PDF Repair Manual Manitou MLT 625 MT 625 Telehandler - 9 MB
This complete repair manual provides all the information needed to service and overhaul the Manitou MLT 625 and MT 625 series telehandlers.
It offers step-by-step procedures, detailed specifications, and clear diagrams for every system, from the engine to the hydraulics.
This manual is designed for professional mechanics to perform complex repairs with accuracy and confidence.
Keep your telehandler in peak condition with this essential guide.
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647230 EN (30/05/2018)
MLT 625-75 H SERIES 1-E3
MLT-X 625-75 H SERIES 1-E3
MT 625 T COMFORT SERIES 2-E3
MT 625 TURBO SERIES 2-E3
MT-X 625 T COMFORT SERIES 2-E3
MT-X 625 TURBO SERIES 2-E3
REPAIR MANUAL
--- Page 3 ---
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
pages
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
(28/01/2014) 00-00-M176EN
--- Page 4 ---
GENERAL CHARACTERISTICS AND
MT-X 625 Turbo / SPECIFICATIONS 5
MT-X 625 T COMFORT
00
Data from the Operator’s Manuel :
CHARACTERISTICS AND FLUIDS l 647421 from 10/06/2013
Désignation Valeur Désignation Type Quantité
Lift truck weight with forks 4710 kg Fuel Tank Diesel fuel 63 ℓ
Boom weight 900 kg Engine oil SHELL Oil / RIMULA R4L 15W40 CI4 11,2 ℓ
Weight per Front unladen 2210 kg Cooling circuit Cooling liquid (protection - 25° / -35°) 12 ℓ
axle with forks Rear unlade 2500 kg Hydraulic oil tank MANITOU Oil / Hydraulic ISO VG 46 115 ℓ
Drag strain 3485 daN Brake system MANITOU Oil / Mineral brake fluid 1ℓ
Front transfer box MANITOU Oil / SAE80W90 0,75 ℓ
Front/ rear
MANITOU Oil / Special immersed brakes 4 ℓ / 3,8 ℓ
axle differential
Front/ rear
MANITOU Oil / SAE80W90 0,8 ℓ / 0,9 ℓ
wheels reducers
DIMENSIONS
Item Value
A (mm) 1200
B (mm) 2300
C (mm) 991
C1 (mm) 928
D (mm) 3894
D1 (mm) 3831
D2 (mm) 3275
E (mm) 5094
F (mm) 1492
F1 (mm) 1492
G (mm) 240
G1 (mm) 330
G2 (mm) 253
I (mm) 603
J (mm) 797
K (mm) 1015
L (mm) 45
N (mm) 1314
O (mm) 125
P2 (°) 37
P3 (°) 52
R (mm) 3150
S (mm) 6651
T (mm) 3935
U1 (mm) 1920
U2 (mm) 2054
V (mm) 4700
V1 (mm) 765
V2 (mm) 3310
W (mm) 1813
Y (°) 12
Z (°) 117
(06/01/2014) 00-01-M176EN
--- Page 5 ---
10
ENGINE COMPONENTS LOCATION
pages
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FAN CONTROL (FOR MLT 625-75 H / MLT-X 625-75 H ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . 3
(07/01/2014) 10-03-M176EN
--- Page 6 ---
ENGINE CONTROL AND ADJUSTMENT A5
180°
10
C - REPLACING THE CRANKSHAFT LIP SEAL
Procedure applied as standard as from engine No. AUO138
(October 2010).
REMOVAL
- Remove the crankshaft pulley (1).
1
- Remove the worn seal (2).
2
bb Be careful not to damage the aluminium seal bearing surface.
REFIT
- Apply clean engine oil to the seal bearing surface (3).
- Oil the outside of the new seal.
- Insert the new seal into the crankcase.
3 NOTE: You can press the seal home using a special tool or 55 mm socket.
bb The seal must be pushed all the way in to the crankcase
housing to avoid the pulley rubbing on the seal.
(07/01/2014) 10-04-m176EN
--- Page 7 ---
ENGINE CONTROL AND ADJUSTMENT B9
Remove the fan (Item 9).
10
9
Cut the belt (Item 10), remove and dispose of it (Cutting pliers).
10
Unscrew the 3 screws (Item 11) in the pulley assembly (Item 12).
11 Remove the pulley assembly (Item 12).
12
REFITTING
Place the new belt 2 (Item 13) on the pulley 1 (Item 14).
Fit the pulley assembly (Item 14) on the engine with screws
(Item 15)
14
15 13
(30/05/2018) 10-04-M176EN
--- Page 8 ---
ENGINE CONTROL AND ADJUSTMENT B19
H - FAN CONTROL OPERATION
LOCATION
10
Fan direction reversal
electrovalve
Fan control hydraulic Fan control hydraulic
engine pump
Fan speed control
electrovalve
I – FUNCTION
⇒⇒ To adjust the speed of the engine cooling fan according to the temperature (engine and
transmission).
