XPRT MLT 625 Training

Denomination

MLT 625 75 H
MLT = Manitou Loader Telescopic
6

= Max height: 6 meters

25 = Max load capacity: 2.5 tons

75 = Engine 75 HP
S1

= Series 1

E3

= Euro 3

New Agricultural Range

MLT 625-75 H

Current Range

MLT 625-75 H

Series 1 E3

MLT 735-120 LSU

MLT 735 T 120 LSU

Series 6 E3

MLT 940 T-120 LSU

T 120
LSU
MLT 845
Series
4 E3

Unit Identification

Specifications

Specifications

Specifications

Specifications

Specifications

Specifications

Specifications
Load Charts are in pounds and
feet so there is no need to
convert the weight.

What is the capacity where the

green dot is located?

Instruments and Controls

Instruments and Controls

Instruments and Controls

Instruments and Controls

NOTE: The location of the switches may vary

depending on the options.
A - WARNING LIGHTS
B - REAR FOG LIGHTS

C - REVOLVING LIGHT
D - FRONT AND REAR WORKING LIGHTS OPTION
JIB HEAD LIGHTS
E - OPTION REAR WINDOW DE-ICING
F - NEUTRALISATION OF HYDRAULIC
MOVEMENTS
G - GEAR SELECTION. Gears can be selected while driving.
SLOW SPEED: Use for handling, switch in the up position, the indicator lamp is off.
HIGH SPEED: Use on the road, switch in down position, the high speed indicator lamp comes on.
H - WHEEL ALIGNMENT INDICATOR LAMPS
I - PARKING BRAKE

Instruments and Controls

J - DISABLING THE "AGGRAVATING" HYDRAULIC MOVEMENT

CUT-OFF
K - OPTION ATTACHMENT HYDRAULIC LOCKING DEVICE OR
OPTION JIB HEAD SOLENOID VALVE OR OPTION JIB HEAD
SOLENOID VALVE + ATTACHMENT HYDRAULIC LOCKING
DEVICE
L - OPTIONAL ATTACHMENT HYDRAULIC CONTROL FORCED
OPERATION
M - OPTION BLUE HEADLIGHTS OR OPTION ELECTRICAL JIB
PROVISION
N - REVERSIBLE VENTILATION CONTROL
The system cleans the radiator core and the grille of the engine
cover by reversing the air flow.
(Position A): The indicator light is on, the fans rotation is reversed for
a few seconds every 3 minutes.
(Position B): The indicator light is off, the fan is in normal operating
mode.

JSM Joystick
Controls

Control
A - Lifting and tilting control lever.
B - Telescoping control button.
C - Attachment control button.

LIFTING THE LOAD

- The lever A backwards when lifting.
- The lever A forwards when lowering.
TILT OF CARRIAGE
- The lever A to the left for reverse tilt.
- The lever A to the right for forward tilt.
TELESCOPING
- Button B forwards for extending.
- Button B backwards for retracting.
ATTACHMENT
- Button C forwards or backwards.

FORWARD/NEUTRAL/REVERSE GEAR
SELECTION
When operating this control, the lift truck
should be travelling at slow speed and not
accelerating.
FORWARD: Push the knob forward
(position A).
REVERSE: Pull the knob backward
(position B). (An OPTIONAL reversing light
and audible reversing alarm indicate that
the lift truck is travelling in reverse).
NEUTRAL

JSM Joystick
Controls
C

21

Hydraulic Component Location and Function

PD
D

B
A

23

PH
BMH
P

BCM
A

Hydraulic Pump

Hydraulic fan motor + inverse valve

hydraulic valve Bank

Supply block + Accumulator

Hydraulic proportional manipulator block

Aggravating cut off movements block

Orbitrol

Double hydraulic pump

Maximum
torque:
280 Nm

31 cm3
11 cm3

Hydraulic fan motor + inverse valve

Flow
inversion
SV/Y20

One way
valve

Tank

Flow
regulation
TS/Y19

Supply

Compensating cylinder + Compensating

isolation valve

One way valves

Tightening
torque at
45/50 Nm

Isolation
valve
(300b)

Steering pump (Orbitrol)

Supply

Right side

Valve Bank
LS
Left side

Tank

Hydraulic proportional manipulator block

Tilt down
Tank

Tilt up

Lowering

Supply
Lifting
MANITOU
Ref

Husco Code

Aggravating cut off movements block

Y14
(Lowering
cut off EV)
Lowering

Y15 (Tilting
cut off EV)

