MLT625 XPRT Service Training.ppt

7/25/2019 MLT625 XPRT Service Training.ppt

1/158

XPRT MLT 625 Training


2/158

MLT 625 75 H

MLT

6

25

= Manitou Loader Telescopic

= Max height: 6 meters

= Max load capacity: 2.5 tons

! = uro !

"enomination

#$ = #eries$

= ngine 75 H%75


3/158

MLT 940 T-120 LSU

New Agricultural Range &urrent 'ange

Series 6 E3

Series 4 E3

Series 1 E3

MLT 625-75 H

MLT 735-120 LSU

MLT 625-75 H

MLT 735 T 120 LSU

MLT 845 T 120 LSU


4/158

Unit Identification


5/158


6/158


7/158


8/158

Specifications


9/158

#peci(ications


10/158

#peci(ications


11/158

#peci(ications

# (


12/158

#peci(ications

# i(i i


13/158

#peci(ications


14/158

Specifications

Load &harts are in pounds and

(eet so there is no need tocon)ert the *eight.

+hat is the capacity *here the

green dot is located,


15/158

Instruents and !ontrols


16/158

Instruments and Controls


17/158



18/158


-T: The location o( the s*itches may )arydepending on the options.

/ 0 +/'-1- L1HT#

3 0 '/' 4 L1HT#

& 0 'L1- L1HT

" 0 4'-T /-" '/' +'1- L1HT# %T1-

13 H/" L1HT#

0 %T1- '/' +1-"+ "01&1-

4 0 -8T'/L1#/T1- 4 H9"'/8L1&

MM-T#

0 /' #L&T1-. ears can e selected *hile dri)ing.

#L+ #%": 8se (or handling; s*itch in the up position; the indicator lamp is o((.

H1H #%": 8se on the road; s*itch in do*n position; the high speed indicator lamp comes on.

H 0 +HL /L1-M-T 1-"1&/T' L/M%#

1 0 %/'1- 3'/

/

3

&

"

4

H

1


19/158

Instruments and Controls 0 "1#/3L1- TH


20/158

#M oysticA

&ontrols

&ontrol

/ 0 Li(ting and tilting control le)er.

3 0 Telescoping control utton.& 0 /ttachment control utton.

L14T1- TH L/"

0 The le)er / acA*ards *hen li(ting.

0 The le)er / (or*ards *hen lo*ering.

T1LT 4 &/''1/

0 The le)er / to the le(t (or re)erse tilt.

0 The le)er / to the right (or (or*ard tilt.

TL#&%1-

0 3utton 3 (or*ards (or extending.

0 3utton 3 acA*ards (or retracting./TT/&HM-T

0 3utton & (or*ards or acA*ards.

/

3 &


21/158

#M oysticA

&ontrols

"#R$AR%&N'UTRAL&R'('RS'GEAR

SELECTION

+hen operating this control; the li(t trucA

should e tra)elling at slo* speed and not

accelerating.

4'+/'": %ush the Ano (or*ard

>position /?.

''#: %ull the Ano acA*ard

>position 3?. >/n %T1-/L re)ersing light

and audile re)ersing alarm indicate that

the li(t trucA is tra)elling in re)erse?.

-8T'/L

2$

/

3&


22/158

)*draulic !oponent Location and "unction


23/158

P

DBA

BMHP

BCMA

PDD

PH2!


24/158

Hydraulic %ump


25/158

Hydraulic fan motor + inverse valve


26/158

hydraulic valve Bank


27/158

Supply block + Accumulator


28/158

Hydraulic proportional manipulator block


29/158

Aggravating cut o movements block


30/158

!rbitrol

Double hydraulic pump


31/158

11 cm3

31 cm3

Maximumtorque:

280 Nm

Double hydraulic pump


32/158

One wayvalve

Flowregulation

TS/1!

Flowinver"ion

S#/20

Tan$

Su%%ly

Hydraulic fan motor + inverse valve

Compensating cylinder + Compensating


33/158

Compensating cylinder + Compensatingisolation valve

One way valve"

&"olationvalve

'300()

Tig*tening

torque at+,/,0 Nm

Steering pump "!rbitrol#


34/158

Steering pump "!rbitrol#

-ig*t "i.e

et "i.e

Su%%ly

Tan$

#alve an$S



35/158


MN&TO-e

4u"co 5o.e

Su%%ly

Tan$

Tilt .own

Tilt u%

iting

owering



36/158

1+'oweringcut o6 7#)

1, 'Tiltingcut o6 7#)

Tan$

Tilting.own

owering

Tilting u%iting

Su%%ly

Tilting.own

18 'itingcut o6 7#)

owering

iting

1+'owering

cut o6 7# )




37/158

10 'Tele"co%e%ro%ortional 7#)

11'ttac*ement%ro%ortional

7#)

12 '4y.raulic

cut o6 7#)

13 'ar$ing

(ra$e 7#)

8 'Tele"co%e"election 7#)

!

