Manitou Telehandler MT 625,MLT 625,MT-X 625 H HA 75K ST5 S1 S2 Repair Manual 647745EN – PDF DOWNLOAD

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Manitou Telehandler MT 625,MLT 625,MT-X 625 H HA 75K ST5 S1 S2 Repair Manual 647745EN – PDF DOWNLOAD

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Manitou Telehandler MT 625,MLT 625,MT-X 625 H HA 75K ST5 S1 S2 Repair Manual 647745EN – PDF DOWNLOAD

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Manitou Telehandler MT 625,MLT 625,MT-X 625 H HA 75K ST5 S1 S2 Repair Manual 647745EN – PDF DOWNLOAD

MT 625 H 75K ST5 S1
MT 625 H COMFORT 75K ST5 S1
MT 625 HA 75K ST5 S1
MLT 625 H 75K ST5 S1
MT-X 625 H 75K ST3A S2
MT-X 625 H COMFORT 75K ST3A S2
MLT-X 625 H 75K ST3A S2

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 effi cient, dependable and profi table combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.

TABLE OF CONTENTS:

Manitou Telehandler MT 625,MLT 625,MT-X 625 H HA 75K ST5 S1 S2 Repair Manual 647745EN – PDF DOWNLOAD

Cover page …………………………………………………………….. 1
LIST OF ABBREVIATIONS……………………………………………………. 4
Table of content ……………………………………………………….. 7
GR00_GENERAL, CHARACTERISTICS AND SAFETY…………………………………… 9
GENERAL INSTRUCTIONS AND SAFETY NOTICE…………………………………. 11
GENERAL CHARACTERISTICS AND SPECIFICATIONS……………………………… 17
GENERAL LOCATION…………………………………………………….. 19
GENERAL CONTROL AND ADJUSTMENT………………………………………… 21
STANDARD TIGHTENING TORQUES……………………………………….. 22
METRIC – IMPERIAL UNIT CONVERSION………………………………….. 23
GR10_ENGINE…………………………………………………………….. 25
ENGINE GENERAL CHARACTERISTICS ANDSPECIFICATIONS………………………… 27
SPECIFICATIONS: V3307 CR ST5………………………………………. 28
SPECIFICATIONS: V3307-DI-T-E3B…………………………………….. 29
ENGINE CIRCUITS OVERVIEW……………………………………………… 31
ENGINE: V3307 CR ST5……………………………………………… 32
FUEL CIRCUIT: OVERVIEW OF THE FUEL SYSTEM……………………….. 32
COOLING SYSTEM: LOWER BYPASS SYSTEM…………………………….. 32
EXHAUST CIRCUIT: AFTER-TREATMENT DEVICES………………………… 33
ENGINE COMPONENTS LOCATION……………………………………………. 35
ENGINE: V3307 CR ST5 (MT & MLT)……………………………………. 36
ENGINE ELEMENTS………………………………………………. 36
AIR INTAKE LINE………………………………………………. 37
EXHAUST PIPE…………………………………………………. 37
FUEL CIRCUIT…………………………………………………. 38
ACCELERATOR PEDAL…………………………………………….. 39
ENGINE: V3307-DI-T-E3B (MT-X & MLT-X)………………………………. 40
ENGINE ELEMENTS………………………………………………. 40
AIR INTAKE LINE………………………………………………. 41
EXHAUST PIPE…………………………………………………. 41
FUEL CIRCUIT…………………………………………………. 42
ACCELERATOR PEDAL…………………………………………….. 43
ENGINE CONTROL AND ADJUSTMENT…………………………………………. 45
12.1.1 ENGINE CONTROLS AND ADJUSTMENTS V3307 ST5 (MT & MLT)…………… 46
FAN CONTROL OPERATION (MLT)LOCATION…………………………….. 55
II – DESCRIPTION OF THE FAN HYDRAULIC MOTOR……………………… 56
III – THE THREE MODES OF OPERATION……………………………… 57
IV – CONTROL…………………………………………………. 58
FAN CONTROL SYSTEM ARCHITECTURE DIAGRAM:………………………… 59
