 in.

16.5 : 1 2300 rpm 750 rpm 91 cv / 77 kw-DIN 70020 289 Nm - 391,8 Lbf ft

COOLING SYSTEM: Type

Water cooled-closed circuit with bypass.

Fan N°. of blades Diameter

8 500 mm - 19.1 in

Thermostat Start to open

82° C

(180°F)

ELECTRICAL CIRCUIT : Ground Battery Alternator

Negative 12 V - 125 AH 12 V - 55 AH with voltage regulator incorporated.

BRAKES: Type

Disc brakes in oil bath

Page

7

MVT 1340 L

R E PA I R M A N U A L

TRANSMISSION : Type Type N° of forward speeds N° of reverse speeds Forward / reverse N° Wheel drive

Rexroth Hydrostatic Pump and motor with variable displacement 2 2 Electrohydraulic 4

HIDRAULIC CIRCUIT : Main circuit Type of pump Flow rate Nominal pressure

Gear type 80 L/min - 21,1 US GPM 270 bars - 3857 psi

Cooling and frame leveling circuit Type of pump Flow rate Nominal pressure

Gear type 38 L/min - 10 US GPM 120/80 bars - 1714/1142 psi

Power steering circuit Type of pump Flow rate Nominal pressure

Gear type 38 L/min - 10 US GPM 140 bars - 2000 psi

Max. Travel Speed Forward and reverse-unloaded: Forward and reverse - loaded:

28 Km/h - 17,4 mph 5 Km/h - 3,1 mph

Tire sizes Front and rear

15,5 - 25 NHS SGL

Tire Pressures Front and rear

3 bars - 45 psi

Page

8

MVT 1340 L

R E PA I R M A N U A L

Lifting Speed unloaded boom retracted

91 ft / min (13 sec)

Lowering Speed unladed boom retracted

118 ft / min (10 sec)

Telescopic Speed unloaded - Extension

55 ft/ min (24 sec)

Telescopic Speed unloaded - Retract

85 ft / min (15,5 sec)

Fork Dimensions (lenght x width x thickness)

1200 x 150 x 50 mm 48 x 5,9 x 1,96 in

Fork Spread

1350 mm - 53 in

Load Center

600 mm - 24 in

Rated Capacity and std equipement.

3600 kg - 8000 Ibs

Weigth with std carriage and forks

9630 kg - 21230 Ibs

Axle Ground Weight Front axle - unloaded Rear axle - unloaded

Loaded weight with std carriage and forks

3550 kg - 7826 Ibs 6080 kg - 13400 Ibs

12680 kg - 29186 Ibs

Loaded with telescopic arm retracted and forks at 20 cm up (8 in) - Front axle - Rear axle

10700 kg - 23590 Ibs 2530 kg - 5576 Ibs

Tow Bar Pull - unloaded - loaded

6700 kg - 14770 Ibs 7100 kg - 15650 Ibs

Page

9

MVT

R E PA I R M A N U A L

OILS - GREASES - FLUIDS - FUEL - FILTERS LUBRICATED PART

CAPACITY

RECOMMENDED PRODUCT

- ENGINE CRANKCASE

8,1 L

oil RIMULA X OIL 15W/40

- FRONT WHEEL FINAL DRIVES - REAR WHEEL FINAL DRIVES

0,8 L 0,8 L

oil SHELL DONAX TD

10 - 11 L 2,5 L 10 - 11 L

oil SHELL DONAX TD

- HYDRAULIC OIL TANK

110 L

oil SHELL TELLUS T46

- BRAKING SYSTEM

0,08 L

oil SHELL LHM S.8214.B

- FRONT AXLE DIFFERENTIAL - GEARBOX - REAR AXLE DIFFERENTIAL

Grease SHELL EP2

- GENERAL GREASING

Grease SHELL BARBATIA GREASE4

- TELESCOPIC BOOM LUBRICATION - COOLING SYSTEM

15 L

SHELL ANTIFREEZE

- FUEL TANK

120 L

Diesel fuel

NOTE : HYDROSTATIC TRANSMISSION FILTER, HYDRAULIC FILTER AND ENGINE OIL AND FILTER MUST BE CHANGED AFTER INITIAL 50 HRS OF OPERATING TO INSURE WARRANTY PROTECTION.

Page

10

MVT 1130 L

R E PA I R M A N U A L

SCHEDULED MAINTENANCE FILTERS AND BELT

2

5

1 3 4

8

6

7

50 H (I° COUPON)

300 H (II° COUPON)

REPLACE

REPLACE

Every 300 H

CLEAN

REPLACE

Every 450 H

3 Transmission oil filter

REPLACE

REPLACE

Every 450 H

4 Fuel filter cartridge

REPLACE

REPLACE

Every 450 H

5 Hydraulic oil filter cartridge (exhaust)

REPLACE

REPLACE

Every 450 H

DESCRIPTION

1 Engine oil filter 2 Air filter cartridge

▲

6 Hydraulic oil tank vent

▲

REPLACEMENT SCHEDULE

Every 450 H

7 Hydraulic oil filter cartridge (intake)

CHECK

CHECK

Every 900 H

8 Air filter safety cartridge ▲

CHECK

CHECK

Every 900 H

: In a very dusty atmosphere reduce the time interval and replace parts in advance

Page

11

MVT 1130 L

R E PA I R M A N U A L

OPERATION SCHEDULE

PARTS INVOLVED

A Every day or every 10 hours of service

A1 A2 A3 A4 A5

-

B Every 50 hours of service

B1 B2 B3 B4 B5

- Air filter cartridge ▲ - Hydraulic oil level - Tyre pressure and wheel tightening - Radiator grill - Telescopic arm wear pads ■

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15

- Alternator belt tension/crankshaft - Front and rear axle differential oil level - Front and rear wheel final driver oil level - Oil in 2-speed reduction gear on axle - Battery - Grease telescopic arm articulation pin - Grease rapid connection articulation pin - Grease fork tilting cylinder foot and head pins - Grease lifting cylinder foot and head pins - Grease compensation cylinder foot and head pins - Grease cab door - Grease front and rear wheel pivot pins - Grease rear axle oscillation bushings - Grease cross journal and transmission shaft u-joint - Grease the leveling cylinder foot and head pins

C Every 150 hours of service

Engine oil level Cooling liquid level Gearbox oil level Clean fuel pre-filter Bleed the fuel supply circuit (if necessary)

CHECK CLEAN GREASE REPLACE ADJUST EMPTY

FREQUENCY

OPERATION N°

CHAPTER

MAINTENANCE AND LUBRICATION TABLE

X X X X X

X

X X X X X X X X X X X X X X X X X X X X X

X X X X X X X X X X

D Every 300 hours of service

D1 - Engine oil D2 - Engine oil filter

X X

E Every 450 hours of service

E1 E2 E3 E4 E5 E6

X X X X X

- Air filter cartridge - Fuel filter cartridge - Transmission oil filter - Hydraulic oil filter cartridge (drain) - Sfiato olio idraulico trasmissione - Fuel supply pump

X

X

Page

12

F Every 900 hours of service

OPERATION N°

CHAPTER

FREQUENCY

F1 F2 F3 F4 F5 F6 F7 F8

PARTS INVOLVED

CHECK CLEAN GREASE REPLACE ADJUST EMPTY

MVT 1130 L

R E PA I R M A N U A L

- Air filter safety cartridge - Hydraulic oil - Hydraulic oil filter cartridge (“suction rose”) - Front and rear axle differential oil - Oil in front and rear wheel final driver - Oil in 2-speed reduction gear on axle - Fuel tank - Alternator belt/crankshaft

G Every 1800 G1 - Engine valve clearance hours of G2 - Injectors service G3 - Alternator and starter motor

X X X X X X

X X X

X X X X X

FOR THESE OPERATIONS CONSULT YOUR AGENT OR DEALER

NOTE : To be performed once a year if the truck has not reached these work times. ▲

: In a very dusty atmosphere reduce the time interval and replace parts in advance.

■

: Every 10 hours service until the first 50 hours, plus one last time at 150 hours.

Page

13

MVT 1340 L

R E PA I R M A N U A L

SCHEDULED MAINTENANCE FILTERS AND BELT

2

5

1 3 4

8

9

7

6

DESCRIPTION

50 H (I° COUPON)

300 H (II° COUPON)

REPLACE

REPLACE

Every 300 H

CLEAN

REPLACE

Every 450 H

3 Transmission oil filter

REPLACE

REPLACE

Every 450 H

4 Fuel filter cartridge

REPLACE

REPLACE

Every 450 H

5 Hydraulic oil filter cartridge (exhaust)

REPLACE

REPLACE

Every 450 H

1 Engine oil filter 2 Air filter cartridge

▲

6 Hydraulic oil tank vent

▲

REPLACEMENT SCHEDULE

Every 450 H

7 Hydraulic oil filter cartridge (intake)

CHECK

CHECK

Every 900 H

8 Air filter safety cartridge ▲

CHECK

CHECK

Every 900 H

9 Engine belt

CHECK

CHECK

Every 900 H

: In a very dusty atmosphere reduce the time interval and replace parts in advance Page

14

MVT 1340 L

R E PA I R M A N U A L

OPERATION SCHEDULE

PARTS INVOLVED

A Every day or every 10 hours of service

A1 A2 A3 A4 A5

-

B Every 50 hours of service

B1 B2 B3 B4 B5

- Air filter cartridge ▲ - Hydraulic oil level - Tyre pressure and wheel tightening - Radiator grill - Telescopic arm wear pads ■

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16

- Alternator belt tension/crankshaft - Front and rear axle differential oil level - Front and rear wheel final driver oil level - Oil in 2-speed reduction gear on axle - Battery - Grease telescopic arm articulation pin - Grease rapid connection articulation pin - Grease fork tilting cylinder foot and head pins - Grease lifting cylinder foot and head pins - Grease compensation cylinder foot and head pins - Grease cab door - Grease front and rear wheel pivot pins - Grease rear axle oscillation bushings - Grease cross journal and transmission shaft u-joint - Grease the leveling cylinder foot and head pins - Grease the autriggers cylinder foot and head pins

