Manitou Telehandler MVT 628 T Comfort Line Repair Manual 648019 - PDF DOWNLOAD

REF : 648019 (EN)

COSTRUZIONI INDUSTRIALI VIA ENRICO FERMI 5 41013 CASTELFRANCO EMILIA MODENA ☎ 059/950511

IL VOSTRO CONCESSIONARIO :

REPAIR MANUAL

MVT 628 T ine L t r o f Com

PART 1ND

08/2000

1a DATA DI PUBBLICAZIONE 1st DAT PUBLICATION INFORMAZIONI CATALOGO INFORMATION CATALOGUE CATALOGUE INFORMATION KATALOG AUSKUNFT

1ére DATE D'EDITION 1st DATUM AUSGABE

DATA DI PUBBLICAZIONE DATE D'EDITION DATE PUBLICATION DATUM AUSGABE

08/00

OSSERVAZIONI OBSERVATION OBSERVATION BEMERKUNG

Text and illustrations herewith enclosed may not be reproducet, not even in part and by any means.

Because of the possible time lag beween the introduction of technical modifications (an on-going process the aim of which is to offer products which are being continually improved) and the latest up date of the manual, we must point out, for the sake of correctness, that the data contained in this edition are liable to change at any time and are therefore not biding.

R E PA I R M A N U A L

MVT 628 T

INDEX CHAPTER REPAIR MANUAL

PAGE FROM 1 TO 32

- Characteristics

4

- Oils - greases - fluids - fuel - filters

7

- Scheduled maintenance

8

- MVT 628 electrical system

11

- Movement hydraulic system

20

- Steering and brake hydraulic system

22

- Hydrostatic transmission system

24

- Hydraulics - Checking pressures

26

- Removing intake and drain filter

29

- Troubleshooting

30

- Transmission checks and adjustments

32

Page

1

R E PA I R M A N U A L

MVT 628 T

INDEX CHAPTER REPAIR MANUAL

PAGE FROM 61 TO 91

- Braking circuit

61

- Instructions for removing and reassembling the booms

63

- Replacing the boom lines

64

- Removing the swing cylinder

69

- Removing the extension cylinder

70

- Removing the telescopic extension

73

- Removing the telescopic boom from the machine

74

- Removing the lift cylinder from the machine

77

- Removing the compensation cylinders

78

- Dismantling the lift cylinder

79

- Dismantling the swing cylinder

80

- Dismantling the extension cylinder

81

- Removing the compensation cylinder

82

- Removing the engine

83

- Removing the wheels

91

Page

2

R E PA I R M A N U A L

MVT 628 T

INDEX CHAPTER REPAIR MANUAL

PAGE FROM 92 TO 116

- Removing the front and rear differential axle - Removing the front differential axle and hydrostatic motor

92

- Removing the hydrostatic motor only

95

- Removing the rear differential axle

96

- Removing the oil and water radiator

98

- Removing the directional control valve

101

- Safety system

102

-

106 107 108 109 110 111 112 113 114 115 116

Parking brake Hydraulics (Hydrostatic transmission) Hydraulics (Main circuit) Hydraulics (Main circuit) Hydraulics (Swing and optionals circuit) Hydraulics (Compensation and swing circuit) Hydraulics (Lifting and extension circuit) Hydraulics (Fan circuit) Hydraulics (Steering circuit) Hydraulics (Servocontrols circuit) Pedals (Brake and accelerator)

INDEX CHAPTER - Dismantling front-rear axle - Gearbox maintenance and repair instruction - Repairs motor A 6 VM - Repairs Pump A 4 VG 71 DA - Perkins engine repair manual

Page

3

MVT 628 T

R E PA I R M A N U A L

SPECIFICATIONS Engine - Type - Cylinders number - Number of strokes - Injection system - Firing order - Displacement - Bore - Stroke - Volumetric ratio - Nominal rpm - Idling rpm - Power - Maximum torque

PERKINS 1004.40T 4 4 direct 1.3.4.2.

3990 cm3 100 mm 127 mm 17,25 : 1 2300 rpm 750 rpm 105 cv / 77 Kw - DIN 70020 1400 rpm 380 Nm - 38,7 Kgm

Cooling system: - Type - Suction double speed fan

Water cooled 2000 rpm < 85° C 3200 rpm ≥ 85° C

Number of blades - Diameter

8 500 mm

Thermostat - Complete open

82°C

Electrical circuit : - Ground - Battery - Alternator - Voltage regulator - Starting

Negative 12 v - 125 Ah 12 v - 55 Ah incorporated in the alternator 12 v

Brake : - Type - Service brake

Disc brakes in oil bath Foot pedal actuated on both axles

- Parking brake

Hydraulic actuated on front axle negative type

Page

4

MVT 628 T

R E PA I R M A N U A L

Transmission - Type - Type

Hydrostatic Pump and motor with variable displacement

- Gear box - N° of forward speeds - N° of reverse speeds - Reverser

hydraulically operated 2 2 Electrohydraulic

Hydraulic circuit - Lifting, tilting of telescopic boom and device - Type of pump Delivery Pressure

Gear type 80 l/min 235 bar

Steering circuit - Type of pump - Delivery - Pressure

circuito load sensing 160 bar

Specifications - Maximum speed - Forward : unloaded : Unload - Reverse : unloaded :Loaded

35 Km/h 10 km/h

- Tire sizes - Front - Rear

16/70-20 10PR 16/70-20 10PR

- Tire pressures - Rear - Front

3,5 bar 3,5 bar

Page

5

MVT 628 T

R E PA I R M A N U A L

Lifting speed (telescopic boom retracted) unloaded:

57 m / min (6,5 sec)

Lowering speed (telescopic boom retracted) unloaded:

74 m / min (5 sec)

Telescopic boom speed - Unloaded extension - Unloaded retract

19,1 m / min (8 sec) 29,4 m / min (5,2 sec)

Fork dimensions (lenght x width x thickness)

1200 x 125 x 40 mm

External fork spread

1040 mm

Spread by center

500 mm

Rated capacity with std equipment

2800 Kg

Weights with std carriage and forks

5600 kg

Axle ground weights with std equipment - Front unloaded - Rear unloaded

2875 kg 2725 kg

Loaded weights with std carriage and forks

8400 kg

Loaded and with telescopic arm retracted (forks at 20 cm up) - Front - Rear

7270 kg 1130 kg

Drawbar pull - Unload - Loaded

4440 kg 5700 kg

Vibrations Arm accelleration Body (feet or seated part) accelleration

≤ 2,5 m/s2 ≤ 0,5 m/s2

Noiseless (86/662/CEE) Acustic power Acustic pressure in the control seat

LwA 103,7 dB LpA 80,8 dB Page

6

MVT 628 T

R E PA I R M A N U A L

OILS – GREASES – FLUIDS- FUEL - FILTERS COMPONENTS FOR LUBRICATION

CAPACITY

RECOMMENDED PRODUCT

- ENGINE

8,1 L

oil RIMULA X OIL 15W/40

- FRONT WHEEL FINAL DRIVE - REAR WHEEL FINAL DRIVE

0,8 L 0,8 L

oil SHELL DONAX TD

10 - 11 L 2,5 L 10 - 11 L

oil SHELL DONAX TD

80 L

oil SHELL TELLUS T46

0,08 L

oil SHELL LHM S.8214.B

- FRONT AXLE DIFFERENTIAL - GEARBOX - REAR AXLE DIFFERENTIAL - HYDRAULIC FLUID TANK - BRAKING CIRCUIT

Grease SHELL EP2

- GENERAL GREASING

Grease SHELL SUPER GREASE G2

- TELESCOPIC BOOM GREASING - COOLING CIRCUIT

15 L

SHELL ANTIFREEZE

- FUEL TANK

95 L

Diesel

N.B. :

HYDROSTATIC TRANSMISSION FILTER, HYDRAULIC FILTER AND ENGINE OIL AND FILTER MUST BE CHANGED AFTER THE FIRST 50 WORKING HOURS TO GUARANTEE SAFETY.