12.1.1 ENGINE CONTROLS AND ADJUSTMENTS V3307-DI-T-E3B (MT-X & MLT-X)…… 60
ENGINE REMOVAL………………………………………………………. 69
ENGINE REMOVAL V3307 ST5 (MT & MLT)………………………………… 70
ENGINE V3307-DI-T-E3B (MT-X & MLT-X)……………………………….. 74
ENGINE REFIT………………………………………………………… 87
ORDER OF INSTALLATION OF SILENT BLOCKS……………………………… 88
LEVELS – VERIFICATION – TESTING……………………………………. 88
ENGINE SPECIFIC TOOLING………………………………………………. 89
FITTING WEDGE FOR ELASTIC DRIVE BELT……………………………….. 90
ELECTRONIC TENSION METER………………………………………….. 90
GR20_TRANSMISSION……………………………………………………….. 91
TRANSMISSION SCHEMATIC DIAGRAMS……………………………………….. 93
DRIVE TRAIN……………………………………………………… 94
HYDROSTATIC TRANSMISSION MT 625……………………………………. 95
FORWARD GEAR SCHEMATIC DIAGRAM…………………………………. 95
FLUID FLOW DISPLAY IN FORWARD GEAR……………………………… 96
REVERSE GEAR SCHEMATIC DIAGRAM…………………………………. 97
REVERSE GEAR FLUID FLOW DISPLAY………………………………… 98
COOLING SYSTEM……………………………………………….. 99
HYDROSTATIC TRANSMISSION MLT 625……………………………………100
FORWARD GEAR SCHEMATIC DIAGRAM………………………………….100
FLUID FLOW DISPLAY IN FORWARD GEAR………………………………101
REVERSE GEAR SCHEMATIC DIAGRAM………………………………….102
REVERSE GEAR FLUID FLOW DISPLAY…………………………………103
COOLING SYSTEM………………………………………………..104
TRANSMISSION COMPONENTS LOCATION……………………………………….105
HYDROSTATIC TRANSMISSION CIRCUIT……………………………………106
MT 625 – MT-X 625……………………………………………..106
MLT 625 – MLT-X 625……………………………………………106
TRANSMISSION CONTROL AND ADJUSTMENT…………………………………….107
HYDROSTATIC TRANSMISSION PRESSURE TEST PORT LOCATION………………….108
PRESSURE TEST PORT VALUES………………………………………….108
TOWING PROCEDURE………………………………………………….109
TIGHTENING TORQUES………………………………………………..110
TRANSMISSION REMOVAL………………………………………………….111
COMPONENTS LOCATION……………………………………………….112
PREPARATION AND SAFETY INSTRUCTIONS…………………………………112
HYDROSTATIC PUMP………………………………………………….113
HYDROSTATIC MOTOR…………………………………………………115
TRANSMISSION REFIT……………………………………………………117
COMPONENTS LOCATION……………………………………………….118
PREPARATION AND SAFETY INSTRUCTIONS…………………………………118
HYDROSTATIC PUMP………………………………………………….118
HYDROSTATIC MOTOR…………………………………………………119
SPECIFIC TRANSMISSION TOOLING………………………………………….121
BASIC MANOMETER BOX……………………………………………….122
DIGITAL MANOMETER BOX……………………………………………..123
GR40_BRAKE………………………………………………………………125
BRAKE CHARACTERISTICS AND SPECIFICATIONS………………………………..127
SERVICE BRAKE / PARKING BRAKE………………………………………129
BRAKE CONTROL AND ADJUSTMENT…………………………………………..131
BRAKE AND INCHING PEDAL ADJUSTMENT………………………………….132
BLEEDING PROCEDURE………………………………………………..134
SPECIFIC BRAKE TOOLING………………………………………………..139
BRAKE FLUID BLEEDER……………………………………………….140
GR50_BOOM……………………………………………………………….141
BOOM CHARACTERISTICS AND SPECIFICATIONS…………………………………143
DUPLEX BOOM………………………………………………………144
BOOM COMPONENTS LOCATION………………………………………………145
INDEX OF COMPONENT CODES…………………………………………..146