C Every 150 hours of service

Engine oil level Cooling liquid level Gearbox oil level Clean fuel pre-filter Bleed the fuel supply circuit (if necessary)

CHECK CLEAN GREASE REPLACE ADJUST EMPTY

FREQUENCY

OPERATION N°

CHAPTER

MAINTENANCE AND LUBRICATION TABLE

X X X X X

X

X X X X X X X X X X X X X X X X X X X X X X

X X X X X X X X X X X

D Every 300 hours of service

D1 - Engine oil D2 - Engine oil filter

X X

E Every 450 hours of service

E1 E2 E3 E4 E5 E6

X X X X X

- Air filter cartridge - Fuel filter cartridge - Transmission oil filter - Hydraulic oil filter cartridge (drain) - Sfiato olio idraulico trasmissione - Fuel supply pump

X

X

Page

15

F Every 900 hours of service

OPERATION N°

CHAPTER

FREQUENCY

F1 F2 F3 F4 F5 F6 F7 F8

PARTS INVOLVED

CHECK CLEAN GREASE REPLACE ADJUST EMPTY

MVT 1340 L

R E PA I R M A N U A L

- Air filter safety cartridge - Hydraulic oil - Hydraulic oil filter cartridge (“suction rose”) - Front and rear axle differential oil - Oil in front and rear wheel final driver - Oil in 2-speed reduction gear on axle - Fuel tank - Alternator belt/crankshaft

G Every 1800 G1 - Engine valve clearance hours of G2 - Injectors service G3 - Alternator and starter motor

X X X X X X

X X X

X X X X X

FOR THESE OPERATIONS CONSULT YOUR AGENT OR DEALER

NOTE : To be performed once a year if the truck has not reached these work times. ▲

: In a very dusty atmosphere reduce the time interval and replace parts in advance.

■

: Every 10 hours service until the first 50 hours, plus one last time at 150 hours.

Page

16

R E PA I R M A N U A L

MVT

Page

17

R E PA I R M A N U A L

MVT

Page

18

R E PA I R M A N U A L

MVT

Page

19

R E PA I R M A N U A L

MVT

Page

20

R E PA I R M A N U A L

MVT

Page

21

R E PA I R M A N U A L

MVT

Page

22

R E PA I R M A N U A L

MVT

Page

23

R E PA I R M A N U A L

MVT

Page

24

R E PA I R M A N U A L

MVT

Page

25

R E PA I R M A N U A L

MVT

Page

26

ELECTRIC SYSTEM

MVT 1130 L

TABLE 1

R E PA I R M A N U A L

Page

27

ELECTRIC SYSTEM

MVT 1130 L

TABLE 2

R E PA I R M A N U A L

Page

28

ELECTRIC SYSTEM

MVT 1130 L

TABLE 3

R E PA I R M A N U A L

Page

29

ELECTRIC SYSTEM

MVT 1130 L

TABLE 4

R E PA I R M A N U A L

Page

30

ELECTRIC SYSTEM

MVT 1130 L

TABLE 5

R E PA I R M A N U A L

Page

31

ELECTRIC SYSTEM

MVT 1130 L

TABLE 6

R E PA I R M A N U A L

Page

32

ELECTRIC SYSTEM

MVT 1130 L

TABLE 7

R E PA I R M A N U A L

Page

33

. . . . . . . . . .

D2 E1 E2 E3 E4 E5 E6 E7 E8 E9

F11 .

F12 .

F10 .

Horn (tab. 2) Horn back-up alarm (tab. 3) Battery 12volts (tab. 1) Steering column switches command lights & horn (tab. 2) Shift-lever switches command (tab. 3) Starting consens relay Forward travelling relay Reverse travelling relay Telescopic length-out relay Telescopic length-in relay Optional out boom relay Optional in boom relay Fan cooling hydraulic oil relay Warning light indicator parking brake relay Flasher lights unit (tab. 3) Fusible 7,5A : Horn (tab. 2) Fusible 5A : Gauges + check control warning light indicators (tab. 1) Fusible 3A : Predisposition key switch feeding (tab. 2) Fusible 7,5A : Stop lights (tab. 1) Fusible 5A : Direction lights (tab. 2) Fusible 15A : Resistance heater electrofan (tab. 4) Fusible 10A : Front windscreen wiper + glass washing pump (tab. 4) Fusible 7,5A : Rear & upper windscreen wiper (tab. 4) Fusible 10A : Predisposition for front work lights (tab. 6) Fusible 10A : Solenoid-valve safety system (tab. 4) Fusible 7,5A : Rotary beacon (tab. 5) Fusible 10A : Predisposition for solenoid-valves rear axle block (tab. 7)

F13 . Fusible 10A : Predisposition for rear work lights (tab. 6) F14 . Diode 1A : Availability (tab. 6) F15 . Fusible 10A : Predisposition key switch feeding (tab. 2) F16 . Fusible 7,5A : Engine stop (tab. 6) F17 . Fusible 10A : Shift-lever switches & solenoid-valves (tab. 3) F18 . Fusible 10A : Lateral oscillation solenoid-valves (tab. 5) F19 . Fusible 10A : Solenoid-valves telescopic lngth & optional boom + push-button boom’s (tab. 6) F20 . Fusible 5A : Front right & rear left lights position (tab. 2) F21 . Fusible 5A : Front left & rear right lights position (tab. 2) F22 . Fusible 10A : Dipped beam (tab. 2) F23 . Fusible 10A : High beam (tab. 2) F24 . Fusible 15A : Predisposition for conditioned air (tab. 6) F25 . Fusible 25A : Predisposition direct feeding (tab. 2) F26 . Fusible 10A : Warning flasher lights + cab light (tab. 2) F27 . Fusible 15A : Predisposition for manplatform (tab. 6) F28 . Fusible 7.5A : Fan cooling hydraulic oil solenoid-valve (tab. 6) G1 . Generator (tab. 1) H1 . Engine hours gauge (tab. 1) KEY. Ignition switch (tab. 1) I1 . Stop lights pressure switch (tab. 1) I2 . Warning flasher lights switch (tab. 2) I3 . Parking brake microswitch (tab. 3) I4 . Safety system microswitch (tab. 4) I5 . Restore block safety system switch (tab. 4) I6 . Resistance heater electrofan switch (tab. 4) I7 . Front windscreen wiper & glass washing pump switch (tab. 4) I8 . Rear & upper windscreen wiper (tab. 4) L10 M1 M2 M3 M4 M5 M6 P1 P2

L9

L8

L7

L5 L6

I20 I21 I22 I23 I24 L1 L2 L3 L4

I14 I15 I16 I17 I18 I19

I10 I11 I12 I13

I9

. Lateral oscillation break microswitch (tab. 5) . Lever switches lateral oscillation (tab. 5) . Rotary beacon switch (tab. 5) . Fuel level switch (tab. 5) . Air cleaner filter obstruction pressure switch (tab. 5) . Engine oil low pressure switch (tab. 5) . Engine cooling thermo switch (tab. 5) . Brake oil level switch (tab. 5) . Engine cooling thermo switch (tab. 6) . Hydraulic oil thermo switch (tab. 6) . Optional boom’s consentement switch (tab. 6) . Optional boom out push-button (tab. 6) . Optional boom in push-button (tab. 6) . Telescopic length-out push-button (tab. 7) . Telescopic length-in push-button (tab. 7) . Hydraulic boom’s break switch (tab. 4) . Generator warning light indicator (tab. 1) . Driving beams light indicator (tab. 2) . Lift truck direction light indicator (tab. 3) . Parking brake warning light indicator (tab. 3) . Empty fuel warning light indicator (tab. 5) . Air cleaner filter obstruction warning light indicator (tab. 5) . Low engine oil pressure warning light indicator (tab. 5) . High engine cooling temperature warning light (tab. 5) . Low brake oil level warning light indicator (tab. 5) . Available red warning light indicator (tab. 5) . Starting motor (tab. 1) . Resistance electrofan heater motor (tab. 4) . Glass washing pump (tab. 4) . Front windscreen wiper motor (tab. 4) . Rear windscreen wiper motor(tab. 4) . Upper windscreen wiper motor(tab. 4) . Rear left stop light (tab. 1) . Rear right stop light (tab. 1)

ELECTRIC SYSTEM

F9 .

F8 .

F7 .

F4 .

F5 .

F6 .

F3 .

E10 .

F1 .

F2 .

. . . .

A1 A2 B1 D1

ELECTRICAL EQUIPMENT MVT 1130L MANITOU CAB.1996 COMPONENTS LIST (drawing reference No.722)

R E PA I R M A N U A L

MVT 1130 L

Page

34

Front right position light (tab. 2) Rear left position light (tab. 2) Front left position light (tab. 2) Rear right position light (tab. 2) Front left dipped beam (tab. 2) Front right dipped beam (tab. 2) Front left high beam (tab. 2) Front right high beam (tab. 2) Cab light (tab. 2) Front left lift truck direction light (tab. 2) Rear left lift truck direction light (tab. 2) Front right lift truck direction light (tab. 2) Rear right lift truck direction light (tab. 2) Rotary beacon (tab. 5) Front right outline light (tab. 2) Rear left outline light (tab. 2) Front left outline light (tab. 2) Rear right outline light (tab. 2) Forward solenoid-valve (tab. 3) Reverse solenoid-valve (tab. 3) Safety system solenoid-valve (tab. 4) Lateral oscillation left solenoid-valve (tab. 5) Lateral oscillation right solenoid-valve (tab. 5) Fan cooling hydraulic oil solenoid-valve (tab. 6) Engine stop solenoid-valve (tab. 6) Optional boom out solenoid-valve (tab. 6) Optional boom in solenoid-valve (tab. 6) Telescopic legth-out solenoid-valve (tab. 7) Telescopic length-in solenoid-valve (tab. 7) Safety system unit (tab. 4) Level fuel gauge (tab. 5) Level fuel sender (tab. 5) Preheater (tab. 1) Examples : AB0.5 = sky-blue s. 0,5 mm2 AB = sky-blue s. 1 mm2

A : sky-blue B : white C : orange G : yellow H : grey L : dark-blue M : brown N : black R : red S : rose V : green Z : purple

COLOUR KEY

ELECTRIC SYSTEM

S7 .

