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Manitou MLT 625-75 H ST3B REPAIR MANUAL – PDF DOWNLOAD
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Manitou MLT 625-75 H ST3B REPAIR MANUAL – PDF DOWNLOAD
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Description
Manitou MLT 625-75 H ST3B REPAIR MANUAL – PDF DOWNLOAD
FILE DETAILS:
Manitou MLT 625-75 H ST3B REPAIR MANUAL – PDF DOWNLOAD
Language : English
Pages :378
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Manitou MLT 625-75 H ST3B REPAIR MANUAL – 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 – BOOM115
BOOM CHARACTERISTICS AND SPECIFICATIONS117
DUPLEX BOOM118
BOOM COMPONENTS LOCATION119
INDEX OF COMPONENT CODES120
LOCATION OF THE DUPLEX BOOM MAIN COMPONENTS120
BOOM CONTROL AND ADJUSTMENT121
DUPLEX BOOM REMOVAL122
GENERAL INFORMATION122
PREPARATION AND SAFETY INSTRUCTIONS122
TELESCOPE CYLINDER REMOVAL123
BOOM T1 REMOVAL126
DUPLEX BOOM REFIT127
PREPARATION AND SAFETY INSTRUCTIONS127
BOOM T1 REASSEMBLY128
SHIM INSTALLATION RECOMMENDATIONS131
TIGHTENING TORQUE132
REFITTING THE TELESCOPE CYLINDER133
BOOM REMOVAL137
DUPLEX BOOM138
GENERAL INFORMATION138
PREPARATION AND SAFETY INSTRUCTIONS138
PLATFORM HARNESS141
Removal141
Refit142
BOOM REFIT143
DUPLEX BOOM144
GENERAL INFORMATION144
PREPARATION AND SAFETY INSTRUCTIONS144
SPECIFIC BOOM TOOLING147
PIPE END PIECES148
GR40 – BRAKE 99
BRAKE CHARACTERISTICS AND SPECIFICATIONS101
SERVICE BRAKE / PARKING BRAKE103
BRAKE CONTROL AND ADJUSTMENT105
BRAKE AND INCHING PEDAL ADJUSTMENT106
BLEEDING PROCEDURE108
SPECIFIC BRAKE TOOLING113
HYDRAULIC BRAKE BLEEDER114
GR70 – HYDRAULICS149
HYDRAULIC CHARACTERISTICS ANDSPECIFICATIONS151
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 SELECTOR164
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 + ACCUMULATOR175
AGGRAVATING MOVEMENT CUT-OFF BLOCK177
STEERING PUMP / STEERING UNIT OSPC 160 LS179
COUNTERBALANCE VALVE VBSN181
COMPENSATION INSULATION VALVE VIC183
HYDRAULIC SCHEMATIC DIAGRAMS185
KEY186
HYDRAULIC DIAGRAM187
MT 625 H TURBO ST3B / MT 625 H COMFORT ST3B187
MT 625 HA 75K ST3B S1188
MLT 625-75 H ST3B189
MLT 625-75 H ST3B “Elite”190
HYDRAULIC COMPONENTS LOCATION191
KEY192
LOCATION192
HYDRAULIC CONTROL AND ADJUSTMENT193
PRESSURE PORTS194
VALUES194
LOCATION195
DISTRIBUTOR TIGHTENING TORQUES196
HYDRAULIC COMPONENTS REMOVAL197
COMPONENTS LOCATION198
HYDRAULIC PUMP199
MT 625 H TURBO ST3B / MT 625 H / HA COMFORT ST3B199
MLT 625-75 H ST3B199
DISTRIBUTOR201
ACCUMULATOR BLOCK202
MT/MLT (except MT HA and MLT combined movements)202
MT HA and MLT combined movements202
SUCTION STRAINER203
BACKUP ELECTRIC PUMP204
8 EV HYDRAULIC BLOCK205
HYDRAULIC COMPONENTS REFIT207
COMPONENTS LOCATION208
HYDRAULIC PUMP209
MT 625 H TURBO ST3B / MT 625 H / HA COMFORT ST3B209
MLT 625-75 H ST3B209
DISTRIBUTOR211
MT/MLT (except MT HA and MLT combined movements)211
ACCUMULATOR BLOCK212
MT/MLT (except MT HA and MLT combined movements)212
SPECIFIC HYDRAULIC TOOLING213
BASIC MANOMETER BOX214
DIGITAL MANOMETER BOX215
GR80 – ELECTRICITY217
ELECTRICAL CHARACTERISTICS ANDSPECIFICATIONS219
WIRING220
FUSES AND RELAYS220
ELECTRICAL CONNECTORS225
OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM (Except MTHA)230
OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM (MT HA)231
INPUTS/OUTPUTS232
DASHBOARD MODULE – A1232
TRANSMISSION COMPUTER – A2233
MAIN ECU – SPU 25-15 – A3234
MAIN ECU – SPU 40-26 – A3236
TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS239
A4+A5JSM240
A6ANTI-THEFT OUTPUT241
B1REVERSING BUZZER241
B2HORN242
B7HYDRAULIC CLOGGING FILTER CONTACT242
B8MASTER CYLINDER PRESSURE SWITCH243
B9INCHING PEDAL ANGLE SENSOR243
B11BOOM ANGLE SENSOR244