Page

7

MVT 628 T

R E PA I R M A N U A L

ROUTINE MAINTENANCE FILTERING ELEMENTS AND BELTS 2

5

1 3 4

8

6

DESCRIPTION

MANITOU REFERENCE

50 H (I° COUPON)

300 H (II° COUPON)

REPLACEMENT SCHEDULE

476954

REPLACE

REPLACE

Every 300 H

504507

CLEAN

REPLACE

Every 450 H

3 Transmission oil filter

485695

REPLACE

REPLACE

Every 450 H

4 Fuel filter cartridge

49660

REPLACE

REPLACE

Every 450 H

5 Hydraulic oil filter cartridge (exhaust)

606047

REPLACE

REPLACE

Every 450 H

6 Suction strainer for hydraulic oil tank

448269

7 Hydraulic oil filter cartridge (intake)

513752

CHECK

CHECK

Every 900 H

8 Air filter safety cartridge ▲

514161

CHECK

CHECK

Every 900 H

9 Engine belt

503965

CHECK

CHECK

Every 900 H

1 Engine oil filter 2 Air filter cartridge

▲

9

7

▲

Every 450 H

: Reduce the periodicity and advance the replacement in a dusty atmosphere.

Page

8

MVT 628 T

R E PA I R M A N U A L

FREQUENCY OF OPERATIONS

A Daily and every 10 hours service

B Every 50 hours service

C Every 150 hours service

COMPONENTS

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

- Engine oil level - Injector mainetance - Change injector - Top up cooling circuit - Drain cooling circuit - Check specific weight of coolant liquid - Check fuel level - Clean fuel pre-filter - Bleed fuel intake circuit - Clean and change cooling circuit (if necessary)

B1 B2 B3 B4 B5 B6

- Air filter cartridge ▲ - Hydraulic fluid level - Tyre pressure and wheel nut tightness - Radiator grille - Telescopic boom shoes ■ - Brake circuit fluid level

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15

- Alternator/crankshaft belt tension - Front and rear axle differential oil level - Front and rear wheel final drive oil level - Oil of 2-speed reduction gear on axle - Battery - Grease telescopic boom articulation pin - Grease snap coupling articulation pin - Grease snap coupling connecting-rod pin - Grease lifting cylinder top and bottom pins - Grease compensation cylinder top and bottom pins - Grease cab door - Grease front and rear wheel pivot pins - Grease rear axle float bushes - Grease transmission shaft cross-journal and universal joint - Grease anti-tipping device pin

CHECK CLEAN GREASE REPLACE ADJUST DRAIN

FREQUENCY

OPERATION N°

CHAPTER

MAINTENANCE AND LUBRICATION TABLE

X X X X X X X X X X

X

X X X X X X X X X X X X X X X X X X X X X X

X X X X X X X X X X

D Every 300 hours service

D1 - Engine oil D2 - Engine oil filter

X X

E Every 450 hours service

E1 E2 E3 E4 E5 E6

X X X X X

- Air filter cartridge - Fuel filter cartridge - Transmission oil filter - Hydraulic fluid filter cartridge (drain) - Bleed transmission hydraulic fluid - Fuel feeder pump

X

X

Page

9

OPERATION N°

CHAPTER

FREQUENCY

COMPONENTS

CHECK CLEAN GREASE REPLACE ADJUST DRAIN

MVT 628 T

R E PA I R M A N U A L

F Every 900 F1 - Air filter safety cartridge hours service F2 - Hydraulic fluid F3 - Hydraulic oil filter cartridge (suction rose intake) F4 - Front and rear axle differential oil F5 - Front and rear axle wheel final drive oil F6 - Transmission casing oil F7 - Fuel tank F8 - Alternator/crankshaft belt G Every 1800 G1 hours service G2 G3 G4

- Engine valve gaps - Injectors - Alternator and starter motor - Turbo-charger

X X X X X X

X X X

X X X X X X

FOR THESE OPERATIONS, CONSULT YOUR AGENT OR DEALER

N.B. : To be carried out annually if the truck has not reached these operating times. ▲

: In a very dusty atmosphere reduce the interval and replace earlier.

■

: Every 10 working hours up to 50 hours; last time after 150 working hours.