LOCATION OF THE DUPLEX BOOM MAIN COMPONENTS………………………….146
BOOM CONTROL AND ADJUSTMENT……………………………………………147
DUPLEX BOOM REMOVAL……………………………………………….148
DUPLEX BOOM REFIT…………………………………………………153
SHIM INSTALLATION RECOMMENDATIONS…………………………………..157
TIGHTENING TORQUE…………………………………………………158
REFITTING THE TELESCOPE CYLINDER……………………………………159
BOOM REMOVAL…………………………………………………………163
DUPLEX BOOM………………………………………………………164
GENERAL INFORMATION……………………………………………164
PREPARATION AND SAFETY INSTRUCTIONS……………………………..164
PLATFORM HARNESS………………………………………………167
BOOM REFIT…………………………………………………………..169
DUPLEX BOOM………………………………………………………170
SPECIFIC BOOM TOOLING…………………………………………………173
PIPE END PIECES…………………………………………………..174
GR70_HYDRAULICS………………………………………………………….175
HYDRAULIC CHARACTERISTICS ANDSPECIFICATIONS……………………………..177
TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS…………………………..177
COMPLETE ELECTROVALVE (OPTION)………………………………….178
5000CC……………………………………………………….179
5000CC DISTRIBUTOR (INLET ELEMENTS)………………………….179
5000CC DISTRIBUTOR (LIFTING ELEMENT)…………………………181
5000CC DISTRIBUTOR (TILTING ELEMENT)…………………………183
5000CC DISTRIBUTOR (ATTACHMENT ELEMENT)………………………185
5000CC DISTRIBUTOR (TELESCOPE ELEMENT)……………………….187
3 POSITION STEERING SELECTOR……………………………………189
DISTRIBUTOR 5000………………………………………………190
DISTRIBUTOR 5000 (INLET ELEMENTS)……………………………190
DISTRIBUTOR 5000 (INLET ELEMENTS)……………………………191
DISTRIBUTOR 5000 (LIFTING ELEMENT)…………………………..192
DISTRIBUTOR 5000 (LIFTING ELEMENT)…………………………..193
DISTRIBUTOR 5000 (TILTING ELEMENT)…………………………..194
DISTRIBUTOR 5000 (TILTING ELEMENT)…………………………..195
DISTRIBUTOR 5000 (ATTACHMENT ELEMENT)………………………..196
DISTRIBUTOR 5000 (ATTACHMENT ELEMENT)………………………..197
DISTRIBUTOR 5000 (ATTACHMENT ELEMENT)………………………..198
FEED BLOCK + ACCUMULATOR……………………………………….200
AGGRAVATING MOVEMENT CUT-OFF BLOCK………………………………201
STEERING PUMP / STEERING UNIT OSPC 160 LS / ORBITROL………………202
SVaTluEeEsR inINdicGa tPivUe MonPly / STEERING UNIT OSPC 160 LS…….203
COUNTERBALANCE VALVE VBSN………………………………………204
COMPENSATING ISOLATION VALVE VIC………………………………..205
HYDRAULIC SCHEMATIC DIAGRAMS…………………………………………..207
KEY……………………………………………………………..208
HYDRAULIC DIAGRAM…………………………………………………209
MT/MT-X 625 H TURBO /-/ MT/MT-X 625 H COMFORT…………………….209
MT 625 HA…………………………………………………….210
MLT 625 / MLT-X 625……………………………………………211
MLT 625 / MLT-X 625 – cumulative movements option…………………212
HYDRAULIC COMPONENTS LOCATION………………………………………….213
KEY……………………………………………………………..214
LOCATION…………………………………………………………214
HYDRAULIC CONTROL AND ADJUSTMENT……………………………………….215
PRESSURE TEST PORTS……………………………………………….216
VALUES……………………………………………………….216
LOCATION……………………………………………………..217
DISTRIBUTOR TIGHTENING TORQUES……………………………………..218
HYDRAULIC COMPONENT REMOVAL……………………………………………219
COMPONENTS LOCATION……………………………………………….220
HYDRAULIC PUMP……………………………………………………221
MT 625 / MT-X 625……………………………………………..221
