Manitou Telehandler MLT 630, MLT 730 115D ST5 S1V CP Repair Manual 647973EN – PDF DOWNLOAD

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Manitou Telehandler MLT 630, MLT 730 115D ST5 S1V CP Repair Manual 647973EN – PDF DOWNLOAD

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Manitou Telehandler MLT 630, MLT 730 115D ST5 S1V CP Repair Manual 647973EN – PDF DOWNLOAD

Language : English
Pages : 550
Downloadable : Yes
File Type : PDF
Size: 55.6 MB

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DESCRIPTION:

Manitou Telehandler MLT 630, MLT 730 115D ST5 S1V CP Repair Manual 647973EN – PDF DOWNLOAD

MLT 630 115D ST5 S1
MLT 630 115D V ST5 S1
MLT 630 115D V CP ST5 S1
MLT 730 115D V ST5 S1
MLT 730 115D V CP ST5 S1

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TABLE OF CONTENTS:

Manitou Telehandler MLT 630, MLT 730 115D ST5 S1V CP Repair Manual 647973EN – PDF DOWNLOAD

00 GENERAL AND SAFETY CHARACTERISTICS 15
00 1 LIST OF ABBREVIATIONS 15
00 2 FOREWORD 17
00 3 MAINTENANCE RULES 17
00 4 WORK DURING THE WARRANTY PERIOD 20
00 5 MAINTENANCE POSITION 20
00 6 EXPLANATION OF SYMBOLS 21
00 7 LIST OF SUPPLIER DOCUMENTATION 21
00 8 CHARACTERISTICS AND SPECIFICATIONS 22
00 8 1 Lubricants and fuels 22
00 8 2 Weights and forces 22
00 8 3 Dimensions – MLT 630 115D ST5 S1 23
00 8 4 Dimensions – MLT 630 115D V ST5 S1 24
00 8 5 Dimensions – MLT 630 115D V CP ST5 S1 25
00 8 6 Dimensions – MLT 730 115D V ST5 S1 27
00 8 7 Dimensions – MLT 730 115D V CP ST5 S1 28
00 9 LOCATION 29
00 9 1 Name and identification plates 29
00 10 CONTROL AND ADJUSTMENT 30
00 10 1 Metric – imperial unit conversion 30
00 10 2 Standard tightening torques 31
10 ENGINE 33
10 1 CHARACTERISTICS AND SPECIFICATIONS 33
10 1 1 Engine characteristics 115 hp 33
10 1 2 Diesel exhaust fluid (DEF) 33
10 1 3 Fan control 34
10 1 4 Conditions of elements associated with ST5 fan control 34
10 2 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 36
10 2 1 Ventilation principle diagram 36
10 2 2 Intake system and EGR 36
10 2 3 Lubrication system 37
10 2 4 Cooling system 38
10 2 5 Fuel system 39
10 2 6 DEF system schematic diagram 40
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10 2 7 DEF circuit 41
10 3 LOCATION 42
10 3 1 Diesel location system 42
10 3 2 Air intake circuit 44
10 3 3 Exhaust system 45
10 3 4 Water cooling system 46
10 3 5 Engine location 47
10 3 6 Fuel injection circuit 48
10 4 CONTROL AND ADJUSTMENT 49
10 4 1 DEF pump cleaning preparation 49
10 4 2 DEF pump cleaning procedure 49
10 4 3 DEF pump cleaning procedure with the engine diagnostic tool 50
10 4 4 Fan check points 51
10 4 5 Engine load level 51
10 4 6 SCR system bleed time 52
10 4 7 Engine start-up authorization conditions 52
10 4 8 Stationary regeneration authorization conditions 52
10 4 9 Location of exhaust tightening torques 53
10 5 REMOVAL 55
10 5 1 Disconnect the battery 55
10 5 2 Removing the belt casing 55
10 5 3 Remove the air filter 55
10 5 4 Remove the alternator 55
10 5 5 Remove the starter 56
10 5 6 Removing the expansion tank with support 57
10 5 7 Removing the DEF injector 57
10 5 8 Removing the SCR 57
10 5 9 Remove the intermediate tube 58
10 5 10 Remove the DOC-DPF 58
10 5 11 Remove the DOC-DPF converter with support 59
10 5 12 Remove the fan motor 59
10 5 13 Remove the radiator 62
10 5 14 Remove the air conditioning compressor 63
10 5 15 Remove the turbo exhaust outlet tube 63
10 5 16 Removing the turbo 64
10 5 17 Remove the engine 64
10 5 18 Remove the additional fuel tank 67
TABLE OF CONTENTS
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10 6 TROUBLESHOOTING 67
10 6 1 Fault table 67
10 7 SPECIFIC TOOLING 70
10 7 1 DEF flush kit 70
10 7 2 Electronic belt tensiometer 70
20 TRANSMISSION 71
20 1 CHARACTERISTICS AND SPECIFICATIONS 71
20 1 1 Compaq + specifications 71
20 1 2 MPower Box specifications 71
20 1 3 Transfer gearbox characteristics 367 71