B12+B21 WHEEL ALIGNMENT SENSOR245
B13TRANSMISSION SPEED SENSOR245
B34FUEL GAGE246
B35AIR FILTER SWITCH247
B+/IG-LALTERNATOR247
E15ROTATING BEACON LIGHT248
S2STARTER IGNITION SWITCH248
S11BRAKE FLUID SWITCH249
S34BOOM RETRACTED SWITCH249
Y3+Y4FORWARD AND REVERSE ELECTROVALVE250
Y8+Y9TELESCOPING EV + ATTACHMENT251
Y10+Y11 EV HYD PROPORTIONAL TELESCOPING + ATTACHMENT251
Y12 HYDRAULIC CUT-OFF EV (VS)252
Y13NEGATIVE BRAKE EV252
Y14+Y18 LOWERING + LIFTING PROPORTIONAL CUT-OFF EV253
Y15TILTING CUT-OFF EV (VCI)253
Y19FAN SPEED EV (TS)254
Y20FAN DIRECTION EV (SV)255
ELECTRICAL SCHEMATIC DIAGRAMS257
ELECTRICAL DIAGRAM CODIFICATION EXAMPLE258
CABLE IDENTIFICATION ON AN ELECTRICAL WIRING HARNESS259
POSITION OF WIRING HARNESSES BY DIAGRAM260
ELECTRICAL DIAGRAMS BY FUNCTION264
1 – STARTING264
2 – CAN266
3 – TRANSMISSION268
4 – HYDRAULIC MOVEMENTS (MT 625 H)270
4 – HYDRAULIC MOVEMENTS (MLT 625 & MT 625 HA)272
5 – SENSORS274
6 – LIGHTING AND SIGNALLING 276
7 – OPTIONS / FAN278
8 – ACCESS (For MT HA)280
ELECTRICAL COMPONENTS LOCATION283
KEY284
CONNECTORS284
DIODES AND SPLICES288
2D LOCATION290
CAB HARNESSES290
HARNESS ASSEMBLY291
MAIN HARNESS MT625 H292
ENGINE HARNESS293
3D LOCATION294
MAIN HARNESS IN CAB294
MAIN HARNESS ON FRAME295
HARNESS IN ENGINE HOUSING296
MAIN HARNESS MT 625 HA / MLT (combined movements option)297
ELECTRICAL CONTROL AND ADJUSTMENT299
“BOOM ANGLE” ANGULAR SENSOR ADJUSTMENT300
OPERATION300
ON-TRUCK ADJUSTMENT PROCEDURE300
LONGITUDINAL STABILITY INDICATOR (LLMI)302
ERROR CODES302
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE303
STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE)304
STRAIN GAUGE RECALIBRATION (CLIENT PROCEDURE)305
“AGGRAVATING” HYDRAULIC MOVEMENTS CUT-OFF306
LED ILLUMINATION ACCORDING TO CHANGES IN GAUGE SIGNAL306
INCLINOMETER CALIBRATION (MT HA)307
DASHBOARD CALIBRATION MENU308
LIFT TRUCK SERIAL NUMBER DISPLAY308
RESETTING THE PARTIAL HOUR METER308
INCHING BRAKE PEDAL CALIBRATION309
TELESCOPING SPEED CALIBRATION309
ATTACHMENT FLOW RATE CALIBRATION310
FORCED OPERATION311
MAINTENANCE HOUR METER RESET311
SELECTION OF SPEED UNIT KM/H OR MPH (except MT TURBO)311
ECOMODE312
END OF CALIBRATION MENU312
ELECTRICAL COMPONENTS REMOVAL313
SPU 40-26 ECU314
EMERGENCY KEY – HANDLING KEY /ORH – INCLINOMETER314
JSM on BMEP316
ELECTRICAL COMPONENTS REFIT317
STRAIN GAUGE318
ELECTRICAL TROUBLESHOOTING325
READING OF ERROR CODES326
DASHBOARD ERROR CODES326
PAD ERROR CODES326
ERROR CODES / CONTROL UNITS327
Dashboard ECU (A1)327
Transmission ECU (A2)328
Hydraulic system ECU 25 – 15 (A3)329
Hydraulic system ECU 40 – 26 (A3)331
ELECTRICAL SPECIFIC TOOLING335
DIAGNOSTIC TOOLS336
VERSION 1336
VERSION 2338
ENGINE ADAPTATION KIT339
BREAKOUT BOXES340
ELECTROVALVE ADAPTER340
DRIVER’S CAB CHARACTERISTICS ANDSPECIFICATIONS343
AIR CONDITIONER344
OPERATING PRINCIPLE344
OPERATION DESCRIPTION345
DESCRIPTION OF COMPONENTS346
DRIVER’S CAB COMPONENTS LOCATION349
AIR CONDITIONING350
DRIVER’S CAB CONTROL AND ADJUSTMENT351
AIR CONDITIONER352
ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT352
R134a REFRIGERANT FLUID CHARACTERISTICS354
SAFETY MEASURES FOR HANDLING R134a354
REFRIGERANT FLUID LOAD FOR THE AIR-CONDITIONING CIRCUIT355
CHARGING METHOD355
FUNCTIONAL CHECKS356
ANTI-ICING SAFETY MONITORING359
AIR-CONDITIONING INSPECTION FORM360
DRIVER’S CAB REMOVAL361
REPLACING AIR-CONDITIONER COMPONENTS362
DRIER FILTER362
PRESSURE SWITCH363
THERMOSTAT364
PRESSURE REDUCER366
EVAPORATOR368
CONDENSER FAN370
CONDENSER371
HOSES372
COMPRESSOR373
DRIVER’S CAB TROUBLESHOOTING375
AIR-CONDITIONER FAULT DIAGNOSTICS376
FAULTY AIR-CONDITIONING376
FAULTY VENTILATION377
FAULTY HEATING377
S.M 11/24
