Manitou MLT 625-75 H ST3B MT 625 H COMFORT ST3B MT 625 H TURBO ST3B MT 625 HA 75K ST3B S1 Repair Manual 647469 – PDF DOWNLOAD

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Manitou MLT 625-75 H ST3B MT 625 H COMFORT ST3B MT 625 H TURBO ST3B MT 625 HA 75K ST3B S1 Repair Manual 647469 – PDF DOWNLOAD

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DESCRIPTION:

Manitou MLT 625-75 H ST3B MT 625 H COMFORT ST3B MT 625 H TURBO ST3B MT 625 HA 75K ST3B S1 Repair Manual 647469 – PDF DOWNLOAD

PREAMBLE:

This chapter deals with the general instructions and safety notice during inspection and maintenance
work.
Other instructions and warnings are indicated in each chapter concerned.
In order to reduce accident risks, make sure to:
– Follow the instructions in the truck operating and maintenance manual.
⇒ This manual should be found in all trucks.
– Please follow all safety instructions.
– Use the appropriate tools for any work to be performed.
– Use original Manitou spare parts.
Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily
harm and even death.
An efficient, dependable and profitable combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.

TABLE OF CONTENTS:

Manitou MLT 625-75 H ST3B MT 625 H COMFORT ST3B MT 625 H TURBO ST3B MT 625 HA 75K ST3B S1 Repair Manual 647469 – PDF DOWNLOAD