S8 .

S9 .

S10 .

S11 .

ST1 .

ST2 .

T1 .

TR .

S6 .

S5 .

P3 .

P4 .

P5 .

P6 .

P7 .

P8 .

P9 .

P10 .

P11 .

P12 .

P13 .

P14 .

P15 .

P16 .

P17 .

P18 .

P19 .

P20 .

S1 .

S2 .

S3 .

S4 .

R E PA I R M A N U A L

MVT 1130 L

Page

35

ELECTRIC SYSTEM

MVT 1340 L

TABLE 1

R E PA I R M A N U A L

Page

36

ELECTRIC SYSTEM

MVT 1340 L

TABLE 2

R E PA I R M A N U A L

Page

37

ELECTRIC SYSTEM

MVT 1340 L

TABLE 3

R E PA I R M A N U A L

Page

38

ELECTRIC SYSTEM

MVT 1340 L

TABLE 4

R E PA I R M A N U A L

Page

39

ELECTRIC SYSTEM

MVT 1340 L

TABLE 5

R E PA I R M A N U A L

Page

40

ELECTRIC SYSTEM

MVT 1340 L

TABLE 6

R E PA I R M A N U A L

Page

41

ELECTRIC SYSTEM

MVT 1340 L

TABLE 7

R E PA I R M A N U A L

Page

42

. . . . . . . . . .

D2 E1 E2 E3 E4 E5 E6 E7 E8 E9

F11 .

F12 .

F10 .

Horn (tab. 2) Horn back-up alarm (tab. 3) Battery 12volts (tab. 1) Steering column switches command lights & horn (tab. 2) Shift-lever switches command (tab. 3) Starting consens relay Forward travelling relay Reverse travelling relay Telescopic length-out relay Telescopic length-in relay Optional out boom relay Optional in boom relay Fan cooling hydraulic oil relay Warning light indicator parking brake relay Flasher lights unit (tab. 3) Fusible 7,5A : Horn (tab. 2) Fusible 5A : Gauges + check control warning light indicators (tab. 1) Fusible 3A : Predisposition key switch feeding (tab. 2) Fusible 7,5A : Stop lights (tab. 1) Fusible 5A : Direction lights (tab. 2) Fusible 15A : Resistance heater electrofan (tab. 4) Fusible 10A : Front windscreen wiper + glass washing pump (tab. 4) Fusible 7,5A : Rear & upper windscreen wiper (tab. 4) Fusible 10A : Predisposition for front work lights (tab. 6) Fusible 10A : Solenoid-valve safety system (tab. 4) Fusible 7,5A : Rotary beacon (tab. 5) Fusible 10A : Solenoid-valves rear axle block (tab. 7)

F13 . Fusible 10A : Predisposition for rear work lights (tab. 6) F14 . Diode 1A : Availability (tab. 6) F15 . Fusible 10A : Predisposition key switch feeding (tab. 2) F16 . Fusible 7,5A : Engine stop (tab. 6) F17 . Fusible 10A : Shift-lever switches & solenoid-valves (tab. 3) F18 . Fusible 10A : Lateral oscillation & stabilizers solenoid-valves (tab. 5) F19 . Fusible 10A : Solenoid-valves telescopic lngth & optional boom + push-button boom’s (tab. 6) F20 . Fusible 5A : Front right & rear left lights position (tab. 2) F21 . Fusible 5A : Front left & rear right lights position (tab. 2) F22 . Fusible 10A : Dipped beam (tab. 2) F23 . Fusible 10A : High beam (tab. 2) F24 . Fusible 15A : Predisposition for conditioned air (tab. 6) F25 . Fusible 25A : Predisposition direct feeding (tab. 2) F26 . Fusible 10A : Warning flasher lights + cab light (tab. 2) F27 . Fusible 15A : Predisposition for manplatform (tab. 6) F28 . Fusible 7.5A : Fan cooling hydraulic oil solenoid-valve (tab. 6) G1 . Generator (tab. 1) H1 . Engine hours gauge (tab. 1) KEY. Ignition switch (tab. 1) I1 . Stop lights pressure switch (tab. 1) I2 . Warning flasher lights switch (tab. 2) I3 . Parking brake microswitch (tab. 3) I4 . Safety system microswitch (tab. 4) I5 . Restore block safety system switch (tab. 4) I6 . Resistance heater electrofan switch (tab. 4) I7 . Front windscreen wiper & glass washing pump switch (tab. 4) I8 . Rear & upper windscreen wiper (tab. 4) L10 M1 M2 M3 M4 M5 M6 P1

L9

L8

L7

L5 L6

I20 I21 I22 I23 I24 I25 L1 L2 L3 L4

I14 I15 I16 I17 I18 I19

I10 I11 I12 I13

I9

. Lateral oscillation break microswitch (tab. 5) . Lever switches lateral oscillation (tab. 5) . Rotary beacon switch (tab. 5) . Fuel level switch (tab. 5) . Air cleaner filter obstruction pressure switch (tab. 5) . Engine oil low pressure switch (tab. 5) . Engine cooling thermo switch (tab. 5) . Brake oil level switch (tab. 5) . Engine cooling thermo switch (tab. 6) . Hydraulic oil thermo switch (tab. 6) . Optional boom’s consentement switch (tab. 6) . Optional boom out push-button (tab. 6) . Optional boom in push-button (tab. 6) . Telescopic length-out push-button (tab. 7) . Telescopic length-in push-button (tab. 7) . Lifted boom condition microswitch (tab. 7) . Hydraulic boom’s break switch (tab. 4) . Generator warning light indicator (tab. 1) . Driving beams light indicator (tab. 2) . Lift truck direction light indicator (tab. 3) . Parking brake warning light indicator (tab. 3) . Empty fuel warning light indicator (tab. 5) . Air cleaner filter obstruction warning light indicator (tab. 5) . Low engine oil pressure warning light indicator (tab. 5) . High engine cooling temperature warning light (tab. 5) . Low brake oil level warning light indicator (tab. 5) . Available red warning light indicator (tab. 5) . Starting motor (tab. 1) . Resistance electrofan heater motor (tab. 4) . Glass washing pump (tab. 4) . Front windscreen wiper motor (tab. 4) . Rear windscreen wiper motor(tab. 4) . Upper windscreen wiper motor(tab. 4) . Rear left stop light (tab. 1)

ELECTRIC SYSTEM

F9 .

F8 .

F7 .

F4 .

F5 .

F6 .

F3 .

E10 .

F1 .

F2 .

. . . .

A1 A2 B1 D1

ELECTRICAL EQUIPMENT MVT 1340 L MANITOU CAB.1996 COMPONENTS LIST (drawing reference No.727)

R E PA I R M A N U A L

MVT 1340 L

Page

43

Rear right stop light (tab. 1) Front right position light (tab. 2) Rear left position light (tab. 2) Front left position light (tab. 2) Rear right position light (tab. 2) Front left dipped beam (tab. 2) Front right dipped beam (tab. 2) Front left high beam (tab. 2) Front right high beam (tab. 2) Cab light (tab. 2) Front left lift truck direction light (tab. 2) Rear left lift truck direction light (tab. 2) Front right lift truck direction light (tab. 2) Rear right lift truck direction light (tab. 2) Rotary beacon (tab. 5) Front right outline light (tab. 2) Rear left outline light (tab. 2) Front left outline light (tab. 2) Rear right outline light (tab. 2) Forward solenoid-valve (tab. 3) Reverse solenoid-valve (tab. 3) Safety system solenoid-valve (tab. 4) Lateral oscillation left solenoid-valve (tab. 5) Lateral oscillation right solenoid-valve (tab. 5) Fan cooling hydraulic oil solenoid-valve (tab. 6) Engine stop solenoid-valve (tab. 6) Optional boom out solenoid-valve (tab. 6) Optional boom in solenoid-valve (tab. 6) Telescopic legth-out solenoid-valve (tab. 7) Telescopic length-in solenoid-valve (tab. 7) Electrovalve Nr. 1 rear axle block (tab. 7) Electrovalve Nr. 2 rear axle block (tab. 7) Safety system unit (tab. 4) Level fuel gauge (tab. 5) Level fuel sender (tab. 5) Preheater (tab. 1) Examples : AB0.5 = sky-blue s. 0,5 mm2 AB = sky-blue s. 1 mm2

A : sky-blue B : white C : orange G : yellow H : grey L : dark-blue M : brown N : black R : red S : rose V : green Z : purple

COLOUR KEY

ELECTRIC SYSTEM

S7 .

S8 .

S9 .

S10 .

S11 .

S12 .

S13 .

ST1 .

ST2 .

T1 .

TR .

S6 .

S5 .

P2 .

P3 .

P4 .

P5 .

P6 .

P7 .

P8 .

P9 .

P10 .

P11 .

P12 .

P13 .

P14 .

P15 .

P16 .

P17 .

P18 .

P19 .

P20 .

S1 .

S2 .

S3 .

S4 .

R E PA I R M A N U A L

MVT 1340 L

Page

44

MVT 1130 L

HYDRAULIC MANOEUVERING SYSTEM

R E PA I R M A N U A L

Page

45

R E PA I R M A N U A L

MVT 1130 L

KEY TO MVT 1130 L HYDRAULIC MANOEUVERING SYSTEM R F.R. C.A. P. EVS VL VC* VC VT1 VT2 V.A. M RFS A ECM P.I. P.V. VLGV D ECL VL* M.V.

