TRANSMISSION

20

- TRANSMISSION SCHEMATIC DIAGRAMS

- TRANSMISSION COMPONENTS LOCATION
- TRANSMISSION CONTROL AND
ADJUSTMENT
- TRANSMISSION REMOVAL
- TRANSMISSION REFIT
- SPECIFIC TRANSMISSION TOOLING

647030DE/EN

(PUMP SERIES A4VG)

M

- TRANSMISSION CHARACTERISTICS AND

SPECIFICATIONS

647031FR/EN

(ENGINE A6VM SERIE 63)

M

- TRANSMISSION CONTROL AND

ADJUSTMENT

647375

(GEAR DANA SERIES 360/59)

M

647379

(GEAR DANA SERIES

357/216)

20

TRANSMISSION SCHEMATIC DIAGRAMS

page
REXROTH HYDROSTATIC TRANSMISSION LAYOUT FORWARD MOVEMENT . . . .3
REXROTH HYDROSTATIC TRANSMISSION LAYOUT REVERSING MOVEMENT . . .4

(06/06/2012)

20-02-M184EN

TRANSMISSION SCHEMATIC DIAGRAMS

20

20-02-M184EN

(06/06/2012)

TRANSMISSION SCHEMATIC DIAGRAMS

REXROTH HYDROSTATIC TRANSMISSION LAYOUT FORWARD MOVEMENT

Legend:
High pressure
Low pressure
Control air

Drainage pressure

PF

Loading pressure
Suction pressure

S.

T P

20

B A

MC

EV(S27)
EV(S28)

VSLR

Return to discharge
70

CR

See 70 - hydraulics Chapter

Hydraulic manifold

EV(S21) Forward movement solenoid valve

EV(S22) Reversing solenoid valve
EV(S27) Fast speed solenoid valve
EV(S28) Slow speed solenoid valve

CR

FORWARD MOVEMENT

VCLR
3 bar

EV
(S22)

EV
(S21)

b
R

T1

Rear disk brakes

FDAV

Front disk brakes

M.

I.C. engine

MC

Brake pump

M.I.

Engine with variable displacement

PF

Brake pedal

P.I.

Hydrostatic pump

R.

Oil tank

RAD.

Radiator

S.

Oil tank

VCLR

Slow-fast control cylinder

VSLR

Slow-fast selector valve

a
Ps

T2

Fa

Fe

MB
B

450bar

M.

FDAV

FDAR

450bar

35bar

440bar

P.I.

A
X1

X2

M.I.

MA

FDAR
X1

X2

70

FRONT
AXLE

RAD.

REAR
AXLE

R.

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20-02-M184EN

TRANSMISSION SCHEMATIC DIAGRAMS

REXROTH HYDROSTATIC TRANSMISSION LAYOUT REVERSING MOVEMENT

Legend:
High pressure
Low pressure

20

Control air
EV(S27)
EV(S28)

VSLR

MC

B A

Drainage pressure

PF

Loading pressure
Suction pressure

S.

T P

Return to discharge
70

CR

See 70 - hydraulics Chapter

Hydraulic manifold

EV(S21) Forward movement solenoid valve

EV(S22) Reversing solenoid valve
EV(S27) Fast speed solenoid valve
EV(S28) Slow speed solenoid valve

CR

REVERSING MOVEMENT

VCLR
3 bar

EV
(S22)

EV
(S21)

T1

Rear disk brakes

FDAV

Front disk brakes

M.

I.C. engine

MC

Brake pump

M.I.

Engine with variable displacement

PF

Brake pedal

P.I.

Hydrostatic pump

R.

Oil tank

RAD.

Radiator

S.

Oil tank

VCLR

Slow-fast control cylinder

VSLR

Slow-fast selector valve

b
R

FDAR

Ps

T2

Fa

Fe

MB

450bar

M.
450bar

FDAV

35bar

440bar

P.I.

A
X1

X2

FDAR

M.I.

MA

X1

X2

70

FRONT
AXLE

RAD.

REAR
AXLE

R.