'attac*ement "election

7#)

7F 9lter

ar$ing(ra$e

connection

pp y

5oil" re"i"tance

8 o*m" or 8;!; 12; 13

2;2 o*m" or 10et 11



38/158

pp y

re""urete"t %ort

'in)

re""urete"t %ort

'%)

ar$ing(ra$e

%re""ureSwitc*'"a*r)

Su%%lyTan$


39/158

Main relief

valve

(235b)

Flow

divide r

element

Liftingelem

ent

Tiltingelem

ent

Atta

cheme

ntelement

Tele

scope

element

Tank

!ppl"

teering

L

teerings!ppl"

Anti#shockrod side(2$5b)

Anti#shock%arrel

side(2$5b)

Anti#shock

(&'b)

Anti#shock(2$5b)

)

elemen

t

y


40/158

Compensating isolation valve


41/158

T+e purpose of t+e copensation ,al,e-

eep the toolBucAet position le)el *ith the mo)ement o( up

B do*n (unction o( the oom.

&ompensation


42/158

Compensating isolation valve


43/158

&ounteralance )al)e

The aim: #upports the cylinder in case o( hose reaAage. &ylinder mo)ement reCuires the starting o( the

engine Limits maximum pressure due to impacts.

& l l


44/158

ChargeCharge

effectiveeffective

L

3ulletin 1T 7D6

&ounteralance )al)e

a.a. adita/le 0 153 & inuteadita/le 0 153 & inute

a. L adita/le 0 451 & 41 inutesa. L adita/le 0 451 & 41 inutes

Reffe

ring

PrEn

1!"

#1""$

norm

e


45/158

#chematic:

C1 C2

V1 V2

Max pressureadEustment

/nti return )al)eTemporisation

scre*

#pool

&ounteralance )al)e


46/158

#ectional )ie*

4lo* &ontrol

#cre*

/nti return )al)e

#poolMax pressure

adEustment

&ounteralance )al)e


47/158

"escription

%iston side 'od side

4lo* control scre*

locA nutMax pressure

adEustment

&ounteralance )al)e


48/158

/dEustment and checAing

1( the mo)ements are sharp >too (ast B EerAy? or too slo* >delay in

comparison to the control?; the adEustment o( the scre* 3 is reCuired

.

The distance / is a re(erence = optimum setting (rom (actory.

A= $7mm

!

&ounteralance )al)e


49/158

$arning t+e setting of t+is ,al,e engages *our ci,il and criinal lia/ilit* in

case of accident7 T+is ,al,e ust necessaril* /e sealed

$ARRANT8 $ILL ' (#I% I" TAMP'R'% $IT)

&ounteralance )al)e

To e ale to adEust a counter alance )al)e; a test ench is reCuired..

The procedure is descried in the

Safet*

cartridge

Technical in(ormation nr 6FD


50/158

A= $7mm

!

1t is possile to G unlocA the conter alance )al)e in order to release the pressure to e

ale to disconnect the it (rom the cylinder.

$0'emo)e the time delay scre* 3

20'emo)e the locA nut >&? (rom the time delay scre*>3?.

!0Tighten the time delay scre* >3? manually up to the end o( stroAe.

I0 Tighten the time delay scre* >3? o( $ rotation *ith a tool.

&ounteralance )al)e

IMP#RTANT-


51/158

!*lindersIMP#RTANT-

+hen replacing or *orAing on a cylinder (or *arranty

purpose record the #/HL -umer


52/158

)*draulic Testing


53/158

Hydraulic Circuit

Hydraulic Test &ircuit


54/158




55/158


3oost pressure is adEusted on the

hydrostatic pump

Main pressure is adEusted on themain )al)e


56/158

)*dostatic %ri,e !oponent Location and "unction


57/158

)*drostatic Transission

&haracteristics


58/158

&haracteristics

/xial piston pump H$ B I5 (or MLT 625J Proportional EV pilot

J I5 cm!J H% against pressure (lo* regulation

%ressureJ Boost at 25b

J HP at 400b for MLT 625

/xial piston motor H$ B KF (or MLT 625J Proportional EV pilot capacity regulation

J 80 c!