= = = = = = = = = = = = = = = = = = = = = =

Oil tank Exhaust filter Suction filter Gear pump Anti-overturning electrovalve Lifting cylinder Tiltimg cylinder Compensation cylinder 1st extension cylinder 2nd extension cylinder Optional cylinder Hydraulic controls manipulator Parking brake tap Accumulator Hydraulic movements control electrovalve Hydrostatic pump Fan pump Limiting turns fan valve Control valve Leveling control electrovalve Leveling cylinder Fan engine

Page

46

MVT 1340 L

HYDRAULIC MANOEUVERING SYSTEM

R E PA I R M A N U A L

Page

47

R E PA I R M A N U A L

MVT 1340 L

KEY TO MVT 1340 L HYDRAULIC MANOEUVERING SYSTEM R = F.R. = C.A. = P. = EVS = VL = VC* = VC = VT1 = VT2 = V.A. = M = RFS = A = ECM = P.I. = P.V. = VLGV = D = ECL = VL* = I = M.V. = VBPP = CBPP =

Oil tank Exhaust filter Suction filter Gear pump Anti-overturning electrovalve Lifting cylinder Tiltimg cylinder Compensation cylinder 1st extension cylinder 2nd extension cylinder Optional cylinder Hydraulic controls manipulator Parking brake tap Accumulator Hydraulic movements control electrovalve Hydrostatic pump Fan pump Limiting turns fan valve Control valve Leveling control electrovalve Leveling cylinder Hydraulic steering Fan engine Rear axle locking valve Rear axle locking cylinder

Page

48

HYDRAULIC STEERING - BRAKE SYSTEM

R E PA I R M A N U A L

MVT

Page

49

R E PA I R M A N U A L

MVT

KEY TO MVT 1130 L - 1340 L HYDRAULIC STEERING - BRAKE SYSTEM P.M. V.D. D3 P.F. M.C. R. FDAV M. F. P.

= = = = = = = = = =

Hydraulic steering Steering cylinder Steering control valve Brake pedal Brake pump Brake oil tank Front axle disc brake Engine Exhaust filter Double gear pump

Page

50

MVT

TRANSMISSION HIDRAULIC SYSTEM

R E PA I R M A N U A L

Page

51

MVT

R E PA I R M A N U A L

HYDRAULICS PRESSURE TESTING

Fig. 1

➩

There are four male pressure gauges adapters provided to test the pressures of various circuits of the hydraulic system : (Fig.1 / 2 /3).

A 0 - 600 bar (0 - 8700 PSI ) pressure gauge will be required to check system pressures.

Connect hose part N°72340 and pressure gauge N°58179 at these fittings.

The relief valve adjustments are made as follows (Fig. 4) 1) Remove the cap. ref. 1 2) Adjust the pressure as follows:

Fig. 2

Rotate screw Ref. 2 clock wise to increase the pressure, rotate counter clock wise to decrease it.

➩

A) Main relief pressure must be set at 270 bar (3857 PSI) for boom lift / lowering, boom retraction and accessory functions: To check this pressure setting adapt the 0-600 bar (0-8700 PSI) pressure gauge to quick coupler shown in Fig. 1.

Adjust main relief valve (Ref. 3-Fig. 5) to obtain correct setting.

B) To test compensating base end circuit relief, an adapter has been provided at the R.H . compensating cylinder base fittings.

Install adapter hose and 0 - 600 bar (0-8700 PSI) pressure gauge to this port (Fig. 3).

➩ Fig. 3

Fig. 4

☞

1

➩

☞2

Page

52

MVT

R E PA I R M A N U A L

C) Compensating cylinder pressure relief (base end) must be set at 270 bar (3857 PSI).

Rotate fork carriage totally rearward lower quickly the boom to read this pressure setting.

Adjust relief as necessary at port relief on control valve (Ref. 1-Fig. 5) .

Compensating cylinder rod end relief must be set at 160 bar (2286 PSI).

Connect gauge to the main circuit pressure gauge (Fig. 6).

Tilt forward totally, accelerate engine at max rpm and you will read the pressure on the gauge.

Adjust the pressure trough the relief (Ref. 2-Fig. 5).

Fig. 5

4

1

2

3

Fig. 6 D) The telescopic cylinder relief must be set at 220 bar (3200 PSI).

Connect gauge to the main circuit pressure gauge (Fig. 6).

Completely extend boom section at the end of the stroke to read this pressure.

This should be a maximum pressure reading of 220 bar (3200 PSI).

Adjust pressure relief as required (Ref. 4-Fig. 5).

1

Page

53

MVT

R E PA I R M A N U A L

E) The adapters mounted on the double pump along the R.H. side of the engine are used to test pressure in steering circuit, frame leveling and cooling fan (Fig. 7).

To check the pressure in steering, fit the pressure gauge to adapter (Ref. 1-Fig. 7).

Fig. 7

➩2

-Turn the wheels completely right or left to the end of stroke.

-Accelerate engine to max rpm -When the steering is at the end of stroke read the pressure on the gauge .

To adjust the pressure complete the following.

- Remove the steering pump from the dashboard without removing the hoses - Adjust the pressure, setting relief valve (Ref. 1-Fig. 8) to 160 bar (2285 PSI).

- To check pressure in frame leveling circuit, fit pressure gauge to adapter (Ref. 2-Fig. 7).

- Frame level right or left completely at the end of stroke read pressure through port 2 Fig. 7.

- Adjust the pressure through the reliev valve on the gear pump (Fig. 9).

➩1 Fig. 8

1

Fig. 9

➩

Page

54

MVT

R E PA I R M A N U A L

SAFETY VALVE Removing a safety valve from all hydraulic cylinders ATTENTION: -The safety valve retains hydraulic fluid in the cylinders: -Exercice great caution when dismalting any cylinder safety valve.

-The boom must be lowered to the ground prior to remove the valve.

- the frame leveling cylinder or its safety valve, the boom must be lowered to the ground and the frame locked with two spacers (see Fig.10 and Fig.11), to prevent sudden side tilt of the machine : When you have mounted the safety valve on a frame tilting cylinder or when you have mounted the frame tilting cylinder on the machine after a repair, always remember to make the following operations: 1) start the engine 2) hoist the boom about two feet (max) 3) level completely the frame to the right and to the left at full stroke many times, in order to completely fill the cylinder with oil and prevent dangerous cavitations that would cause the machine to tilt uncontrollably.

Fig. 11

Fig. 10

1 1

Page

55

MVT

R E PA I R M A N U A L

REMOVING THE SUCTION SCREEN AND RETURN LINE FILTER 1) Return line filter - remove the four screw on the filter cap ref.1 (Fig.12) - remove the filter cap 2 (Fig.12) - remove the filter cartridge ref.3 (Fig.12) Replace the filter cartridge with a new one 2) Suction screen - remove the complete line filter ref.4 (Fig.12) and the drain plug ref.5 (Fig.12) drain the oil tank completely.

- wash the oil tank with kerosene and then dry it carefully removing all the dirt inside - remove the screen element ref.6 (Fig.12) - install a new screen element - fill the oil tank with new hydraulic oil.

WARNING : some air can enter the hydraulic circuit, always remember to complete the following operations: 1) start the engine 2) lift the boom up of two feet from the ground 3) completely level the frame to the right and to the left at full stroke many times in order to completely fill the cylinder with oil and prevent dangerous cavitations that could cause the machine to fall: Then operate all the hydraulic movements of the machine to the end of their stroke many times to bleed the air, stopping the engine and releasing the pressure from the circuit will help this bleeding.

Fig. 12

1

2

3

{ 4

5 6

Page

56

MVT

R E PA I R M A N U A L

HYDRAULICS Fig. 13

- FAULTS, CAUSES, CURES Fault: 1) There is no pressure in the hoisting /lowering cylinder circuit and in the telescope cylinder circuit:

1 Cause: - the gear pump Ref. 1 (Fig. 13) mounted on the transmission is not operating properly - the relief valve 1 (Fig. 14) of the correspondent control valve is locked open Fig. 14

Cure: - remove the relief valve 1 (Fig. 14) and make sure it works properly - if the cause isn’t the relief valve replace the gear pump 1 (Fig. 13) 3 Fault: 2) During the lowering or the hoisting of the boom, the compensation/cylinder doesn’t work Cause: - the relief valve 2 or 3 (Fig: 14) are not set at the right pressure or they are locked

2

1

Cure: - If this happens during the boom hoisting test the opening pressure of the relief valve 3 (Fig. 14) or replace it: - If this happens during the boom lowering, test the opening pressure of the relief valve 2 (Fig. 14) or replace it:

Page

57

MVT

R E PA I R M A N U A L

HYDRAULICS FAULT

CAUSE

CURE

Excessive resistance in suction line

Clean the suction screen

Faulty pump

Replace

Too low oil level

Fill

- Noise in the valves

Valve spool wear

Replace

- Inadequate pressure in the system

Resistance in suction line

Clean the suction screen

Air in suction line

Restore tank level

Relief valve

Reset or recondition or replace

Excessive resistance in suction line

Clean filter and lines

Air in suction line

Restore tank oil level

Relief valve spring broken

Replace

Pump wear

Recondition or replace

- Excessive noise in the pump and lines

- Inadequate rate of flow

- Pump overheating

Page

58

Mechanical zero (neutral)

JET : DIA.0,8

}

ON MANITOU TRUCKS THE PUMP HEAD IS ROTADED OF 90° REGARDING THE FIGURE.

90°

HP Relief Valve - high (for reverse or foward gear).

End of Control Screw

Booster Pressure Connection Relief Valve

Booster Pressure Connection Charge 58/89

Start of Control Screw - (start of reg).

HP Relief Valve - high (for reverse or foward gear).

DR Valve (end of reg.)

R E PA I R M A N U A L

MVT

TRANSMISSION INSPECTION AND ADJUSTMENTS

Page

59

MVT

R E PA I R M A N U A L

1

CHECK/ADJUST BOOST PRESSURE

Shims

Pump A4VG

40.56

Booster valve

- The pumps A 4 VG 40-56 are equipped with a boost valve that is adjustable by means of shims (6). (40 bar).

A 1 mm thick shim will give approximately 4 bar of pressure adjustment.

Page

60

R E PA I R M A N U A L

2

MVT

ADJUSTMENT OF SWASHPLATE “O” POSITION

-

Install two 100 bar gauges at the HP test points.

Ensure the parking brake is released, the truck supported on blocks (wheels free to turn).

Engine running at idle.

Drive selector in neutral position.

Unscrew the locknut of the “O” adjuster (19 mm ring spanner). Screw in very slowly the screw (6 mm allen key) until movement is seen on the pressure gauge.

- Make a mark relative to the allen key position, slowly turn the screw in the opposite direction until movement is seen on the other pressure gauge, mark the position of the allen key.

Turn the adjuster back so that the allen key is exactly central between the two marks.

