Página 1 MANUEL DE RÉPARATION REPARATURANLEITUNG MANUAL DE REPARACIÓN MANUALE RIPARAZIONE This document has been printed from MANITOU BF Head o ce: 430, Rue de l’Aubinière 44150 Ancenis - FRANCE Share capital: 39,548,949 euros 857 802 508 RCS Nantes Tel: +33 (0)2 40 09 10 11...
Página 2 MANITOU BF. Any violation of the aforementioned may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU BF and may not be used without express and formal authorization.
Página 3 Contents GENERAL INSTRUCTIONS AND SAFETY NOTICE CHARACTERISTICS AXLE ASSEMBLY - AXLE DISMANTLING AXLE 416 - 100 TELESCOPIC BOOM DISASSEMBLY OF THE JIB HYDRAULIC HYDRAULIC DIAGRAM ELECTRICITY ELECTRIC DIAGRAM TRANSMISSION OPERATION (ADJUSTMENT) OF TRANSMISSION...
Página 4 CHARACTERISTICS BT 420 Série 3-E2 BT 425 Série 3-E2 0-1-M127 EN 28 / 01 / 2006...
Página 6 BT 420 S 3-E2 - BT 425 S 3-E2 ÉRIE ÉRIE BT 420 S 3-E2 - BT 425 S 3-E2 ÉRIE ÉRIE...
Página 7: Cooling Circuit
CHARACTERISTICS BT 420 Série 3-E2 - BT 425 Série 3-E2 I.C. ENGINE - Type PERKINS 404C-22 - Number of cylinders 4 in line - Number of strokes - Inlet system Natural aspiration - Injection system Indirect - Ignition sequence 1.3.4.2. - Clearance of rocker valve (cold) .
Página 8 YDROSTATIC TRANSMISSION HYDROSTATIC PUMP MANNESMANN REXROTH - Type A4 VG 40 DA variable displacement pump with automatic power governor - Gear reverser Electromagnetic 12V MAIN PUMP - Displacement MAX. 40 cm3/r MIN. 0 cm3/r - Flow rate at 2990 rpm MAX. 120 l/min MIN.
Página 9: Hydraulic Circuit
CHARACTERISTICS BT 420 Série 3-E2 RONT TYRE DIMENSIONS PRESSURE TYRE LOAD PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND 11,5/80-15,3 12PR AS FARM 5,3 BAR FRONT UNLADEN 837.5 KG KG/CM2 KG/CM2 CONTINENTAL / TUBELESS FRONT LADEN...
Página 10 PECIFICATIONS - Level of sound pressure in the driver's cab LpA (accordng to standard prEN 12053 : 1995) - Level of sound power in the LwA environment (according to directive 2000/14 CE guaranteed) - Speed of movement of lift truck in standard configuration on horizontal ground .
Página 11 CHARACTERISTICS BT 425 Série 3-E2 RONT TYRE DIMENSIONS PRESSURE TYRE LOAD PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND 11,5/80-15,3 12PR AS FARM 5,3 BAR FRONT UNLADEN 837.5 KG KG/CM2 KG/CM2 CONTINENTAL / TUBELESS FRONT LADEN...
Página 12 PECIFICATIONS - Level of sound pressure in the driver's cab LpA (accordng to standard prEN 12053 : 1995) - Level of sound power in the LwA environment (according to directive 2000/14 CE guaranteed) - Speed of movement of lift truck in standard configuration on horizontal ground .
Página 13 DIMENSIONS AND LOAD CHART : BT 420 / BT 425 Série 3-E2 BT 420 Série 3-E2 BT 425 Série 3-E2 50° 50° 0.5m 0.5 m 40° 40° 1500 3.90 3.86 30° 30° 20° 20° 10° 10° 0° 0° -2° -2° 2.86 2.35 1.90...
Página 14 BT 420 BT 425 Série 3 Série 3 1100 mm 1100 mm 1800 mm 1800 mm 1065 mm 896 mm 925 mm 3550 mm 3381 mm 3410 mm 4650 mm 4481 mm 1146 mm 1146 mm 1105 mm 1105 mm 235 mm 235 mm 235 mm...
