HYDRAULIC

- HYDRAULIC CHARACTERISTICS AND

SPECIFICATIONS

- HYDRAULIC SCHEMATIC DIAGRAMS

- HYDRAULIC COMPONENTS LOCATION

- HYDRAULIC CONTROL AND

ADJUSTEMENT

- HYDRAULIC SPECIFIC TOOLING

70
 HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS

HYDRAULIC COMPONENTS DATA SHEETS

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

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(21/06/2011) 70-01-M186EN
70

70-01-M186EN (21/06/2011)
 Hydraulic characteristics and 1
specifications

STEERING PUMP/DIRECTIONAL BLOCK OSPC 200 LS

Values for information purposes only.

T
P
Role:
L - Direct and dose the flow in order to supply the
steering circuit.
R
- It is a rotating valve.

LS

R L

1. Secondary relief valve.

1 2. Pump valve.

2 3. Main pressure relief valve.

70
200 cm³/tr

LS - P : Pressure.
- T : Return to tank.
- R : Exit towards the right side.
- L : Exit towards the left side.
- LS : Pilot line.
T P

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________

(03/09/2008) F70-3-0003EN
 2 Hydraulic characteristics and
specifications

Values for information purposes only.

R L

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

T P

R L

When there is an impact on a wheel, the pressure increases in the

line. This pressure opens the valve which enables the resulting
pressure to be evacuated and therefore protects the hydraulic
and mechanical steering components.
LS

T P

R L
70

When the wheels are locked to a maximum, the steering circuit

increases in pressure, the LS line activates the relief valve and
enables flow to the tank.
LS

T P

What use do the two valves that are located opposite each other on the top part of the diagram
have?

What is the maximum pressure permitted in the steering circuit?

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

F70-3-0003EN (03/09/2008)
 Hydraulic characteristics and 1
specifications

COUNTER BALANCE VALVE d1

Values for information purposes only.

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

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

V1 engine.

- Limits max. pressure due to impacts.

V2

70
C1 C2
1 3
1. Temporization screws.
2
2. By-pass valve.
4
3. Slide with max. adjustment screw.

V1 V2 4. Non-return valve.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(03/09/2008) F70-3-0008EN
 2 Hydraulic characteristics and
specifications

Values for information purposes only.

C1 C2

V1 V2

Return control during cylinder descent.

C1 C2

V1 V2
70

When a position is secured, no component is able to exert sufficient pressure to open the
valve.

Only a pressure peak due to an impact can open it.

C1 C2

V1 V2

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

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
F70-3-0008EN (03/09/2008)
 Hydraulic characteristics and 3
specifications

Values for information purposes only.

What is the valve opening pressure on the diagram?

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

70
If the temporization screw is either screwed or unscrewed, what effect does it have
on movement?

(03/09/2008) F70-3-0008EN
 4 Hydraulic characteristics and
specifications
70

F70-3-0008EN (03/09/2008)
 Hydraulic characteristics and 1
specifications

DOUBLE EXTENSION BALANCING VALVE bf2,3

Values for information purposes only.

Role:

- Insulates the cylinder in case of hose breakage.

C1

C2 - Cylinder movement requires the starting of the I.C.

engine.

V1 - Limits max. pressure due to impacts.

V2

70
C1 C2
300b 1 1 300b 1. Balancing valve.

2. By-pass ring.
2 2

3 3. Temporization screws.
V1 3 V2

Maximum pressure (bar) 350

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(01/02/2011) F70-3-0015EN
 2 Hydraulic characteristics and
specifications
70

F70-3-0015EN (01/02/2011)
 Hydraulic characteristics and 1
specifications

DISCHARGE VALVE Bf1

Values for information purposes only.

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

1. Non-return valve

70
2. Tank slide.