Lock the locknut.

CHECKING ADJUSTMENT Remove the low pressure gauges from the HP circuit and install two 600 bar gauges: 1° Check the start of regulation in forward and reverse drive using a tachometer.

Select forward drive, increase the engine speed slowly until the wheel begin to turn record the engine speed.

Repeat the same in reverse drive.

Compare the two readings; they should be identical.

2° Check the pilot and HP readings.

Select forward drive, apply foot brake, accelerate progressively to maximum speed.

Record the forward HP and forward pilot pressure.

Repeat the same operation in reverse. The valves should be the same.

Page

61

MVT

R E PA I R M A N U A L

3. A. CHECK AND ADJUST START OF REGULATION

Control valve

Start of regulation

START OF REGULATION: • •

Check the engine speed at idle depending on machine type. It should be 750 to 850 rpm.

Select forward drive, gradually increase the engine speed until the wheels start to move - check the engine speed.

It should be between 1050 and 1100 rpm. If not adjust the screw on the end of the regulation valve.

• Screw in to delay the start of regulation.

• Screw out to advance the start of regulation.

•

Adjustment of the start of regulation outside its specified limits will change the performance curve of the pump.

•

Confirming the adjustment is correct is done as described in step 2 point 2.

Page

62

MVT

R E PA I R M A N U A L

3. B CHECK AND ADJUST END OF REGULATION:

End of regulation

CHECK: - The truck is supported on blocks, inching valve by passed, brackes applied (foot and park).

- Drive reserver in forward drive.

- Select forward drive.

- Engine at low idle - check rpm.

- Gradually increase the engine speed until the forward HP reading is 400 bar. At this point check engine speed and compare with specifications. (BT420/425 = 2500 rpm, MSI 40/50 = 1650 rpm, MA 460/470 = 1800 rpm, MVT 1130 L/1340 L =1800 rpm).

END OF REGULATION: The adjustment of the pump end of regulation (e.g. BT425 = 2500 rpm) is obtained using an eccentric screw which restricts the pump flow creating back pressure against the swash plate.

This adjustment can only be set using a test bench.

IMPORTANT The slot in the eccentric screw should point towards the boost pump (opposite to A4V pump where slot pointed to drive shaft). The adjustment must not go beyond 90 to the left or right. Do not exceed or damage nay occur.

Page

63

R E PA I R M A N U A L

MVT

4. CHECK AND ADJUST HP VALVES • The HP valves are checked with the truck supported on blocks with the brakes applied • It is also necessary to by-pass the inching (TH7) valve(s) with a flexible hose.

• Also, if fitted, by-pass the parking brake drive isolation system.

• Overset the DR valve (1) to check the pressure of the HP valves.

Screw the adjuster in 1 turn. The HP valves pressure should be 450 bar.

(During this test the engine speed should drop 570-600 rpm).

After the HP valves have been checked the DR valve should be re-set to 440 bar.

CALIBRATION OF HP RELIEF VALVES : A 4 VG 40-56 DA series pump • Remove the complete relief valve • Tighten screw 3 to increase the pressure • Loosen to reduce 1 turn = approximately 44 bar

Page

64

R E PA I R M A N U A L

MVT

CHECKS BEFORE PRESSURE TESTING - Check the trasmission oil level.

- Check there are no leaks at hoses or unions.

- Check the electrical connections at the solenoid.

- Make sure the circuit is filled with oil. In some cases the filter should be filled with oil prior installation.

- Confirm correct connection of pilot hoses: * Port x1 on pump to X1 on motor, * Port x2 on pump to X2 on motor.

- In all cases, the pilot hose be opposite the HP hose (e.g. If the HP for forward drive is on the right of the motor the forward pilot hose must be on the left).

- Install the pressure gauges for boost, pilot, HP and housing checks. ❑ PREPARATION - For safety purposes support the front wheels on blocks (disconnect 4 wd shaft if applicable).

- Crank the engine a few times with the fuel shut off solenoid disconnected, to ensure the circuit is charged with oil - The boost pressure during cranking should be around 15 bar. “Never run the transmission without boost pressure”.

- Reconnect the fuel shut off solenoid.

- Start the engine and run for a few minutes at idle.The boost pressure should be between min 25 and max 40 bar. A tibering gauge indicates cavitation in the system.With the drive selector in neutral the pressure in the two HP circuits should be the same as the boost pressure

- When the oil temperature is 50 to 60 C check the engine speed: - Idle speed, - Maximum speed - Maximum speed under load.(See specifications).

Page

65

MVT

R E PA I R M A N U A L

5. ADJUSTMENT MOTOR DISPLACEMENT CHANGEOVER A) CHECK MINIMUM DISPLACEMENT (MAX. SPEED): • The check is made driving the truck on level ground with the engine a full speed in forward drive

HIGH PRESSURE REGULATION PRESSURE

CHANGEOVER PRESSURE

• Connect two 600 bar pressure gauges as shown above. At maximum drive speed the two gauges should read the same. This signifies that both sides of the Servo piston are subject to the same pressure and the motor is at its minimum displacement.

B ) CHECK START OF REGULATION: • With the wheels raised from the ground and the truck supported on blocks gradually apply the brake pedal to raise the pressure in the HP circuits (inching valve by-passed).

• Watch the two gauges. When the HP gauge shows 200/250 bar the changeover pressure will drop then the HP will continue to rise until it reaches the setting of the DR valve.

• The changeover point can be adjusted by the screw.

Page

66

R E PA I R M A N U A L

MVT

C) MAXIMUM DISPLACEMENT : ( MAX.TRACTIVE FORCE ) • To make this adjustment, the machine should be chocked (brakes locked).

The check is made at maximum IC engine speed in forward drive.

• The switching pressure (large section side of control cylinder) must be around zero bars.

• Adjust the control screw as required (tighten to increase the switching pressure, loosen to reduce).

• A check on the tractive force (using a hook) should then be carried out (refer to “AideMemoire Service” for values).

Page

67

MVT

R E PA I R M A N U A L

BRAKE SYSTEM DRAINING PROCEDURE Fill the resevoir 1 (fig. 15) with the correct fluid (see oil-greases-liquids-fluel pag. 13) and maintain the level above the botton of the tank throughout the draining procedure: Caution: USE OF INCORRECT FLUID WILL CAUSE SERIOUS DAMAGE USE ONLY MINERAL BASED PRODUCTS Fit a tube drain screw 2 (Fig. 15) ensuring that the free end of tube is immersed in fluid contained in a suitable can 3 (Fig. 15) Open the drain screw and apply one rapid full stroke of the pedal followed by three rapid short strokes from the half-way pedal position; push the pedal to end of stroke and keep it until the drain screw is closed again.

Continue draining normally until all air is dispelled, closing, the drain screws with the pedal fully depressed: Repeat the procedure for all the brakes and finally top up fluid reservoir to correct level: NOTE: “Power bleeding” of this circuit will greatly reduce time required to perform this task

Fig. 15

1

2

3 Page

68

MVT

R E PA I R M A N U A L

PARKING BRAKE DISASSEMBLY OF THE PARKING BRAKE CYLINDER (Fis. 16) Set the truck on a flat surface with thermic engine on and chock the wheels.

1) Loosen the nut and the lock nut (A) 2) Unthread the screw (B) from the eyelet (C) 3) Stop the thermic engine 4) Disconnect the hydraulic hose (D-Fig. 17) 5) Unscrew the screw (E) 6) Take off the cylinder of the parking brake from the front axle 7) Lock the cylinder from the side of the bottom (F) in a clamp 8) Unthread the lock nut (G) keeping the rod stopped (H) with a wrench 9) Unscrew the eyelet (C) keeping stopped the rod (H) 10) Unscrew the cylinder head (I) 11) Unthread the spring (L) and the rod (H) 12) Execute the replacement of the joints kit

Fig. 16

B

G I

C

L

A

E LOCTITE 270 - H

M

F

Page

69

MVT

R E PA I R M A N U A L

REASSEMBLY OF THE PARKING BRAKE CYLINDER (Fis. 16) Reassembly of the parking brake cylinder.

1) Grease the inside of the cylinder liner side rod (F) to avoid damages of the joint of the piston (M) lock it in a clamp.

2) Screw the rod (H) to the piston (M) using LOCTITE 270 3) Thread the rod (H) and the spring (L) in the cylinder, side bottom (F) 4) Screw the cylinder head (I) 5) Screw the eyelet (C) as in the position before, keeping stopped the rod (H) 6) Connect the hydraulic hose (D Foto. 19) and start the thermic engine 7) Replace the parking brake cylinder on the front axle as in figure 17 8) Screw the screw (E) 9) Thread the screw (B) in the eyelet (C) 10) Screw the nut and lock it with the lock nut (A) 11) Adjust the parking brake cylinder, placing the eyelet axle (C) at about 72,5 mm from plain surface of the cylinder (I) (see Fig. 17) paying attention that the two levers are on the limit switch screws 12) Tighten the lock nut with loctite 242

Fig. 17

☞

D

72,5

Page

70

MVT

REPAIR MANUAL

THE DISASSEMBLY AND ASSEMBLY OF THE BOOMS RECOMMENDATIONS HOSES Fit them by positioning the mark at the top for correct movement of hoses.

At the rear of the boom position correctly the hoses.

(See Fig. 18)

FIG. 18

E 16

PURGING TELESCOPING CYLINDERS - For a correct operating of the simultaneous boom, retract fully the telescopes by tilting the valve-bank lever. Maintain the valve-bank lever in this position in order to charge the cylinders. Extend slightly the telescopes then retract once more.

FITTING OF THE PADS - Tighten the screws HC (without head) by hand to the end of threads in the insert.

- Fit the nut.

- Wedge if necessary, then tighten the nut Torque : 92.6 N.m +/- 25% FITTING OF LOWER PADS OF THE BOOM FOOT

Pad

E 22

FITTING OF LOWER PADS OF THE INTERMEDIATE TELESCOPE

Pad

Wedging

E 23

Pin

Screw

FITTING OF UPPER AND LOWER AND LATERAL OF THE INSIDE BOOM Insert

Wedging

FITTING OF UPPER E LATERALI PADS OF THE BOOMS Screw

Wedging

Pad

3 mini

E 24

Wedging

Screw

E 25

Pad

Insert

Page

73

MVT

REPAIR MANUAL

BOOM HOSE REPLACEMENT FIG. 19

A) Boom assembly consist of steel hydraulic tubing on the outside of the boom and “travelling - hose” inside the boom.