Page

10

2

1

Nota Bene

B1

G1

G

XX

M10

3

11

HR

GN

N

Rpm

CHECK LAMP

3/7

E8

L1

V4.0

SH

RN

CHECK LAMP

= Connessione centralina controllo spie

ST1

CHECK LAMP

HR

H4.0 50

30

M10

M

M1

B

V

B

27

23

1 2 3

24

P 0

58

30

N

21

15/54

N

22

50

17

19

KEY

F21

TR

LN2.5

F10

P6 N

R

P7

F1

17

CHECK LAMP 12

7

06

8

CN 11

L2.5

33

F33

CHECK LAMP

BR

4

Page

5

CHECK LAMP

M4 R4

CHECK LAMP

M10

12

L2.5

28

6

CHECK LAMP

9

N

R

R

I12

RV

N18 GN

R

N34

M2.5

N

N0

N54

N10

N33

R2.5

RN

N39

19

CN

ELECTRICAL SYSTEM

10

CHECK LAMP

V4.0 13

TABLE 1

15

R E PA IR M A N UA L

MVT 628 T

18

16

14

N0

1

L2

1

N

N

2

CL

02

CHECK LAMP

0

2

N

G

Nota Bene

P3

F17

VG

XX

P2

F31

3

P1

N50

N

GN

P4

F18

CG1.5 CV1.5 LN

F28

N

GN

SG

= Connessione centralina controllo spie

N

G

08

G

F32

CHECK LAMP

F30

4

Page

5

RN

P5

A2

L

F4

6

N10

N

Z

Z

Z

N

GN

X15

7

M2.5

P9

R13

8

N34

85

86

N

HN

87

30

B

87a

F19

VG

P10

9

R2.5

N

HN

CN

10

CHECK LAMP 10

L3 N

CR

04

CHECK LAMP 11

N33

P11

F20

F22

12

GN

N

VN

RB

P12

P17

F23

13

1

N

VN

09

CHECK LAMP

CN

0

L4

14

GR

4

2

RB

N

N

P14

6

P13

1

L

3

LN

8

LN

N 10

5

RN

LV

03

CHECK LAMP

N18

15

N39

16

TABLE 2

7

RN

N

LN

I20

P15

17

N

L

P16

N34 N10 N19

M2.5 RN HN

LN

L

SG

N

L

N33

N0

N52

N51

N37

N36

N38

R2.5

GR

N18

AB

19

GN

ELECTRICAL SYSTEM

18

R E PA IR M A N UA L

MVT 628 T

12

1

N0

C

SG

+

GR

N

2

Nota Bene

XX

L5

3/17

RH

F2

E5

BV

= Connessione centralina controllo spie

N

HL

1 0 2

E12

4

AG

01

N

31

CHECK LAMP

3

CHECK LAMP

07

L0.5

R

FLASHER LIGHT

SG

N37

5

GR

X14

6

N36

1/6

7

RN

NB

E8

R14

3/18

85

86

9

M4.0

HB

E6

87

F24

BV

30

10

N10

3/13

11

N34

HB

E7

P18

F13

12

R2.5

A1

LR

LR

N

CH

P19 N

N

N

S2 N

S3

E6

LR

MG

N

I2

BV

L6

GM CH

N

SB

SB

3/9

CH

N

GZ

GZ

9

5

I33

3/5

S5

0

1

RN

E5

14

3/11

1

RN 10

BV

16

E7

13

N33

15

TABLE 3

17

N

RN

M4.0

SB

26

CHECK LAMP

N0

N10

N34

ELECTRICAL SYSTEM

18

R E PA IR M A N UA L

MVT 628 T

Page

13

19 8

N0

1

N

AG1.5

2

Nota Bene

S6

CN1.5

I4

4/4

XX

-

s

+

9

N

5

AG1.5

I21

4/2

N

C

RN

RN

10

E10

= Connessione centralina controllo spie

MR

MV

LR

VH

VB

V

ST4

0

1

RN1.5 2

M5

1 0

7

3

5

CV

1

CV

M3

VB

RN1.5nr.8

N

M

CH

1

CELLA DI CARICO

Page

3

centralina

4

2

N

M

BG

BG

4

CB

6

8

CH

N

9

10

I22 2

M6

1 0

F9

N

M

1

3

RN1.5nr.9

M

5

7

MB

2

M7

BG

4

RN1.5nr.9

N

M

H

6

8

HB

RN

N

9

10

I23

1

P8

0

F25

1

N

AB

AB

5

AB

RN

N

9

10

N

N0

N10

RN

I24

N34

19

M2.5

ELECTRICAL SYSTEM

5

CB 7

CV

E10

6

F8

8

F26

9

AB

10

RN

12

N10

13

N38

14

M2.5

15

N34

17

TABLE 4

18

R E PA IR M A N UA L

MVT 628 T

14

16

11

N0

1

1

N

N

XX

ZB1.5

N

RN

I26

P22

N

9

10

= Connessione centralina controllo spie

P21

ZN1.5

5

ZN1.5

9

0

N

1

1

RN1.5

5

I25

F12

ZB1.5

RN

10

1

Nota Bene

P20

0

2

RN1.5

3

F11

4

N

GL

1

P23

0

1

N

GL

GL

5

HN

RN

N

9

10

I27 CHECK LAMP SN

25

SN

SN

RN

L7

ST2

N

S

L

T1

GN

CHECK LAMP BN

34

BN

BN

RN

L8

ST3

B

T

T2

GN

CHECK LAMP HV

35

L9

N

I11

HV

HV

RN

H

36

H

H

CHECK LAMP HG

L10 32

I7

RN

N10

RN

L11

N

N0.5

I13

HG

HG

RN

N0

N77

N34

M2.5

RN 1.5 nr.12

N18

19

GN

ELECTRICAL SYSTEM

5

HN

6

RN

7

N19

8

N10

10

M2.5

11

N34

13

GN

14

N18

t

CHECK LAMP 16

TABLE 5

17

R E PA IR M A N UA L

MVT 628 T

Page

15

18

15

12 9

N0

1

N

2

t

Nota Bene

XX

N

I6

N

I9

ZV

N

CZ

6/3

S1

= Connessione centralina controllo spie

t

4

ZV

5

6/6

3

E9

6

E9

N

M

S4

7

RN

F3

S11

6/9

F27

9

F5

MS

E1

I28

N

RG

S7

6/12

N

RL

S8

6/11

6/8

E2

E2

SM

I29

13

E1

12

RN

1

14

N10

0

6/15

N

LB

BL

E3

I30

9

10

1

5

RN

LB

15

M2.5

I32

16

N34

N

HS

S9

6/14

E3

6/18

ZG

E4

I31

18

TABLE 6

11

N

S10

N

BH

6/17

N0

N10 RN

E4

N34

M2.5

ELECTRICAL SYSTEM

19

R E PA IR M A N UA L

MVT 628 T

Page

16

17

10 8

1

N0

N

N

XX

L12

I14

NG

NG

RN

Nota Bene

NG

31

CHECK LAMP

2

N2.5

M

B2.5

7/6

E11

7/4

L

MV

F14

= Connessione centralina controllo spie

M4

F6

CB

E11

6

RN

F29

MV

F15

F7

F16

MR

I15

MN

I16

MB

I17

MV

0 1 2 3

VB

N10

3

t

M2.5

8

L2.5

M2

I3

V2.5 N1.5

M

C2.5 9

N34

N2.5

SN2.5

1

X24

0

RN 1.5 nr.12

11

RN 1.5 nr.12

4

Page

5

1

5

9

10

RN

I24

N54

N1.5

R

GN

LN

L

N18

16

G

17

N50

N52

N51

X21

ELECTRICAL SYSTEM

7

SN2.5

N77

N

TABLE 7

15

R E PA IR M A N UA L

MVT 628 T

17

19

18

14

13

12

10

F15

F14

Reversing beeper (tab.3) Horn (tab.2) Battery 12 Volt (tab.1) Boom extension relay (tab.6) Boom retraction relay (tab.6) Optional extension relay (tab.6) Optional retraction relay (tab.6) Forward travel relay (tab.3) Reversing relay (tab.3) Reversing lights and beeper relay (tab.3) Starting enabling relay (tab.1-3) Hydraulic fluid cooling electric fan control solenoid valve relay (tab.6) Anti-tipping relay (tab.4) Conditioner relay (tab.7) Intermittence unit (tab.3) Fuse 7.5A : Brake lights (tab.1) Fuse 10A : Rexroth travel system (tab.3) Fuse 7.5A : Engine stop (tab.6) Fuse 10A : Horn (tab.2) Fuse 7.5A : Hydraulic fluid cooling electric fan solenoid valve (tab.6) Fuse 30A : Conditioner compressor (tab.7) Fuse 15A : Cab ventilation electric fan (tab.7) Fuse 15A : Front windscreen wiper + screen washer (tab.4) Fuse 15A : Rear and upper screen wiper + screen washer (tab.4) Fuse 10A : Direction indicator lights + instrumentation (tab.1) Fuse 15A : Front working lights (tab.5) Fuse 15A : Rear working lights (tab.5) Fuse 7.5A :Reversing lights and beeper (tab.3) Diode 1A : Cab ventilation electric fan first speed (tab.2) Diode 1A : Cab ventilation electric fan second speed (tab.2) I11 I12 I13 I14 I15

I7 I8 I9

F30 F31 F32 F33 G1 I1 I2 I3 I4 I6

F29

F28

F25 F26 F27

F23 F24

F19 F20 F21 F22

F18

F17

F16

Diode 1A : Cab ventilation electric fan third speed (tab.2) Fuse 7.5A : Right front and left rear sidelights (tab.2) Fuse 7.5A : Left front and right rear sidelights (tab.2) Fuse 10A : Dipped headlights (tab.2) Fuse 10A : Full beam headlights (tab.2) Fuse 25A : Thermal starter (tab.1) Fuse 10A : Emergency lights + cab ceiling light (tab.2) Fuse 3A : Available for radio (tab.2) Fuse 5A : Direct power supply, not used (tab.2) Fuse 10A : Revolving light (tab.4) Fuse 7.5A : Anti-tipping system (tab.4) Fuse 10A : Boom movement solenoid valve system (tab.6) Fuse 5A : Key-controlled power supply, not used (tab.2) Fuse 3A : Conditioner pressure switch (tab.7) Fuse 15A : Not used (tab.2) Fuse 25A : Not used (tab.2) Fuse 30A : Not used (tab.2) Fuse 80A : General power supply (tab.1) Alternator (tab.1) Not used Parking brake microswitch (tab.3) Cab ventilation solenoid valve switch (tab.7) Hydraulic operations disabling button (tab.4) Hydraulic fluid temperature thermal contact (tab.6) Engine oil pressure switch (tab.5) Not used Engine water temperature thermal contact (tab.6) Engine air filter pressure switch (tab.5) Brake light pressure switch (tab.1) Brake fluid level switch (tab.5) Hydraulic fluid level switch (tab.7) Conditioner thermostat (tab.7) L9 L10 L11 L12 M1 M2 M3 M4 M5 M6 M7 P1 P2 P3 P4 P5 P6

