Manitou MLT 630_730 647699EN Repair Manual – PDF DOWNLOAD
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Manitou MLT 630_730 647699EN Repair Manual – PDF DOWNLOAD
Size : 51.8 MB
Format : PDF
Language : English
Type of document: Repair Manual
Model:
– MLT 630 105D ST4 S2
– MLT 630 105D V ST4 S2
– MLT 630 105D V CP ST4 S2
– MLT 730 115D V ST4 S1
– MLT 730 115D V CP ST4 S1
Content:
– General characteristics and safety
– ENGINE SPECIFICA TION
– TRANSMISSION
– BRAKE
– BOOM
– HYDRAULICS
– Electricity
– DRIVER’S CA B
– OPTIONS & ATTACHMENTS
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VIDEO PREVIEW OF THE MANUAL:
DESCRIPTION:
Manitou MLT 630_730 647699EN Repair Manual – PDF DOWNLOAD
MLT 630 105D ST4 S2
MLT 630 105D V ST4 S2
MLT 630 105D V CP ST4 S2
MLT 730 115D V ST4 S1
MLT 730 115D V CP ST4 S1
GENERAL INSTRUCTIONS AND SAFETY NOT ICE
00.1.1 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 MLT 630_730 647699EN Repair Manual – PDF DOWNLOAD
General characteristics and safety……………………………………………………. 1
Page de garde / Front page……………………………………………………….. 1
Sommaire général – General table of content………………………………………… 3
00…………………………………………………………………………….. 9
GENERAL, CHARACTERISTICS AND SAFETY……………………………………………….. 10
00.1 GENERAL INSTRUCTIONS AND SAFETY NOTICE…………………………………….. 10
00.1.1 PREAMBLE………………………………………………………….. 10
00.1.2 SERVICING POSITION…………………………………………………. 10
00.1.3 EXPLANATION OF SYMBOLS……………………………………………… 11
00.1.4 SERVICING RULES……………………………………………………. 12
00.2 GENERAL CHARACTERISTICS AND SPECIFICATIONS…………………………………. 15
00.2.1 CHARACTERISTICS……………………………………………………. 15
00.2.2 LUBRICANTS AND FUEL………………………………………………… 15
00.2.3 DIMENSIONS………………………………………………………… 16
00.3 GENERAL LOCATION………………………………………………………… 17
00.3.1 LOCATION OF NAME AND IDENTIFICATION PLATE…………………………….. 17
00.4 GENERAL CONTROL AND ADJUSTMENT……………………………………………. 18
00.4.1 STANDARD TIGHTENING TORQUES…………………………………………. 18
00.4.2 METRIC – IMPERIAL UNIT CONVERSION……………………………………. 19
BOOM………………………………………………………………………………. 21
50…………………………………………………………………………….. 21
BOOM…………………………………………………………………………… 22
50.1 Boom characteristics and specifications……………………………………. 22
50.1.1 DUPLEX BOOM……………………………………………………….. 22
50.2 Boom location…………………………………………………………… 23
50.3 Boom control and adjustment………………………………………………. 23
50.3.1 Mount the boom pads with insert……………………………………… 23
50.3.2 Secure the pins……………………………………………………. 23
50.4 Boom removal – refit…………………………………………………….. 23
50.4.1 Remove the telescopic cylinder………………………………………. 23
BRAKE……………………………………………………………………………… 27
40…………………………………………………………………………….. 27
BRAKE………………………………………………………………………….. 28
40.1 – BRAKE characteristics and specifications…………………………………. 28
40.1.1 Brake components characteristics…………………………………….. 28
40.1.2 TRAILER BRAKE VALVE………………………………………………… 28
40.2 Brake diagrams………………………………………………………….. 29
40.3 Brake location………………………………………………………….. 29
40.3.1 Hydraulic control………………………………………………….. 29
40.3.2 Mechanical control with sensor………………………………………. 29
Standard tow tractor with cable tension sensor…………………………… 30
40.4 Brake control and adjustment……………………………………………… 30
40.4.1 Brake valve tightening torque……………………………………….. 30
40.4.2 Master valve adjustment and tightening torque…………………………. 30
40.4.3 Trailer brake valve tightening torque………………………………… 30
40.4.4 Towing……………………………………………………………. 31