B) When hose replacement inside the boom becomes necessary, lower forks to ground, apply parking brake, chock front wheels and disassemble the protection of the hoses under the boom (Fig. 19).

☞ ☞

REPLACEMENT TILTING AND OPTIONAL CIRCUIT HOSES

C 26

FIG. 20

☞

☞

1) Remove black back cover from frame (see Fig. 20).

F 68

2) Remove the pressure in the hydraulic system acting on the cab controls (see Fig. 21).

FIG. 21

☞

➪ ➩

☞

FIG. 22

☞☞

3) Dismantle the upper hydraulic hoses guide in the rear of boom (Fig. 22).

ee

➪ ➩

E 19

Page

74

MVT

REPAIR MANUAL

FIG. 23

4) Dismantle the lower hydraulic hoses guide in the rear of boom (Ref. 1-Fig. 23).

☞

E 16

1

FIG. 24

5) Disconnect hoses fasten a rope to the tilting or optional hose end (Fig. 24 Ref. 1 or 2).

☞1 E 17

1

☞ 6) Pull the old hoses from the rear of the machine.

2 2

FIG. 25

7) Fasten a rope to the curve of the lower side hose on the front tip boom (Fig. 25).

8) Pull the hose from the rear of the machine.

9) Set free the two old hose ends and fastenthe rope to the new hose.

E2

10) Pull the rope from the boom front head until the hose goes out.

Page

75

MVT

REPAIR MANUAL

FIG. 26

11) Connect the flexible hose to the tilting or optional cylinder valve paying attention that the hose curve is upwards (Fig. 26 Ref. 1).

☞ 1

E 18

FIG. 27

12) Assemble the upper guide paying (Fig. 27) attention that the curve is upwards.

13) Fasten the hose curve to the rope.

E 19

FIG. 28

14) Pull the rope from the boom end until the hose goes out (Fig. 28).

15) Connect the hose to the tube.

E2

Page

76

MVT

REPAIR MANUAL

FIG. 29

☞

☞

16) When connecting the two hoses to the inside telescope cylinder, pay attention at the mark on the hose, it has to be in the upper position (Fig. 29).

E 63

17) Assemble the lower guide on the rear side of the boom (Ref. 1-Fig. 30).

18) Start the thermic engine.

19) Check the hoses movement inside the boom they don't have to fall on the side,if it happens loosen the fitting and rotate the hose until it will stay standing fine. (Fig. 31).

☞

FIG. 30

E 16

1

IMPORTANT FIG. 31

If the telescopic booms are out of phase you must correct them by pulling the retract lever and keeping it held untill the inner boom is completely retracted.

ATTENTION

E 64

If the phase difference exceed 4-6 inches (as the drawing shows) the boom's hydraulic pipes could be seriously damaged.

4 - 6 inches

Page

77

MVT

REPAIR MANUAL

REMOVAL OF TILTING CYLINDER Fig. 32

- Put the machine on a level surface and apply the parking brake.

- Remove the hydraulic pressure from the circuit .

- Disconnect the hoses of the tilt cylinder (take care of the mark).

2 F 70

- Protect the threads of the hydraulic connections on the tilting cylinder valve.

☞

- Support the carriage (Ref. 1-Fig. 32).

- Remove the lower pin (Ref. 2-Fig. 32).

1

- Support the cylinder.

Fig. 33

- Remove the upper pin (Ref. 1-Fig. 33).

- Lift the boom holding the cylinder.

1

☞

F 71

Page

78

MVT

REPAIR MANUAL

REMOVAL OF THE CYLINDER FROM THE SMALL TELESCOPE Fig. 34

☞

- Position the machine on a flat surface and apply the parking brake.

☞ F 69

1

☞

- Remove the silencer exhaust muffler (Ref. 1Fig. 34) placed in the rear right side of the chassy.

Fig. 35

- Position the boom horizontally and align the foot pin of the inner telescope cylinder with the hole in the chassy. (Fig. 35).

1

- Remove the pin (Ref. 1-Fig. 35) taking it off from the rear right side of the chassy.

☞

F 72

Fig. 36

- Extend the telescope to get access to the rod end pin (Ref. 1-Fig. 36).

- Remove the rod end pin.

- Retract the telescope.

1

F 73

☞

Page

79

MVT

REPAIR MANUAL

- Remove the clamps and hose guide at the rear of the boom (Ref. 1-Fig. 37).

- Remove the fixing screws of the lower pads of the small telescope.

☞ ☞

FIG. 37

1

1

E 16

FIG. 38

- Put a rest under the cylinder at the rear of the boom (Ref. 1-Fig. 38).

- Place the hoses situated at the rear of the boom on the R.H. and L.H. sides (Fig. 38).

E 32

☞

1

FIG. 39

- Remove the valve at the foot of the cylinder (Fig. 39).

- Remove the foot cylinder pin (Ref. 1-Fig.40).

E 31 - Sling the cylinder and extract it by the rear of the boom (Fig. 41).

Fig. 40 FIG. 41

1 E 33

☞

F 72

Page

80

MVT

REPAIR MANUAL

REMOVAL OF THE SMALL TELESCOPE FIG. 42

- Set the boom horizontal.

- Remove the cylinder of the small telescope (See procedure on previous page).

E 34 - Disconnect and pull from the back of the boom the hoses of the tilting cylinder and of the optional circuit (Fig. 42).

Fig. 43

- Remove the rear lower pads of the small telescope if fitted (Ref. 1-Fig. 43).

REAR

- Hook the telescope and extend it slightly.

- Remove the pads and the shims at the front of the intermediate telescope, take care to the mark of their place and the wedging (Ref. 1-Fig. 44).

D 100 1

→

→

- Remove the small telescope with a hoist (Fig. 45).

Fig. 44

Fig. 45

→

→

FRONT

→

→ E1

1

E 35

→

Page

81

→

MVT

REPAIR MANUAL

REMOVAL OF THE INTERMEDIATE TELESCOPE CYLINDER

FIG. 46

- Remove the clamp (Ref. 1-Fig. 46).

1

E 36

☞

- Remove the circlips and the pin of the rod (Ref. 3-Fig. 46).

3

☞

- Disconnect the hose item (Ref. 2-Fig. 46) (Head, cylinder)

2

FIG. 47

- Disconnect the hoses at the foot of cylinder (Fig. 47).

- Remove the circlips and pin at the foot of cylinder.

E 37

FIG. 48

- Sling the cylinder, disengage and lift it forward (Fig. 48).

E 38

Page

82

MVT

REPAIR MANUAL

REMOVAL OF INTERMEDIATE TELESCOPE - This operation requires the removal of the small telescope and its cylinder, the removal of the intermediate telescope cylinder (See previous pages)

- Extend slightly the telescope forward (Fig. 49)

FIG. 49

E 61

- Remove the pads and shims at the front of the jib foot (Fig. 50). Note the value of adjustment and the position of the pads.

FIG. 50

- Pull on the intermediary telescope to disengage the foot of the jib (Fig. 51 and 52). Support the telescope with a sling (Fig. 53).

E 60

FIG. 53

FIG. 52

E 40

FIG. 51

E 60

E 39

Page

83

MVT

REPAIR MANUAL

REMOVING THE TELESCOPIC BOOM Fig. 54

- Position the truck on a flat surface and remove the fork carriage assembly.

- Lower the telescopic boom until the quick fit is on an appropriate rest (Fig. 54).

D 96

Fig. 55

- Adjust the telescopic boom until the compensation cylinder rod pin is in line with the hole in the chassy (Ref. 1-Fig. 55).

1

F 74

☞

- Unscrew the compensations cylinders rod eye pin retainer screws and remove the pins (Fig. 55).

Fig. 56

- Lift the boom until the the lifting cylinder pin is above the cab (Fig. 56).

E 67

Page

84

MVT

REPAIR MANUAL

Fig. 57

- Take a belt or sling connected to another crane and pass it around the cylinder to support it (Fig. 57).

- Stop the engine.

E 68

Fig. 58

- Hold the telescopic boom with a crane or a lift by the lugs (Fig. 58).

- Hold the lifting cylinder with a sling connected to a lift (Fig. 58).

Foto C3/4

Fig. 59

- Back off the retainer screw and remove the pin of the lift cylinder, rod side (Ref. 1-Fig. 59).

1 Foto C3/6

☞

- Lower the lift cylinder, with the bridge crane, until it is inside the chassis.

Page

85

MVT

REPAIR MANUAL

Fig. 60

- Disconnect the hoses on the back of the boom (Ref. 1,2,3,4,5,6-Fig. 60).

24 6 1F375 5

Fig. 61

- Unscrew the retainer screws and remove the central pin of the boom (Ref. 1-Fig. 61).

1

Foto C3/14

Fig. 62

- The telescopic boom can now be removed with the crane (Fig. 62).

Foto C3/4

Page

86

MVT

REPAIR MANUAL

REMOVING THE LIFT CYLINDER

Fig. 63

After removing the telescopic boom, the lift cylinder can be removed.

☞

- Disconnect the hoses of the cylinder (Ref. 1,2-Fig. 63).

1 - Fit a sling into the eye on the lift cylinder and lift it vertically using a crane.

2

☞

Foto C4/1

- Unscrew the retainer screw of the pin (Ref. 1-Fig. 64).

Fig. 64

Foto 3 C4/2

- Remove the retainer pin of the cylinder (Ref. 1-Fig. 65).

Fig. 65

The cylinder can be removed.

Foto C4/3

4

Page

87

MVT

REPAIR MANUAL

REMOVING THE COMPENSATION CYLINDERS

Fig. 66

- Disconnect the hoses of the cylinder (Ref. 1,2,3,4-Fig. 66).

- Pass abelt or sling through the eye of the compensation cylinder.

1 2 Foto C5/1

3

4

Fig. 67

- Unscrew the retainer screw of the pin (Ref. 1-Fig. 67).