I16 I17 I20 I21 I22 I23 I24 I25 I26 I27 I28 I29 I30 I31 I32 I33 Key L1 L2 L3 L4 L5 L6 L7 L8

Conditioner pressure switch (tab.7) Conditioner switch (tab.7) Emergency light switch (tab.2) Anti-tipping reset switch (tab.4) Front windscreen wiper switch (tab.4) Rear and top screen wiper switch (tab.4) Revolving light switch (tab.4) Front working light switch (tab.5) Rear working light switch (tab.5) Reversing light switch (tab.5) Boom extraction button (tab.6) Boom retraction button (tab.6) Optional extension button (tab.6) Optional retraction button (tab.6) Optional operation enabling button (tab.6) Low-high speed travel switch (tab.3) Starter switch (tab.1) Battery charge warning light (tab.1) Side-light pilot light (tab.2) Dipped headlight pilot light (tab.2) Full-beam headlight pilot light (tab.2) Direction indicator light pilot light (tab.3) Parking brake engaged warning light (tab.3) Low fuel level warning light (tab.5) Engine water max. temperature warning light (tab.5) Air filter fouled warning light (tab.5) Engine oil low pressure warning light (tab.5) Brake fluid low level warning light (tab.5) Hydraulic fluid low level warning light (tab.7) Starter motor (tab.1) Cab ventilation electric fan motor (tab.7) Screen washer pump (tab.4) Conditioner compressor (tab.7) Front windscreen wiper motor (tab.4) Rear screen wiper motor (tab.4) Upper screen wiper motor (tab.4) Numberplate light (tab.2) Right front side-light (tab.2) Left rear side-light (tab.2) Left front side-light (tab.2) Right rear side-light (tab.2) Left rear brake light (tab.1)

ELECTRICAL SYSTEM

F11 F12 F13

F10

F9

F6 F7 F8

E10 E11 E12 F1 F2 F3 F4 F5

A1 A2 B1 E1 E2 E3 E4 E5 E6 E7 E8 E9

KEY TO USERS REXROTH MANITOU MVT 628 ELECTRICAL SYSTEM ( reference to drawing n°1682 )

R E PA I R M A N U A L

MVT 628 T

Page

18

P7 Right rear brake light (tab.1) P8 Revolving light (tab.4) P9 Left front dipped headlight (tab.2) P10 Right front dipped headlight (tab.2) P11 Left front full beam headlight (tab.2) P12 Right front full beam headlight (tab.2) P13 Left front direction indicator light (tab.2) P14 Left rear direction indicator light (tab.2) P15 Right front direction indicator light (tab.2) P16 Right rear direction indicator light (tab.2) P17 Cab ceiling light (tab.2) P18 Left rear reversing light (tab.3) P19 Right rear reversing light (tab.3) P20 Front working light (tab.5) P21 Rear working light (tab.5) P22 Left rear fog light (tab.5) P23 Right rear fog light (tab.5) S1 Hydraulic fluid cooling electric fan solenoid valve (tab.6) S2 Forward travel solenoid valve (tab.7) S3 Reverse travel solenoid valve (tab.7) S4 Engine stop solenoid valve (tab.6) S5 Double displacement solenoid valve (tab.7) S6 Anti-tipping solenoid valve (tab.4) S7 Boom extensions solenoid valve (tab.6) S8 Boom retraction solenoid valve (tab.6) S9 Optional extension solenoid valve (tab.6) S10 Optional retraction solenoid valve (tab.6) ST1 Engine rpm-counter instrument (tab.1) ST2 Fuel level instrument (tab.5) ST3 Engine water temperature instrument (tab.5) ST4 Anti-tipping instrument (tab.4) T1 Fuel level transmitter (tab.5) T2 Engine water temperature transmitter (tab.5) TR Thermal starter (tab.1) X14 Direction indicators control lever (tab.3) X15 Lights control lever (tab.2) H :Grey L : Blue M :Brown N :Black

R : Red S : Pink V : Green Z : Purple

ABø0.5 = Light blue/white gauge 0.5 mm2 AB = Light blue/white gauge 1 mm2

Examples:

A : Light blue B :White C :Orange G :Yellow

KEY TO COLOURS

R E PA I R M A N U A L

ELECTRICAL SYSTEM MVT 628 T

Page

19

MVT 628 T

MOVIMENT HYDRAULIC SYSTEM

R E PA I R M A N U A L

Page

20

R E PA I R M A N U A L

MVT 628 T

KEY TO MOVEMENT HYDRAULIC SYSTEM R. F.R. F.A. P. VL VC* VC VT V.A. MCM A SM P.I. D M.V. LS I.D.

= = = = = = = = = = = = = = = = =

Hydraulic fluid tank Drain filter Intake filter Gear double pump Lifting cylinder Tilting cylinder Compensation cylinder Extension cylinder Optional cylinder Control lever Pressur booster Movements selector Hydrostatic pump Directional control valve Fan motor Load sensig Power steering unit

Page

21

MVT 628 T

BRAKE/STEERING HYDRAULIC SYSTEM

R E PA I R M A N U A L

Page

22

R E PA I R M A N U A L

MVT 628 T

KEY TO BRAKE/STEERING HYDRAULIC SYSTEM I.D. V.D. D.S. P.F. M.C. S. FDAV R. F.R. F.A. P. D M.V. LS

= = = = = = = = = = = = = =

Power steering unit Steering cylinder Steering directional control valve Brake pedal Brake pump Brake hydraulic fluid tank Front axle disc brake Hydraulic fluid tank Drain filter Intake filter Gear double pump Directional control valve Fan motor Load sensig

Page

23

MVT 628 T

TRANSMISSION HYDRAULIC SYSTEM

R E PA I R M A N U A L

Page

24

R E PA I R M A N U A L

MVT 628 T

KEY TO TRANSMISSION HYDRAULIC SYSTEM P.I. M.I. R F.R. F.A. M. V.I.

= = = = = = =

Hydrostatic pump Movement pump Hydraulic fluid tank Drain filter Intake filter Engine Inching valve

Page

25

MVT 628 T

R E PA I R M A N U A L

HYDRAULICS CHECKING PRESSURES

Fig. 1

There are 2 pressure testing connections used to check the pressures of the various circuits of the hydraulic system: (Fig.1 / 2).

Use a 0-600 bar pressure gauge to check the system pressures.

Connect the line ref. 72340 and the pressure gauge ref.

58179 to these connections.

1

The directional control valve relief valve must be adjusted as follows (Fig. 3): 1) Undo the lock-nut 2) Screw in the screw Ref. 2 clockwise to increase the pressure, turn anticlockwise to decrease A) The relief valve pressure must be 235 bar (3857 PSI) with boom raised / lowered, boom retracted and accessory functions.

To check the pressure, connect the 0-600 bar (0-8700 PSI) pressure gauge to the snap connection shown Fig. 1.

Adjust the relief valve (Ref. 3-Fig. 4) to obtain the correct setting.

B) For checking the pressure of the compensation circuit, there is a snap connection on the right-hand side of the chassis on the bottom of the compensation cylinder.

Fit the 0-600 bar (0-8700 PSI) pressure gauge to the pressure testing connection shown in Fig. 2.

Fig. 2

1

Fig. 3

2 1 Page

26

MVT 628 T

R E PA I R M A N U A L

C) The pressure of the compensation cylinder, bot tom end, must be set at 280 bar (3857 PSI).

Swing the fork support fully backward (forks pointing upward) and lower the boom slowly to read the setting pressure.

Adjust the valve on the directional control valve if necessary. (Ref. 1-Fig. 4) .

The damping valve of the compensation cylinder rod must be at 180 bar (2286 PSI).

Connect the pressure gauge to the main pressure circuit in the engine compartment (Fig. 5).

Swing the fork support fully forward (forks pointing downward), bring the engine to maximum rpm and read the pressure on the pressure gauge.

