Manitou Telehandler MTL 634-1030 Repair Manual_647412 – PDF DOWNLOAD
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Manitou Telehandler MTL 634-1030 Repair Manual_647412 – PDF DOWNLOAD
Size : 55.7 MB
Format : PDF
Language : English
Brand: Manitou
Type of machine: Forklift
Type of document: Repair Manual
Model: Manitou Telehandler MLT 634 120 PS ST3B, MLT 634 120 ST3B S1
MLT 732 100D ST3B S1, MLT 735 100 ST3B, MLT 735 120 PS ST3B
MLT 735 120 ST3B, MLT 741 100 ST3B, MLT 741 120 PS ST3B
MLT 741 120 ST3B, MT 732 100D ST3B S1, MT 732 EASY 75D ST3B S1
MT 932 100D ST3B S1, MT 932 EASY 75D ST3B S1, MT 1030 EASY 75D ST3B S1
MT 1030 EASY 75D ST3B S2
Date: 2018
Number of Pages: 438 Pages
Part Number: 647412
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
DESCRIPTION:
Manitou Telehandler MTL 634-1030 Repair Manual_647412 – PDF DOWNLOAD
MLT 634 120 PS ST3B
MLT 634 120 ST3B S1
MLT 732 100D ST3B S1
MLT 735 100 ST3B
MLT 735 120 PS ST3B
MLT 735 120 ST3B
MLT 741 100 ST3B
MLT 741 120 PS ST3B
MLT 741 120 ST3B
MT 732 100D ST3B S1
MT 732 EASY 75D ST3B S1
MT 932 100D ST3B S1
MT 932 EASY 75D ST3B S1
MT 1030 EASY 75D ST3B S1
MT 1030 EASY 75D ST3B 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 MTL 634-1030 Repair Manual_647412 – PDF DOWNLOAD
Pdg647412EN………………………………………………………… 0
TABLE OF CONTENTS…………………………………………………… 5
00-GENERAL CHARACTERISTICS AND SAFETY……………………………… 7
GENERAL INSTRUCTIONS AND SAFETY NOTICE…………………………. 9
GENERAL CHARACTERISTICS AND SPECIFICATIONS……………………… 15
CHARACTERISTICS………………………………………….. 16
FLUIDS………………………………………………….. 16
DIMENSIONS………………………………………………. 16
DIMENSIONS MT / MLT (except MT 1030)……………………. 16
DIMENSIONS MT 1030……………………………………. 18
GENERAL LOCATION…………………………………………….. 19
LOCATION OF NAME AND IDENTIFICATION PLATE…………………… 20
GENERAL CONTROL AND ADJUSTMENT………………………………… 21
STANDARD TIGHTENING TORQUES……………………………….. 22
10-ENGINE………………………………………………………. 23
ENGINE GENERAL CHARACTERISTICS ANDSPECIFICATIONS………………… 25
CHARACTERISTICS………………………………………….. 26
POLLUTION MANAGEMENT……………………………………… 26
INJECTION CYCLE………………………………………….. 27
BOSCH CP4.1 HIGH PRESSURE PUMP…………………………….. 28
ENGINE CIRCUITS FLOW DIAGRAM………………………………….. 29
AIR INTAKE CIRCUIT AND EGR (Exhaust Gas Recirculation)……….. 30
LUBRICATION CIRCUIT………………………………………. 31
COOLING SYSTEM…………………………………………… 32
FUEL CIRCUIT…………………………………………….. 33
ENGINE COMPONENTS LOCATION……………………………………. 35
ENGINE COMPONENTS (100 and 120 HP)…………………………. 36
ENGINE COMPONENTS (75 HP)…………………………………. 37
WATER AND AIR COOLING SYSTEM (100 and 120 HP)……………….. 38
WATER AND AIR COOLING SYSTEM (75 HP)……………………….. 39
HYDRAULIC VENTILATION SYSTEM (100 and 120 HP )………………. 40
HYDRAULIC VENTILATION SYSTEM (75 HP)……………………….. 41
DIESEL FUEL CIRCUIT………………………………………. 42
FUEL INJECTION CIRCUIT……………………………………. 43
EGR (Exhaust Gas Recirculation) CIRCUIT…………………….. 44
ENGINE CONTROL AND ADJUSTMENT…………………………………. 45
PREPARATION AND SAFETY INSTRUCTIONS………………………… 46
COMPONENT REMOVAL / REFIT…………………………………. 46
A – MOVABLE ENGINE COVER REMOVAL……………………….. 46
B – RADIATOR AND FAN MOTOR REMOVAL…………………….. 46
C – RADIATOR AND FAN MOTOR REFIT………………………. 47
D – FAN HYDRAULIC MOTOR REMOVAL / REFIT………………… 48