20-02-M184EN

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20

TRANSMISSION COMPONENTS LOCATION

page
MHT 10120 HYDROSTATIC TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC TRANSMISSION 4

(20/02/2012)

20-03-M184EN

TRANSMISSION COMPONENTS LOCATION

20

20-03-M184EN

(20/02/2012)

TRANSMISSION COMPONENTS LOCATION

20

MHT 10120 HYDROSTATIC TRANSMISSION

Rear axle
Hydrostatic
pump
Gearbox

Radiator

Hydrostatic
motor

Shaft

Front axle

(20/02/2012)

20-03-M184EN

TRANSMISSION COMPONENTS LOCATION

20

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

Rear axle
Hydrostatic
pump
Gearbox

Radiator

Hydrostatic
motor
Shaft

Front axle

20-03-M184EN

(20/02/2012)

20

TRANSMISSION CONTROL AND ADJUSTMENT

page
CHECKING THE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
PRESSURE CONTROL POINTS ON A4VG 71 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CONTROL AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BOOST PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CASING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A6VM 107 MOTOR PRESSURE CONTROL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SWITCHING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING AND ADJUSTING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TRANSMISSION ADJUSTMENT POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
A4VG PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A6VM MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHECKS BEFORE STARTING UP THE TRANSMISSION OR AFTER
A REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
STARTING UP: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHECKING AND ADJUSTING THE BOOST PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
ADJUSTING THE PUMP MECHANICAL 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
CHECKING THE ADJUSTMENT: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECKING AND ADJUSTING THE START OF REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . .9
BEGINNING OF THE REGULATION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHECKING AND ADJUSTING THE END OF REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
CHECK: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
END OF THE REGULATION:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CHECKING AND ADJUSTING THE HP LIMITERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
ADJUSTING THE HP LIMITERS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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20-04-M184EN

TRANSMISSION CONTROL AND

ADJUSTMENT

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

A. CHECK MINIMUM DISPLACEMENT (MAX SPEED): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. CHECKING THE BEGINNING OF THE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
C. MAX DISPLACEMENT: (MAX. TRACTION FORCE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REGULATING THE HYDROSTATIC TRANSMISSION PRESSURES . . . . . . . . . . . . . . . . . . . . . .13

20

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

ADJUSTING THE BOOST PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REGULATING THE VEHICLE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CHECKING PILOT PRESSURE PS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TROUBLE-SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
PUMP/MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
MANITOU - HYDROSTATIC TRANSMISSION REGULATION CHART A4VG--DA / A6VM--DA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

20-04-M184EN

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TRANSMISSION CONTROL AND

ADJUSTMENT

CHECKING THE PRESSURE

PRESSURE CONTROL POINTS ON A4VG 71 PUMP
Control air socket

20

Casing pressure connections

HP pressure socket

Boost pressure socket

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

2 Connectors 165711 (Ref. 55) (M 14 x 150)

2 Pressure gauge sockets 58181 (Ref. 49) (M 8 x 100)
2 Pressure gauges (0 - 40 bar)
2 Test flexible tubes 549887

HIGH PRESSURE
2 Pressure gauge sockets 477484 (Ref. 51) (M 12 x 1.5)
2 Pressure gauges (0 - 600 bar)
2 Test flexible tubes 549887
BOOST PRESSURE
1 Connector + pressure gauge socket assembly 199175 (Ref. 53.1) (M 18 x 1.5)
1 Pressure gauge (0 - 40 bar)
1 Test flexible tubes 549887
CASING PRESSURE
1 Pressure gauge socket 477484 (Ref. 51) (M 12 x 1.5)
1 Pressure gauge (0 - 40 bar)
1 Test flexible tubes 549887
(24/02/2012)

20-04-M184EN

TRANSMISSION CONTROL AND

ADJUSTMENT

A6VM 107 MOTOR PRESSURE CONTROL POINTS

20

HP socket

Switching pressure
socket

NOTE: The actual assembly of the motor differs from that shown in the Figure since it is rotated
through 180.
Necessary (the case must contain basic pressure gauge sockets Ref. 549671 + Hydromatik Kit Ref. 209572)
20-09 Special tools for the transmission
HIGH PRESSURE
1 Pressure gauge socket 58189 (Ref. 52) (M 14 x 150)
1 Pressure gauge (0 - 600 bar)
1 Test flexible tubes 549887
SWITCHING PRESSURE
1 Pressure gauge socket 477484 (Ref. 51) (M 12 x 150)
1 Pressure gauge (0 - 600 bar)
1 Test flexible tubes 549887

20-04-M184EN

(24/02/2012)