Adjust the pressure using the valve (Ref. 2-Fig. 4) if necessary.

Fig. 4 1

4 2

3

Fig. 5 D) The pressure of the boom extension cylinder must be set at 220 bar (3200 PSI).

Connect the pressure gauge to the main pressure circuit in the engine compartment (Ref. 1-Fig. 5).

Completely extend the boom to the limit position to read the pressure.

The pressure must be 220 bar (3200 PSI).

Adjust the relief valve if necessary (Ref. 4-Fig. 4).

1

E) The pressure testing connections on the double pump in the right-hand side of the engine are used to check the pressure of the steering circuit, in the cooling fan and in the boom operating system.

To check the pressure in the steering circuit, connect the pressure gauge to the pressure testing connection.

- Lock the wheels completely to the left or right to the limit position.

- Bring the engine to maximum rpm.

- When the steering system is in the limit position, read the pressure on the pressure gauge.

- The system is supplied with the pressure set at the optimum level of 160 bar (2285 PSI) (Ref. 1-Fig. 6).

Fig. 6

1

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27

MVT 628 T

R E PA I R M A N U A L

- Remember to make a check if the power steering system itself is replaced. If the pressure is not at this level, adjust the relief valve to 160 bar(2285 PSI).

Fig. 7

1

2

F) The speed of 3200 rpm is obtained when the pressure in the fan circuit is about 120 bar.

- The speed of 2000 rpm is obtained when the pressure in the circuit is about 50 bar.

- The fan speed must be measured with the engine at maximum rpm, with the aid of the rev-counter.

- The fan is of suction type.

Fig. 7 a 1

N.B.: To facilitate adjustment of the speed (3200 rpm) a jumper should be placed across one of the two temperature probes during the adjustment.

(Ref 1,2 - Fig.7 )

Page

28

R E PA I R M A N U A L

MVT 628 T

REMOVING THE INTAKE AND DRAIN FILTER INTAKE FILTER

Fig. 8

- Raise the boom.

- Remove the filter and the drain cap to empty the fluid tank completely.

- Wash the tank thoroughly with kerosene, dry it and remove internal dirt.

- Remove the filter element (Fig. 8).

- Install a new filter element.

- Completely refill the tank with hydraulic fluid.

HYDRAULIC SYSTEM FILTER (DRAIN)

Fig. 9

- Raise the boom.

- Remove the filter cartridge (Fig. 9) and replace it with an original spare part.

Fig. 10 HYDROSTATIC SYSTEM FILTER (INTAKE) - Remove the protective guard - Remove the filter cartridge (Fig. 10).

- Replace the cartridge full of fluid and replace it with an original spare part.

- Start up the machine and leave the engine to idle at minimum rpm for 1-2 minutes.

- Perform the first movements in both directions, keeping the engine at minimum rpm.

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29

MVT 628 T

R E PA I R M A N U A L

HYDRAULICS Fig. 11

TROUBLESHOOTING Defect: 1) No pressure in the hydraulic circuit:

1

Cause: - The gear pump (Ref. 1 - Fig. 11) installed on the transmission is not working correctly.

- The relief valve 1 (Fig. 12) of the control system concerned is opened and jammed.

Solution: - Remove the relief valve 1 (Fig. 12) and make sure that it is working correctly.

Fig. 12

- If the cause is not the relief valve, replace the gear pump 1 (Fig. 11).

1

Defect: 2) During lifting or lowering of the boom, the compensation cylinder does not work.

2

Cause: - The damping valves 2 or 3 (Fig: 12) are not correctly set or are jammed.

3

Solution: - If the problem occurs during lifting of the boom, check the opening pressure of the damping valve 2 (Fig. 12) or replace it.

- If the problem occurs during lowering of the boom, check the opening pressure of the damping valve 3 (Fig. 12) or replace it.

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30

MVT 628 T

R E PA I R M A N U A L

HYDRAULICS DEFECTS - Excessive noise in the pump and circuit

CAUSES

SOLUTIONS

Excessive intake resistance

Clean the intake filter

Pump faulty

Replace

Fluid level too low

Top up

- Noise in valves

Valve worn

Replace

- Pressure too low in circuit

Excessive intake resistance

Clean the intake filter

Air in intake circuit

Top up level in tank

Relief valve

Adjust, overhaul or replace

High intake resistance

Clean filter and circuits

Air in intake circuit

Top up level in tank

Relief valve spring broken

Replace

Pump worn

Replace or overhaul

- Flow-rate too low

- Pump overheating

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31

H Y D R O M AT I K T R A N S M I S S I O N

MVT 628 T

SPECIFIC ADVANTAGES OF HYDROMATIK TRANSMISSION UNITS In addition to the traditional features of hydrostatic transmission systems (freedom of transmission installation, minimum space requirements, instant drive reversal, no clutches, dynamic braking), HYDROMATIK transmission units have the following advantages: 1) Specific output of A 4 VG pumps is the highest on the market.

2) High speed A 4 VG pumps and A 6 VM motors.

3) Bent axis design of A 6 VM motors, the pistons have no shoes, this allows 90% of rated load torque to be transmitted on start-up and produces a wide control range.

4) Continuos automatic variation of transmission ratio, controlled by the operator (accelerator pedal) or according to the load, and consequently a better use of the installed capacity.

5) Conventional drive with accelerator pedal and brake and inching pedal.

6) The DA control acts as a “maximum load power control”.Pumps with DA control are used universally on diesel engines and do not require any power calibration,thus making the corresponding settings easier.

The DA control allows peak pressure and maximum displacement to be reached well befor the maximum diesel engine speed (1600-2000 rpm), and therefore maximum machine power or 75% of the travel speed are achieved within a favourable fuel consumption range and a restricted noise level range.

7) When used on loaders, a high average travel speed and maximum propulsive force for a favourable diesel engine is possible. The efficiency of the machine (hourly capacity:hourly consumption) is also very high.

8) The inching valve coupled up to the brake pedal clearance stroke allows the driver to reduce the machine speed whilst increasing the IC engine speed, and, consequently, the delivery of the pump supplying the various hydraulic movements. It is therefore possible to achieve maximum lifting speed at low travel speed, hence more efficient handling.

Thanks to the inching valve, when the driver brakes,firstly hydrostatic braking of the machine occurs, then the brakes are activated, giving economy and long life to the braking system.

9) Limited negative impact on diesel engine speed at full load.

10) No diesel engine overload.

11) When immobilized, diesel power is not transformed into heat; the HP relief valves are not activated due to the combined restoring force-DR valve system.

12) Displacement of the A 6 VM variable motor controlled by the same pilot pressure as the pump (still the only system of this type on the market).

13) The installation of the DA controlled variable motor allows the pump module to be better adapted to the power of the IC engine (and not to the apparent power of the machine) Thus, the constant power delivery range of the pump is maximized and is still satisfactory with the transfer of power to the working hydraulics.

14) HP locking system on the A 6 VM motor permitting detection of the torque direction in relation to the direction of travel, thus avoiding untimely braking in stoppage.

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32

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

BASIC DIAGRAM OF HYDROSTATIC TRANSMISSION SYSTEMS

1

2

4

3 5

6

6

Regolation and Inversion

1) PERKINS engine

type 1004.40T

2) Variable displacement hydrostatic pump

type A4VG71DA

3) Variable displacement hydrostatic engine

type A6VM160DA

4) Booster pump gear 5) Booster relief valve 6) High pressure valves

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33

H Y D R O M AT I K T R A N S M I S S I O N

MVT 628 T

DESCRIPTION OF HYDROMATIK A 4 VG..DA/A 6 VM..DA TRANSMISSION UNIT OPERATION GENERAL By its principle, hydrostatic transmission adapts the torque provided by the IC engine to the wheels according to the resistance by the vehicle and the speed at which the driver wishes to travel.