MLT 625-75 H ST3B, MT 625 H COMFORT ST3B, MT 625 H TURBO ST3B, MT 625 HA 75K ST3B S1 1
HOW TO USE THIS REPAIR MANUAL ? 3
GLOSSARY 4
SUMMARY 7
GR00 – GENERAL, CHARACTERISTICS AND SAFETY 9
GENERAL INSTRUCTIONS AND SAFETY NOTICE 11
PREAMBLE 12
MAINTENANCE POSITION 13
RULES FOR MAINTENANCE 14
GENERAL CHARACTERISTICS AND SPECIFICATIONS 17
CHARACTERISTICS AND FLUIDS 18
DIMENSIONS 18
GENERAL LOCATION 19
LOCATION OF NAME AND IDENTIFICATION PLATE 20
GENERAL CONTROL AND ADJUSTMENT 21
STANDARD TIGHTENING TORQUES 22
METRIC – IMPERIAL UNIT CONVERSION 23
GR10 – ENGINE 25
ENGINE CHARACTERISTICS AND SPECIFICATIONS 27
CHARACTERISTICS 28
ENGINE CIRCUITS FLOW DIAGRAM 29
FUEL SYSTEM : OVERVIEW OF FUEL SYSTEM 30
COOLING SYSTEM : BOTTOM BYPASS SYSTEM 30
EXHAUST SYSTEM : AFTER TREATMENT DEVICES 31
ENGINE COMPONENTS LOCATION 33
ENGINE ELEMENTS 34
ENGINE CONTROL AND ADJUSTMENT 35
PREPARATION AND SAFETY INSTRUCTIONS 36
FAN GRILL REMOVAL 36
ALTERNATOR BELT REMOVAL / REFIT 36
ALTERNATOR REMOVAL / REFIT 36
STARTER REMOVAL 37
FAN REMOVAL 37
RADIATOR REMOVAL 37
REPLACING THE FAN BELT (MLT) – (up to n°980031 – except: n°977248 & n°977225) 38
REPLACING THE FAN BELT (MLT) – (from n°980032 – and n°977248 & n°977225) 40
AIR CONDITIONER BELT REMOVAL / REFIT (OPTION) 42
FAN HYDRAULIC ENGINE REMOVAL / REFIT (MLT) 42
REMOVAL 42
REFITTING 44
TESTING 44
WATER PUMP REMOVAL / REFIT 44
REMOVAL 44
REFITTING 45
EXHAUST REMOVAL 45
ENGINE FUSE BOX REMOVAL 45
ENGINE ECU REMOVAL 46
FAN CONTROL OPERATION (MLT) 47
LOCATION 47
I – FUNCTION 47
II – DESCRIPTION OF FAN HYDRAULIC ENGINE 48
III – THE THREE MODES OF OPERATION 49
IV – CONTROL 50
ENGINE REMOVAL 53
PREPARATION AND SAFETY INSTRUCTIONS 54
ENGINE REMOVAL 55
A – BONNET AND DRAINING 55
B – HOSES 55
C – ELECTRICITY 55
D – DISMANTLING 56
ENGINE REFIT 59
PREPARATION AND SAFETY INSTRUCTIONS 60
ENGINE REFIT 60
ORDER OF INSTALLATION OF SILENT BLOCKS 60
LEVELS – VERIFICATION – TESTING 60
SPECIFIC ENGINE TOOLING 61
FAN BELT FITTING TOOL 62
ELECTRONIC TENSION METER 62
GR20 – TRANSMISSION 63
TRANSMISSION SCHEMATIC DIAGRAMS 65
DRIVE TRAIN 66
MT 625 H TURBO ST3B / MT 625 H / HA COMFORT ST3B 67
HYDROSTATIC TRANSMISSION IN FORWARD GEAR 67
HYDROSTATIC TRANSMISSION IN REVERSE GEAR 69
HYDROSTATIC TRANSMISSION COOLING 71
MLT 625-75 H ST3B 72
HYDROSTATIC TRANSMISSION IN FORWARD GEAR 72
HYDROSTATIC TRANSMISSION IN REVERSE GEAR 74
HYDROSTATIC TRANSMISSION COOLING 76
TRANSMISSION COMPONENTS LOCATION 77
HYDROSTATIC TRANSMISSION CIRCUIT 78
MT 625 H TURBO ST3B / MT 625 H / HA COMFORT STB 78
MLT 625-75 H ST3B 78
TRANSMISSION CONTROL AND ADJUSTMENT 79
HYDROSTATIC TRANSMISSION PRESSURE TEST PORT LOCATION 80
PRESSURE TEST PORT VALUES 80
TOWING PROCEDURE 81
TIGHTENING TORQUES 82
TRANSMISSION REMOVAL 83
COMPONENTS LOCATION 84
PREPARATION AND SAFETY INSTRUCTIONS 84
HYDROSTATIC PUMP 85
MT 625 H TURBO ST3B / MT 625 H / HA COMFORT ST3B 85
MLT 625-75 H ST3B 86
HYDROSTATIC MOTOR 87
TRANSMISSION REFIT 89
COMPONENTS LOCATION 90
PREPARATION AND SAFETY INSTRUCTIONS 90
HYDROSTATIC PUMP 90
LEVELS – VERIFICATION – TESTING 91
HYDROSTATIC MOTOR 91
SPECIFIC TRANSMISSION TOOLING 93
BASIC MANOMETER BOX 94
DIGITAL MANOMETER BOX 95
GR50 – BOOM 115
BOOM CHARACTERISTICS AND SPECIFICATIONS 117
DUPLEX BOOM 118
BOOM COMPONENTS LOCATION 119
INDEX OF COMPONENT CODES 120
LOCATION OF THE DUPLEX BOOM MAIN COMPONENTS 120
BOOM CONTROL AND ADJUSTMENT 121
DUPLEX BOOM REMOVAL 122
GENERAL INFORMATION 122
PREPARATION AND SAFETY INSTRUCTIONS 122
TELESCOPE CYLINDER REMOVAL 123
BOOM T1 REMOVAL 126
DUPLEX BOOM REFIT 127