40.4.5 Brake valve pressure connector………………………………………. 31
40.4.6 Adjust the parking brake……………………………………………. 31
40.4.7 BRAKE PEDAL ON MLT 630 105 D………………………………………… 32
40.4.8 BRAKE PEDAL ON MLT 630 105D V + CP ST4 S2 / MLT 730 115D V + CP ST4 S1…… 33
40.5 Brake removal – refitting………………………………………………… 34
40.5.1 Remove the brake valve……………………………………………… 34
Refit……………………………………………………………….. 34
DRIVER’S CA B………………………………………………………………………. 35
85…………………………………………………………………………….. 35
DRIVER’S CAB……………………………………………………………………. 36
85.1 DRIVER’S CAB CONTROL AND ADJUSTMENT……………………………………….. 36
85.1.1 TIGHTENING TORQUES…………………………………………………. 36
CAB SILENT BLOCK……………………………………………………… 36
AIR-CONDITIONING……………………………………………………… 36
85.2 Driver’s cab removal – refit……………………………………………… 37
85.2.1 Cab removal……………………………………………………….. 37
85.2.2 REMOVE THE WINDSCREEN………………………………………………. 40
PROCEDURE FOR OPENING THE COMPACT PROTECTIVE GRILLE………………………. 40
Procedure for opening the standard protective grille……………………… 41
85.2.3 Cab lower trim removal……………………………………………… 43
85.2.4 Upper dashboard removal…………………………………………….. 43
85.2.5 Heating block removal………………………………………………. 45
85.3 Specific cab tooling…………………………………………………….. 46
85.3.1 Cab grill hinge kit ……………………………………………….. 46
Electricity………………………………………………………………………… 47
80…………………………………………………………………………….. 47
Electricity…………………………………………………………………….. 50
80.1 Electricity characteristics and specifications……………………………… 50
80.1.1 Location of relays and fuses………………………………………… 50
80.1.2 Screen menus………………………………………………………. 51
80.1.3 Electrical network architecture……………………………………… 53
80.1.4 Electrical network architecture details………………………………. 54
80.1.5 ECU Inputs / Outputs……………………………………………….. 55
X13 / X25 – SCREEN (A9)……………………………………………….. 55
X14 – NAVIGATOR (A4)………………………………………………….. 56
X80 – MAIN ECU SPU 40-26 (A2)………………………………………….. 57
X81 – MAIN ECU SPU 40-26 (A2)………………………………………….. 58
X82 – MAIN ECU SPU 40-26 (A2)………………………………………….. 59
X274 – ENGINE ECU (A2)………………………………………………… 60
X275 – ENGINE ECU (A2)………………………………………………… 61
X311 – Transmission ECU V – RC12-10-30 (A10)…………………………….. 62
X312 – Transmission ECU V – rC12-10-30 (A10)…………………………….. 63
X356 – BACK-UP ECU SPU 25-15 (A3)………………………………………. 64
X357 – BACK-UP ECU SPU 25-15 (A3)………………………………………. 65
80.1.6 Electricity component sheets………………………………………… 66
X1/X2 – STARTER IGNITION SWITCH………………………………………… 66
X10 – LIGHTING COMMUTATOR SWITCH……………………………………….. 66
X11 / X12 – WIPER STALK……………………………………………….. 67
X34 – Outside air temperature sensor……………………………………. 67
X56 – ROTATING BEACON LIGHT……………………………………………. 68
X74 – ACCELERATOR POTENTIOMETER………………………………………… 68
X75 / X76 – JSM………………………………………………………. 69
X77 – BMEP…………………………………………………………… 70
X90 TO X94 – DSB (DOUBLE SWITCH BOARD)………………………………….. 71
X121 – BRAKE PEDAL ANGLE SENSOR (PS)……………………………………. 72
X225 – DEF TANK ANALOG GAUGE…………………………………………… 73
X245 – BOOST AIR TEMPERATURE SENSOR…………………………………….. 74
X246 – Oil temperature sensor………………………………………….. 74
X247 – Hydraulic oil temperature sensor…………………………………. 75
X252 – VENTILATION CONTROL ELECTROVALVE…………………………………. 75
X253 – VENTILATION REVERSAL ELECTROVALVE………………………………… 76
X336 – HYDROSTATIC OIL TEMPERATURE SENSOR ………………………………. 76
X343 – Main tank FUEL LEVEL SENSOR……………………………………… 77
X344 – Additional tank FUEL LEVEL SENSOR………………………………… 77
80.2 Wiring diagrams…………………………………………………………. 79