⇒⇒ To temporarily reverse the direction of flow to unclog the bonnet intake grilles.
(30/05/2018) 10-04-M176EN
--- Page 9 ---
ENGINE REMOVAL 3
ORDER OF DISMANTLING
Stage 1 HYDRAULIC PUMP REMOVAL
10
Stage 2 COMPLETE “BOX + ENGINE ASSEMBLY” REMOVAL
Stage 3 COOLER REMOVAL
Stage 4 ENGINE REMOVAL
Stage 5 HYDROSTATIC PUMP REMOVAL
(06/02/2012) 10-06-M176EN
--- Page 10 ---
ENGINE REMOVAL 13
Using a 13 mm wrench, unscrew the 2 screws (6) that hold the
6
cooler in position (7) on the box (8).
7
10
6
8
Remove the cooler (7).
(06/02/2012) 10-06-M176EN
--- Page 11 ---
ENGINE REFIT 7
Mount the 2 attachment screws (11) of the third silent block (12)
(19 mm socket).
Comply with torque tightening: 7 daN.m ±10 %.
10
11
12
11
Refit the air hose (13) on the air filter (14).
Tighten the clamp (15).
14
15
13
(06/02/2012) 10-07-M176EN
--- Page 12 ---
10
SPECIFIC ENGINE TOOLING
pages
FAN BELT FITTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(06/02/2012) 10-09-M176EN
--- Page 13 ---
TRANSMISSION SCHEMATIC DIAGRAMS A5
MT 625 TURBO / MT 625 T COMFORT / MT-X 625 TURBO / MT-X 625 T COMFORT
FLUID FLOW DISPLAY IN FORWARD GEAR (VIEW 2)
Key:
Suction pressure
Boost pressure
High Pressure
Low Pressure
Cooling pressure
Drainage pressure
RF Oil cooler
Y6 Hydrostatic engine 2P proportional
20
electrovalve
Y7 electrovalve BDP (Brake Pressure Defeat)
RF Y8 Telescope electrovalve + or - direction
Y9 Attachments electrovalve + or - direction
Y10 Proportional hydraulic pilot electrovalve
(Telescope)
Y11 Proportional hydraulic pilot electrovalve
(Attachment)
Y12 Hydraulic cut-off electrovalve (TUV)
Y9
Y8
Y12
Pe A
L1
L2
B
M3
Y11
Y6
Y10 S B
Y7
70
A
For
wa
rd g
ear
(07/01/2014) 20-02-M176EN
--- Page 14 ---
TRANSMISSION SCHEMATIC DIAGRAMS B5
MLT 625-75 H / MLT-X 625-75 H
FLUID FLOW DISPLAY IN FORWARD GEAR (VIEW 2)
Key:
Suction pressure
Boost pressure
High Pressure
Low Pressure
Cooling pressure
Drainage pressure
MHRV Fan drive hydraulic motor
20
RF Oil cooler
Y6 Hydrostatic engine 2P proportional solenoid
valve
RF
Y7 Electrovalve BDP (Brake Pressure Defeat)
Y8 Telescope electrovalve + or - direction
Y9 Attachments electrovalve + or - direction
Y10 Proportional hydraulic pilot electrovalve
(Telescope)
Y11 Proportional hydraulic pilot electrovalve
Y9 (Attachment)
Y8
Y12 Hydraulic cut-off electrovalve (TUV)
Y12
A
L1 Pe
MH
RV L2
B
M3
Y11
Y6
Y10 S B
Y7
70
A
For
wa
rd g
ear
(07/01/2014) 20-02-M176EN
--- Page 15 ---
TRANSMISSION CONTROL AND
ADJUSTMENT 3
TOWING PROCEDURE
If the lift truck is not on level ground, chock it so that it does not descend the slope.
bb The lift truck must be towed at very slow speed (less than 5 km/h) over the shortest possible
distance (less than 100 m).
- For towing a lift truck, the high pressure relief valves must be unlocked to avoid damaging the
hydrostatic transmission, and the parking brake on the front axle must be released.
20
- Switch on lift truck ignition.
- Set the forward/reverse selector to neutral.
- Release the hand brake.
UNLOCKING THE HIGH PRESSURE RELIEF VALVES:
1
- Open the engine bonnet.
- Loosen the nuts (1) on the hydrostatic pump (2) by no more
1 2 than three turns.
RELEASING THE PARKING BRAKE ON THE FRONT AXLE:
- Unscrew the screws (3) on the front axle, remove the shims (4)
and fully retighten the screws (3).
4
3 TOWING:
- Switch on the hazard warning lights.
- Since there will be no steering or braking assistance, operate the
steering and pedal slowly avoiding sudden or jerky movements.
- After towing, retighten screws (1) (tightening torque 70 N.m).
- Unscrew the screws (3), refit the shims (4) and retighten the
screws (3) (tightening torque 95 - 115 N.m).