PREPARATION AND SAFETY INSTRUCTIONS 127
BOOM T1 REASSEMBLY 128
SHIM INSTALLATION RECOMMENDATIONS 131
TIGHTENING TORQUE 132
REFITTING THE TELESCOPE CYLINDER 133
BOOM REMOVAL 137
DUPLEX BOOM 138
GENERAL INFORMATION 138
PREPARATION AND SAFETY INSTRUCTIONS 138
PLATFORM HARNESS 141
Removal 141
Refit 142
BOOM REFIT 143
DUPLEX BOOM 144
GENERAL INFORMATION 144
PREPARATION AND SAFETY INSTRUCTIONS 144
SPECIFIC BOOM TOOLING 147
PIPE END PIECES 148
GR40 – BRAKE 99
BRAKE CHARACTERISTICS AND SPECIFICATIONS 101
SERVICE BRAKE / PARKING BRAKE 103
BRAKE CONTROL AND ADJUSTMENT 105
BRAKE AND INCHING PEDAL ADJUSTMENT 106
BLEEDING PROCEDURE 108
SPECIFIC BRAKE TOOLING 113
HYDRAULIC BRAKE BLEEDER 114
GR70 – HYDRAULICS 149
HYDRAULIC CHARACTERISTICS ANDSPECIFICATIONS 151
COMPLETE ELECTROVALVE (OPTION) 153
5000CC DISTRIBUTOR (INLET ELEMENTS) 154
5000CC DISTRIBUTOR (LIFTING ELEMENT) 156
5000CC DISTRIBUTOR (TILTING ELEMENT) 158
5000CC DISTRIBUTOR (ATTACHMENT ELEMENT) 160
5000CC DISTRIBUTOR (TELESCOPE ELEMENT) 162
3-POSITION STEERING SELECTOR 164
DISTRIBUTOR 5000 (INLET ELEMENTS) 165
DISTRIBUTOR 5000 (LIFTING ELEMENT) 167
DISTRIBUTOR 5000 (TILTING ELEMENT) 169
DISTRIBUTOR 5000 (ATTACHMENT ELEMENT) 171
DISTRIBUTOR 5000 (TELESCOPING ELEMENT) 173
FEED BLOCK + ACCUMULATOR 175
AGGRAVATING MOVEMENT CUT-OFF BLOCK 177
STEERING PUMP / STEERING UNIT OSPC 160 LS 179
COUNTERBALANCE VALVE VBSN 181
COMPENSATION INSULATION VALVE VIC 183
HYDRAULIC SCHEMATIC DIAGRAMS 185
KEY 186
HYDRAULIC DIAGRAM 187
MT 625 H TURBO ST3B / MT 625 H COMFORT ST3B 187
MT 625 HA 75K ST3B S1 188
MLT 625-75 H ST3B 189
MLT 625-75 H ST3B “Elite” 190
HYDRAULIC COMPONENTS LOCATION 191
KEY 192
LOCATION 192
HYDRAULIC CONTROL AND ADJUSTMENT 193
PRESSURE PORTS 194
VALUES 194
LOCATION 195
DISTRIBUTOR TIGHTENING TORQUES 196
HYDRAULIC COMPONENTS REMOVAL 197
COMPONENTS LOCATION 198
HYDRAULIC PUMP 199
MT 625 H TURBO ST3B / MT 625 H / HA COMFORT ST3B 199
MLT 625-75 H ST3B 199
DISTRIBUTOR 201
ACCUMULATOR BLOCK 202
MT/MLT (except MT HA and MLT combined movements) 202
MT HA and MLT combined movements 202
SUCTION STRAINER 203
BACKUP ELECTRIC PUMP 204
8 EV HYDRAULIC BLOCK 205
HYDRAULIC COMPONENTS REFIT 207
COMPONENTS LOCATION 208
HYDRAULIC PUMP 209
MT 625 H TURBO ST3B / MT 625 H / HA COMFORT ST3B 209
MLT 625-75 H ST3B 209
DISTRIBUTOR 211
MT/MLT (except MT HA and MLT combined movements) 211
ACCUMULATOR BLOCK 212
MT/MLT (except MT HA and MLT combined movements) 212
SPECIFIC HYDRAULIC TOOLING 213
BASIC MANOMETER BOX 214
DIGITAL MANOMETER BOX 215
GR80 – ELECTRICITY 217
ELECTRICAL CHARACTERISTICS ANDSPECIFICATIONS 219
WIRING 220
FUSES AND RELAYS 220
ELECTRICAL CONNECTORS 225
OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM (Except MTHA) 230
OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM (MT HA) 231
INPUTS/OUTPUTS 232
DASHBOARD MODULE – A1 232
TRANSMISSION COMPUTER – A2 233
MAIN ECU – SPU 25-15 – A3 234
MAIN ECU – SPU 40-26 – A3 236
TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS 239
A4+A5 JSM 240
A6 ANTI-THEFT OUTPUT 241
B1 REVERSING BUZZER 241
B2 HORN 242
B7 HYDRAULIC CLOGGING FILTER CONTACT 242
B8 MASTER CYLINDER PRESSURE SWITCH 243
B9 INCHING PEDAL ANGLE SENSOR 243
B11 BOOM ANGLE SENSOR 244
B12+B21 WHEEL ALIGNMENT SENSOR 245
B13 TRANSMISSION SPEED SENSOR 245
B34 FUEL GAGE 246
B35 AIR FILTER SWITCH 247
B+/IG-L ALTERNATOR 247
E15 ROTATING BEACON LIGHT 248
S2 STARTER IGNITION SWITCH 248
S11 BRAKE FLUID SWITCH 249
S34 BOOM RETRACTED SWITCH 249
Y3+Y4 FORWARD AND REVERSE ELECTROVALVE 250
Y8+Y9 TELESCOPING EV + ATTACHMENT 251