MLT 625 / MLT-X 625……………………………………………221
DISTRIBUTOR………………………………………………………223
ACCUMULATOR BLOCK…………………………………………………224
SUCTION STRAINER………………………………………………….225
BACKUP ELECTRIC PUMP (Only on MT 625 HA)…………………………….226
8 EV HYDRAULIC BLOCK………………………………………………227
HYDRAULIC COMPONENTS REFIT…………………………………………….229
COMPONENTS LOCATION……………………………………………….230
HYDRAULIC PUMP……………………………………………………231
MT 625 / MT-X 625……………………………………………..231
MLT 625 / MLT-X 625……………………………………………231
DISTRIBUTOR………………………………………………………233
ACCUMULATOR BLOCK…………………………………………………234
SPECIFIC HYDRAULIC TOOLING…………………………………………….235
BASIC MANOMETER BOX……………………………………………….236
DIGITAL MANOMETER BOX……………………………………………..237
GR80_ELECTRICITY…………………………………………………………239
ELECTRICAL CHARACTERISTICS ANDSPECIFICATIONS…………………………….241
WIRING…………………………………………………………..243
FUSES AND RELAYS………………………………………………243
ELECTRICAL CONNECTORS………………………………………….248
OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM (Except MTHA)…………….253
OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM (MT HA)………………….254
INPUTS/OUTPUTS……………………………………………………255
X13 – DASHBOARD MODULE (A1)…………………………………….255
X55 – MAIN ECU MT HA _ SPU 40-26 (A3)……………………………256
X56 – MAIN ECU MT HA _ SPU 40-26 (A3)……………………………257
X57 – MAIN ECU MT HA _ SPU 40-26 (A3)……………………………258
X56 – MAIN ECU MT/MLT _ SPU 25-15 (A3)………………………….. 0
X57 – MAIN ECU MT/MLT _ SPU 25-15 (A3)………………………….. 0
X174 – ENGINE ECU MT/MLT (A13)………………………………….261
X175 – ENGINE ECU MT/MLT (A13)………………………………….262
X292 / X295 / X298 / X 299 / C4 / C5 – TRANSMISSION ECU – A2……….263
X410 – ENGINE ECU MT-X/MLT-X _ SPU 25-15 (A16)……………………264
X411 – ENGINE ECU MT-X/MLT-X _ SPU 25-15 (A16)……………………265
TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS…………………………..266
X1 / X2 – STARTER IGNITION SWITCH (S2)…………………………..266
X6 – ROTATING BEACON LIGHT (E15)………………………………..266
X20 – AIR FILTER SWITCH (B35)…………………………………..267
X21 HYDRAULIC FILTER CLOGGING CONTACT (B7)……………………….267
X22 – BRAKE FLUID SWITCH (S11)………………………………….268
X38 – REVERSING BUZZER (B1)…………………………………….268
X39 – HORN (B2)……………………………………………….269
X62 TRANSMISSION SPEED SENSOR (B13)……………………………..269
X63 FUEL GAUGE (B34)…………………………………………..270
X64 – MASTER CYLINDER PRESSURE SWITCH (B8)……………………….271
X65 / X66 – WHEEL ALIGNMENT SENSOR (B12+B21)……………………..271
X67 – JSM (A4+A5)……………………………………………..272
X93 – NEGATIVE BRAKE EV (Y13)…………………………………..273
X100 – BOOM ANGLE SENSOR (B11)………………………………….274
X118 – ANTI-THEFT OUTPUT (A6)…………………………………..275
X134 – BOOM RETRACTED SWITCH (S34)………………………………275
X134 – FORWARD AND REVERSE ELECTROVALVE (Y3+Y4)…………………..276
X139 – INCHING PEDAL ANGLE SENSOR (B9)…………………………..276
X179 – ACCELERATOR PEDAL ANGLE SENSOR (B25)………………………277
X264 / X265 – TELESCOPING + ATTACHMENT EV (Y8+Y9)…………………277
X266 / X267 – TELESCOPING + ATTACHMENT PROPORTIONAL EV (Y10+Y11)……278