3. Pilot electrovalve.
3
C VD

Ø0,7

P T
2
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(03/05/2011) F70-3-0044EN
 2 Hydraulic characteristics and
specifications
70

F70-3-0044EN (03/05/2011)
 HYDRAULIC SCHEMATIC DIAGRAMS

Pages
Série D - Série 4 :

– MT-X 732 Série D-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– MT-X 1030 ST Série 4-E3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

70

(21/06/2011) 70-02-M186EN
 2 Hydraulic schematic diagrams
MT-X 732 Série D-E3

HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
CA Suction strainer S6
CSP Counterbalance valve I24/I34/G37
CSD Double counter balance valve K37
D 4 component valve O35
EE Inlet section S24
EA(O) Attachment component S25
EL Lifting component S28
EI Tilt component S30
ET Telescoping component S32
EF Closing component S34
D3 3 position steering valve A12
Position 1: short steering
Position 2: front wheel steering
Position 3: crab position
FDAV Front disc brake K3
FR Return filter O15
M Turbo i.c. engine Q7 1104d-44t/1104d-44ta
Idle speed 930 rpm
Nominal loaded speed 2200 rpm
Full speed unladen 2380 rpm (1104d-44t)
Full speed unladen 2400 rpm (1104d-44 ta)
MC Master cylinder E4
N Level S4
70

P Pump equipment Q4
PAAV(O) Front attachment plug (option) E22
PD Steering pump C11
PP Pressure port O24
R Hydraulic tank S5
RLF Brake fluid tank A5
VC Compensation cylinder DE I28 110x55 c310 (mt 7 and 9)
VI Tilt cylinder DE E28 120x60 c416 (mt 7 and 9)
VD Discharge valve O10
VDAV Front steering cylinder DE K5 90x45 c80x2
VDAR Rear steering cylinder DE K11 90x45 c80x2
VL Lifting cylinder DE G24 140x70 c720 (mt 7 and 9)
VT DE telescoping cylinder I33 70x50 c2700 (mt 7)
VT1 DE telescoping cylinder I38 100x60 c2600 (mt 9)
VT2 DE telescoping cylinder G38 80x50 c2600 (mt 9)
VACM(O) Movement cut-off valve (option) Q18

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

70-02-M186EN (21/06/2011)
 Hydraulic schematic diagrams 3
MT-X 732 Série D-E3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

2 A B T
A 3 1 A

3 2 1
RLF AV AR
D3
3 2 1
P

R L
C B2 B1 PD 200b 200b C

200 cm3/tr
MC

LS 140b
E E

T P
VI
PAAV(O)

C1 C2
VL CSP 315b +15
0
G G

110b
V1 V2

VC VT

I C1 C2 I
CSP 335b
C1 C2
335b CSP
FDAV VDAV VDAR
30b
V1 V2

70
K 30b K
V1 V2
ES. AR.
ES. AV.

M M

PP
C P A1 B1 A2 B2 A3 B3 A4 B4 T
O VD 280b 280b
190b 190b D O
EF CF OUT P1 FR
6b
5b

LS VACM(O)
M
P 10 μm absolute
absolu 1ère monte
first mount
21.99 cm3/tr IN 15 μm absolu PR.spares parts
absolute
Q 21.99 cm3/tr Q
P T

250b

CA EE EA(O) EL EI ET EF
Niveau level
Average moyen:: N 125 μm
104L absolu
absolute
S S
R Capacity
Capacité 128 liter
128 litres Réserve direction

(21/0/2011) 70-02-M186EN
 4 Hydraulic schematic diagrams
MT-X 1030 ST Série 4-E3

HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
CA Suction strainer S9 VDAV Front steering cylinder DE K4 90x45 c80x2
CSP Counterbalance valve I32/C34/I39 VI Tilt cylinder DE A34 120x60 c416
CSD Double counter balance valve K38 VL Lifting cylinder DE G33 140x70 c720
CPD Double counterbalance valve I28 VSD Right stabilizer cylinder DE I26 125x60 c200
D 6 component valve O38 VSG Left stabilizer cylinder DE I30 125x60 c200
EE Inlet section S23 VT1 DE telescoping cylinder I40 100x60 c2850
EA Optional equipment component S25 VT2 DE telescoping cylinder G40 80x50 c2850
ESD Right stabilizer section S27 VVT(O) Ts locking cylinder DE (option) A22 60x45 c183
ESG Left stabilizer section S29
EL Lifting component S31
EI Tilt component S34
ET Telescoping component S36
EF Closing component S38
D3 3 position steering valve A13
Position 1: short steering
NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
Position 2: front wheel steering
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
Position 3: crab position 3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
EVTF(O) Boom head electrovalve (option) E23
FDAV Front disc brake K2
FDAR Rear disc brake K14
FR Return filter O15
M Turbo i.c. engine Q9 1104d-44t/1104d-44ta
Idle speed 930 rpm
70