☞

1 Foto C5/2

Fig. 68

- Remove the retainer pin of the compensation cylinder (Ref.1-Fig. 68).

- The cylinder can be removed.

- Remove the other cylinder using the same procedure.

Foto1C5/3

Page

88

MVT 1340 MVT L

REPAIR MANUAL

REMOVING THE REAR AXLE LOCK CYLINDER

Fig. 69

- Position the machine on a flat surface and apply the parking brake.

- Disconnect the hydraulic hoses from the cylinder (Ref. 1Fig. 69).

- Disconnect the two plugs from the electrovalves (Ref. 2Fig. 69).

E 43

☞1

2

☞

Fig. 70

- Disassemble the rod end pin (Ref. 1-Fig. 70).

☞ 1 E 44

- Disconnect the foot end pin holding the cylinder (Ref. 1Fig. 71).

Fig. 71

☞

E 45

1

Page

89

MVT

REPAIR MANUAL

LIFTING CYLINDER DISMANTLING

C 25

DISMANTLING - Loosen the ring Ref. 10 - Extract from the cylinder body the assembly rod + piston - Remove the piston Ref. 16 locking allen screw - ATTENTION screw fitted with loctite.

- Unscrew the cylinder piston .

- Take off the cylinder piston.

- Dismantle the o ring Ref. 12 and the sealing ring Ref 13 of the piston.

- Dismantle the o rings Ref. 18 and 11, the seal Ref. 9 and the 2 sealing rings Ref. 7 and 8 of the ring.

- Change the seals and the components if necessary.

- ATTENTION to the reassembly way REASSEMBLY Reverse operation to the dismantling way.

Note: - When installing, allen screw has to be fitted with loctite for threads.

- Cover the seals with hydraulic oil.

- When assembling the guide rings Ref. 13 “Avoid to have the guide rings cut "

Page

90

MVT

REPAIR MANUAL

TILTING CYLINDER DISMANTLING

D 91

DISMANTLING - Loosen the ring Ref. 20 - Extract from the cylinder body the assembly rod + piston - Remove the piston Ref. 6 locking ring nut - ATTENTION ring nut fitted with loctite.

- Unscrew the cylinder piston .

- Take off the cylinder piston.

- Dismantle the o ring Ref. 11 and the sealing ring Ref 10 of the piston.

- Dismantle the o rings Ref. 12 and 15, the seal Ref. 13 and the sealing ring Ref. 14 of the ring.

- Change the seals and the components if necessary.

- ATTENTION to the reassembly way.

REASSEMBLY Reverse operation to the dismantling way.

Note: - When installing, ring nut has to be fitted with loctite - Cover the seals with hydraulic oil.

- When assembling the guide rings Ref. 10 “Avoid to have the guide rings cut "

Page

91

MVT

REPAIR MANUAL

1st TELESCOPE CYLINDER DISMANTLING

D 92

DISMANTLING - Loosen the ring Ref. 9 - Extract from the cylinder body the assembly rod + piston - Remove the piston Ref. 3 locking allen screw - ATTENTION screw fitted with loctite.

- Unscrew the cylinder piston Ref. 2.

- Take off the cylinder piston.

- Dismantle the o ring Ref. 6 and the 2 sealing rings Ref 4 and 5 of the piston.

- Dismantle the o rings Ref. 13 and 8, the 2 sealing rings Ref. 10 and 11 of the closing ring.

- Change the seals and the components if necessary.

- ATTENTION to the reassembly way.

REASSEMBLY Reverse operation to the dismantling way.

Note: - When installing, allen screw has to be fitted with loctite for threads.

- Cover the seals with hydraulic oil.

- When assembling the guide rings Ref. 5 “Avoid to have the guide rings cut "

Page

92

MVT

REPAIR MANUAL

2nd TELESCOPE CYLINDER DISMANTLING

D 93

DISMANTLING - Loosen the ring Ref. 9 - Extract from the cylinder body the assembly rod + piston - Remove the piston Ref. 3 locking allen screw - ATTENTION screw fitted with loctite.

- Unscrew the cylinder piston Ref. 2.

- Take off the cylinder piston.

- Dismantle the o ring Ref. 6 and the 2 sealing rings Ref 4 and 5 of the piston.

- Dismantle the o rings Ref. 13 and 8, the 2 sealing rings Ref. 10 and 11 of the closing ring.

- Change the seals and the components if necessary.

- ATTENTION to the reassembly way.

REASSEMBLY Reverse operation to the dismantling way.

Note: - When installing, allen screw has to be fitted with loctite for threads.

- Cover the seals with hydraulic oil.

- When assembling the guide rings Ref. 5 “Avoid to have the guide rings cut "

Page

93

MVT

REPAIR MANUAL

COMPENSANTING CYLINDER DISMANTLING

D 94

DISMANTLING - Loosen the ring Ref. 5 - Extract from the cylinder body the assembly rod + piston - Dismantle the nut Ref. 13 - Take off the cylinder piston.

- Dismantle the o ring Ref. 11 and the sealing ring Ref. 9 of the piston.

- Dismantle the o rings Ref. 4 and 15, the seal Ref. 6 and the sealing ring Ref. 7 of the closing ring.

- Change the seals and the components if necessary.

- ATTENTION to the reassembly way.

REASSEMBLY Reverse operation to the dismantling way.

Note: - Cover the seals with hydraulic oil.

- When assembling the guide rings Ref. 9 “Avoid to have the guide rings cut "

Page

94

MVT

REPAIR MANUAL

LEVELING CYLINDER DISMANTLING

D 95

DISMANTLING - Loosen the ring Ref. 11 - Extract from the cylinder body the assembly rod + piston - Remove the piston Ref. 4 locking allen screw - ATTENTION screw fitted with loctite.

- Unscrew the cylinder piston Ref. 5.

- Take off the cylinder piston.

- Dismantle the o ring Ref.6 and the sealing ring Ref. 7 of the piston.

- Dismantle the o rings Ref. 12 and 16, the seal Ref. 10 and the sealing rings Ref. 8 and 9 of the ring.

- Change the seals and the components if necessary.

- ATTENTION to the reassembly way.

REASSEMBLY Reverse operation to the dismantling way.

Note: - When installing, allen screw has to be fitted with loctite for threads.

- Cover the seals with hydraulic oil.

- When assembling the guide rings Ref. 7 “Avoid to have the guide rings cut "

Page

95

MVT MVT 1340 L

REPAIR MANUAL

REAR AXLE LOCK CYLINDER DISMANTLING

D 94

DISMANTLING - Loosen the ring Ref. 5 - Extract from the cylinder body the assembly rod + piston - Dismantle the nut Ref.13 - Take off the cylinder piston.

- Dismantle the o ring Ref. 11 and the sealing ring Ref 9 of the piston.

- Dismantle the o rings Ref. 4 and 15, the seal Ref.6 and the sealing ring Ref. 7 of the closing ring.

- Change the seals and the components if necessary.

- ATTENTION to the reassembly way.

REASSEMBLY Reverse operation to the dismantling way.

Note: - Cover the seals with hydraulic oil.

- When assembling the guide rings Ref. 9 “Avoid to have the guide rings cut "

Page

96

MVT

R E PA I R M A N U A L

ENGINE DISMANTLING Fig. 1 - Place the truck on a flat surface, the thermic engine has to be stopped.

- Lift the engine hood.

- Support the hood to the maximum opening with a sling and dismantle the gas loaded springs, (Ref. 1-Fig. 1).

1 1

- Lower the hood and dismantle the hinges fastening screws.

- Take off the hood.

Fig. 2 - Dismantle exhaust pipe protection plate, (Ref. 1-Fig. 2).

- Dismantle the grates fixed to the casing placed to the rear of the engine, (Ref. 2-Fig. 2).

- Dismantle the exhaust pipes placed on the exhaust manifold side of the engine and on the exhaust muffler, (Ref. 1,2-Fig. 3).

1

2

Fig. 3

2 1

Page

97

MVT

R E PA I R M A N U A L

Fig. 4

- Dismantle the metallic hoses mounted on the engine pre-filter, (Ref. 1-Fig. 4).

- Dismantle the engine pre-filter support, (Ref. 2-Fig. 4).

2 2

3

3 1

1

- Dismantle the air suction hose on the intake manifold of the engine, (Ref. 3-Fig. 4).

Fig. 5 - Disconnect the positive and negative cable on the battery, (Ref. 1,2-Fig. 5).

2

1 - Remove battery hold down strap (Ref. 3Fig. 5),

4 3

- Take off the battery, (Ref. 4-Fig. 5).

Page

98

MVT

R E PA I R M A N U A L

- Dismantle the side closing casing, engine compartment (Ref. 1-Fig. 6)

Fig. 6 1

1

Fig. 7 - Dismantle the battery support (Ref. 1-Fig. 7).

1

1

1

- Dismantle the hoses of cooling system on the engine (Ref. 1,2-Fig. 8).

Fig. 8

1 2

Page

99

MVT

R E PA I R M A N U A L

- Disconnect the hydraulic hoses mounted on the pump on side of the engine (Ref. 1,2-Fig. 9) and (Ref. 1,2-Fig. 10).

Fig. 9

1 2

Fig. 10

- Disconnect the hydraulic hoses mounted on the main pump , (Ref. 1-Fig. 11) and (Ref. 1-Fig. 12).

1

2

Fig. 11

Fig. 12

1

1

Page

100

MVT

R E PA I R M A N U A L

Fig. 13

- Disconnect all the hydraulic hoses mounted on the hydrostatic pump to the engine, REF. 1-2-34-5-6-7-8 (Fig. 13) and (Ref. 1-Fig. 14).

1

8 2 3

4 6 5

7

Fig. 14 - Disconnect the metallic hose mounted on the engine filter (Ref. 1-Fig. 15).

1

- Disconnect the accelerator cable placed on the engine, (Ref. 1-Fig. 16).

Fig. 16

1

Fig. 15

1

Page

101

MVT

R E PA I R M A N U A L

- Disconnect the electric cable on the alternator, (Ref. 1-Fig. 17).

- Disconnect the electric cable on the starting motor, (Ref. 1-Fig. 18).