Página 15 FILTERS CARTRIDGES AND BELTS I.C. ENGINE I.C. ENGINE OIL FILTER ALTERNATOR BELT Part number : 702577 Part number : 703259 Change : 500 H Change : 1000 H DRY AIR FILTER CARTRIDGE AUTOMATIC VACUUM-CLEANING PRE-FILTER Part number : 227959 (OPTION) Clean : 50 H* Part number : 240334 Change : 500 H*...
Página 16 Mechanical transmission for 20 L. 546330 axles and boxes SAE 80W90 55 L. 546221 209 L. 546220 FRONT WHEELS REDUCERS 2x0,55 Liter MANITOU Oil 2 L. 499237 Mechanical transmission for 20 L. 546330 axles and boxes SAE 80W90 55 L. 546221 209 L.
Página 17 LUBRICANTS AND FUEL ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER JIB PADS MANITOU Grease 1 Kg. 161 590 Multipurpose NLGI 2 GREASING OF THE JIB MANITOU Grease 1 Kg. 554 973 Multipurpose HD NLGI 2 5 Kg. 554 974...
Página 18 DÉMONTAGE PONT 416 - 100 30-3-9 FR 13 / 07 / 2001...
Página 24 D1240203 MFG. BY CLARK-HURTH COMPONENTS S.P.A. 38062 Arco (Trento) MADE IN ITALY D1240011 D1240204...
Página 29 Silicone Silicona Grasso (al Litio) Grasa (al Litio)
Página 33 F1241535 F1241536 F1241537 F1241538 F1241539 F1241540...
Página 35 F1241541 F1241542 F1241543 F1241830 16 17 F1241545 F1241546...
Página 37 D1240198 F1241547 F1241548...
Página 39 16 17 F1241549 F1241550 F1241551 F1241552 F1241943 F1241640...
Página 41 F1241555 F1241556 F1241557 F1241554 F1241556 F1241594...
Página 43 F1241558 F1241559 F1241560 F1241561 F1241562 F1241563...
Página 45 F1241564 F1241565 F1241566 F1241567 F1241568 F1241569...
Página 47 F1241570 F1241571 D1240205 F1241572 F1241573 F1241574...
Página 49 F1241575 D1240199...
Página 51 F1241576 F1241577 F1241578 F1241579 F1241580 F1241581...
Página 53 F1241572 F1241582 F1241583 F1241584 F1241566 F1241831...
Página 55 F1241567 F1241585 F1241586 F1241583 F1241587 F1241561...
Página 57 F1241560 D1240206 F1241643 D1240207 F1241574 F1241573...
Página 59 F1241588 F1241589 F1241552 D1240208...
Página 61 F1241535 F1241536 F1241590 F1241591 D1240200...
Página 63 F1241592 F1241590 F1241594 F1241593...
Página 65 F1241832 F1241833 F1241834 F1241835 F1241836 F1241837...
Página 67 F1241595 F1241838 F1241839...
Página 69 F1241542 F1241545 F1241597 F1241598 F1241599 F1241600...
Página 71 10 11 F1241601 F1241602 F1241603 F1241604 F1241605 F1241606...
Página 73 F1241607 F1241608 D1240201...
Página 75 F1241608 F1241609 F1241610 F1241605 10 11 F1241611 F1241612...
Página 77 F1241613 F1241614 F1241615 F1241616 D1240239 F1241617...
Página 79 F1241598 F1241615 F1241619 F1241620 9 10 F1241621 F1241622...
Página 81 F1241623 F1241602 D1240202...
Página 83 25 mm 25 mm 25 mm F1241624 F1241625 8 mm 8 mm 8 mm F1241626 D1240212 F1241627 D1240213...
Página 85 F1241939 D1240214 T20C T20A T20B T20D F1241495 D1240216 F1241628 F1241630...