80.2.1 MLT 630 105D ST4 S2………………………………………………… 79
Position by diagram…………………………………………………… 79
Diagram 1 – Starting………………………………………………….. 85
Diagram 2 – CAN………………………………………………………. 88
Diagram 3 – Transmission………………………………………………. 90
Diagram 4 – Hydraulic movements………………………………………… 92
Diagram 5 – Sensors…………………………………………………… 94
Diagram 6 – Ventilation, wipers and air-conditioning……………………… 96
Diagram 7 – Options…………………………………………………… 98
Diagram 8 – Lights and signals………………………………………….100
80.2.2 MLT 630 105D V + CP ST4 S2 / MLT 730 115D V + CP ST4 S1…………………103
Position by diagram……………………………………………………103
Diagram 1 – Starting…………………………………………………..109
Diagram 2 – CAN……………………………………………………….112
Diagram 3 – Transmission……………………………………………….114
Diagram 4 – Hydraulic movements…………………………………………116
Diagram 5 – Sensors……………………………………………………118
Diagram 6 – Ventilation, wipers and air-conditioning………………………120
Diagram 7 – Options……………………………………………………122
Diagram 8 – Lights and signals………………………………………….124
80.3 Electrical location………………………………………………………126
80.3.1 Parts list…………………………………………………………126
80.3.2 3D Frame MLT 630 105D V + CP ST4 S2 / MLT 730 115D V + CP ST4 S1…………132
80.3.3 3D Frame MLT 630 105D ST4 S2…………………………………………133
80.3.4 3D Cab…………………………………………………………….134
80.3.5 3D Engine………………………………………………………….135
80.3.6 2D Frame MLT 630 105D V + CP ST4 S2 / MLT 730 115D V + CP ST4 S1…………136
80.3.7 2D Frame MLT 630 105D ST4 S2…………………………………………137
80.3.8 2D Cab…………………………………………………………….138
80.3.9 2D engine………………………………………………………….139
80.3.10 2D Valve Bank……………………………………………………..140
80.3.11 2D Diesel Pump…………………………………………………….141
80.4 ELECTRICITY REMOVAL-REFIT…………………………………………………142
80.4.1 Remove the engine ECU……………………………………………….142
80.4.2 Remove the main ECU “SPU 40-26”………………………………………143
80.4.3 Remove the dashboard screen………………………………………….143
80.4.4 Remove – Replace JSM on BMEP…………………………………………144
80.4.5 Strain gauge refit………………………………………………….145
Location……………………………………………………………..145
Axle preparation………………………………………………………146
Characteristics of products used………………………………………..146
Characteristics of fastening screws……………………………………..147
Assembly precautions and tightening torque……………………………….147
80.4.6 Adjust the strain gauge……………………………………………..150
80.5 Electrical troubleshooting………………………………………………..150
80.5.1 Error codes (DTC)…………………………………………………..150
DTC ECU HARMONY screen (X13)……………………………………………150
Main ECU DTC SPU 40-26 (X80 – X81 – X82)…………………………………151
Engine ECU DTC EDC17CV52 (X274 – X275)…………………………………..155
Transmission ECU DTC V+ RC12-10-30 (X311 – X312)………………………….172
Auxiliary ECU DTC SPU 25-15 (X356 – X357)………………………………..203
80.6 Specific electric tooling…………………………………………………206
80.6.1 BREAKOUT BOXES……………………………………………………..206
80.6.2 Electrovalve adapter………………………………………………..206
80.6.3 DIAGNOSTIC TOOLS……………………………………………………207
DIAGNOSTICS CASE………………………………………………………207
CONNECTIONS TO LIFT TRUCK……………………………………………..208
ENGINE ADAPTATION KIT………………………………………………….208
ENGINE SPECIFICA TION………………………………………………………………..209
10……………………………………………………………………………..209
ENGINE SPECIFICATION……………………………………………………………..211
10.1 Engine characteristics and specifications…………………………………..211
10.1.1 Characteristics…………………………………………………….211
10.1.2 Diesel exhaust fluid (DEF)…………………………………………..211
Characteristics……………………………………………………….211
Levels……………………………………………………………….211
Wintering…………………………………………………………….211