Nominal loaded speed 2200 rpm

Full unladen speed (1104d-44t) 2380rpm
Full unladen speed (1104d-44ta) 2400 rpm
MC Master cylinder E3
N Level S6
P Pump equipment Q6
PAAV Front attachment plug C21
PAAV(O) Front attachment plug (option) C20
PD Steering pump C12
PFR(O) Trailer brake plug integrated in the vafr (option) G9
PRF(O) Leakage return plug (option) E17
PP Pressure port O22
R Hydraulic tank S7
RLF Brake fluid tank C4
SCFR(O) Circuit selector (trailer brake option) E8
VACM(O) Movement cut-off valve (option) O17
VAFR(O) Trailer brake valve (option) G8
VAI Insulation valve A26
VASS Stabilizer safety valve K28
VC Compensation cylinder DE E34 110x55 c310
VD Discharge valve O12
VDAR Rear steering cylinder DE K12 90x45 c80x2

70-02-M186EN (21/06/2011)
 Hydraulic schematic diagrams 5
MT-X 1030 ST Série 4-E3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

VVT(O)
2 A B T
3 1 VAI
A A
3 2 1 VI
AV AR
D3
3 2 1
P
C1 C2
PAAV
CSP 315b
+15
0
R L
PD 200b 200b
C C2 C
C4
110b
RLF PAAV(O)
C1 C3 V1 V2
200 cm3/tr
VC

LS 140b
B2 B1
SCFR(O) PRF(O) EVTF(O)
E P1 P2 E
V1 V2
T P
S
MC Ø1
OPTION
Option
FREINAGE
Trailer brake
REMORQUE P T

G Y VL VT2 G
VAFR(O)
N LS
PFR Ø 0.7
B C1 C2
CSP 315b +15
0

VSD VSG
C1 C2 C1 C2 C1 C2
110b
I 280b 100b 100b 280b CSP 335b I
V1 V2
CPD
V1 V2 V1 V2 VT1
VASS 30b
FDAV VDAV FDAR B B
VDAR V1 V2

70
A A C1 C2
K CSD 300b 300b K
ES. AR.
ES. AV.

V1 V2

M M

PP
C VD
O VACM(O) P A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 A6 B6 T O
P1 FR D
280b 280b 190b 190b
EF CF OUT
6b
5b

LS
M 10 μm absolute
absolu 1ère monte
first mount
P
15 μm absolute
absolu PR.spares parts
IN
Q 21.99 cm3/tr Q
21.99 cm3/tr P T

250b

CA
level : N
Niveau moyen:
Average 125 μm EE EA ESD ESG EL EI ET EF
S 104L absolu
absolute S

R Capacity
Capacité128
128liter
litres Réserve direction

(21/0/2011) 70-02-M186EN
 6 Hydraulic schematic diagrams
70

70-02-M186EN (21/06/2011)
 HYDRAULIC COMPONENTS LOCATION

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

70

(21/06/2011) 70-03-M186EN
 2 Hydraulic components location

HYDRAULIC CIRCUITS KEY

Hydraulic circuits:
1 - Main 4 - Jib supply compensation
2 - Jib 5 - Stabilisator
3 - Telescoping lift 6 - Steering

Representation on circuit Electric

Item Designation code
1 2 3 4 5 6 equivalence
CA SUCTION STRAINER x
CSP COUNTER BALANCE VALVE (Lift cylinder) x
CSP COUNTER BALANCE VALVE (Tilt cylinder) x
CSP COUNTER BALANCE VALVE (VT) x
D DISTRIBUTOR x x x x
D3 3 POSITION STEERING VALVE x
Ess.Ar. REAR AXLE x
Ess.Av. FRONT AXLE x
FR FILTRE RETOUR x
MA HYDRAULIC CONTROL LEVER x
P HYDRAULIC PUMP x x
PD STEERING PUMP x
R HYDRAULIC TANK x x
VC COMPENSATING CYLINDER x
VD DISCHARGE VALVE x
VI TILT CYLINDER x
70

VL LIFT CYLINDER x
VSD RIGHT HAND STABILIZER CYLINDER x
VSG LEFT HAND STABILIZER CYLINDER x
VT TELESCOPING CYLINDER x
VT1 1 TELESCOPING CYLINDER x
VT2 2 TELESCOPING CYLINDER x