Página 87 F1241629 F1241631 F1241615 F1241614 T..F1241618 F1241632...
Página 89 F1241633 D1240350 17 18 F1241938 F1241635 22 23 F1241633 F1241636...
Página 91 F1241598 F1241597 F1241637 F1241638 F1241639...
Página 93 2 3 4 F1241618 F1241617 F1241542 F1241840...
Página 95 Ø30 Ø30 Ø35 Ø20 Ø35.10 Acciaio Ni Cr Mo 5 Cementazione Temperato Ø34 0.80 Ø34 Ø20 Ø38.8 Ø35.10 D1240255 Ø48 Ø20 Ø58.5 Ø34.8 D1240258 D1240259 Ø19.01 05 x 45° Ø30 Ø30 05 x 45° Ø5.25 Ø40 5 x 45° 1 x 45° 5 x 45°...
Página 96 Ø158.5 Ø134 Ø90 Ø85 Ø50 n° 4 fori Ø50 n° 4 fori 1 x 45° Ø22 Ø22 Ø148 Ø127.6 D1240253 D1240254 Ø40 Ø30 3 x 15° 3 x 30° + 0.1 Ø29.9 -- 0.2 Ø25 + 0.1 Ø34.9 Ø80 -- 0.2 Ø52 Ø96 + 0.1...
Página 97 Ø40 Ø30 Ø12 5 x 45° Ø60 2 x 45° Ø90 2.5 x 20° 45° Ø135 + 0.1 29.8 Ø150 -- 0 Ø45 Ø160 Ø54 Ø179 D1240247 Ø188 D1240248 Ø100 Ø79.4 Ø45 Ø22.5 n° 2 pezzi Ø18.5 n° 2 pezzi D1240263 D1240261...
Página 98 Ø13.5 n° 2 pezzi D1240262 2 x 45° 2 x 30° + 0.0 1 x 45° Ø79.9 0.02 -- 0.05 Ø38.5 Ø41 + 0.1 Ø59.8 -- 0 Ø80 Ø89 -- 0.1 D1240246 D1240249 + 0.1 Ø8 -- 0.0 D1240265...
Página 99 0.5x45° 0.5x45° 12° 45' 12° 45' 2x45° n° 2 pezzi n° 2 pezzi D1240260 Temp Acciaio Ni Cr Mo 5 Zigrinato Forzato 2 x 45° 0.5 x 45° D1240245...
Página 100: Disassembly Of The Jib
DISASSEMBLY OF THE JIB 50-3-M127 EN 28 / 01 / 2006...
Página 102 CONTENTS - ELEMENTS OF THE JIB P 5 à 9 - ADJUSTMENT AND IMMOBILIZATION OF THE JIB WEAR PADS P 1 et 11 - REMOVAL OF THE TILTING CYLINDER P 12 et 13 - REMOVAL OF THE CARRIAGE P 14 et 15 - REMOVAL OF THE TELESCOPE P 16 et 17 - REMOVAL OF THE TELESCOPING CYLINDER...
Página 104 HEAD OF THE JIB BT 420 Série 3-E2 - BT 425 Série 3-E2...
Página 105 CARRIER BT 420 Série 3-E2...
Página 106 CARRIER BT 425 Série 3-E2...
Página 107 FOOT OF THE JIB BT 420 Série 3-E2 / BT 425 Série 3-E2...
Página 108 JIB HYDRAULIC CIRCUIT BT 420 Série 3-E2 / BT 425 Série 3-E2...
Página 109 - Check that the screws are fully tightened to the end of the thread. - Apply MANITOU locking compound Réf. 187526 on the nuts item. 1 (Fig. B). - Replace and tighten the nuts item. 1 (Fig. B) (tightening torque 92.6 N.m ± 25 %).
Página 110 - Check that the screws are tightened right to the end of the thread. - Apply MANITOU locking compound Réf. 187526 on the nuts item. 1 (Fig. D).. - Replace and tighten the nuts item. 1 (Fig. D) (tightening torque 92.6 N.m ± 25 %).