10.1.3 Injection cycle…………………………………………………….212
Effects of fuel pre-injection…………………………………………..212
Effects of fuel post-injection………………………………………….212
10.1.4 Bosch CP4.1 high pressure pump……………………………………….213
10.2 Engine Schematic Diagrams…………………………………………………214
10.2.1 Intake circuit and EGR………………………………………………214
10.2.2 Lubrication circuit…………………………………………………215
10.2.3 Cooling circuit…………………………………………………….216
10.2.4 Fuel circuit……………………………………………………….217
10.2.5 DEF (Diesel Exhaust Fluid) circuit……………………………………218
10.3 Engine components location………………………………………………..219
10.3.1 Engine components…………………………………………………..219
10.3.2 Water and air cooling circuit………………………………………..221
10.3.3 Diesel fuel circuit…………………………………………………222
10.3.4 Fuel injection circuit………………………………………………223
10.3.5 EGR circuit………………………………………………………..224
10.3.6 DEF circuit………………………………………………………..225
10.4 Engine controls and adjustments……………………………………………226
10.4.1 Engine start-up authorization conditions………………………………226
10.4.2 DEF regeneration……………………………………………………226
10.4.3 DEF pump…………………………………………………………..226
10.4.4 Engine load level…………………………………………………..226
10.4.5 Fan control………………………………………………………..227
A – function………………………………………………………….227
B – principle of operation……………………………………………..227
C – schematic diagram………………………………………………….228
D – hydraulic engine description………………………………………..228
E – conditions of fan control-related components………………………….229
10.4.6 Orientation of DE suspension silent blocks – mechanical lift truck……….230
10.4.7 Orientation of DE suspension silent blocks – hydrostatic lift truck………230
10.4.8 Engine tightening torques……………………………………………231
10.4.9 Engine suspension tightening torques – mechanical lift truck…………….231
10.4.10 Engine suspension tightening torques – hydrostatic lift truck…………..232
10.4.11 Diesel fuel circuit tightening torques……………………………….232
10.4.12 Exhaust and DEF system tightening torques…………………………….233
10.4.13 Cooling system tightening torques……………………………………234
10.4.14 Heating system tightening torques……………………………………235
10.5 Engine removal – refitting………………………………………………..235
10.5.1 Remove the engine ECU……………………………………………….235
10.5.2 Remove the additional diesel fuel tank………………………………..235
10.5.3 Remove the DEF tank…………………………………………………236
10.5.4 Removing the engine cover……………………………………………237
10.5.5 Remove the expansion tank……………………………………………237
10.5.6 Remove the SCR……………………………………………………..238
10.5.7 Remove the mixer tube……………………………………………….239
Refit………………………………………………………………..239
10.5.8 Remove the DOC……………………………………………………..239
10.5.9 Refit the exhaust line………………………………………………240
10.5.10 Remove the air conditioning compressor……………………………….240
10.5.11 Remove the engine housing…………………………………………..240
10.5.12 Remove the engine………………………………………………….241
10.5.13 Remove the fan motor……………………………………………….244
Refit………………………………………………………………..245
10.5.14 Alternator removal…………………………………………………246
10.5.15 Water pump removal…………………………………………………246
10.5.16 Turbo-compressor removal……………………………………………246
10.6 Engine troubleshooting……………………………………………………246
10.7 Specific engine tooling…………………………………………………..246
10.7.1 Special engine tooling………………………………………………246
10.7.2 Electronic tension meter…………………………………………….246
10.7.3 DEF FLUSH KIT………………………………………………………247
HYDRAULICS………………………………………………………………………….249
70……………………………………………………………………………..249
HYDRAULICS………………………………………………………………………250