E – RADIATOR REMOVAL………………………………….. 49
G – NEW ENGINE OIL DIPSTICK FITTING INSTRUCTIONS………… 50
H – FIXED ENGINE COVER REMOVAL…………………………. 51
I – EXHAUST REMOVAL / REFIT ………………………….. 51
J – AIR-CONDITIONING BELT REMOVAL (option)……………… 51
K – AIR-CONDITIONING BELT REFIT (option)……………….. 52
L – DRIVE BELT REMOVAL………………………………… 52
M – AIR-CONDITIONING COMPRESSOR REMOVAL…………………. 53
N – STARTER MOTOR REMOVAL……………………………… 53
O – ALTERNATOR REMOVAL………………………………… 54
P – WATER PUMP REMOVAL………………………………… 54
Q – TURBO REMOVAL…………………………………….. 55
R – ENGINE SHOCK ABSORBER REMOVAL………………………. 55
FAN DRIVE……………………………………………….. 56
A – FUNCTION…………………………………………. 56
B – PRINCIPLE OF OPERATION…………………………….. 56
C – SCHEMATIC DIAGRAM…………………………………. 56
D – DESCRIPTION OF HYDRAULIC MOTORS…………………….. 57
E – CONDITIONS OF FAN CONTROL-RELATED COMPONENTS…………. 58
ENGINE REMOVAL………………………………………………. 61
PREPARATION AND SAFETY INSTRUCTIONS………………………… 62
ENGINE REMOVAL…………………………………………… 62
A – GRILL AND DRAINING HATCH…………………………… 62
B – AIR AND WATER HOSES……………………………….. 62
C – HEATING CIRCUIT…………………………………… 63
D – LOWER HOSES AND FILTER SUPPORT BRACKETS……………… 63
E – ELECTRICITY………………………………………. 63
F – VENTILATION PUMP AND EXHAUST HOSES………………….. 64
G – SILENT BLOCS AND UNIVERSAL JOINT……………………. 64
H – LIFTING………………………………………….. 64
I – STANDARD ENGINE REPLACEMENT………………………… 65
ENGINE REFIT………………………………………………… 67
PREPARATION AND SAFETY INSTRUCTIONS………………………… 68
ENGINE REFIT…………………………………………….. 68
POST REFIT ENGINE INSPECTION………………………………. 68
ENGINE TROUBLESHOOTING……………………………………….. 69
FAULT TABLE……………………………………………… 70
Error indicator lamp………………………………….. 72
IGNITION SWITCHING TEST:………………………………….. 72
START-UP CONDITIONS………………………………………. 72
LACK OF POWER……………………………………………. 72
INJECTION CODE…………………………………………… 73
FAN DRIVE CHECK POINTS……………………………………. 73
ENGINE ERROR CODES……………………………………….. 73
SPECIFIC ENGINE TOOLING………………………………………. 75
FAN BELT FITTING TOOL…………………………………….. 76
ELECTRONIC TENSION METER………………………………….. 76
ADDITIONAL ENGINE TOOLS…………………………………… 76
20-TRANSMISSION…………………………………………………. 77
TRANSMISSION SCHEMATIC DIAGRAMS……………………………….. 79
TRANSMISSION DRIVE CHAIN / MANUAL GEAR RATIOS (Compact+)……… 80
TRANSMISSION DRIVE CHAIN / GEAR RATIOS (PG 115)……………… 81
MANUAL TRANSMISSION OPERATION OVERVIEW……………………… 82
POWERSHIFT TRANSMISSION OPERATION OVERVIEW………………….. 84
TRANSMISSION COMPONENTS LOCATION………………………………. 87
MECHANICAL TRANSMISSION AND GEAR BOX COOLING………………… 88
TRANSMISSION CONTROL AND ADJUSTMENT……………………………. 89
TIGHTENING TORQUE………………………………………… 90
MECHANICAL TRANSMISSION……………………………….. 90
ANGLE GEAR BOX OUTPUT SHAFT……………………………. 90
POWERSHIFT (PG 115) GEAR BOX………………………………. 91
COMPONENTS…………………………………………… 91
SHAFT AND CLUTCH……………………………………… 92
GEARS……………………………………………….. 92
OPERATING LOGIC………………………………………. 93
TRANSMISSION SYSTEM…………………………………… 93
PRESSURE TEST PORT LOCATIONS…………………………… 95
TABLE OF PRESSURES……………………………………. 96
ECU…………………………………………………. 96
TRANSMISSION REMOVAL…………………………………………. 97
PREPARATION AND SAFETY INSTRUCTIONS………………………… 98
GEAR BOX REMOVAL (COMPACT +)………………………………. 98
TRANSMISSION TROUBLESHOOTING…………………………………..105
POWERSHIFT PG 115 6-SPEED TRANSMISSION………………………106