Y14
(Lowering
cut off EV )

Tank
Lowering

Tilting
down

Lifting
Tilting up
Tilting
down

Supply

Y18 (Lifting
cut off EV)

Lifting

Supply block + Accumulator

Coils resistance

EF filter

- 8 ohms for Y8,

Y9, Y12, Y13
-2,2 ohms for Y10
et Y11
Y9
(attachemen
t selection
EV)

Y13 (Parking
brake EV)
Y11
(Attachement
proportional
EV)

Parking
brake
connection
Y8 (Telescope
selection EV)

Y12 (Hydraulic
cut off EV)
Y10 (Telescope
proportional EV)

Supply block + Accumulator

Telescope
retract
command

Telescope
extend
command
Output toward
cut off block or
manipulator

Attachement
way 1 command
Tank

Supply

Pressure
test port
(Pin)
Parking
brake
pressure
Switch
(Psahr)
Pressure
test port
(Pp)

Attachement
way 2 command

Ajustable jet
(DR)

Hydraulic valve bank

Anti-shock
(245b)

Anti-shock
rod side
(245b)

Steering
LS
Supply
Tank

Anti-shock
Barrel
side(245b)

Steering
supply
Telescope element

Attachement element

Tilting element

Lifting element

VS element

(235b)

Flow divider element

Main relief
valve

Anti-shock
(180b)

Compensating isolation valve

Compensation
The purpose of the compensation valve:
Keep the tool/bucket position level with the movement of up
/ down function of the boom.

Compensating isolation valve

Counterbalance valve
The aim:

Supports the cylinder in case of hose breakage.

Cylinder movement requires the starting of the
engine
Limits maximum pressure due to impacts.

Counterbalance valve
Charge
effective

97
9
r
1
9ffe
5
e
4
R
n1
E
Pr rme
no
ing

max admitable = 0,5 / minute

max L admitable = 150 mm / 10 minutes

Bulletin IT 796

Counterbalance valve
Schematic:
Spool

Temporisation
screw

C1

C2

V1

V2

Max pressure
adjustment

Anti return valve

Counterbalance valve
Sectional view

Anti return valve

Max pressure
adjustment

Spool

Flow Control
Screw

Counterbalance valve
Description
Max pressure
adjustment

lock nut

Flow control screw

Piston side

Rod side

Counterbalance valve
Adjustment and checking
If the movements are sharp (too fast / jerky) or too slow (delay in
comparison to the control), the adjustment of the screw B is required
.
The distance A is a reference = optimum setting from factory
.
C
B

A= 17mm

Counterbalance valve
Safety
cartridge

To be able to adjust a counter balance valve, a test bench is required..

The procedure is described in the
Technical information nr 609

Warning! the setting of this valve engages your civil and criminal liability in
case of accident. This valve must necessarily be sealed!
WARRANTY WILL BE VOID IF TAMPERED WITH!

Counterbalance valveC
B

A= 17mm
It is possible to unlock the conter balance valve in order to release the pressure to be
able to disconnect the it from the cylinder.

1-Remove the time delay screw B

2-Remove the lock nut (C) from the time delay screw(B).
3-Tighten the time delay screw (B) manually up to the end of stroke.
4- Tighten the time delay screw (B) of 1 rotation with a tool.

IMPORTANT:

Cylinders

When replacing or working on a cylinder for warranty

purpose record the SAHL Number

Hydraulic Testing

Hydraulic Circuit

Hydraulic Test Circuit

Hydraulic Test Circuit

Boost pressure is adjusted on the
hydrostatic pump

Main pressure is adjusted on the

main valve

Hydostatic Drive Component Location and Function

Hydrostatic Transmission

Characteristics
Axial piston pump H1 / 45 for MLT 625
Proportional EV pilot
45 cm3
HP against pressure flow regulation

Pressure
Boost at 25b
HP at 400b for MLT 625

Axial piston motor H1 / 80 for MLT 625

Proportional EV pilot capacity regulation
80 cm3

Hydrostatic Pump
Boost pressure

Case pressure

High Pressure
Port
Reverse pilot line

Forward pilot
line

Suction

Tank return

High Pressure
Port

Components location
Forward pilot
line (M4)
Tank Return (L1)

HP (B)

Reverse pilot line

(M5)

HP (A)
Suction (S)

Case pressure
(L2)

Components location
Return tank
(M14 bleeding)
Forward HP (MB)

Reverse HP (MA)

Boost pressure
(M3)