20 2 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 72
20 2 1 Compact+ (C+) mechanical transmission 72
20 2 2 Hydrostatic transmission diagram 74
20 3 LOCATION 77
20 3 1 Location of mechanical transmission and gearbox cooling 77
20 3 2 Location of Compaq + ports 78
20 3 3 Location of MpowerBox ports 78
20 3 4 Location of hydrostatic transmission 79
20 3 5 Location of ports BT 367 80
20 4 CONTROL AND ADJUSTMENT 80
20 4 1 General authorization conditions for carriage movement 80
20 4 2 Check the machine configurations 80
20 4 3 Hydrostatic auto-calibration 80
20 4 4 ECO Mode on hydrostatic lift truck 81
20 4 5 Adjust the hydrostatic motor sensor 81
20 4 6 Pressure control 83
20 4 7 Checking adjustment of pump A4VG71 series 32 83
20 4 8 Hydrostatic transmission tightening torque 84
20 4 9 Mechanical transmission tightening torque 85
20 4 10 MPower Box tightening torque 85
20 4 11 Towing procedure 86
20 4 12 Free the wheels by removing the universal joints 86
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20 5 REMOVAL 86
20 5 1 Remove the angle gearbox 86
20 5 2 Remove the manual gearbox 87
20 5 3 Remove the hydrostatic pump 88
20 5 4 Remove the transfer box 89
20 5 5 Remove the hydrostatic motor 91
20 5 6 Remove the engine flywheel damper 92
20 6 TROUBLESHOOTING 92
20 6 1 Transmission troubleshooting 92
20 7 SPECIFIC TOOLING 92
20 7 1 Digital manometer box 92
20 7 2 Basic manometer box 93
30 AXLE 94
30 1 CHARACTERISTICS AND SPECIFICATIONS 94
30 1 1 Characteristics of axle 212 94
30 1 2 Characteristics of axle 212 with service and parking brake 95
30 1 3 Characteristics of axle 212 with service brake 96
30 2 CONTROL AND ADJUSTMENT 96
30 2 1 Check of axle braking discs 96
30 2 2 Axle stop adjustment 96
30 2 3 Axle tightening torques 96
40 BRAKE 97
40 1 CHARACTERISTICS AND SPECIFICATIONS 97
40 1 1 Brake component characteristics 97
40 1 2 Service brake – Specifications of oil bath disc brakes 97
40 1 3 Standard tow tractor with cable tension sensor 98
40 1 4 Trailer pneumatic braking operation 98
40 1 5 Technical sheets for electrical components 99
40 2 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 105
40 2 1 Hydraulic diagram of the brakes 105
40 2 2 Schematic diagram of trailer pneumatic braking operation 105
TABLE OF CONTENTS
647973EN-USM134(A-03/2021) 7
40 3 LOCATION 108
40 3 1 Location of the service brake and trailer braking system 108
40 3 2 Location of parking brake components 109
40 3 3 Location of pneumatic braking 110
40 4 CONTROL AND ADJUSTMENT 111
40 4 1 Check of brake disc wear 111
40 4 2 Brake valve tightening torques 111
40 4 3 Settings and tightening torques of the double priority valve 111
40 4 4 Trailer brake valve tightening torques 111
40 4 5 towing procedure 112
40 4 6 Brake valve pressure connector 112
40 4 7 Adjust the parking brake sensor 112
40 4 8 Transmission mechanics MLT 630 113
40 4 9 Hydrostatic transmission (MLT 6/7 V) 115
40 4 10 Bleeding the braking circuit 118
40 5 REMOVAL 119
40 5 1 Remove the brake valve 119
40 6 REFIT 119
40 6 1 Put back the brake valve 119
50 LIFT STRUCTURE 120
50 1 CHARACTERISTICS AND SPECIFICATIONS 120
50 1 1 General characteristics – duplex booms 6 and 7 m 120
50 2 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 120
50 2 1 Duplex booms kinematics 6 and 7 m 121
50 3 LOCATION 123
50 3 1 Location of components – duplex boom 6 and 7 m 123
50 4 CONTROL AND ADJUSTMENT 124
50 4 1 Adjust the telescope’s retraction and extension time 124
50 4 2 Adjust the fixed pads using screws and inserts on the duplex boom 124
50 4 3 Chock the boom hinges 125
50 4 4 Duplex boom tightening torques 127
50 4 5 Adjust the limit stop for the single carriage of the duplex boom 129
8 647973EN-USM134(A-03/2021)
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50 5 REMOVAL 130
50 5 1 Prepare for complete boom removal 130
50 5 2 Prepare to remove the internal boom components 130