DESCRIPTION…………………………………………..106
E.C.U. CONTROL………………………………………..106
OUTPUT CONTROL………………………………………..107
INPUT CONTROL…………………………………………107
START-UP DIAGNOSTICS/ERROR VERIFICATION FLOW CHART………..108
SPECIFIC TRANSMISSION TOOLING………………………………….109
BASIC MANOMETER SET……………………………………….110
DIGITAL MANOMETER SET……………………………………..111
GEAR BOX REMOVAL TOOLS…………………………………….112
30-AXLE…………………………………………………………113
AXLE CONTROL AND ADJUSTMENT……………………………………115
TIGHTENING TORQUE…………………………………………116
AXLE…………………………………………………116
40-BRAKE………………………………………………………..117
BRAKE CHARACTERISTICS AND SPECIFICATIONS………………………..119
SERVICE BRAKE…………………………………………….120
PARKING BRAKE…………………………………………….121
BRAKE COMPONENTS LOCATION……………………………………..123
HYDRAULIC BRAKE CIRCUIT……………………………………124
BRAKE CONTROL AND ADJUSTMENT…………………………………..125
BRAKE REMOVAL………………………………………………..135
MASTER CYLINDER REMOVAL……………………………………136
50-BOOM…………………………………………………………137
BOOM CHARACTERISTICS AND SPECIFICATIONS…………………………139
DUPLEX BOOM………………………………………………140
TRIPLEX BOOM……………………………………………..140
BOOM COMPONENTS LOCATION………………………………………141
LOCATION OF DUPLEX BOOM MAIN COMPONENTS (6 and 7 m)…………..142
LOCATION OF TRIPLEX BOOM MAIN COMPONENTS (9 and 10 m) ………..143
BOOM CONTROL AND ADJUSTMENT……………………………………145
TIGHTENING TORQUES/GREASING………………………………..146
TELESCOPE HEAD PAD REMOVAL…………………………………147
BOOM BASE PAD REPLACEMENT………………………………….147
TELESCOPE CYLINDER REMOVAL ………………………………..147
PREPARATION AND SAFETY INSTRUCTIONS…………………………149
REMOVING TELESCOPES T1+T2………………………………….150
TELESCOPE T2 REMOVAL………………………………………153
SHIM INSTALLATION AND GREASING AREA RECOMMENDATIONS…………..154
BOOM REMOVAL…………………………………………………155
PREPARATION AND SAFETY INSTRUCTIONS…………………………156
BOOM REMOVAL……………………………………………..157
70-HYDRAULICS……………………………………………………159
HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS…………………….161
ACCUMULATOR BLOCK…………………………………………163
COUNTERBALANCE VALVE………………………………………165
SDM 140/4 DISTRIBUTOR……………………………………..167
SDM 140/2 DISTRIBUTOR……………………………………..173
DISTRIBUTOR SX 14 S (INLET ELEMENT)…………………………175
DISTRIBUTOR SX 14 S (TILTING ELEMENT)……………………….177
DISTRIBUTOR SX 14 S (CLOSING ELEMENT)……………………….179
DISTRIBUTOR SX 14 S (LIFTING ELEMENT)……………………….181
DISTRIBUTOR SX 14 S (TELESCOPE – ATTACHMENT ELEMENTS)…………185
POWER ASSISTED BRAKE MASTER CYLINDER………………………..187
CASAPPA MVP 60 PUMP……………………………………….189
STEERING PUMP/STEERING UNIT OSPC 200 LS……………………..193
TILTING CUT-OFF VALVE (VCI)……………………………….. 0
FLOW DISTRIBUTOR………………………………………….197
HYDRAULIC SCHEMATIC DIAGRAMS…………………………………..199
MLT 634 + MLT 735 + MLT 741………………………………..201
KEY………………………………………………….201
HYDRAULIC DIAGRAM……………………………………..203
MT 732 + MT 932 + MT 1030 EASY 75D ST3B S2 + MLT 732………….204
HYDRAULIC DIAGRAM……………………………………..204
KEY………………………………………………….205
MT 1030 EASY 75D ST3B S1…………………………………..206
KEY………………………………………………….206
HYDRAULIC DIAGRAM……………………………………..207
HYDRAULIC COMPONENTS LOCATION………………………………….209
KEY……………………………………………………..210
HYDRAULIC COMPONENT LOCATION (MLT except MLT 732)…………….211
HYDRAULIC COMPONENT LOCATION (MT + MLT 732)………………….212
HYDRAULIC CONTROL AND ADJUSTMENT……………………………….213
DISTRIBUTOR CONTROL LOGIC………………………………….214