3
4
(30/09/2015) 20-04-M176EN
--- Page 16 ---
BRAKE CHARACTERISTICS AND SPECIFICATIONS
pages
SERVICE BRAKE / PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
40
(29/09/2015) 40-01-M176EN
--- Page 17 ---
BRAKE CONTROL AND ADJUSTMENT 7
17
18
Drain service brake on front axle:
- Install a transparent recuperation tube on the vent screw (Item 17).
- Loosen the vent screw, then when the brake fluid flows without air bubbles, retighten the vent screw.
40
Drain parking brake on front axle:
- Carry out the same operation on the vent screw (Item 18).
- Top up the brake fluid tank level.
(07/02/2012) 40-04-M176EN
--- Page 18 ---
BOOM COMPONENTS LOCATION 3
LOCATION OF THE DUPLEX BOOM MAIN COMPONENTS
T1
VI
FIXED ELEMENT
X134
50
VE
VT
(11/04/2014) 50-03-m176EN
--- Page 19 ---
BOOM CONTROL AND ADJUSTMENT 9
Insert telescope T1 into the foot of the boom using a sling (Item 2)
2 and a jib crane.
Remove the support stand (Item 3).
T1
3
4
Place the 4 pad cages (Item 4)
4
Place the bottom front slide pads (Item 5) ensuring that they are
mounted in the correct direction.
Grease the sliding surfaces of the pads (o RECOMMENDATIONS
FOR FITTING BLOCKS AND GREASING AREAS).
5 5
4 4
50
Insert telescope T1 into the boom foot (Item 6) to within 400 mm
6
of the end.
T1
m m
400
Place the top front pads (Item 7) in the correct direction and with
7 the correct clearance.
7
Grease the sliding surfaces of the pads (o RECOMMENDATIONS
FOR FITTING BLOCKS AND GREASING AREAS).
(20/01/2014) 50-04-M176EN
--- Page 20 ---
BOOM REMOVAL 3
Remove the screw (Item 1) (17 mm wrench).
Remove the pin (Item 2) from the compensating cylinder (Item 3).
2
1
3
Disconnect the electrical
connector (Item 4) located
5 at the base of the boom.
Unscrew the boom angle
4
sensor ball joint (Item 5)
50
Disconnect all hydraulic pipes and remove the clamp.
Place a container under the pipes to collect the oil.
Remove the retaining bracket (Item 10) securing the 2 pipes
(Item 11) by removing the screw.
10
11
11
(12/02/2014) 50-06-M176EN
--- Page 21 ---
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
HYDRAULIC COMPONENT SHEETS
–– COMPLETE ELECTROVALVE
–– DISTRIBUTOR 5000 (INLET ELEMENT)
–– DISTRIBUTOR 5000 (LIFTING ELEMENT)
–– DISTRIBUTOR 5000 (TILTING ELEMENT)
–– DISTRIBUTOR 5000 (ATTACHMENT ELEMENT)
–– DISTRIBUTOR 5000 (TELESCOPING ELEMENT)
70
–– FEED BLOCK + ACCUMULATOR
–– AGGRAVATING MOVEMENT CUT-OFF BLOCK
–– STEERING BLOCK
–– COUNTERBALANCE VALVE VBSN
–– COMPENSATION INSULATION VALVE VIC
(09/02/2012) 70-01-M176EN
--- Page 22 ---
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 1
DISTRIBUTOR 5000 (ATTACHMENT ELEMENT) d1
Values indicative only
Role:
- Enables several actuators to be supplied according to pilot-operated
distribution spool position.
A B
2 3 1 2
1. Distribution spool
2. Pilot head
3. Non-return valve
70
3
2b 2A 2B
LS P 1b 1A 1B 3b 3A 3B 4b 4A 4B
245 bar 245 bar 245 bar 180 bar D
T
235 bar
8 bar
P
Pp
1a 2a 3a 4a
EL EI 1 2 EA 2 ET
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(13/02/2012) F70-3-0051EN
--- Page 23 ---
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS 1
COUNTERBALANCE VALVE VBSN
Values indicative only
On lifting cylinder On telescoping cylinder
3
V1
VE 3 1
210 bar
1 V1 V2 2
210 bar
VT
VL V2 2
VE
70
2
1
3
Operation:
Pilot-assisted counterbalance valves are a combination of two valves; a non-return valve and a pressure
relief valve. The non-return valve allows free flow from the distributor (chamber 2) to the load (chamber 1),
while a pilot-assisted direct acting pressure relief valve controls the flow from chamber 1 to chamber 2.
The effective pressure relief valve setting is lowered by the pilot pressure at port 3 to a value determined
by the pilot ratio.
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(14/02/2012) F70-3-0056EN
--- Page 24 ---
HYDRAULIC SCHEMATIC DIAGRAMS A5
HYDRAULIC DIAGRAM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
3 2 1 VVT(O)