The transmission ratio varies continuosly and automatically.

The agent enabling the power to be transmitted is mineral oil which is pratically incompressible and which is able to withstand substantial loads.

The HYDROMATIK A 4 VG.. DA/A 6 VM..DA transmission system consists of two separate organs.

1° An A 4 VG axial piston pump of a plate design, flange-mounted on to the diesel engine and driven directly by the flywheel by means of a flexible coupling.

2° An A 6 VM hydraulic axial piston motor of a bent axis design, flange-mounted on to a coupling case and a transfer case and driving the two axle shafts via a differential.

The pump and the hydraulic motor are linked together by a series of hoses, as are various accessories required for operation of the system: reservoir,filter,drain and return to the cooler, etc.

The pump absorbs the maximum power supplied by the IC engine and converts it into hydraulic power (product of the pressure generated and the delivery rate).

The hydraulic motor receives the hydraulic power and absorbs it completely. The output shaft is then given a torque and speed which is transferred to the axle and distributed to the wheels.

The variation in the transmission ratio is obtained by the variation in the displacement of the pump and the hydraulic motor.

The pilot pressure acts against the high pressure on the servo positioner in a set ratio (1/3).

The preponderance of one in relation to the other determines whether the motor is controlled or not .

The minimum motor displacement is limited by a butt screw.

A control system sets the motor switching time.

Page

34

VARIABLE CAPACITY PUMP

IC ENGINE

TUBI FLESSIBILI AD ALTA PRESSIONE

BOOSTER PUMP

FILTER

RESERVOIR

HP HOSE

OIL COOLER

VARIABLE DISPLACEMENT MOTOR

T R A N S M I S S I O N

F I N A L

BRAKE

BRAKE

H Y D R O M AT I K T R A N S M I S S I O N

MVT 628 T

KINEMATIC CHAIN OF THE TRANSMISSION UNIT

Page

35

IMPIANTO IDRAULICO (Trasmissione idrostatica) HYDRAULIQUE (Circuit transmission hydrostatique) HYDRAULIC (Hydrostatic transmission circuit) HYDRAULIK (Hydrostatik getriebekreis) HIDRAULICO (Transmision hidrostatica)

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

MVT 628 T

Page

36

VARIABLE DISPLACEMENT PUMP A4VG 71 DA

ENGINE PERKINS 1004-40T

INCHING VALVE

TANK

HYDRAULIC TANK

VARIABLE DISPLACEMENT ENGINE A6VM 160 DA

H Y D R O M AT I K T R A N S M I S S I O N

MVT 628 T

Page

37

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

PUMP A 4 VG / DA Like the A 4 VG series, this pump is fitted with: ❑ a tachometric control device, ❑ a plate restoring force control device, but also: ❑ a DR control known as a "flow cut-off valve" with pressure hold.

MOST IMPORTANT From size 71, a locking screw for the plate oscillation bearings is fitted to the side of the pump fixing flange. Do not mistake this for pressure connecting plug.

ORIFICE Ø 0,8÷1,2 DR VALVE

HP VALVE INCHING VALVE OUTLET

PS

“DA” REGULATION CARTRIDGE

HP VALVE MAXIMUM BOOSTER VALVE ZERO MECHANICAL SET

FINE TUNING SCREW Page

38

H Y D R O M AT I K T R A N S M I S S I O N

MVT 628 T

SECTIONAL VIEW OF PUMP A 4 VG / DA

Page

39

H Y D R O M AT I K T R A N S M I S S I O N

MVT 628 T

MOTOR A 6 VM / DA Series 6 variable displacement motor - for open and closed circuits - design: axial tapered pistons with sealing rings and bent axis. Size 28 to 200.

Adapted to mobile and stationary applications.

Its wide control range allows this motor to meet high speed and torque requirements.

Its displacement is continuosly variable in the ratio: V g max / V g min = 4,85.

The output speed is proportional to the flow absorbed and inversely proportional to the displacement. The output torque varies according to the difference in pressure between the high and low pressure outlets, and according to the displacement.

Special features: -

Wide control range for hydrostatic transmission systems.

Various displacement control devices.

Reduced cost due to the elimination of the gearbox or the use of smaller pumps.

Compact, robust tapered bearings.

High specific output.

Good start-up characteristics.

Page

40

H Y D R O M AT I K T R A N S M I S S I O N

MVT 628 T

CONTROL CARTRIDGE OPERATION The pilot pressure is drawn via the control cartridge slide valve into the booster circuit. At maximum IC engine speed, the pilot pressure is a few bars lower than the booster pressure.

On idling (850 rpm) the booster flow which passes through the calibrated opening in the control cartridge slide valve is sufficient to create a drop in pressure capable of displacing the slide valve 1 (Page 42) against the force of the spring 2 (Page 42). The pilot pressure is therefore nil.

When the operator accelerates in order to move forward (to approximately 1050 rpm), the booster flow increases; the drop in pressure before the calibrated opening is now sufficient to move the slide valve to the left, against the spring, thus revealing the pilot opening.

When the pilot pressure reaches approximately 6 to 7 bar, the servocontrol cylinder begins to move, tilting the plate of the variable capacity pump. The pump begins to discharge (start of control). The greater the engine speed, the more the booster flow increases thus increases thus leading to a rise in the pilot pressure and therefore increased influence on the pump and greater machine speed.

To halt this process, the operator stops accelerating, the booster flow drops, the pressure drop is reduced and the spring 2 (Page 42) pushes back the slide valve 1 (Page 42) thus closing the booster passage to the pilot conduit. The residual pilot pressure is discharged towrads the housing.

Page

41

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

CONTROL CARTRIDGE OPERATION

VARIABLE CAPACITY PUMP SERVOCONTROL CYLINDER

FWD/N/RR DRIVESOLENOID VALVE BOOSTER PRESSURE RELIEF VALVE REP. 2

REP. 1 CONTROL CARTRIDGE

ACCELERATOR START OF CONTROL ADJUSTING SCREW

Page

42

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

PILOT CIRCUIT

PS

Inching valve

Page

43

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

DR VALVE

Pilot Needle

Bronze Slide Valve

Adjusting Screw

Hole in Collar for Leaks Spring

HP Selector

Seat

❖

Control Slide Valve

IMPORTANT In the event of a considerable drop in the IC engine speed, check that the pilot needle has not become stuck in the slide valve

Page

44

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

DR VALVE 1°)

FUNCTION To cut off flow while maintaining pressure. This corresponds to a return of the pump displacement to the “O” before the HP valve calibration is reached.

This valve anticipates HP relief valve activation on acceleration and deceleration (rapid rise in pressure).

The peak pressure is reduced by the HP relief valves which also protect the circuit against ultra-rapid fluctuations. The calibration range for cutting off the flow while maintaining pressure covers the whole working pressure range. The corresponding calibration values should however be 20 bar lower than those of the HP relief valves.

- Reduced transmission noise.

- Wider control range.

Composition of the DR Valve 1) 2)

HP circuit sensor flow selector.

A slide valve which connects the pilot circuit to the tank in order to release the pump from the pilot control while maintaining the 400 bar level (control starts at 6 to 7 bar, control ends at 20 bar with maximum flow).

The DR valve allows the flow to be reduced while retaining maximum torque.

2°)

OPERATION The HP or MB pushes the HP circuit selector upwards or downwards thus closing the opposite low pressure port (in a HP direction of A to B, the HP traverses the centre of the selector through a small channel).

In all cases, the HP then pushes the needle 4 which in turn raises the control slide valve 3 which creates a partial connection between the control opening and return thuis reducing the pilot pressure.

The effect of this is to reduce the pump displacement, thus reducing the flow while maintaining the 400 bar HP (flow reduction for a maximum torque).