Hydrostatic Pump


59/158

*everse pilot line

Forward pilotline

%oost press!re+ase press!re

,igh -ress!re-ort

,igh -ress!re-ort

Tank ret!rn

Hydrostatic Pump

!ction

Components location


60/158

Forward pilotline (M$)

,- (%)

,- (A)

Tank *et!rn (L&)

!ction ()

*everse pilot line(M5)

+ase press!re(L2)

Components location

Components location


61/158

*et!rn tank(M&$ bleeding)

Forward ,- (M%)

%oost press!re(M3)

*everse ,- (MA)

,ole to e.ternalfilter

Components location

96 t*o speed solenoid


62/158

Tank ret!rn

*everse ,-

Forward,-

,-

*eg!lationpress!re

)*drostatic Motor

+ase press!re

960t*o speed solenoid

970%ump control (rom raAe pedal

Components location


63/158

,- (M5)

*everse ,- (MA)

-ress!rereg!lation (M$)

p

Components location


64/158

*everse ,- (A)Forward ,- (%)

Forward ,- (M%)

Tank ret!rn

+ase press!re

p

/lectronic transmission +ontrol


65/158

FN-

-oller"

&nc*ing%otentiometer

75 S7-

4y.ro"tatic%um%

75 > @@@ A

Transmission Can-Bus

75 lig*t ault

Negative(ra$e


66/158

)*dostatic S*ste Testing



67/158

%ressure test port >%%? is

located on the dri)e motor

on the (ront axle and isaccess )ia the top co)er.

%ressure is tested at idle

and (ull throttle




68/158

* * g

1n order to stall the

hydraulic system

you must remo)e

the connectors on

the raAe pressure

>%sahr? signal

s*itch.

) d t ti S t T ti


69/158


There are t*ohigh pressure

relie( )al)es

located on the

pump.

The relie( )al)es

are non0

adEustale.


70/158

'lectrical S*sten oard Tec+nologies

#n oard

Tec+nologies


71/158

Tec+nologies

Here are the

areas that

maAe the MLT

625 a )ery

uniCue

machine .

+e *ill talA

aout each o(

the systems

that maAe this

a )ersatile

machine.


72/158

#M

C!$$%C&!' P($ &ension

*,

- . / 0round

1 -2 / supply

, Signal

3neutral ./ out of

$eutral -2 /

4neutral ./ out of

$eutral -2 /

Signal

5

neutral ./ out of

$eutral -2 /

2neutral ./ out of

$eutral -2 /

lectrical &omponent

# d T + l i


73/158

Strain gauge

M&

#eat sensor>normallyo(( ?

#M 'oller '$ '2 B0

4-'

)erride

T1-

sensor

3oom

angle

sensor

HYD-ECU

P"#

BCMA

Mo)ement B #tailty

#n oard Tec+nologies

BA

#


74/158

T1- sensor

$!I

3oom angle sensor

C!$$%C&%! P($ &ension

*-54

- -2 /

2 -2 /

5 Signal

4 Signal

C!$$%C&!' P($ &ension

*-..

- . /

2 -2 /

5 Signal

4 . /

3 -2 /

Signal

lectrical - $5FFF M"L#


75/158


76/158


77/158


78/158

/lectronic transmissionTransmission Can-Bus


79/158

FN-

-oller"

&nc*ing%otentiomete

r

75 S7-

4y.ro"tatic%um%

75 > @@@ A

Transmission Can Bus

75 lig*t ault

Negativera$e

lectrical architecture


80/158


81/158



82/158




83/158




84/158


Man0Machine 1nter(ace >MM1?


85/158




86/158




87/158



88/158

#creen "isplay on the MM1


89/158



90/158



91/158



92/158



93/158

rror &odes as Listed in the #er)ice Manual


94/158


95/158

9u/ota 'ngine !+aracteristics


96/158

The -+ uota F7 #eries engines ha)e een designed to comply *ith

%/ 1nterim Tier I ption emissions regulations.