Fig. 17

1

Fig. 18

- Disconnect the electric cable on the preheating glow plug, (Ref. 1-Fig. 19).

1 - Disconnect the electric cable on the water temperature sender mounted on the engine cooling hoses, (Ref. 1-Fig. 20).

Fig. 20

Fig. 19

1 1

Page

102

MVT

R E PA I R M A N U A L

- Disconnect the electric cable on the solenoid injection pump, (Ref. 1-Fig. 21).

Fig. 21

1

- Disconnect the electric wire from the engine temperature sender (Ref. 1-Fig. 22).

Fig. 22

1

- Disconnect the ground cable, (Ref. 1-Fig. 23).

Fig. 23

1

Page

103

R E PA I R M A N U A L

- Attach chain hoist to lifting eyes on engine (Fig. 24).

- Disconnect the motor mounts inside chassy (Ref. 1-Fig. 25).

MVT Fig. 24

Fig. 25

- Disconnect the motor mounts outside chassy (Ref. 1-Fig. 26).

Fig. 26 Take off the complete engine.

Reinstall in reverse order.

Page

104

MVT

R E PA I R M A N U A L

REMOVING THE WHEELS - Position the truck on a flat surface, with the engine off.

- With the aid of a crane or lift, connect to holes “A” on the right and left of the chassis (Fig. 27).

- Lift the front of the truck and unscrew the fixing bolts using a 30 mm socket wrench.

- Remove the wheels.

- Carry out the same operations for the front wheels, lifting the chassis from point “B” (Fig. 27).

- Remove the wheels.

CAUTION : When replacing the wheels, tighten the fixing bolts to 550 Nm.

Fig. 27

B

A A

Page

105

MVT

R E PA I R M A N U A L

REMOVING THE FRONT AND REAR DIFFERENTIAL AXLE REMOVING THE FRONT DIFFERENTIAL AXLE AND THE HYDROSTATIC MOTOR Fig. 28

- After the front wheels have been removed, the front axle and the hydrostatic motor fixed to it can be removed.

- With the aid of a crane or lift, raise the front of the truck using holes “A” on the right and left of the chassis (Fig. 28).

A A

Fig. 29

- Unscrew the screws securing the drive shaft flange (Ref. 1-Fig. 29).

1

Fig. 30 - Remove the retainer of the “low/high speed” selection cable (Ref. 1-Fig. 30).

1

Page

106

MVT

R E PA I R M A N U A L

- Disconnect the hoses 1-2-3-4-5 (Fig. 31) from the hydrostatic motor.

Fig. 31

1

2

3

4

5

- Disconnect the hoses from the steering cylinder (Ref. 1-Fig. 32).

Fig. 32

1

Page

107

MVT

R E PA I R M A N U A L

Fig. 33

- Disconnect the hose from the parking brake actuator (Ref. 1-Fig. 33).

2 1

- Disconnect the hose from the service brake actuator (Ref. 2-Fig. 33).

- Position a pallet trolley under the axle.

Fig. 34 - Unscrew the bolts connecting the front axle to the chassis (Ref. 1-Fig. 34).

- Raise the chassis with a crane.

1

- The front differential axle and hydrostatic motor can now be removed.

Page

108

MVT

R E PA I R M A N U A L

REMOVING THE HYDROSTATIC MOTOR ONLY Fig. 35

- Position the truck on a flat surface with the engine off.

1

- Disconnect the hoses 1-2-3-4-5 (Fig. 35) from the hydrostatic motor.

2

3

4

5

- Support the hydrostatic motor with a sling or a support and unscrew the bolts securing it (Ref. 1-Fig. 36).

- The hydrostatic motor can now be removed Fig. 36

1

1

Page

109

MVT

R E PA I R M A N U A L

REMOVING THE REAR DIFFERENTIAL AXLE After removing the rear wheels, the rear axle can be removed.

Fig. 37 - Lift the rear of the truck using point "B" (Fig. 37).

B

Fig. 38

- Unscrew the screws securing the drive shaft flange (Ref. 1-Fig. 38).

1

Fig. 39

- Disconnect the left-hand and right-hand hoses from the steering cylinder (Ref. 1-Fig. 39).

1

Page

110

MVT

R E PA I R M A N U A L

Fig. 40

- Disconnect the hose from the service brake actuator (Ref. 1-Fig. 40).

1

- Position a pallet trolley under the differential axle.

Fig. 41

- Unscrew the bolts securing the front and rear support of the rear axle (Ref. 1-Fig. 41).

- Raise the chassis with a bridge crane.

The rear differential axle can now be removed.

1

Page

111

MVT

R E PA I R M A N U A L

REMOVING THE WATER AND OIL RADIATOR

Fig. 42

- Position the truck on a flat surface with the engine off.

- Place a container under the radiator and open the tap to empty out the cooling liquid (Ref. 1-Fig. 42).

Fig. 43

- Place a container under the radiator and empty out the hydraulic oil, disconnecting the hoses (Ref. 1,2-ILL. 43).

1

2

- Remove the rear housing of the boom (Ref. 1-Fig. 44).

1

Fig. 44

1

Page

112

MVT

R E PA I R M A N U A L

Fig. 45 - Remove the upper and lower radiator intake collar (Ref. 1-Fig. 45 and Ref. 1-Fig. 46).

- Remove the cooling circuit vent pipe (Ref. 1Fig. 47).

1

Fig. 46

Fig. 47

1

1

- Remove the cooling circuit fan pipe (Ref. 1-Fig. 48).

Fig. 48

1

1

Page

113

MVT

R E PA I R M A N U A L

- Unscrew the radiator side and rear fixing screws (Ref. 1,2-ILL. 49).

The radiator is now free and can be lifted from the chassis with a bridge crane.

Fig. 49

1

1

2

Page

114

MVT

R E PA I R M A N U A L

REMOVING THE CONTROL VALVE - Position the truck on a flat surface.

- Raise the telescopic boom to its maximum height.

- Stop the engine.

- Disconnect the control valve delivery, drain and control lines (Ref. 1,2,3,4,5,6,7,8,9,10,11ILL. 50).

- Disconnect the cylinder delivery lines (Ref. 1,2,3,4,5,6,7,8-Fig. 51).

- Unscrew the screws fixing the control valve to the chassis (Ref. 9-Fig. 51).

Fig. 50

Fig. 51

2 3 4

5

6 9

7 8 9 10 1

5

1

6 2

7

3

8 4

Page

115

MVT

R E PA I R M A N U A L

REMOVING THE CAB

Fig. 52

- Position the truck on a flat surface with the engine off.

- Disconnect the battery terminals.

- Disconnect all the electric wires and connections under the control panel.

1

ATTENTION : all the electric wires enter the cab in a single group (Ref. 1-Fig. 52).

2

- Disconnect the throttle cable on the engine (Ref. 1-Fig. 53).

Fig. 53

- Disconnect the electrical wire of the windscreen washing fluid in the back, under the cab.

- Disconnect the ground wire between the cab and the frame (Ref. 2-Fig. 52).

1

- Disconnect the hoses 1-2 and 3-4 on the power steering (ILL. 54).

Fig. 54

1 2 4

3

Page

116

MVT

R E PA I R M A N U A L

Fig. 55

- Disconnect the hoses on the inching valve fixed to the pedals (Ref. 1,2,3-ILL. 55).

1

23

Fig. 56 - Disconnect the hoses 1-2-3 on the steering control valve in the rear under the cab (ILL. 56).

1 2 3

- Disconnect the pilot hoses on the directional control valve (Ref. 1,2,3,4,5,6,7,8-ILL. 57).

Fig. 57

1 2

3

4

5 6 7 8

Page

117

MVT

R E PA I R M A N U A L

Fig. 58

- Disconnect the drain and feeding hoses of the manipulator (Ref. 1-ILL. 58).

- Disconnect the feeding hoses of the accumulator (Ref. 2-ILL. 58).

- Dismount the accumulator (Ref. 3-ILL. 58).

- Disconnect the drain and feeding hoses of the electrovalve (Ref. 4-ILL. 58).

- Dismount the electrovalve (Ref. 5-ILL. 58) from the cab unscrewing the screw (Ref. 6ILL. 58).

1 2

3

5

4

6

Fig. 59 - Disconnect the hose from the parking brake actuator (1, ILL. 59).

3

1 2

Fig. 60 - Disconnect the hoses 1 from the powerassisted braking unit (ILL. 60).

1

Page

118

MVT

R E PA I R M A N U A L

Fig. 61

- After disconnecting all the numbered details, connect a bridge crane or a lift to the cab at points “A” and “B” (Fig. 61).

A

B

Fig. 62

➟

➟

- Unscrew the front and rear screws fixing the cab to the chassis (Fig. 62 + 63).

Fig. 63

The cab can be removed.

➟

➟

ATTENTION : Check that none of the components disconnected previously is damaged.

Pay special attention to the heating lines, throttle cable, and hydraulic pilot lines of the directional control valve.

Page

119

R E PA I R M A N U A L

MVT

PARKING BRAKE AND SPEED CHANGE LEVER

Page

120

R E PA I R M A N U A L

MVT

HYDRAULIC (TRANSMISSION HYDROSTATIC)

Page

121

R E PA I R M A N U A L

MVT

HYDRAULIC (HYDRAULIC CONTROLS)

Page

122

R E PA I R M A N U A L

MVT

HYDRAULIC (TELESCOPE CIRCUIT TILTING)

Page

123

R E PA I R M A N U A L

MVT

HYDRAULIC (LIFTING - COMPENSATION CIRCUIT)

Page

124

MVT

R E PA I R M A N U A L

HYDRAULIC (LEVELING SYSTEM)

Page

125

MVT

R E PA I R M A N U A L

HYDRAULIC (FAN CIRCUIT)

Page

126

MVT

R E PA I R M A N U A L

HYDRAULIC (STEERING CIRCUIT)

Page

127

R E PA I R M A N U A L

MVT

PEDALS LINKAGE (BRAKE AND ACCELERATOR)

Page

128

R E PA I R M A N U A L

MVT 1340 L

HYDRAULIC (LOCK REAR OSCILLATION)

Page

129