TRANSMISSION CONTROL AND

ADJUSTMENT

CHECKING AND ADJUSTING THE TRANSMISSION

TRANSMISSION ADJUSTMENT POINTS
A4VG PUMP

DR valve

20

Disk mechanical 0
adjuster
HP Valve
DA regulator valve
DA regulation start adjuster
Supercharger valve

HP Valve
Adjustment cam of plate
regulation end

A6VM MOTOR
Minimum displacement
adjuster screw (do not
disrupt the adjustment)
Switching
regulation
adjuster screw

(24/02/2012)

20-04-M184EN

TRANSMISSION CONTROL AND

ADJUSTMENT

CHECKS BEFORE STARTING UP THE TRANSMISSION OR AFTER A REPAIR

20

Check the oil level in the tank.

Check to ensure that all the connections of the hose pipes are tightened properly.
Check the electrical connections of the solenoid valves.
Ensure that the circuit is filled properly, and at the same time fill the oil filter before fitting it.
Check to ensure the control air tubes are fitted correctly:
X1 pump with X2 motor,
X2 pump with X1 motor.
In all the cases, the control air connection is opposite to the HP hose pipes. (For example: if the HP
hose pipe for forward movement is to the RH of the motor, the forward movement control air hose
pipe will be to the LH, and the other way around for the reversing).
Connect the boost pressure socket pressure gauges - control air - HP - casing.
STARTING UP:
For reasons of safety, place the vehicle on stands.
Let the I.C. engine run without moving the vehicle to bleed the circuit properly. (disconnect the wire
of the stop solenoid valve on the injection pump).
Make sure that the boost pressure increases at least to 15 bar on running the starter motor.
"DO NOT start up the transmission with insufficient boost pressure, as there is risk of wear of the
transmission".
Reconnect the stop solenoid valve on the injection pump.
Run the I.C. engine for a few minutes at minimum speed. Boost pressure 35 - 40 bar.
Unstability of the needle indicates air intake (emulsified oil in the tank, and cavitation noise of the
transmission).
Inverter in neutral in the two HP circuit inlets. The pressure is equal to the boost pressure.
Heat the oil in the circuit by accelerating progressively (keep the hand brake locked to allow
measurement of the HP with load blocked).
When the oil is at a minimum temperature of 50- 60 check the engine speed: at minimum, at
maximum without load. (See technical specifications).

20-04-M184EN

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TRANSMISSION CONTROL AND

ADJUSTMENT

20

CHECKING AND ADJUSTING THE BOOST PRESSURE

The A4VG 71 series pump is equipped with an adjustable limiter.

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

FE boost pressure socket

(24/02/2012)

20-04-M184EN

TRANSMISSION CONTROL AND

ADJUSTMENT

20

ADJUSTING THE PUMP MECHANICAL 0

Connect two small scale (40 - 100 bar) pressure gauges on the HP pressure sockets.
Make sure the hand brake is disengaged and that the vehicle is on stands (wheels suspended in the air):
Engine running at minimum speed.
Speed inverter in neutral.
Slacken the lock nut of the mechanical "0" adjuster screw (hex wrench 19). Turn the screw gently
(using an Allen wrench 6) clockwise until the lowest HP variation is seen.
Make a marking in the direction of the wrench.
Operate in the anticlockwise direction to change the HP in the other direction of movement.
Make a marking in the direction of the wrench.
Then turn the adjuster screw until the wrench is in the centre of the two markings made earlier.
Tighten the lock nut.
CHECKING THE ADJUSTMENT:
Connect the 2 pressure gauges on the HP sockets 600 bar scale:
1 - Check the beginning of the adjustment in forward movement and reversal with an rpm counter.
Accelerate the I.C. engine gently - selector in forward movement - until the wheels start moving.
Measure the I.C. engine rotation speed.
Repeat the operation with reversing movement.
Check the two I.C. engine rotation speeds which must be identical.
2 - Check the Hp and corresponding control air - wheels blocked - forward movement inverter selector
- accelerate the I.C. engine progressively up to max. speed.
Measure the forward movement and forward movement control air HP pressures.
Repeat the operation with reversing movement; the values must be identical.