70.1 Hydraulic characteristics and specifications………………………………..250
70.1.1 Hydraulic component sheets…………………………………………..250
BRVI – Reverse ventilation control unit………………………………….250
MV – Master valve (double priority valve)………………………………..254
D – Distributor SDS 140………………………………………………..255
VAF – Brake valve 55 b (MLT 630 MECHANICAL)………………………………257
VAF – Brake valve 80 b (MLT 630/730 V)…………………………………..258
70.2 Hydraulic diagrams……………………………………………………….259
70.2.1 Keys………………………………………………………………259
70.1.1 Schematic diagrams………………………………………………….260
Flow sharing OPTION……………………………………………………260
70.2.2 Diagram – MLT 630 105D ST4 S2………………………………………..261
70.2.3 Diagram – MLT 630 105D V + CP ST4 S2 / MLT 730 115D V + CP ST4 S1………..262
70.3 Hydraulic location……………………………………………………….263
70.3.1 General location……………………………………………………263
70.3.2 Cooling circuit…………………………………………………….263
70.4 Hydraulic control and adjustment…………………………………………..264
70.4.1 Accumulator block tightening torque…………………………………..264
70.4.2 Distributor tightening torque………………………………………..264
70.4.3 MASTER valve tightening torque……………………………………….264
70.4.4 Adjustment of the load valve on the Master valve (Double Priority Valve)….265
70.4.5 Hydraulic pump tightening torque……………………………………..265
70.5 Hydraulics removal – refit………………………………………………..266
70.5.1 Remove the hydraulic tank……………………………………………266
70.5.2 Remove the hydraulic pump……………………………………………267
70.5.3 Control valve removal……………………………………………….267
70.6 Hydraulic troubleshooting…………………………………………………269
70.6.1 Master valve……………………………………………………….269
70.7 Hydraulic specific tooling………………………………………………..271
70.7.1 INFLATION KIT SET…………………………………………………..271
70.7.2 BASIC MANOMETER BOX…………………………………………………272
70.7.3 DIGITAL MANOMETER BOX……………………………………………….273
OPTIONS – ATTACHMENTS………………………………………………………………..275
110…………………………………………………………………………….275
OPTIONS – ATTACHMENTS…………………………………………………………….277
110 AIR-CONDITIONING OPTION……………………………………………………….277
110.1 Air conditioning characteristics and specifications…………………………277
110.1.1 Description of operation……………………………………………277
110.1.2 Operating principle………………………………………………..278
110.1.3 Air-conditioning ECU Inputs/Outputs………………………………….280
110.1.4 Evaporator temperature probe characteristics………………………….281
110.2 Schematic diagram of automatic air-conditioning…………………………….282
110.2.1 Schematic diagram …………………………………………………282
110.3 Air-conditioning locations……………………………………………….283
110.3.1 Location and tightening torques……………………………………..283
110.3.2 HVAC interior components……………………………………………284
110.3.3 HVAC exterior components……………………………………………284
110.3.4 Automatic air-conditioning locations…………………………………285
Key to locations of automatic air-conditioning……………………………286
110.3.5 Condenser components……………………………………………….286
110.4 Air conditioning controls and adjustments………………………………….287
110.4.1 General check points……………………………………………….287
110.4.2 ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT…………………….287
110.4.3 Safety measures for handling r134a…………………………………..288
110.4.4 Refrigerant fluid load for the air conditioning circuit………………..288
110.4.5 Check the evaporator temperature sensor………………………………289
110.5 Air conditioning removal – refit………………………………………….291
110.5.1 Air-conditioning belt removal……………………………………….291
110.5.2 Air conditioning belt refit…………………………………………292
110.6 Air conditioning troubleshooting………………………………………….293