Hole to external
filter

Y6-two speed solenoid

Y7-Pump control from brake pedal

Hydrostatic Motor

Tank return

Reverse HP

Forward
HP
Case pressure

Regulation
pressure
HP

Components location

HP (M5)

Reverse HP (MA)

Pressure
regulation (M4)

Components location
Forward HP (MB)

Case pressure

Forward HP (B)

Reverse HP (A)

Tank return

Electronic transmission Control

Transmission

Can-Bus
ECU light fault

Rollers

FNR
ECU XXX

Inching
potentiomete
r

ECU SAUER
Hydrostatic
pump

Negative
brake

Hydostatic System Testing

Hydostatic System Testing

Pressure test port (PP) is
located on the drive motor
on the front axle and is
access via the top cover.
Pressure is tested at idle
and full throttle

Hydostatic System Testing

In order to stall the
hydraulic system
you must remove
the connectors on
the brake pressure
(Psahr) signal
switch.

Hydostatic System Testing

There are two

high pressure
relief valves
located on the
pump.
The relief valves
are nonadjustable.

Electrical System/On Board Technologies

On Board
Technologies

Here are the

areas that
make the MLT
625 a very
unique
machine .
We will talk
about each of
the systems
that make this
a versatile
machine.

Electrical Component

JSM

CONNECT
OR
PIN
1

0 V Ground

12 V supply

Signal
neutral 0V out of
Neutral 12 V
neutral 0V out of
Neutral 12 V

5
X67

Tension

4
6
3
2

Signal
neutral 0V out of
Neutral 12 V
neutral 0V out of
Neutral 12 V

On Board Technologies
Movement / Stabilty

BCMA

HYD-ECU

JSM Roller R1
& R2 +/+FNR

Seat sensor
(normally
off )

BA
Override

TIN
sensor

Strain gauge

LLMI

Boom
angle
sensor
PAD

Electrical EN 15000 MODELS

TIN sensor
CONNECTE
O
PIN

X134

X134

Boom angle sensor

12 V

12 V

Signal

Signal

CONNECTO
R
PIN

X100

Tension

Tension

0 V

12 V

Signal

0V

12 V

Signal

Electronic transmission
Transmission

Can-Bus
ECU light fault

Rollers

FNR
ECU XXX

Inching
potentiomete
r

ECU SAUER
Hydrostatic
pump

Negative
Brake

Electrical architecture

Electrical architecture

Electrical architecture

Electrical architecture

Man-Machine Interface (MMI)

Man-Machine Interface (MMI)

Man-Machine Interface (MMI)

Man-Machine Interface (MMI)

Screen Display on the MMI

Screen Display on the MMI

Screen Display on the MMI

Screen Display on the MMI

Screen Display on the MMI

Error Codes as Listed in the Service Manual

Kubota Engine Characteristics

The NEW Kubota 07 Series engines have been designed to comply with
EPA Interim Tier 4 Option emissions regulations.

Specifications

Engine Features
The NEW Kubota 07 Series engines have been
designed to comply with EPA Interim Tier 4 Option
emissions regulations.

The 07 series DI engine are the vertical type 4-cycle

diesel engine featuring the advanced performances

Kubotas original E-CDIS (Center Direct

Injection
System) combustion system, renowned for
clean
combustion in the Kubota V3 (DI) Series,
has been
renovated. The fuel injection pressure was
increased
and the combustion chamber was
redesigned to
achieve a 25 % lower particulate matter
(PM) level

Engine Features
The engine features
individual glow plugs

External EGR system

with EGR cooler

The engine uses a

separated fuel injection
Pump with external fuel
shutoff solenoid and
external shutoff lever

Engine Features

Engine coolant temp hot light

sender located on the thermostat
housing

Engine coolant temp gage sender

located near the rear of the engine

Engine Features

Oil pressure switch located on the

right hand side of the engine on the
outside

The EGR system takes exhaust gas

from the front of the engine and
combines the cooled exhaust gas
with the intake air near the rear.