This action of removing the pilot control from the pump acts in the same way as the restoring forces generated by the HP and the adjustment of the control plate.

Page

45

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

SECTIONAL VIEW OF THE DR VALVE

Locknut

14

9

Adjusting screw

Collar

8

1

End cap

Seal

10

2

Bronze slide valve

Spring

7

3

DR control slide valve

Pilot Collar

8

4

Needle

MB

5

HP selector

MA

6

Seat

Page

46

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

TRANSMISSION ADJUSTMENT POINTS PUMP A 4VG Valve DR

Swashplate zero position

HP Valve

Control valve Start of regulation

Boost of valve

HP Valve Eccentric for valve plate adjustement

MOTOR A 6VM Minimum displacement stop (do not readjust) A6VM DA

regulation screw

N.B.: True installation of the motor differs from what is shown in the figure in that it is rotated 90°.

Page

47

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

CHECKING AND REGULATING TRANSMISSION 1

CHECKING AND REGULATING BOOSTER PRESSURE

G

The pump - series A 4 VG 71 - is equipped with an adjustable limiting device.

To increase booster pressure, tighten the screw.

To maximum combustion engine operating rate, 30 bar.

The pump is equipped with a pressure outlet as indicated in the figure

FE

“FE” PRESSURE BOOSTER OUTLET

Page

48

H Y D R O M AT I K T R A N S M I S S I O N

2

MVT 628 T

ADJUSTMENT OF SWASHPLATE “O” POSITION

-

Install two (40÷100 bar) gauges at the HP test points.

Ensure the parking brake is released, the truck supported on blocks (wheels free to turn).

Engine running at idle.

Drive selector in neutral position.

Unscrew the locknut of the “0” adjuster (19 mm ring spanner). Screw in very slowly the screw (6 mm allen key) until movement is seen on the pressure gauge.

- Make a mark relative to the allen key position, slowly turn the screw in the opposite direction until movement is seen on the other pressure gauge, mark the position of the allen key. Turn the adjuster back so that the allen key is exactly central between the two marks.

Lock the locknut.

CHECKING ADJUSTMENT: Remove the low pressure gauges from the HP circuit and install two 600 bar gauges: 1° Check the start of regulation in forward and reverse drive using a tachometer.

Select forward drive, increase the engine speed slowly until the wheel begin to turnrecord the engine speed.

Repeat the same in reverse drive.

Compare the two readings; they should be identical.

2° Check the pilot and HP readings.

Select forward drive, apply foot brake, accelerate progressively to maximum speed.

Record the forward HP and forward pilot pressure.

Repeat the same operation in reverse.The valves should be the same.

Page

49

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

3. A TRANSMISSION INSPECTION AND ADJUSTMENTS

Control valve

Start of regulation

START OF REGULATION : •

Check the engine speed at idle depending on machine type. It should be ~ 850 rpm.

•

Select forward drive, gradually increase the engine speed until the wheels start to move - check the engine speed.

It shoud be between 1050 rpm. If not adjust the screw on the end of the regulation valve.

• Screw into delay the start of regulation.

• Screw out to advance the start of regulation.

•

Adjustment of the start of regulation outside its specified limits will change the performance curve of the pump. Check systematically the end of the regulation “400 bar for the engine mentioned”.

•

Confirming the adjustment is correct is done as described in step 2 point 2.

Page

50

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

3. B CHECK AND ADJUST END OF REGULATION:

End of regulation

CHECK: - The truck is supported on blocks, inching valve by passed, brakes applied (foot and park).

- Drive reverser in forward drive.

- Select forward drive.

- Engine at low idle-check rpm.

- Gradually increase the engine speed (1600÷1800 rpm) until the forward HP reading is 400 bar. At this point check engine speed and compare with specifications.

END OF REGULATION: The adjustment of the pump end of regulation is obtained using an eccentric screw which restricts the pump flow creating back pressure against the swash plate.

WARNING This adjustment can only be set using a test bench.

It cannot be modified in any way without prior authorization from the manufacturer.

IMPORTANT The slot in the eccentric screw should point towards the boost pump(opposite to A4VG pump where slot pointed to drive shaft). The adjustment must not go beyond 90 to the left or right-Do not exceed or damage may occur.

As for the HP adjustment, this adjustment has to be done with the DR valve overcalibrated.

Page

51

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

4

CHECK AND ADJUST HP VALVES

• The HP valves are checked with the truck upported on blocks with the brakes applied.

It is also necessary to by-pass the inching valve with a flexible hose.

Also, if fitted, by-pass the parking brake drive isolation system.

RIF • Overset the DR valve (1) to check the pressure of the HP valves.

Screw the adjuster in 1 turn.

RIF 2

The HP limiting devices - Ref. 2 - shall be set to 510 bar. During this operation, a remarkable droop of the combustion engine speed will take place, around 500 ÷ 600 rpm.

MB MA

After checking the HP, set the DR valve -Ref. 1- to a value 20 bar lower than HP Ref. 2.

RIF 2

CALIBRATION OF THE HP RELIEF VALVE: A 4 VG 71 DA series pump • Remove the lead seal A. • Remove the cap B. • Loosen the locknut D. • Turn screw E to increase the pressure.

• Refit the cap having installed a new lead seal.

RIF 2

B E

A C

D

Page

52

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

TRANSMISSION A4VG-A6VM CHECKS BEFORE PRESSURE TESTING - Check the transmission oil level.

- Check there are no leaks at hoses or unions.

- Check the lectrical connections at the solenoid.

- Make sure the circuit is filled with oil. In some cases the filter should be fitted with oil prior installation.

- Confirm correct connection of pilot hoses: * Port X1 on pump to X2 on motor, * Port X2 on pump to X1 on motor.

- In all cases, the pilot hose be opposite the HP hose (e.g. If the HP for forward drive is on the right of the motor the forward pilot hose must be on the left).

- Install the pressure gauges for boost, pilot, HP and housing checks. ❑ PREPARATION: - For safety purposes support the front wheels on blocks (disconnect 4 wd shaft if applicable).

- Crank the engine a few times with the fuel shut off solenoid disconnected, to ensure the circuit is charged with oil.

- The boost pressure during cranking should be around 15 bar. “Never run the transmission without boost pressure”.

- Connect the fuel shut off solenoid.

- Start the engine and run for a few minutes at idle. The boost pressure should be between 30 bar. A flickering gauge indicates cavitation the in the system.

With the drive selector in neutral the pressure in the two HP circuits be the same as the boost pressure.

- By pass the inching valve(s) using flexible hose.

- When the oil temperature is 50° to 60° C check the engine speed : - Idle speed - Maximum speed - Maximum speed under load (See specifications).

Page

53

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

PUMP A 4 VG 71 PRESUSRE MEASURING POINTS Case pressure

Pilot pressure

X1 R

X2 MB MA

High pressure HP

G Boost pressure Necessary (the portable tool box must always contain base manometers Ref. 549671 + Hydromatik kit Ref. 209572) - Drive pressure • • • •

2 2 2 2

Connectors 165711 (Ref. 55) (M 14 x 150) Manometer outlets 58181 (Ref. 49) (M 8 x 100) Manometers (0÷40 bar) Flexible test hoses 549887

- High pressure • 2 Manometer outlets 477484 (Ref. 51) (M 12 x 1,5) • 2 Manometers (0÷600 bar) • 2 Flexible test hoses 549887 - Booster pressure • 1 Kit of connectors + manometer outlet 199175 (Ref. 53.1) (M 18 x 1,5) • 1 Manometer (0÷40 bar) • 1 Flexible test hoses 549887 - Body pressure • 1 Manometer outlet 477484 (Ref. 51) (M 12 x 1,5) • 1 Manometer (0÷10 bar) • 1 Flexible test hoses 549887 Page

54

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

A 6 VM 160 PRESSURE MEASURING POINTS

HP connection G

Changeover pressure

N.B.: True installation of the motor differs from what is shown in the figure in that it is rotated 90°.