110.6.1 Temperature TROUBLESHOOTING…………………………………………293
110.6.2 ABNORMAL NOISE ON A/C SYSTEM………………………………………..293
110.6.3 UNPLEASANT SMELL…………………………………………………..293
110.6.4 X39 (C10) – Automatic air-conditioning error codes (DTC)……………….294
110.7 Specific air conditioning tooling…………………………………………294
110.7.1 Fitting wedge for elastic drive belt…………………………………294
110 Intelligent hydraulics OPTION………………………………………………….295
110.1 Intelligent hydraulics characteristics and specifications……………………295
110.2 Location of components…………………………………………………..296
110.2.1 Assembly on 6 or 7 metre boom……………………………………….296
110.2.2 Assembly on 9 metre boom……………………………………………297
TRANSMISSION………………………………………………………………………..299
20……………………………………………………………………………..299
TRANSMISSION…………………………………………………………………….301
20.1 Transmission schematic diagrams……………………………………………301
20.1.1 MECHANICAL TRANSMISSION compact+ (C+)…………………………………301
MECHANICAL TRANSMISSION C+ flow diagram………………………………….301
MECHANICAL TRANSMISSION (C+) operation overview…………………………..302
20.1.2 HYDROSTATIC TRANSMISSION…………………………………………….303
HYDROSTATIC flow diagram ………………………………………………303
Hydrostatic operation block diagrams…………………………………….304
20.2 Transmission locations……………………………………………………305
20.2.1 Mechanical transmission and gear box cooling…………………………..305
20.2.2 Hydrostatic transmission…………………………………………….306
20.3 Transmission controls and adjustments………………………………………307
20.3.1 Hydrostatic auto-calibration…………………………………………307
Preparation…………………………………………………………..307
Explanation and operation of the auto-calibration cycle……………………307
Flow chart……………………………………………………………307
20.3.2 PRESSURE CONTROL …………………………………………………..308
Mechanical transmission………………………………………………..308
Hydrostatic transmission……………………………………………….308
20.3.3 General authorisation conditions for carriage movement………………….308
Acquisition conditions…………………………………………………308
Upkeep conditions……………………………………………………..308
Loss conditions……………………………………………………….308
20.3.4 Verification of hydrostatic carriage configurations…………………….308
20.3.5 Eco Mode on hydrostatic carriages…………………………………….308
20.3.6 Adjust the hydrostatic engine sensor………………………………….309
Preparation…………………………………………………………..309
Adjust the sensor……………………………………………………..309
20.3.7 Mechanical transmission tightening torque……………………………..311
20.3.8 Hydrostatic transmission tightening torque…………………………….311
20.3.9 Towing procedure……………………………………………………312
20.4 Transmission removal – refit………………………………………………312
20.4.1 Remove the engine flywheel damper…………………………………….312
20.4.2 Remove the manual gear box…………………………………………..312
Refit………………………………………………………………..313
20.4.3 Remove the angle gear box……………………………………………313
Refit………………………………………………………………..314
20.4.4 Remove the hydrostatic pump………………………………………….314
20.4.5 Remove the hydrostatic motor…………………………………………315
20.4.6 Remove the transfer box……………………………………………..316
Refit………………………………………………………………..318
20.4.7 Take off the gearbox sensors…………………………………………318
Preparation…………………………………………………………..318
Take off the gearbox sensors……………………………………………319
Refit the gearbox sensors………………………………………………319
20.5 Transmission troubleshooting………………………………………………320
20.6 Specific transmission tooling……………………………………………..321
20.6.1 Basic manometer box…………………………………………………321
20.6.2 Digital manometer box……………………………………………….322
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