Cooling Circuit

Engine Cooling System

Bottom bypass system is designed for improving the
cooling performance of the radiator.
While the temperature of coolant in the engine is
low, the thermostat (1) is held closed and the
coolant is allowed to flow through the bypass pipe
and to circulate in the engine.
When the temperature exceeds the thermostat (1)
valve opening level, the thermostat (1) fully opens
itself to prevent the hot coolant from flowing through
the bypass into the engine.
In this way, the radiator can increase its cooling
performance.
(1) Thermostat
(2) Radiator
(3) Engine
(A) Bypass Opened
(B) Bypass Closed

Engine Cooling System

Engine cooling radiator is
located on the front of the
engine to the left of the
hydraulic oil cooler

Mounted to the right of the

radiator is the hydraulic oil
cooler

Hydostatic oil cooling system

Engine oil cooling system

The engine has a coolant-cooled oil cooler
that not only cools hot oil, but also warms
the cool engine oil shortly after start up.
As shown in the figure, the oil flows inside
the connected cooler plate, where the
coolant is kept circulating outside the
cooler plate, thereby cooling down or
warming the oil.
(A) Oil Inlet Port
(B) Oil Outlet Port
(a) Coolant Inlet Port
(b) Coolant Outlet Port

Steering Circuit

Steering circuit
The aim :

Direct and dose the flow in order to supply the

steering circuit
It is a rotating valve

Steering circuit
Description

Antishock Valve

LS

Steering selector

ORBITROL

Relief valve

Steering circuit
Description

Relief valve

Antishock Valve

Steering circuit
Operation

Turn on left side

Turn on right side

No rotation of
steering

Steering circuit
On MANISCOPIC trucks, there are 3 steering modes

2 wheel steer

Short steering

Crabwise
position

Steering circuit
2 wheel steer

Steering circuit
Crab position

Steering circuit
Short steering

Steering circuit
End of steering cylinder

Steering circuit
Antishock function

Brake Circuit

Brake Circuit

Brake Circuit

Park Brake Circuit

Brake Circuit- Inching Pedal Adjustment

Use a gauge or other
template to check the 7 mm
dimension between push
button washer (Item A)
contact face and shell (Item
B) contact face.
Release rubber pad (Item C)
up to contact with pedal
system support (Item E)
Tighten locknut (Item D) on
brake pedal arm.

INCHING/BRAKING
SAUER MODULE
ADJUSTMENT

Power Train/Axles

Axle

DANA SPICER

Characteristics

Rear axle (221)

Directional
Differential without limited slip & without lock
Wheels alignment sensor

Front axle (211)

Directional
Differential with limited slip (45%)
Service brake in bath of oil (only one side)
Negative parking brake (by the service brake)
Wheels alignment sensor (only MLT)

Components location

Service brake

Service brake
bleeding

Differential lock (not

used)

Parking brake

Parking brake
bleeding

Differential
Steering cylinder

Planetary
Reducer

What oil to use?

Huile MANITOU
Transmission
oil
SAE 80W90

MANITOU oil
Special immerged
ELF SF3
API GL4 LS

LS = Limited slip

132

Checking disc brake wear

- Put brakes under pressure ( press on the brake pedal or pull

hand brake)
- Remove brake fluid level plug
- Checking disc brake ware
Warning, measure S must be 4,5 mm or 3/16 Checking disc brake
ware
Before reassembling, discs the must be dipped in oil
for 12 hours (or 1 night)

Disc brake play checking

- Do not put brake under pressure ( release hand brake - do not touch brake pedal)
- Remove brake fluid level plug
- Check the play between brake discs

Differential

Reducer

3 satellite
reducer

Rear Axle Floats

Boom Components

Boom MLT 625-75 H

DUPLEX BOOM
Consists of 2 components:
1 FIXED
1 MOBILE (T1)
Boom weight: 900 Kg

Boom

Boom MLT 625-75 H

Service

Towing Unit
UNLOCKING THE HIGH PRESSURE LIMITERS
Open the engine hood and Loosen nuts 1 on the hydrostatic pump by no more than three turns.
RELEASING THE PARKING BRAKE ON THE FRONT AXLE
Unscrew the screws 2 on the front axle, remove the shims 3 and fully retighten the screws 2

Test Equipment

Testing Equipment

Testing Equipment- PAD

PN-746120BIS

PAD on MLT 120 LSU

2. Start the PAD

VCI N

Available menus

CD release version
Access card version

3. Choose the type of machine

Select Model

After the Wifi connection to the machine you can only choose global
diagnosis before everything

4. Diagnostic type of selection

ECU identification

The different errors

detected = F2 (BB3)
To have a look at each
parameter in actual time
= PROC (BB3)
Configuration = F1 (BB3)
To calibrate the
theorical sensor and
the learning curve
= F1 (BB3)

5. Read ECU ID

Identification of supplier
reference
And software reference

6. Read Error

The type of Error

(present or saved)
You can delete only
the saved fault

Manitou XPRT Training The End