OPERATING PRINCIPLES OF AGGRAVATING MOVEMENTS CUT-OFF…………216
SX 14 S DISTRIBUTOR REMOVAL………………………………..217
1 – SAFETY INSTRUCTIONS………………………………..217
2 – TROUBLESHOOTING……………………………………218
3 – ESSENTIAL RULES……………………………………220
4 – REMOVAL AND REFITTING OF THE SX 14 S UNIT…………….221
5 – SX 14 S UNIT REPAIR PROCEDURES………………………222
CASAPPA MVP 60 PUMP ADJUSTMENT……………………………..227
PRESSURE TEST PORT VALUES………………………………227
CASAPPA HYDRAULIC PUMP TIGHTENING TORQUES………………..230
HYDRAULIC COMPONENTS REMOVAL…………………………………..233
DISTRIBUTOR REMOVEL (MLT except MLT 732)…………………….234
HYDRAULIC PUMP REMOVAL…………………………………….239
HYDRAULIC SPECIFIC TOOLING…………………………………….243
BASIC MANOMETER SET……………………………………….244
DIGITAL MANOMETER SET……………………………………..245
CASAPPA PRESSURE TEST PORT CONNECTOR………………………..246
80-ELECTRICITY…………………………………………………..247
ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS……………………249
WIRING…………………………………………………..250
FUSES AND RELAYS………………………………………250
ELECTRICAL CONNECTORS………………………………….254
OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM…………………265
INPUTS/OUTPUTS……………………………………………266
MAIN ECU – SPU 25-15 – A3………………………………266
HYDRAULIC PUMP REFIT -A4……………………………….268
ENGINE ECU – A19………………………………………269
GEAR BOX ECU PG115 – A22……………………………….271
DATA SHEETS FOR ELECTRICAL COMPONENTS……………………….272
ELECTRICAL SCHEMATIC DIAGRAMS………………………………….301
ELECTRICAL DIAGRAM CODIFICATION EXAMPLE……………………..302
CABLE IDENTIFICATION ON A WIRING HARNESS…………………….303
POSITION OF CONNECTORS ON DIAGRAMS………………………….304
ELECTRICAL DIAGRAMS……………………………………….308
1 – START-UP / CUSTOMER DIGICODE………………………..308
2 – CAN / ECU ………………………………………..310
3 – TRANSMISSION………………………………………312
4 – HYDRAULIC MOVEMENTS ……………………………….314
5 – SENSORS…………………………………………..316
6 – VENTILATION / AIR CONDITIONING / WIPERS………………318
7 – OPTIONS…………………………………………..320
8 – LIGHTING / SIGNALING……………………………….322
ELECTRICAL COMPONENTS LOCATION…………………………………325
KEY……………………………………………………..326
CONNECTORS……………………………………………326
SPLICES AND FERRITES…………………………………..331
2D LOCATION………………………………………………333
HARNESS ASSEMBLY………………………………………333
MAIN HARNESS………………………………………….334
CAB AND FRONT WORKING LIGHTS HARNESS…………………….335
ENGINE HARNESS………………………………………..336
ADDITIONAL HARNESSES…………………………………..337
DISTRIBUTOR…………………………………………..337
PS GEAR BOX…………………………………………..337
AIR CONDITIONING………………………………………337
3D LOCATION………………………………………………338
HARNESS ASSEMBLY………………………………………338
ENGINE HARNESS………………………………………..339
GROUNDS………………………………………………340
ELECTRICAL CONTROL AND ADJUSTMENT………………………………341
MENU ARCHITECTURE – DASHBOARD DISPLAY……………………….342
“BOOM ANGLE” ANGULAR SENSOR ADJUSTMENT………………………343
OPERATION…………………………………………….343
ON-TRUCK ADJUSTMENT PROCEDURE……………………….343
ERROR CODES………………………………………………345
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE….346
STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE)…..347
STRAIN GAUGE RECALIBRATION (CLIENT PROCEDURE)………………..348
“AGGRAVATING” HYDRAULIC MOVEMENTS CUT-OFF……………………349
LED ILLUMINATION ACCORDING TO CHANGES IN GAUGE SIGNAL…………349
ELECTRICAL COMPONENTS REMOVAL………………………………….351
HYDRAULIC PUMP ECU REMOVAL…………………………………352
SPU REMOVAL………………………………………………352