#peci(ications


97/158

#peci(ications

'ngine "eatures


98/158

The -+ uota F7 #eries engines ha)e een

designed to comply *ith %/ 1nterim Tier I ption

emissions regulations.The F7 series "1 engine are the )ertical type I0cycle

diesel engine (eaturing the ad)anced per(ormances

uota@s original 0&"1# >&enter "irect

1nEection

#ystem? comustion system; reno*ned (or

clean

comustion in the uota ! >"1? #eries;

has een

reno)ated. The (uel inEection pressure *as

increased

and the comustion chamer *as

redesigned to

achie)e a 25 N lo*er particulate matter

>%M? le)el

'ngine "eatures


99/158

xternal ' system

*ith ' cooler

The engine (eatures

indi)idual glo* plugs

The engine uses a

separated (uel inEection

%ump *ith external (uel

shuto(( solenoid and

external shuto(( le)er

'ngine "eatures


100/158

ngine coolant temp hot light

sender located on the thermostathousing

ngine coolant temp gage sender

located near the rear o( the engine

'ngine "eatures


101/158

il pressure s*itch located on the

right hand side o( the engine on theoutside

The ' system taAes exhaust gas

(rom the (ront o( the engine andcomines the cooled exhaust gas

*ith the intaAe air near the rear.


102/158

!ooling !ircuit


103/158

ngine &ooling #ystem


104/158

3ottom ypass system is designed (or impro)ing the

cooling per(ormance o( the radiator.

+hile the temperature o( coolant in the engine is

lo*; the thermostat >$? is held closed and the

coolant is allo*ed to (lo* through the ypass pipe

and to circulate in the engine.

+hen the temperature exceeds the thermostat >$?

)al)e opening le)el; the thermostat >$? (ully opens

itsel( to pre)ent the hot coolant (rom (lo*ing through

the ypass into the engine.

1n this *ay; the radiator can increase its cooling

per(ormance.

>$? Thermostat

>2? 'adiator

>!? ngine

>/? 3ypass pened

>3? 3ypass &losed

ngine &ooling #ystem


105/158

ngine cooling radiator is

located on the (ront o( the

engine to the le(t o( the

hydraulic oil cooler

Mounted to the right o( the

radiator is the hydraulic oil

cooler

g g y

Hydostatic oil cooling system


106/158

ngine oil cooling system


107/158

The engine has a coolant0cooled oil cooler

that not only cools hot oil; ut also *arms

the cool engine oil shortly a(ter start up.

/s sho*n in the (igure; the oil (lo*s inside

the connected cooler plate; *here the

coolant is Aept circulating outside the

cooler plate; therey cooling do*n or

*arming the oil.

>/? il 1nlet %ort

>3? il utlet %ort

>a? &oolant 1nlet %ort

>? &oolant utlet %ort


108/158

Steering !ircuit

#teering circuit


109/158

T+e ai -

"irect and dose the (lo* in order to supply the

steering circuit 1t is a rotating )al)e

#teering circuit

#teering circuit


110/158

ORBITROL

Antishock Valve

Relief valve

Steering selector

L#

"escription

# ee g c cu

#teering circuit


111/158

Relief valve

Antishock Valve

"escription

g

#teering circuit


112/158

peration

g

-o rotation o(

steering

Turn on le(t side

Turn on right side

#teering circuit


113/158

#n MANIS!#PI! truc:s t+ere are ; steering odes

2 w+eel steer S+ort steering !ra/wise

position

g


114/158

#teering circuit


115/158

!ra/ position

g

#teering circuit


116/158

S+ort steering

g

#teering circuit


117/158

nd o( steering cylinder

g

#teering circuit


118/158

/ntishocA (unction

g


119/158

3raAe &ircuit


120/158

3raAe &ircuit


121/158

%arA 3raAe &ircuit


122/158

3raAe &ircuit0 1nching %edal /dEustment


123/158

8se a gauge or other

template to checA the 7 mm

dimension et*een pushutton *asher >1tem /?

contact (ace and shell >1tem

3? contact (ace.

'elease ruer pad >1tem &?

up to contact *ith pedalsystem support >1tem ?

Tighten locAnut >1tem "? on

raAe pedal arm.


124/158


125/158

1-&H1-B3'/1-

#/8' M"8L/"8#TM-T


126/158

Power Train&A.les

/xle


127/158

%ANA SPI!'R%ANA SPI!'R

&haracteristics


128/158

'ear axle >22$?

J "irectionalJ "i((erential *ithout limited slip *ithout locA

J +heels alignment sensor

4ront axle >2$$?J "irectional

J "i((erential *ith limited slip >I5N?

J #er)ice raAe in ath o( oil >only one side?

J -egati)e parAing raAe >y the ser)ice raAe?J +heels alignment sensor >only MLT?

Components location


129/158

ervice brake-arking brake

0ifferential lock (not!sed)

ervice brakebleeding

-arking brakebleeding


130/158

Planetar*

Reducer

Steering c*linder

%ifferential

$+at oil to use


131/158

$+at oil to use

Documents

MLT625 XPRT Service Training.ppt