20-04-M184EN

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TRANSMISSION CONTROL AND

ADJUSTMENT

20

CHECKING AND ADJUSTING THE START OF REGULATION

DA regulator valve

DA regulation start adjuster

BEGINNING OF THE REGULATION:

Measure the I.C. engine speed at the minimum which must be ~ 850 min-1.
The regulation must begin at 1050 min-1. To proceed with regulation, act on the adjuster screw
present on the end of the regulation start valve:
Tighten the screw to delay the beginning of forward movement.
Slacken it to advance the beginning of forward movement.
Modification of the beginning of the adjustment of the forward movement point shifts the field of
regulation of the pump. The end of the adjustment must be systematically checked 400 bar for the
full speed of the motor in question. (1600 - 1800 min-1).
Checking the regulation is equal to checking the "mechanical 0" - Point 2.

(24/02/2012)

20-04-M184EN

TRANSMISSION CONTROL AND

ADJUSTMENT

10

20

CHECKING AND ADJUSTING THE END OF REGULATION

End of regulation
CHECK:

The vehicle must be on stands - brakes locked and inching (brake) in by pass.
Inverter in forward movement.
Motor at minimum, check the rotation speed of the I.C. engine.
Accelerate progressively and check the speed of the I.C. engine (1600 - 1800 min-1) when the HP for
forward movement reaches 400 bar.

END OF THE REGULATION:

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

20-04-M184EN

This adjustment must be made on the bench by the

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

(24/02/2012)

TRANSMISSION CONTROL AND

ADJUSTMENT

11

CHECKING AND ADJUSTING THE HP LIMITERS

Turn the screw (Ref. 1) through one turn.

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

1
2

MB

MA

ADJUSTING THE HP LIMITERS:

A4VG 71 DA series Pump

Remove the lead sealing A.

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

B
2

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20-04-M184EN

20

Checking and adjustment of the HP limiters is done with the forklift truck on stands (wheels suspended
in mid-air) and the brakes locked.
The inching valve must be bypassed to eliminate the pump discharge function.
Overcalibrate the DR valve -Ref. 1- to check the actual calibration value of the HP limiters.

12

TRANSMISSION CONTROL AND

ADJUSTMENT

ADJUSTING THE A6VM MOTOR

20

A. CHECK MINIMUM DISPLACEMENT (MAX SPEED):

The checking is done with: the truck on level ground, engine running at max. speed, moving forwards,
Connect the two 600 bar scale pressure gauges as shown in the Figure. At max. vehicle speed, the
two pressures must be equal. Taking into account the ratio of the control cylinder surface, this means
that the engine is switched in minimum displacement.
For actual checking of the speed (check the vehicle's technical specifications).

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

High pressure
1

(Ref. 1) MINIMUM DISPLACEMENT

ADJUSTER SCREW (tightening the screw will
move the disk downwards. The displacement
will thus increase while the speed will
decrease).

Adjuster screw
for beginning of
the regulation of
switching

Switching pressure

B. CHECKING THE BEGINNING OF THE ADJUSTMENT

When the vehicle is at max. speed, press progressively on the brakes to increase the HP (the inching
valve must be bypassed).
Observe the two pressures. When the HP reaches a value of 260 - 280 bar, the switching pressure will
drop and the HP will continue to increase up to the DR valve calibration value.
The beginning of the adjustment can be set by means of the adjuster screw on the engine.
C. MAX DISPLACEMENT: (MAX. TRACTION FORCE)
To make this adjustment, the lift truck must be blocked (brakes locked).
The checking is done at max. engine speed with the vehicle moving forwards.
The switching pressure (side of the greater cross-section of the control cylinder) must be close to
zero bar.
If necessary, adjust the adjuster screw (tighten to increase the switching pressure, slacken to decrease
the pressure).
The traction force must be checked (at the hook) (for the values, see Use and Maintenance Manual).
20-04-M184EN

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TRANSMISSION CONTROL AND

ADJUSTMENT

13

20

REGULATING THE HYDROSTATIC TRANSMISSION PRESSURES

Mechanical zero
M a - M b
pressure test

Beginning of adjustment
DA regulator
valve

"G" boost pressure

adjustment
HP valves
512 bar

(24/02/2012)

20-04-M184EN

14

TRANSMISSION CONTROL AND

ADJUSTMENT

Mb

Ma

Position the 600 bar scale pressure gauge connector on one of

the pressure test sockets positioned on the hydrostatic pump
marked as "Ma" (Ref. 1) or "Mb" (Ref.2).