50 5 3 Remove the telescopic boom cylinder 130
50 5 4 Remove the complete boom 133
50 5 5 Remove the telescope 136
50 6 REFIT 137
50 6 1 Prepare to reinstall the internal boom components 137
50 6 2 Reinstall the telescope 138
50 7 SPECIFIC TOOLING 139
50 7 1 Pipe end pieces 139
70 HYDRAULICS 140
70 1 CHARACTERISTICS AND SPECIFICATIONS 140
70 1 1 List of hydraulic sheets 141
70 1 2 Hydraulic feed block + accumulator 143
70 1 3 Ventilation control unit + inversion PLM20 16 144
70 1 4 4-element hydraulic distributor SDS 140 147
70 1 5 Double priority valve 149
70 1 6 Hydraulic pump KP30 43 150
70 1 7 Dynamic steering pump OSPC 200 151
70 1 8 3/4 position steering distributor 152
70 1 9 Braking valve 55 bar 153
70 1 10 Braking valve 72 bar 155
70 1 11 trailer brake valve 156
70 1 12 Cooling thermostat valve 159
70 2 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 160
70 2 1 Hydraulic diagram MLT 630 – 730 161
70 2 2 Hydraulic diagram MLT 630 – 730 V 167
70 3 LOCATION 173
70 3 1 Hydraulic components location – MLT 630 115D ST5 S1 (+ options) 173
70 3 2 Hydraulic components location – MLT 630 115D V ST5 S1 (+ options) 174
70 3 3 Hydraulic components location – MLT 630 115D V CP ST5 S1 (+ options) 176
70 3 4 Hydraulic components location – MLT 730 115D V ST5 S1 (+ options) 177
70 3 5 Hydraulic components location – MLT 730 115D V CP ST5 S1 (+ options) 179
TABLE OF CONTENTS
647973EN-USM134(A-03/2021) 9
70 4 CONTROL AND ADJUSTMENT 180
70 4 1 Purge the air from the hydraulic valve bank 180
70 4 2 Adjust of the load valve on the double priority valve 181
70 4 3 Hydraulic distributor tightening torques 181
70 4 4 Tightening torques of the double priority valve 182
70 4 5 Tightening torques of the hydraulic pump 182
70 4 6 Tightening torques of the hydraulic fluid tank 182
70 4 7 Tightening torque of the fan control bloc + inversion 183
70 4 8 Tightening torque of the cooling thermostat valve (hydrostatic versions only) 183
70 5 REMOVAL 183
70 5 1 Preparing and securing the machine before removal of hydraulic components 183
70 5 2 Remove the hydraulic fluid tank 184
70 5 3 Remove the hydraulic pump 185
70 5 4 Remove the hydraulic distributor 185
70 6 TROUBLESHOOTING 186
70 6 1 Troubleshooting on the double priority / master valve 186
70 7 SPECIFIC TOOLING 189
70 7 1 Basic manometer box 189
70 7 2 Digital manometer box 190
70 7 3 Inflation kit 190
80 ELECTRICITY 191
80 1 CHARACTERISTICS AND SPECIFICATIONS 191
80 1 1 Fuses and Relays 191
80 1 2 ECU Inputs/Outputs 192
80 1 3 Technical sheets for electrical components 205
80 2 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 224
80 2 1 Operation overview CAN and LIN – mechanical transmission 224
80 2 2 Operation overview CAN and LIN – hydrostatic transmission 225
80 2 3 Examples of coding on the wiring diagrams 226
80 2 4 Cable marking on an electrical wiring harness 227
80 2 5 Position by diagrams – MLT 630 115D ST5 S1 227
80 2 6 Electrical diagrams – MLT 630 115D ST5 S1 245
80 2 7 Position by diagrams – MLT 6-7 115D VST5 and VCP ST5 S1 269
80 2 8 Electrical diagrams – MLT 6-7 115D VST5 and VCP ST5 S1 285
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80 3 LOCATION 309
80 3 1 3D chassis electrical location MLT 630 155 D + Options (P362 ST5) 311
80 3 2 2D electrical location – mechanical transmission MLT chassis harness 315
80 3 3 3D Electrical Location New MECA Cab + Options 317
80 3 4 2D electrical location – Cabin harness 323
80 3 5 3D Electrical Location Motor MLT 6-7 + Options (P360 ST5) 329
80 3 6 2D electrical location – Motor harness 331
80 3 7 3D Electrical location Boom 6M P360` 335
80 3 8 3D chassis electrical location MLT 630-730 115 D V + Options (P361 ST5) 337
80 3 9 3D chassis electrical location el3D MLT 630-730 115 D VCP ST5 + Options (P361 CP) 341
80 3 10 2D electrical location- MLT V chassis harness 345