X269 – HYDRAULIC CUT-OFF EV (VS) (Y12)…………………………..278
X270 / X377 – LOWERING + LIFTING PROPORTIONAL CUT-OFF EV (Y14+Y18)….279
X275 – TILTING CUT-OFF EV (VCI) (Y15)……………………………279
X289 / X290 – ALTERNATOR (B+/IG-L)………………………………280
X385 – FAN SPEED EV (TS) (Y19)………………………………….281
X386 – FAN DIRECTION EV (SV) (Y20)………………………………282
ELECTRICAL SCHEMATIC DIAGRAMS………………………………………….283
ELECTRICAL DIAGRAM CODIFICATION EXAMPLE……………………………..284
MARKING OF CABLES ON A WIRING HARNESS……………………………….285
MT – MLT WIRING DIAGRAMS…………………………………………..286
POSITION OF WIRING HARNESSES BY DIAGRAM………………………….286
1 – STARTING………………………………………………….290
2 – CAN………………………………………………………292
3 – TRANSMISSION………………………………………………294
4 – HYDRAULIC MOVEMENTS (MT 625 H)#……………………………..296
4 – Combined HYDRAULIC MOVEMENTS OPTION (MLT 625 & MT 625 HA)*……..298
5 – SENSORS…………………………………………………..300
6 – LIGHTING AND SIGNALLING…………………………………….302
7 – OPTIONS / FAN……………………………………………..304
8 – ACCESS (For MT HA)…………………………………………306
MT-X / MLT-X WIRING DIAGRAMS……………………………………….308
POSITION OF WIRING HARNESSES BY DIAGRAM………………………….308
1 – STARTING………………………………………………….312
2 – CAN………………………………………………………314
3 – TRANSMISSION………………………………………………316
4 – HYDRAULIC MOVEMENTS………………………………………..318
5 – SENSORS…………………………………………………..320
6 – LIGHTING AND SIGNALLING…………………………………….322
7 – OPTIONS / FAN……………………………………………..324
ELECTRICAL COMPONENTS LOCATION…………………………………………327
MT – MLT…………………………………………………………328
KEY………………………………………………………….328
CONNECTORS………………………………………………..328
DIODES AND SPLICES…………………………………………332
2D LOCATION…………………………………………………..334
CAB ANNEX HARNESSES………………………………………..334
HARNESS ASSEMBLY…………………………………………..335
MAIN HARNESS MT625 H……………………………………….336
ENGINE HARNESS…………………………………………….337
3D LOCATION…………………………………………………..338
MAIN HARNESS IN CAB………………………………………..338
MAIN HARNESS ON FRAME………………………………………339
HARNESS IN ENGINE HOUSING…………………………………..340
MAIN HARNESS MT 625 HA / MLT (combined movements option)……….341
MT-X – MLT-X……………………………………………………..342
KEY………………………………………………………….342
CONNECTORS………………………………………………..342
DIODES AND SPLICES…………………………………………345
2D LOCATION…………………………………………………..347
MAIN HARNESS MT-X 625 H comfort……………………………..347
ENGINE HARNESS MT-X 625 H comfort……………………………348
3D LOCATION…………………………………………………..349
MAIN HARNESS IN CAB MT-X 625 H comfort……………………….349
MAIN HARNESS ON FRAME MT-X 625 H comfort……………………..350
HARNESS IN ENGINE HOUSING MT-X 625 H comfort………………….351
ELECTRICAL CONTROL AND ADJUSTMENT………………………………………353
“BOOM ANGLE” ANGULAR SENSOR ADJUSTMENT………………………………354
LONGITUDINAL STABILITY INDICATOR (LLMI)……………………………..356
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE………357
STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE)……….358
STRAIN GAUGE RECALIBRATION (CLIENT PROCEDURE)…………………….359
“AGGRAVATING” HYDRAULIC MOVEMENTS CUT-OFF………………………..360