20

GENERAL PRESSURE REGULATION

Regulate the general pressure by acting on adjuster (Ref. 3)

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

ADJUSTING THE BOOST PRESSURE

Position a T-union (Ref. 4) on the hydrostatic pump connector

marked with "G", remove the cover (Ref. 6) of the adjuster (Ref.
7) and fit the connector of a 60 bar scale pressure gauge (ref.
5) on the union.

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

With the engine running at maximum speed and the oil
temperature about 60 degrees, the boost pressure must be
about 35 bar and must vary by not more than 1 or 2 bar between
the minimum and maximum engine rpm.
7

20-04-M184EN

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TRANSMISSION CONTROL AND

ADJUSTMENT

15

REGULATING THE VEHICLE START

Set the I.C. engine speed at about 100rpm more than the
minimum.
Regulate the adjuster (Ref. 8) at the end of the DA valve to
obtain vehicle start up.
Note: This adjustment must be made with the oil cold.

20

CHECKING PILOT PRESSURE "PS"

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

Position a T-union (Ref. 10) on the hydrostatic pump connector,

and fit on the union the connection of a 60 bar scale pressure
gauge (Ref. 11).
The pilot pressure must be between 25 and 30 bar.
11
9
10

Pressure

Value

Maximum

440 bar

Boost pressure

35 bar

Control air

25 / 30 bar

(24/02/2012)

20-04-M184EN

16

TRANSMISSION CONTROL AND

ADJUSTMENT

TROUBLE-SHOOTING
PUMP/MOTOR
Suction
pressure

20

Measuring point

S A4VG pump

Oil tank filter

Suction pipe

Type of oil
Oil temperature

Direction of rotation

Cause
Heat exchanger

Supply pressure
G A4VG pump
Measuring point
Supply pressure
Cause

A6VM MOTOR

Auxiliary pump
Supercharger valve
Wear
Heat exchanger oil temperature

Wear
Washing valve

By-pass valve
Oil temperature
RPM
I.C. engine pump connection (coupling)

Control air

Measuring point
Suction pressure
Supply pressure
Cause

X1/X2 A4VG pump

A6VM MOTOR

Choke valves
DA regulator valve/inching valve/throttle
valve
Pressure cut
Proportional solenoid valve/magnet

High pressure MA/MB A4VG pump

Measuring point
Suction pressure
Supply pressure
Cause

Control piping

A6VM MOTOR

HP-DR valve
Pressure cut
Shifting distribution plate
Wear
Heat exchanger oil temperature

Not blocked
Coupling
Brake
Wear-leaked oil
Oil temperature
Heat exchanger

I.C. engine
Min/Max rpm
Diesel filter
Air filter
Power
20-04-M184EN

(24/02/2012)

TRANSMISSION CONTROL AND

ADJUSTMENT

17

VEHICLE

The diesel engine runs

The vehicle does not stop

A4VG PUMP
Proportional solenoid valve
Beginning of regulation

Cause

The vehicle movement is delayed

20

Mechanical zero

A4VG PUMP
Choke valves
Suction pressure

Cause

Control air
Beginning of regulation
Inching
Strong overload of
I.C. engine

A4VG PUMP

A6VM MOTOR
DR valve
Wear

Beginning of
regulation
Inclination
angle

Shifting distribution
plate

Cause

I.C. engine
Injection pump
Fuel filter
Insufficient
traction force

A4VG PUMP

VEHICLE
Shifting distribution
plate
Pressure cut

A6VM MOTOR
W h e e l
diameter

Control air
Cause

Beginning of
regulation
Control
air piping
X1/X2
Magnet
Inclination
angle

I.C. engine
RPM
Max. transfer
speed is not
reached

VEHICLE

A4VG PUMP
Control air

A6VM MOTOR
Transmission

Inching

Wheels

Cause

Beginning of
regulation
Magnet
Inclination
angle
CC screw
adjustment

I.C. engine
RPM

(24/02/2012)