80 3 11 3D electrical location New Cabin V + Options 349
80 3 12 2D electrical location – Cabin harness 353
80 3 13 3D Electrical Location Motor MLT 6-7 + Options (P360 ST5) 359
80 3 14 2D electrical location – Motor harness 361
80 3 15 3D Electrical location Boom 7M P360 365
80 3 16 2D electrical location – Valve bank harness 367
80 4 CONTROL AND ADJUSTMENT 369
80 4 1 Tightening torques of the engine harness components 369
80 4 2 Harmony display tightening torques 370
80 4 3 JSM tightening torques 370
80 5 REMOVAL 370
80 5 1 Remove the cabin’s fuse and relay access panel 370
80 5 2 Remove the engine fuse and relay access panel 370
80 5 3 Remove the dashboard screen 371
80 5 4 Removing the main ECU 371
80 5 5 Removing the strain gage 372
80 5 6 Removing the BMEP JSM 372
80 6 REFIT 372
80 6 1 Refitting the strain gage 372
80 6 2 Refit the JSM on BMEP 376
80 7 TROUBLESHOOTING 377
80 7 1 Correspondence of injector fault codes 377
80 7 2 Engine error code 378
80 7 3 Error code transmission RC 12–10–30 399
80 7 4 Automatic air conditioning error codes 476
80 7 5 DSB faults 478
TABLE OF CONTENTS
647973EN-USM134(A-03/2021) 11
80 8 SPECIFIC TOOLING 479
80 8 1 Electrovalve adapter 479
80 8 2 Breakout boxes 479
85 OPERATOR STATION 480
85 1 CHARACTERISTICS AND SPECIFICATIONS 480
85 1 1 Description of air conditioning operation 480
85 2 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 481
85 2 1 Schematic diagrams 481
85 3 LOCATION 483
85 3 1 Localisations générales 483
85 3 2 Specific air conditioning locations 485
85 4 CONTROL AND ADJUSTMENT 488
85 4 1 General controls and adjustments 488
85 4 2 Air conditioning controls and adjustments 492
85 5 REMOVAL 496
85 5 1 Removing the cab 496
85 5 2 Removing the windshield with standard grille 498
85 5 3 Removing the windshield with compact grille 499
85 5 4 Removing the door window winder 501
85 5 5 Remove the cab door 504
85 5 6 Removing the windshield wiper motor 505
85 5 7 Removing the cab lower trim 507
85 5 8 Removing the upper dashboard 507
85 5 9 Removing the driver’s seat 509
85 5 10 Removing the armrest block 510
85 5 11 Removing the heating unit 511
85 5 12 Removing the dashboard switches 513
85 6 REFIT 514
85 6 1 Removing the door window winder 514
85 6 2 Air conditioning assembly instructions 516
85 7 TROUBLESHOOTING 517
85 7 1 Troubleshooting on the air conditioning system 517
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85 8 SPECIFIC TOOLING 518
85 8 1 Cab grille hinge kit 518
90 CHASSIS 519
90 1 REMOVAL 519
90 1 1 Remove the engine hood 519
90 1 2 Removing the rear casing 519
90 1 3 Removing the engine housing 519
110 ADDITIONAL EQUIPMENT 521
110 1 MANUAL CENTRAL GREASING 521
110 1 1 Location of the manual central lubrication system 521
110 2 AUTOMATIC CENTRAL GREASING 522
110 2 1 Automatic greasing characteristics and specifications 522
110 2 2 Schematic diagram of the distributors 526
110 2 3 Location of automatic central greasing components 527
110 2 4 Automatic central greasing controls and adjustments 528
110 2 5 Tightening torques of automatic central greasing connections 530
110 2 6 Troubleshooting 530
110 2 7 Error codes table 532
110 3 CAMERA 533
110 3 1 Front, rear and boom head camera system 533
110 3 2 Technical sheets for electrical components 535
110 3 3 3D location of the camera system components 541
110 3 4 Camera system adjustments 542
110 4 INTELLIGENT HYDRAULICS 543
110 4 1 Intelligent Hydraulics system overview 543
110 4 2 Location of Intelligent Hydraulics system components on 6/7 m boom 544
TABLE OF CONTENTS
647973EN-USM134(A-03/2021) 13
120 DIAGNOSTIC TOOLS AND SOFTWARE 546
120 1 DIAGNOSTICS CASE KIT 546
120 2 USB LINK 2 BOX 547
120 3 COMPONENT DIAGNOSTICS BOX 548
120 4 CABLE PLUG OBD – PLUG DEUTZ 548
120 5 CABLE NETWORK M12/RJ45 548

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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