Y10+Y11 EV HYD PROPORTIONAL TELESCOPING + ATTACHMENT 251
Y12 HYDRAULIC CUT-OFF EV (VS) 252
Y13 NEGATIVE BRAKE EV 252
Y14+Y18 LOWERING + LIFTING PROPORTIONAL CUT-OFF EV 253
Y15 TILTING CUT-OFF EV (VCI) 253
Y19 FAN SPEED EV (TS) 254
Y20 FAN DIRECTION EV (SV) 255
ELECTRICAL SCHEMATIC DIAGRAMS 257
ELECTRICAL DIAGRAM CODIFICATION EXAMPLE 258
CABLE IDENTIFICATION ON AN ELECTRICAL WIRING HARNESS 259
POSITION OF WIRING HARNESSES BY DIAGRAM 260
ELECTRICAL DIAGRAMS BY FUNCTION 264
1 – STARTING 264
2 – CAN 266
3 – TRANSMISSION 268
4 – HYDRAULIC MOVEMENTS (MT 625 H) 270
4 – HYDRAULIC MOVEMENTS (MLT 625 & MT 625 HA) 272
5 – SENSORS 274
6 – LIGHTING AND SIGNALLING 276
7 – OPTIONS / FAN 278
8 – ACCESS (For MT HA) 280
ELECTRICAL COMPONENTS LOCATION 283
KEY 284
CONNECTORS 284
DIODES AND SPLICES 288
2D LOCATION 290
CAB HARNESSES 290
HARNESS ASSEMBLY 291
MAIN HARNESS MT625 H 292
ENGINE HARNESS 293
3D LOCATION 294
MAIN HARNESS IN CAB 294
MAIN HARNESS ON FRAME 295
HARNESS IN ENGINE HOUSING 296
MAIN HARNESS MT 625 HA / MLT (combined movements option) 297
ELECTRICAL CONTROL AND ADJUSTMENT 299
“BOOM ANGLE” ANGULAR SENSOR ADJUSTMENT 300
OPERATION 300
ON-TRUCK ADJUSTMENT PROCEDURE 300
LONGITUDINAL STABILITY INDICATOR (LLMI) 302
ERROR CODES 302
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE 303
STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE) 304
STRAIN GAUGE RECALIBRATION (CLIENT PROCEDURE) 305
“AGGRAVATING” HYDRAULIC MOVEMENTS CUT-OFF 306
LED ILLUMINATION ACCORDING TO CHANGES IN GAUGE SIGNAL 306
INCLINOMETER CALIBRATION (MT HA) 307
DASHBOARD CALIBRATION MENU 308
LIFT TRUCK SERIAL NUMBER DISPLAY 308
RESETTING THE PARTIAL HOUR METER 308
INCHING BRAKE PEDAL CALIBRATION 309
TELESCOPING SPEED CALIBRATION 309
ATTACHMENT FLOW RATE CALIBRATION 310
FORCED OPERATION 311
MAINTENANCE HOUR METER RESET 311
SELECTION OF SPEED UNIT KM/H OR MPH (except MT TURBO) 311
ECOMODE 312
END OF CALIBRATION MENU 312
ELECTRICAL COMPONENTS REMOVAL 313
SPU 40-26 ECU 314
EMERGENCY KEY – HANDLING KEY /ORH – INCLINOMETER 314
JSM on BMEP 316
ELECTRICAL COMPONENTS REFIT 317
STRAIN GAUGE 318
ELECTRICAL TROUBLESHOOTING 325
READING OF ERROR CODES 326
DASHBOARD ERROR CODES 326
PAD ERROR CODES 326
ERROR CODES / CONTROL UNITS 327
Dashboard ECU (A1) 327
Transmission ECU (A2) 328
Hydraulic system ECU 25 – 15 (A3) 329
Hydraulic system ECU 40 – 26 (A3) 331
ELECTRICAL SPECIFIC TOOLING 335
DIAGNOSTIC TOOLS 336
VERSION 1 336
VERSION 2 338
ENGINE ADAPTATION KIT 339
BREAKOUT BOXES 340
ELECTROVALVE ADAPTER 340
DRIVER’S CAB CHARACTERISTICS ANDSPECIFICATIONS 343
AIR CONDITIONER 344
OPERATING PRINCIPLE 344
OPERATION DESCRIPTION 345
DESCRIPTION OF COMPONENTS 346
DRIVER’S CAB COMPONENTS LOCATION 349
AIR CONDITIONING 350
DRIVER’S CAB CONTROL AND ADJUSTMENT 351
AIR CONDITIONER 352
ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT 352
R134a REFRIGERANT FLUID CHARACTERISTICS 354
SAFETY MEASURES FOR HANDLING R134a 354
REFRIGERANT FLUID LOAD FOR THE AIR-CONDITIONING CIRCUIT 355
CHARGING METHOD 355
FUNCTIONAL CHECKS 356
ANTI-ICING SAFETY MONITORING 359
AIR-CONDITIONING INSPECTION FORM 360
DRIVER’S CAB REMOVAL 361
REPLACING AIR-CONDITIONER COMPONENTS 362
DRIER FILTER 362
PRESSURE SWITCH 363
THERMOSTAT 364
PRESSURE REDUCER 366
EVAPORATOR 368
CONDENSER FAN 370
CONDENSER 371
HOSES 372
COMPRESSOR 373
DRIVER’S CAB TROUBLESHOOTING 375
AIR-CONDITIONER FAULT DIAGNOSTICS 376
FAULTY AIR-CONDITIONING 376
FAULTY VENTILATION 377
FAULTY HEATING 377

PLEASE NOTE:

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