Página 111 REMOVAL OF THE TILTING CYLINDER REMOVAL OF THE TILTING CYLINDER - Set the forklift truck on a horizontal surface with the handbrake engaged and the gear reverser set to neutral. - Set the jib horizontal - Hold the carriage in position with lifting equipment as shown in figure A. - Stop the engine.
Página 112 REASSEMBLY OF THE TILTING CYLINDER - Reassemble by carrying out in reverse order the operations described in the chapter “REMOVAL OF THE TILTING CYLINDER”, also complying with the following instructions. Fig. E - Check that the tilting cylinder is in good working order. - Clean the articulation axles (item.
Página 113 REMOVAL OF THE CARRIAGE REMOVAL OF THE CARRIAGE - Hold the carriage in position with lifting equipment as shown in figure A. - Remove the circlips retaining the tilting cylinder’s shaft plate and then expel the shaft (Item. 1 Fig. B) If there is an accessory fitted, hold the carriage in position with weges (risk of tipping over).
Página 114 REASSEMBLY OF THE CARRIAGE - Reassemble by carrying out in reverse order the operations described in the chapter “REMOVAL OF THE CARRIAGE”, also complying with the following instructions. Fig. D - Clean the articulation axles (item. 3 Fig. D) before reassembling and apply a thin layer of grease (See chapter: CHARACTERISTICS OF THE LIFT TRUCK in group 0 - GENERAL).
Página 115 REMOVAL OF THE TELESCOPE REMOVAL OF THE TELESCOPE - Set the forklift truck on a horizontal surface with the handbrake engaged and the gear reverser set to neutral. - Telescope the jib to the maximum. - Set the jib horizontal. Stop the engine. Release the hydraulic pressure by operating the levers on the distributor.
Página 116 - Remove the pads and the shims from the head of the jib, taking care to mark them and their position for subsequent re-installation. - Remove the telescope completely from the front of the jib (Fig. D). Ensure the the whole assembly remains balanced and take care when drawing out the four hoses attached to the telescope (Fig.
Página 117 REMOVING THE TELESCOPING CYLINDER REMOVING OF THE TELESCOPING CYINDER - Set the forklift truck on a horizontal surface with the handbrake engaged and the gear reverser set to neutral. - Telescope slightly to access the shaft in the head of the telescoping cylinder and then expel it (Item.
Página 118 REASSEMBLY OF THE TELESCOPING CYLINDER - Reassemble by carrying out in reverse order the operations described in the chapter “REMOVAL OF THE TELESCOPing CYLINDER”, also complying with the following instructions. Fig. E - Clean the articulation axles (item. 6 Fig. E) before reassembling and apply a thin layer of grease (See chapter: CHARACTERISTICS OF THE LIFT TRUCK in group 0 - GENERAL).
Página 119: Hydraulic Diagram
HYDRAULIC DIAGRAM 70-6-721670 EN 28 / 01 / 2006...
Página 121 CONTENTS HYDRAULIC DIAGRAM BT 420 S3-E2 / BT 425 S3-E2...
Página 125 HYDRAULIC DIAGRAM BT 420 Série 3-E2 - BT 425 Série 3-E2 Accessory connector Hydrostatic motor TH7 valve (inching) Suction and return filter Hydrostatic pump I.C. engine Oil tank Hydraulic main pump Oil cooler Steering pump manual Vale bank Telescoping cylinder Compensation cylinder Tilting cylinder Lifting cylinder...
Página 127 m/bc K2 FREIN bl/sa K1 CHARGE J4 FILTRE AIR J3 COLM. FILTR. H. J2 T°C EAU J1 PRESS° HUILE MOTEUR...
Página 129: Operation (Adjustment) Of Transmission
OPERATION (ADJUSTMENT) OF TRANSMISSION 75-8-M127 EN 28 / 01 / 2006...
Página 131 CONTENTS Technicals Characteristics......................1 and 2 Hydrostatic Circuit ........................Hydrostatic Diagram........................Pump A4VG/DA ........................5 to 12 Operation of TH7 Valve (inching) ....................Hydrostatic Transmission Adjustment Sheet ................