LED ILLUMINATION ACCORDING TO CHANGES IN GAUGE SIGNAL……………..360
INCLINOMETER CALIBRATION (MT HA)……………………………………361
DASHBOARD CALIBRATION MENU…………………………………………362
ELECTRICAL COMPONENTS REMOVAL………………………………………….367
COMPONENT REMOVAL (MT / MLT)……………………………………….368
COMPONENT REMOVAL (MT-X / MLT-X)……………………………………370
JSM on BMEP………………………………………………………371
ELECTRICAL COMPONENTS REFIT……………………………………………373
STRAIN GAUGE……………………………………………………..374
ELECTRICAL TROUBLESHOOTING…………………………………………….381
READING OF ERROR CODES…………………………………………….382
DASHBOARD ERROR CODES………………………………………….382
PAD ERROR CODES……………………………………………….382
ERROR CODES / CONTROL UNITS………………………………………..383
Dashboard ECU (A1)…………………………………………….383
Transmission ECU (A2)………………………………………….384
Main ECU A3: SPU25 – 15 / MT_MT-X……………………………….385
Main ECU A3: SPU 40 – 26 / MT-HA………………………………..387
DTC ENGINE ECU ECU A13 – MT/MLT (X174 – X175)…………………….390
DTC ENGINE ECU ECU A16 – MT-X/MLT-X (X400 – X411)…………………391
ELECTRICAL SPECIFIC TOOLING……………………………………………393
DIAGNOSTIC TOOLS………………………………………………….394
BREAKOUT BOXES……………………………………………………398
ELECTROVALVE ADAPTER………………………………………………398
GR85_DRIVER’S CAB………………………………………………………..399
DRIVER’S CAB CHARACTERISTICS ANDSPECIFICATIONS…………………………..401
AIR CONDITIONER…………………………………………………..402
OPERATING PRINCIPLE……………………………………………402
OPERATION DESCRIPTION………………………………………….403
DESCRIPTION OF COMPONENTS………………………………………404
DRIVER’S CAB COMPONENTS LOCATION……………………………………….407
AIR CONDITIONING………………………………………………….408
DRIVER’S CAB CONTROL AND ADJUSTMENT…………………………………….409
AIR CONDITIONER…………………………………………………..410
ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT………………..410
R134a REFRIGERANT FLUID CHARACTERISTICS………………………….412
SAFETY MEASURES FOR HANDLING R134a………………………………412
REFRIGERANT FLUID LOAD FOR THE AIR-CONDITIONING CIRCUIT……………413
CHARGING METHOD……………………………………………….413
FUNCTIONAL CHECKS……………………………………………..414
ANTI-ICING SAFETY MONITORING……………………………………415
AIR CONDITIONING INSPECTION FORM………………………………..416
DRIVER’S CAB REMOVAL………………………………………………….417
REPLACING AIR-CONDITIONER COMPONENTS………………………………..418
DRIER FILTER………………………………………………….418
PRESSURE SWITCH……………………………………………….419
THERMOSTAT……………………………………………………420
REDUCING VALVE………………………………………………..422
EVAPORATOR……………………………………………………424
CONDENSER FAN…………………………………………………426
CONDENSER…………………………………………………….427
HOSES………………………………………………………..428
COMPRESSOR……………………………………………………429
DRIVER’S CAB TROUBLESHOOTING…………………………………………..431
AIR-CONDITIONER FAULT DIAGNOSTICS…………………………………..432
FAULTY AIR-CONDITIONING………………………………………..432
FAULTY VENTILATION…………………………………………….433
FAULTY HEATING………………………………………………..433
GR110_OPTIONS – ATTACHMENTS……………………………………………….435
COMPONENTS LOCATION…………………………………………………..437
35 AND 40 KM/H PREDISPOSITION OPTION………………………………..438

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V