70-03-M186EN (21/06/2011)
 Hydraulic components location 3

1 - MAIN HYDRAULIC CIRCUIT

MT-X732 S.D-E3

MA
VD

CA

FR

70
MT-X1030 S Turbo S4-E3

MA

VD
D

CA

FR

(21/06/2011) 70-03-M186EN
 4 Hydraulic components location

2 - BOOM HYDRAULIC CIRCUIT

MT-X732 S.D-E3

VI

CSP
70

MT-X1030 S Turbo S4-E3

VI
CSP

70-03-M186EN (21/06/2011)
 Hydraulic components location 5

3 - TELESCOPING LIFT HYDRAULIC CIRCUIT

MT-X732 S.D-E3

VT

VL

CSP CSP

70
MT-X1030 S Turbo S4-E3

VT

VL

CSP

CSP

(21/06/2011) 70-03-M186EN
 6 Hydraulic components location

MT-X1030 S Turbo S4-E3

CSP
VT1

CSP
VT2
70

70-03-M186EN (21/06/2011)
 Hydraulic components location 7

4 - BOOM COMPENSATION HYDRAULIC CIRCUIT - BOOM ALIMENTATION

MT-X732 S.D-E3

VC

70
MT-X 1030 S T S4-E3

VC

(21/06/2011) 70-03-M186EN
 8 Hydraulic components location

5 - STABILISATOR HYDRAULIC CIRCUIT

MT-X 1030 S T S4-E3

CSP

VSG

CSP

CSP VSD

CSP

6 - STEERING HYDRAULIC CIRCUIT

70

ESS.AV.

PD

D3
R

ESS.AR.

70-03-M186EN (21/06/2011)
 HYDRAULIC CONTROL AND ADJUSTMENT

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

70
– 2 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE COMPLETE ROD . . . . . . . . . . . 5
– 3 - DISASSEMBLY AND RE-ASSEMBLY OF PISTON AND CYLINDER HEAD . . . . . 8
– 4 - DIS-ASSEMBLY AND RE-ASSEMBLY OF PISTON SEALS . . . . . . . . . . . . . . . . 10
– 5 - DIS-ASSEMBLY AND RE-ASSEMBLY OF CYLINDER HEAD SEALS . . . . . . . . . 11
– 6 - APPLICATION OF THREAD LOCKING COMPOUND . . . . . . . . . . . . . . . . . . . . 12

(24/06/2011 70-04-M186EN
 2 Hydraulic control and adjustment

HYDRAULIC PRESSURE CONTROL

1 - MAIN CIRCUIT

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

Checking and adjusting the pressure relief valve is carried out 1

with full flow and the engine at maximum revolutions.

Checking and adjusting the anti-shock valves is carried out with
minimum flow and the engine operating at 1000 rpm.

Checking and adjusting the main pressure relief valve.

- Connect the pressure gauge to the test port. B
- With the engine at maximum revolutions, activate the accessory
70

circuit control and read the pressure shown on the gauge.

- Main pressure relief valve: 240 bar (MT-X 732)
3
Checking and adjusting anti-shock valves.
2
1
- Prior to carrying out these procedures it is necessary to increase 4
the setting on the main limiter 4 (Fig. B) by 50 bar.
- Connect the pressure gauge to the pressure port.
- Keep the relevant cylinder at the end of its travel and read the
pressure shown on the gauge (See table of values).
- When adjustment operations have been completed, return he
main limiter to: 240 bar (MT-X 732)

Table of values MT-X 732

Key hydraulic rod side

circuit diagram
anti-shock valve
tilt EI piston side 280 b
compensation EI rod side 190 b
anti-shock valve EL piston side 280 b
lifting
anti-shock valve ET piston side 190 b piston side
telescoping

70-04-M186EN (24/06/2011)
 Hydraulic control and adjustment 3

2 - STEERING CIRCUIT

Parts required :

- 1 Manometer 0/400 bar 549 885

or 1 digital manometer (0-600 bar) 554 118
- 1 test hose 549 888
- 1 connector 173 567
- 1 test point 58 181 A

STEERING
Procedure PUMP

- Using a T connector connect the pressure

gauge to the pressure out pipe on the main
pump (port P).