20-04-M184EN

20-04-M184EN

WITH LOAD
ADJUSTMENT
INCHING VALVE

WITH LOAD
CHECK END OF
REGULATION

WITH LOAD
ADJUSTING
CUTTING VALVE DR

WITH LOAD
ADJUSTING HIGH
PRESSURE HP
RAISING THE
CUTTING VALVE DR

MAXIMUM

MAXIMUM

END OF REGULATION

END OF REGULATION

FORWARD
MOVEMENT

REVERSING
MOVEMENT

FORWARD
MOVEMENT

REVERSING
MOVEMENT

MAXIMUM

MAXIMUM

REVERSING
MOVEMENT

FORWARD
MOVEMENT

MAXIMUM

MAXIMUM

BEGINNING OF REGULATION

MAXIMUM

BEGINNING OF REGULATION

MAXIMUM

MINIMUM

I.C.
ENGINE
SPEED

FORWARD
MOVEMENT

REVERSING
MOVEMENT

FORWARD
MOVEMENT

NEUTRAL

ADJUSTING
BOOST
PRESSURE

WITHOUT LOAD
ADJUSTING
BEGINNING OF
REGULATION

INVERTER
POSITION

SITUATION
TRUCK +
checks/adjustments
MADE
FORWARD
REVERSING
MOVEMENT

CONTROL AIR
PRESSURE

HYDROSTATIC PUMP
BOOST
PRESSURE
ZIONE

TYPE OF HYDROSTATIC PUMP

PUMP SERIAL No.
:
TYPE OF HYDROSTATIC MOTOR:
MOTOR SERIAL No.
:

FORWARD
MOVEMENT
REVERSING

HIGH PRESSURE
HP
CASING
DI
WASHING
PRESSURE
UNDERPRESSURE
SUCTION
PUMP

FORWARD
MOVEMENT
WITH LOAD
AT MAX SPEED

FORWARD MOVEMENT
AT
THE TIME OF
SWITCHING
AT MAX SPEED

WITHOUT LOAD
IN MOVEMENT
FORWARD
MOVEMENT
AT MAX SPEED

TRUCK STATE
+
INVERTER
POSITION

HIGH
PRESSURE
HP

CONTROL
CYLINDER
PRESSURE

TOWING FORCE.................................................kg

...................................km/h

MAX. SPEED WITHOUT LOAD:

OIL TEMPERATURE........................................C

TYPE OF OIL

HYDRAULIC ENGINE

4 beginning of regulation: .............. 5 end of regulation 400b: ........ 6 max with load M.av:

I.C. ENGINE SPEED min-1 :

TYPE OF VEHICLE
:
SERIAL No.
:
NUMBER OF HOURS :

1 minimum: ......... 2 max without load: ... 3 max hydraulically loaded:

INSPECTION DATE
DEALER'S NAME
:
TECHNICIAN'S NAME

MANITOU - HYDROSTATIC TRANSMISSION REGULATION CHART - A4VG--DA / A6VM--DA

20
18
TRANSMISSION CONTROL AND
ADJUSTMENT

(24/02/2012)

20

TRANSMISSION REMOVAL

page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC TRANSMISSION . . . . . .4
DISASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISMANTLING THE HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MHT 10120 HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
DISASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DISMANTLING THE HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(23/02/2012)

20-06-M184EN

TRANSMISSION REMOVAL

DISASSEMBLING THE HYDROSTATIC TRANSMISSION

GENERAL INFORMATION

20

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

PREPARATION AND SAFETY INSTRUCTIONS

Position the truck on a level surface.

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

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

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

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

2
5

3
4

20-06-M184EN

(23/02/2012)

TRANSMISSION REMOVAL

Slacken the screws (Ref. 6) and remove the brackets (Ref. 7)

which block the universal shaft (Ref. 8) on the gearbox.
8

20

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

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

(23/02/2012)

Plug all the hydraulic openings of the pumps and motors

to prevent impurities from contaminating the hydraulic
circuit.

20-06-M184EN

TRANSMISSION REMOVAL

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

HYDROSTATIC TRANSMISSION
DISASSEMBLING THE HYDROSTATIC PUMP
1

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

20

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

Secure the pumps by means of belts or ropes to an overhead

crane, passing these through the opening under the boom.
Slacken the screws (Ref. 5) which secure the pump (Ref. 3) to
the I.C. engine.

20-06-M184EN

(23/02/2012)

TRANSMISSION REMOVAL

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

20

Slacken the screws (Ref. 6) and remove the washers (Ref. 7) to

dismantle the hydrostatic pump (Ref. 3) from the movements
pump (Ref. 4).

7
6

DISMANTLING THE HYDROSTATIC MOTOR

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

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

(23/02/2012)

20-06-M184EN

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

20

Remove the vacuum gauge (Ref. 8).

Slacken the screws (Ref. 9) from the flanges (Ref. 10).