Página 133 • Max. capacity at 3000 rpm..............25,2 l./mn HYDRAULIC MOTOR - BT 420 - BT 425 • Hydraulic motor Réf. MANITOU : 208700 MOT-A6VM 80DA/63W-VZB027B(0327 Fixed displacement....................Maximum travel speed (front)................Km/h Maximum travel speed (rear)................. Km/h BT 420 - BT 425 Drawbar pull in load condition ................
Página 134 • Maximum pressure in housings............. bar à 50° C • By-pass set pressure on oil coder ............Recommended oil type in the transmission ............MANITOU HYDRAULIQUE ISO 46 Capacity of transmission oil tank + equipment ............Ref. of transmission filter cartridge : 686 237...
Página 135 HYDROSTATIC TRANSMISSION CIRCUIT BT 420 - BT 425...
Página 136 HYDROSTATIC DIAGRAM BT 420 - BT 425...
Página 137 PUMP A 4 VG / DA PUMP A 4 VG / DA...
Página 138 A4VG | RDE 92 003-01-R/03.03 Instructions de réparations - Vanne basse pression (pression de gavage) Adjustment instructions - Low pressure valve (Boost pressure) Attention! Attention! Respectez les règles de sécurité! Observe safety regulations! Remarque! Note: Réajustage uniquement à la température de service. Readjusting only at operating temperature.
Página 139 RDE 92 003-01-R/03.03 | A4VG Instructions générales de réparations - Position d’origine hydraulique Adjustment instructions - Mechanical "zero position" Attention! Respectez les règles de sécurité! Raccordez les deux chambres de commande avec un flexible de taille nominal 6. Evitement des signaux résiduels du système hydraulique.
Página 140 A4VG | RDE 92 003-01-R/03.03 Instructions générales de réparations - Position d’origine hydraulique Adjustment instructions - Hydraulic "zero position" Raccordez les jauges de pression à X et X . Réglez la position d’origine de sorte que, lorsqu’un bloc est entraîné, les deux jauges de pression indiquent la même pression.
Página 141 RDE 92 003-01-R/03.03 | A4VG Instructions de réparations - HP - valves (Haute pression) et coupure de pression Adjustment instructions - HP- valves (High pressure) and pressure cut-off Attention! Respectez les règles de sécurité Druckabschneidung Vanne HP sans fonction Bypass Pressure cut-off 1.
Página 142 A4VG | RDE 92 003-01-R/03.03 Instructions de réparation - Valve Bypass Adjustment instructions - Bypass valve Véhicule équipé d’une transmission hydrostatique pure ou d’un Vehicle with a pure hydrostatic transmission or with a hydrostatic entraînement hydrostatique avec boîte à engrenage sans drive with gear box without free wheel position.
Página 143 RDE 92 003-01-R/03.03 | A4VG Instructions de réparation - Commande DA Adjustment instructions - DA control Attention ! Respectez les règles de sécurité ! Vérifiez les données de réglage. Pendant la procédure de contrôle, la température de service doit généralement être maintenue à un niveau constant.
Página 144 A4VG | RDE 92 003-01-R/03.03 Instructions de réparation - Commande DA Adjustment instructions - DA control Attention! Observe safety regulations! Check setting data. Operating temperature should be generally kept constant during the checking procedure. Start prime mover, idle speed. Block position Drive direction switch - "0“...
Página 145 INCHING VALVE OPERATION (TH 7 Valve) With the foot off the inching pedal, the tappet 1 is fully in and the oil passes unhindered between port P (pilot pressure in) and port A (pilot pressure out). The oil flows freely through the opening 3 in the slide valve 2.

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Página 7: Cooling Circuit

Página 9: Hydraulic Circuit

Página 100: Disassembly Of The Jib

Página 119: Hydraulic Diagram

Página 129: Operation (Adjustment) Of Transmission

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