- With the engine operating at maximum

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

70
MAIN PUMP

(24/06/2011 70-04-M186EN
 4 Hydraulic control and adjustment

TIGHTENING TORQUES MT-X

N2 J1
J2

N1

R P O Q
M

J
N

B
A
Q H
B

A A G
K B D
N H
G

H D
C
G L
K2 E D
F

C I

K1
C
I
S

Ref Designation Number Size (mm) tightening torque

(N.m)
70

A Vis lever 3 5 24
B Nut M10 3 17 24
C Locknut 5 13 24
D screw M12x20 3 18 24
E screw M5x12 2 4 6,6
F screw M5x14 8 4 6,6
G screw M5x18 6 4 6,6
H screw M5x25 3 4 6,6
I screw M8x25 5 6 24
J Complete pressure relief valve 1 27 42
J1 1 27 42
Complete pressure relief valve (detail)
J2 1 13 24
K Complete pressure relief valve 2 24 42
K1 2 24 42
Complete pressure relief valve (detail)
K2 2 17 24
L Lever M12x200 2 19 42
M Screw hood 24 4 6,6
N Complete pressure relief valve 2 24 42
N1 2 24 42
Complete pressure relief valve (detail)
N2 2 22 24
O Valve 6 8 42
P Plug 1 8 42
Q Plug 2 12 42
R Screw 6 6 24
S Lever 1 19 42
T Lever 1 19 42
70-04-M186EN (24/06/2011)
 Hydraulic control and adjustment 5

CYLINDER DISASSEMBLY
1 - HYDRAULIC LIFTING SYSTEMS STANDARDS

Extracts from Standard Pr EN 1459 - 1997

5.5.2 Hydraulic lifting system

5.5.2.1 Load retention

The lowering of a load due to a leak in the hydraulic system must not exceed 150mm
in 10 minutes with the boom positioned in its least favorable position and the oil at
its normal working temperature.

The average speed of tilt forward caused by oil leaks must not exceed half a degree
per minute.

6.3.3 Static load - leak test (elevation, tilt)

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

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

70
A1 Dis-assembly

- Place the cylinder in a vice fitted with soft jaws.

Rod 1 Body 3 - Tighten the vice moderately only to avoid deforming the
cylinder body.
- Loosen the cylinder head 2 (Fig. A1) with a hook wrench.
- If you have difficulty loosening the cylinder head consult the
paragraph “Dis-assembly” in chapter 6.
- Completely unscrew the cylinder head 2 (Fig. A1).
- Remove the entire rod from the cylinder body.
Cylinder head 2 Piston 4

NOTE: FOR LONG CYLINDERS

- Pull the rod out by 200 mm maximum.

A2 - Unscrew the cylinder head half of one turn (Carry out this
operation very progressively, without any abrupt movements).
- Pull the rod out by some 2500 mm.
- Support the rod by its end to reduce stress on the cylinder
head (Fig. A2).
- Continue to unscrew the cylinder head. If resistance is felt
raise and lower the rod to reduce friction.

Never force the cylinder head to unscrew it as this

might cause it to seize.
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 6 Hydraulic control and adjustment

Inspection

- De-grease and clean the cylinder interior.

- Carry out a visual inspection of the cylinder body. It should be
free of scrapes, burrs, rust etc.

Re-fitting

- Use a brush to apply hydraulic oil to the piston seals.

- Replace the complete rod in the cylinder body 3 (Fig. A1).
- Take care not to damage the piston seals when taking them
past the thread on the piston body.

NOTE: Tightening the cylinder head is different depending on

if the cylinder body has a flange or not (Fig. A4). Follow
the following instructions.CYLINDER WITHOUT FLANGE

- Apply hydraulic oil to the external sealing rings of the cylinder

head.
A3
- Apply Loctite 222 thread locking compound (see chapter 6)
Cylinder
to the cylinder head (Fig. A3).
Thread
head - Screw the cylinder head on.
locking
compound Rod - Tighten using a hook wrench and torque wrench (see
torque, Fig. A4) or use the procedure of tightening by angle
70

(Fig. A4).
- Turn the rod one rotation to ensure the seals are correctly in
place.

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

Comments

- We recommend testing the cylinder before re-fitting it to the

telehandler.
- Move the rod in and out several times.

70-04-M186EN (24/06/2011)
 Hydraulic control and adjustment 7

A4
A4-1
Procedure for tightening the cylinder head using the angle
method.