10

10

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

11

20-06-M184EN

(23/02/2012)

TRANSMISSION REMOVAL

Slacken the remaining screws (Ref. 9) remove the flanges (Ref.

10) and remove the pipes (Ref. 12 and 13)..
10

12

9
9
10

20

13

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

14

and in the upper part.

14

14

Secure the engine (Ref. 1) to an overhead crane by means of

ropes and remove it from the vehicle.

(23/02/2012)

20-06-M184EN

TRANSMISSION REMOVAL

MHT 10120 HYDROSTATIC TRANSMISSION

DISASSEMBLING THE HYDROSTATIC PUMP

20

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

5
4
3

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

20-06-M184EN

(23/02/2012)

TRANSMISSION REMOVAL

DISMANTLING THE HYDROSTATIC MOTOR

20

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

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

5
5
3
6

2
3
6

(23/02/2012)

20-06-M184EN

TRANSMISSION REMOVAL

20

10

20-06-M184EN

(23/02/2012)

20

TRANSMISSION REFIT

page
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
REASSEMBLING THE HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MHT 10120 HYDROSTATIC TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
REASSEMBLING THE HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(23/02/2012)

20-07-M184EN

TRANSMISSION REFIT

REASSEMBLING THE HYDROSTATIC TRANSMISSION

PREPARATION AND SAFETY INSTRUCTIONS

20

Position the truck on a level surface.

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

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

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

HYDROSTATIC TRANSMISSION
REASSEMBLING THE HYDROSTATIC MOTOR
1

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

overhead crane.

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

and in the lower part.

20-07-M184EN

(23/02/2012)

TRANSMISSION REFIT

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

6
6
5

20

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

Fit the remaining screws (Ref. 6) on the flanges (Ref. 5).

6
5

(23/02/2012)

20-07-M184EN

TRANSMISSION REFIT

20

Refit the vacuum gauge (Ref. 8).

Fit the connector (Ref. 9) of the vacuum gauge on the oil filter.
Refit the unions (Ref. 10) on the control air valve (Ref. 11).
10

11

10

Refit the connector (Ref. 12) on the exhaust manifold (Ref. 13).

12

13

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

14

20-07-M184EN

(23/02/2012)

TRANSMISSION REFIT

REASSEMBLING THE HYDROSTATIC PUMP

1

Fit the hydraulic system pump (Ref. 2) on the hydrostatic pump

(Ref. 1) by means of the screws and washers (Ref. 3 and 4).
3

20

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

these under the vehicle.
1

Lift the pumps by means of belts or ropes and an overhead

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

(23/02/2012)

20-07-M184EN

TRANSMISSION REFIT

20

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

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

Reposition the universal shaft (Ref. 8) under the vehicle and

screw it to the rear axle by means of the screws (Ref. 9) and nuts
(Ref. 19) using a 140 Nm tightening torque.
9
10

20-07-M184EN

(23/02/2012)

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

12

20

11

15

15

16

16

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

15
14

16
13

(23/02/2012)

20-07-M184EN

TRANSMISSION REFIT

MHT 10120 HYDROSTATIC TRANSMISSION

REASSEMBLING THE HYDROSTATIC MOTOR

20

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

5
5
3
6

2
3
6

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

20-07-M184EN

(23/02/2012)

TRANSMISSION REFIT

REASSEMBLING THE HYDROSTATIC PUMP

20

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

5
4
3

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

(23/02/2012)

20-07-M184EN

10

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

20

19

17

Use an extremely clean funnel and wipe the upper part

of the oil drum before starting with the filling.

The oil level is correct when it reaches the red dot shown on
the rod (Ref. 17).
Visually inspect for leaks on the tank and pipes.
18

20-07-M184EN

(23/02/2012)

20

SPECIFIC TRANSMISSION TOOLING

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

(20/02/2012)

20-09-M184EN

SPECIFIC TRANSMISSION TOOLING

STANDARD BOX
1

Standard
7
4

20

3
4

6
5

Maniscopic
8

Ref.

Number

549 671

Standard box

549 882

1/9 bar Pressure gauge

549 883

0/40 bar Pressure gauge

549 884

0/60 bar Pressure gauge

549 885

0/400 bar Pressure gauge

549 886

0/600 bar Pressure gauge

549 887

Hose

549 888

Hose for MANISCOPIC

549 889

Fitting for pressure gauge

20-09-M184EN

Description

QT.

(20/02/2012)