GEAR BOX ECU REMOVAL (POWERSHIFT)…………………………..353
ENGINE ECU REMOVAL………………………………………..353
ELECTRICAL COMPONENTS REFIT……………………………………355
STRAIN GAUGE……………………………………………..356
LOCATION……………………………………………..356
AXLE PREPARATION………………………………………357
CHARACTERISTICS OF PRODUCTS USED………………………..357
CHARACTERISTICS OF FASTENING SCREWS……………………..358
ASSEMBLY PRECAUTIONS AND TIGHTENING TORQUE……………….358
STRAIN GAUGE ( 954782)………………………………..359
STRAIN GAUGE ( 954783)………………………………..360
ELECTRICAL TROUBLESHOOTING…………………………………….363
NAVIGATION MENU DISPLAY……………………………………364
SPU 25-15 – A3 ERROR CODES LIST…………………………….364
ENGINE ECU ERROR CODES LIST (DTC)…………………………..366
HYDRAULIC PUMP ERROR CODES LIST…………………………….394
LONGITUDINAL STABILITY INDICATOR (LLMI) ERROR CODE LIST……….394
GEAR BOX ERROR CODE LIST…………………………………..394
ELECTRICAL SPECIFIC TOOLING……………………………………395
SOLUTION 1……………………………………………….396
DIAGNOSTIC CASE……………………………………….396
DIAGNOSTIC CASE: ENGINE ST3B……………………………397
CONNECTION TO TRUCK……………………………………397
SOLUTION 2……………………………………………….398
DIAGNOSTIC CASE……………………………………….398
CONNECTION TO TRUCK……………………………………399
BREAKOUT BOX KIT………………………………………….400
ELECTROVALVE ADAPTER………………………………………400
110-OPTIONS – ATTACHMENTS…………………………………………401
MACHINE OPTION CONFIGURATION…………………………………..403
FORCED OPERATION OPTION……………………………………….405
FORCED OPERATION………………………………………….407
CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT…………..407
FORCED OPERATION SCHEMATIC…………………………………408
ELECTRIC……………………………………………..408
CRC OPTION: TELESCOPE SUSPENSION……………………………….409
OPERATING PRINCIPLES OF THE “CRC” KIT……………………….410
OPERATION…………………………………………….410
TELESCOPE SUSPENSION VALVE (VASF)…………………………..411
SCHEMATIC DIAGRAMS ……………………………………….414
HYDRAULIC SCHEMATIC DIAGRAMS FOR LSU TELEHANDLER………….414
ELECTRICAL SCHEMATIC DIAGRAM……………………………415
OPERATING LOGIC………………………………………….. 0
CIRCUITS…………………………………………………417
HYDRAULIC CIRCUIT……………………………………..417
ELECTRIC CIRCUIT………………………………………418
COMPONENT LOCATION………………………………………..419
ADJUSTMENTS………………………………………………420
POSITION CONTACT SETTING……………………………….420
E.C.S. OPTION (EASY CONNECTING SYSTEM)………………………….421
ATTACHMENT LINE DEPRESSURIZATION (E.C.S OPTION)………………422
OPERATING PRINCIPLE……………………………………422
SCHEMATIC DIAGRAMS…………………………………….423
ELECTRIC………………………………………….423
MANUAL ACCELERATOR OPTION……………………………………..425
LAYOUT…………………………………………………..426
WIRING DIAGRAM……………………………………………426
OPERATING PRINCIPLE……………………………………….426
USE……………………………………………………..426
AIR-CONDITIONING OPTION……………………………………….427
OPERATING PRINCIPLE……………………………………….428
OPERATION DESCRIPTION……………………………………..429
DESCRIPTION OF COMPONENTS………………………………….430
AIR CONDITIONING SYSTEM COMPONENT LOCATION…………………..431
ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT……………432
SAFETY MEASURES FOR HANDLING R134a………………………….432
REFRIGERANT FLUID LOAD FOR THE AIR-CONDITIONING CIRCUIT……….432
CHARGING METHOD…………………………………………..433
FUNCTIONAL CHECKS…………………………………………434
ANTI-ICING SAFETY MONITORING……………………………….436
AIR-CONDITIONING INSPECTION FORM……………………………437
Page vierge…………………………………………………………133
Page vierge…………………………………………………………134
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