- Tighten the cylinder head until it is in contact with the

X cylinder body.
- Put a mark 1 (Fig. A4-1) on the cylinder body and on the
cylinder head.
1 - Further tighten the cylinder head over the distance X (Fig. A4-
1 2).
- Engage the flange with one of the nocks on the cylinder
head.

Tightening torques for cylinder head

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A4-2 flange
THREAD A Ø BORE B Ø FLANGE C TIGHTENING TORQUE DISTANCE X
M43 x 200 40 51 200 à 250 N.m
M48 x 200 45 56 200 à 250 N.m
M53 x 200 50 61 200 à 250 N.m
M58 x 200 55 66 250 à 300 N.m
M63 x 200 60 72 250 à 300 N.m
M66 x 200 63 75 250 à 300 N.m
M68 x 200 65 78 250 à 300 N.m
M73 x 200 70 82 300 à 350 N.m
M78 x 200 75 89 300 à 350 N.m
M83 x 200 80 94 350 à 400 N.m
M88 x 200 85 99 350 à 400 N.m
M93 x 200 90 107 350 à 400 N.m
M98 x 200 95 109 400 à 450 N.m
M104 x 200 100 119 400 à 450 N.m
M109 x 200 105 124 400 à 450 N.m
M114 x 200 110 129 450 à 500 N.m
M124 x 200 120 139 450 à 500 N.m
M129 x 200 125 139 450 à 500 N.m
M134 x 200 130 149 450 à 500 N.m 8 à 9 mm
140 450 à 500 N.m 8,5 à 9,7 mm
150 450 à 500 N.m 9,2 à 10,5 mm
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3 - DISASSEMBLY AND RE-ASSEMBLY OF PISTON AND CYLINDER HEAD

B1 Dis-assembly
Cylinder head 2
Piston 7
- Place the rod in a vice fitted with soft jaws.
Rod 1 Piston 4 Screw 6
Nut 5 - Tighten sufficiently to stop the assembly rotating.
- Loosen the nut 5 (Fig. B1) and completely
unscrew it using a ring spanner. Or, depending
on model, remove the set screw 6 (Fig. 1) with an
Allen key.

NOTE: The set screw 6 (Fig. B1) is fitted with Loctite

and it is locked by striking it with a cold
B2
chisel.
Cylinder head 2
- Dis-assemble the piston 4 (Fig. B2) by pulling it
Rod 1 Piston 4
manually or, depending on model, by unscrewing
the piston 7 (Fig. B1) with a hook wrench.

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

Rod 1
along the rod.

B4 Inspection

Cylinder head 2 - Check the rod for straightness using a dial gauge
Rod 1 along its entire length (Fig. B4).
- Check for flaking, corrosion or scraping on the rod.

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 Hydraulic control and adjustment 9

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

NOTE: B6

• The set screw must be secured with Loctite 243,

PISTON TIGHTENING TORQUE see chapter 6.
1400 • Set screw torque = 20 N.m.
1200 • Use a cold chisel to knock the metal back over the
1000
set screw.
Torque (N.m)

800

600

400

200

70
M20 M30 M40 M50 M60 M70
Thread

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

C1
NOTE:
Sealing rings Never use sharp or cutting tools (screwdrivers, blades etc.)
for fitting or removing seals. It is recommended to work on
workbenches free of swarf.

Dis-assembly

- Remove the piston seals (Fig. C1 or C2).

- Caution, ensure you do not damage the edges or bottom of
the seal grooves.
O-ring
Inspection

C2 - Degrease and clean the piston.

Sealing rings
- Inspect bottoms and sides of the seal grooves for
smoothness and the absence of scrapes.
- The grooves must be clear of foreign bodies.

Re-fitting

- Position the seals as per Fig. C1 or C2.

- When fitting outside seals, expand them sufficiently to slide
them into their grooves, taking care not to break them.
- The inside seal must be fitted by hand.
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O-ring

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5 - DIS-ASSEMBLY AND RE-ASSEMBLY OF CYLINDER HEAD SEALS

D1
NOTE:
Anti-extrusion seal 2
O-ring 3 O-ring 1
Never use sharp or cutting tools (screwdrivers, blades etc.)
for fitting or removing seals. It is recommended to work on
workbenches free of swarf.

Dis-assembly

- Remove the seals from the cylinder head.

- Caution, ensure you do not damage the edges or bottom
Oil scraper 4 of the seal grooves.

Rod seal 5 Inspection

- Degrease and clean the cylinder head.

D2 - Inspect bottoms and sides of the seal grooves for
smoothness and the absence of scrapes.
Seal
- The grooves must be clear of foreign bodies.
- Slide the bare cylinder head over and along the piston
rod. Slide it all the way along the rod.
- The clearance should not be too great, but neither should
it jam.

Re-fitting

70
Plug 1
- Place the seals as per Fig. D1. The lips on the rod seal
should face the pressure side.
- When fitting the rod seal, start by engaging it in the
groove while holding it in place, possibly with your
D3 thumb or possibly with a plug 1 (Fig. D2) with no sharp
Drift 2 edges.
- Push it into its groove with the other hand or with a
smooth drift 2 (Fig. D3). If it proves difficult to fit, soak it
in hydraulic oil at 50°C before fitting.

Seal - Fit the oil scraper ring 4 (Fig. D1) using a mallet and a
pad. The O-rings 1 and 3 (Fig. D1) and the anti-extrusion
seal Ref. 2 (Fig. D1) are fitted by hand.

Plug 1

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 12 Hydraulic control and adjustment

6 - APPLICATION OF THREAD LOCKING COMPOUND

Characteristics

Loctite 222 low strength threadlocker

Application to cylinder head threads

No activator
Fixture time 10 - 30 min.
Cure time 3 - 6 hours
(Pressurizing the cylinder)
With Loctite N Activator
Fixture time 10 - 20 min.
Cure time 2 - 4 hours
(Pressurizing the cylinder)
Shear strength 1,5 - 4 N/mm2

Loctite 243 medium strength threadlocker

Applied to M8 bolts for securing pistons.

No activator
Fixture time 10 - 20 min.
Cure time 3 - 6 hours
(Pressurizing the cylinder)
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With Loctite N Activator

Fixture time 5 - 15 min.
Cure time 2 - 4 hours
(Pressurizing the cylinder)
Shear strength 5 - 7,5 N/mm2

Dis-assembly

If parts fitted with threadlocker cannot be undone with normal tools, it is recommended to heat the
threadlocked zone to 250°C. For this a hot air gun is recommended, rather than a gas torch.

Note

If the temperature is close to 0°C when parts are fitted, it is recommended to use Loctite Activator.
This brings with it the added benefit of a reduction in cure time.

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 HYDRAULIC SPECIFIC TOOLING

pages

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

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

70

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Hydraulic specific tooling

BASIC MANOMETER BOX

This box contains all the components required for

measuring pressure on all Manitou products.

1 2 3 3 4 5 5 6
70

8 7

Basic manometer box .................................................................................549671

Consisting of:

1. 1 Manometer 1/9 bar ..............................................................549882

2. 1 Manometer 0/40 bar ............................................................549883
3. 2 Manometers 0/60 bar ..........................................................549884
4. 1 Manometer 0/400 bar ..........................................................549885
5. 2 Manometers 0/600 bar ........................................................549886
6. 4 Standard hoses ....................................................................549887
7. 2 Hoses for Maniscopic ...........................................................549888
8. 7 Manometer ports ..................................................................549889

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Hydraulic specific tooling

DIGITAL MANOMETER BOX

FUNCTIONS:

• Mano Function: the following combinations can be

displayed:

- Temperature upstream to +/- 2°C

- Pressure upstream P1 with its min. and max. (700 bar
in class 0.1)
- Pressure downstream P2 with its min. and max. (700
bar in class 0.1)
- Differential pressure dP=P1-P

• Hold Function: the operator is able to freeze the display

panel so that he can take notes whenever he wishes

• Unit Function: the operator can change the measurement

unit whenever he wishes (bar, psi, kPa, mCe).

• Tare Function: enables offset to zero

• Leakage test Function: enables the pressure variation to

be measured over a programmed time period

• Recording Function: A max. of 16000 values may be

recorded. The sampling period can be configured.

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• Zero Function: zero is carried out on 2 sensors

Digital Manometer box ...............................................................................662187

Consisting of:

1. 1 dP HP 700 bar Mano digital manometer

2. 1 measurement hose DN2 1215/1620, L = 1,5m, 630 bar
3. 2 measurement hoses DN2 1620/1620, L = 1,5m, 630 bar
4. 2 1620 Manometer adaptors

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Hydraulic specific tooling
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70-09-M186EN (24/06/2011)