Necessary (the portable tool box must always contain base manometers Ref. 549671 + Hydromatik kit Ref. 209572) - High pressure • 1 Manometer outlet 58189 (Ref. 52) (M 14 x 150) • 1 Manometer (0÷600 bar) • 1 Flexible test hoses 549887 - Switching pressure • 1 Manometer outlet 477484 (Ref. 51) (M 12 x 150) • 1 Manometer (0÷600 bar) • 1 Flexible test hoses 549887

Page

55

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

5. ADJUSTING MOTOR DISPLACEMENT CHANGEOVER A) CHECK MINIMUM DISPLACEMENT (MAX.SPEED) : • The check is made driving the truck on level ground with the engine a full speed in forward drive.

• Connect two 600 bar pressure gauges as shown above.At maximum drive speed the two gauges should read the same. This signifies that the both sides of the Servo piston are subject to the same pressure and the motor is at its minimum displacement.

• To effectively check speed (check the machine technical specifications).

CAUTION The manufacturer performs this regulation -Ref. 1at the bench. It cannot be modified in any way without prior authorization from the manufacturer.

Ref. 1 MINIMUM DISPLACEMENT ADJUSTING SCREW HIGH PRESSURE REGULATION PRESSURE

CHANGEOVER PRESSURE N.B.: True installation of the motor differs from what is shown in the figure in that it is rotated 90°.

B) CHECK START OF REGULATION : • With the wheels raised from the ground and the truck supported on blocks gradually apply the brake pedal to raise the pressure in the HP circuits (inching valve by-pass).

• Watch the two gauges. When the HP gauge shows 260÷280 bar the changeover pressure will drop then the HP will continue to rise until it reaches the setting of the DR valve.

• The changeover point can be adjusted by the screw.

Page

56

H Y D R O M AT I K T R A N S M I S S I O N

MVT 628 T

C) MAXIMUM DISPLACEMENT : (MAX. TRACTIVE FORCE) • To make this adjustment, the machine should be chocked (brakes locked).

The check is made at maximum IC engine speed in forward drive.

• The switching pressure (large section side of control cylinder) must be around zero bars.

Adjust the control screw as required (tighten to increase the switching pressure, loosen to reduce).

• A check on the tractive force (using a hook) should then be carried out (refer to “AideMemoire Service” for values) .

Page

57

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

TROUBLESHOOTING - PUMP/MOTOR

Intake pressure

“S” → pump A4VG

intake pipe

oil tank filter type of oil

Measuring point

rotation direction

oil temperature

cause heat exchanger

Feed pressure

“G” → pump A4VG

MOTOR A6VM

auxiliary pump Measuring point

wear

booster valve

Feed pressure

wear oil temperature → heat exchanger

wash valve

cause bypass valve oil temperature r.p.m. combustion engine pump connector (joint)

Drive pressure

X1/X2 → pump A4VG

MOTOR A6VM

throttles measuring point

DA adjusting valve/inching/partialization valve

intake pressure feed pressure

drive piping

pressure cut electrodistributor/magnet

cause

High pressure

MA/MB → pump A4VG

measuring point

intake pressure feed pressure

MOTOR A6VM

valve HP - DR

not locked

cut in pressure

joint

shift in distributor plate

brake

wear

wear - oil carryover

oil temperature → heat exchanger

oil temperature

cause

heat exchanger combustion engine r.p.m. min/max diesel filter air filter power

Page

58

MVT 628 T

H Y D R O M AT I K T R A N S M I S S I O N

TROUBLESHOOTING - MACHINE

PUMP A4VG

Diesel motor running Vehicle not at a standstill

electrodistributor start regulation cause

zero mechanical set

PUMP A4VG

Delay in vehicle movement

throttles intake pressure cause

drive pressure start regulation inching

Combustion engine strongly overloaded

PUMP A4VG

MOTOR A6VM DR valve

start regulation

wear

slope angle

shift in distributor plate causa combustion engine injection pump fuel filter

Insufficient traction power

MACHINE

PUMP A4VG

shift in distributor plate

MOTOR A6VM wheel diameter

start regulation

cut in pressure

drive piping X1/X2

driving pressure

magnet slope angle

cause combustion engine r.p.m.

Max transfer rate not reached

PUMP A4VG

MACHINE

MOTOR A6VM

drive pressure

transmission

start regulation

inching

tires

magnet slope angle CC screw adjustment

cause combustion engine r.p.m.

Page

59

BLOCKED INCHING VALVE ADJUSTMENT

BLOCKED END OF REGULATION CHECK

BLOCK DR VALVE ADJUSTMENT

MAX

MAX

End of regulation

End of regulation

FWD

REV

FWD

REV

MAX

MAX

REV

FWD

MAX

MAX

Start of regulation

MAX

BOOST PRESSURE

: : :

FWD

REV

PILOT PRESSURE

PUMP TYPE SERIAL N° MOTOR TYPE SERIAL N°

FWD

REV

HIGH PRESSURE CASE PRESSURE

SUCTION VACUUM

max fwd drive blocked:

: : : :

HIGH PRESSURE

CONTROL PISTON PRESSURE

DRAWBAR PULL.................................................kg

...................................km/h

TRAVEL SPEED (MAX) :

OIL TEMPERATURE.........................................°C

OIL TYPE

FWD DRIVE BLOCKED MAX SPEED

FWD DRIVE AT POINT OF DISPLACEMENT CHANGE OVER

MAX FWD DRIVE SPEED

MACHINE CONDITION + DRIVE LEVER POSITION

HYDROSTATIC MOTOR

start of regulation: ..................

4................

5 end of regulation 400 b: .......... 6

IC ENGINE SPEED IN RPM

TYPE OF MACHINE SERIAL N° HOURS RUN

HYDROSTATIC PUMP

Start of regulation

MAX

IDLE

ENGINE SPEED

3

: : :

max with hydraulicc blocked:.....................

FWD

REV

FWD

NEUTRAL

BOOST VALVE ADJUSTMENT

AT MAX SPEED CONTROL CARTRIDGE ADJUSTMENT

DRIVE LEVER POSITION

max speed: ......................

STATE OF MACHINE + CONTROLS

2

BLOCKED CHECK HP VALVE (DR.VALVE OVERSET)

1

idle: .........

DATE OF CHECK NAME OF DEALR NAME OF ENGINEER

MANITOU - HYDROSTATIC TRANSMISSION CHECK SHEET - A4VG--DA / A6VM--DA

H Y D R O M AT I K T R A N S M I S S I O N

MVT 628 T

Page

60

MVT 628 T

R E PA I R M A N U A L

BRAKING CIRCUIT VENTING PROCEDURE Fill the tank 1 (Fig. 13) with the correct fluid (see Oils - greases - liquids - fuel page 7) and keep the level between the two marks punched onto the tank using the venting procedure: Connect the hose to the vent screw A (Fig. 13) making sure that the end of the hose is submerged in the fluid in the tank 3 (Fig. 13). Then repeat the operation, connecting the hose to the vent screw B. Undo the vent screw, press the pedal fully down and in this position tighten the screw.

Re-prime the brake pump by pressing the pedal several times, then repeat the operation described previously to facilitate venting of the fluid.

Continue the venting procedure until all the air has been expelled, tightening the screws with the pedal completely depressed.

Repeat the procedure for all the brakes and then restore the fluid in the tank to the correct level.

N.B.: Use of the special venting equipment will reduce the time normally taken for this operation

Caution: THE USE OF UNSUITABLE FLUID WILL CAUSE SERIOUS DAMAGE TO THE CIRCUIT; USE MINERAL OILS ONLY.

Fig. 13 1

B A 3

Page

61

MVT 628 T

R E PA I R M A N U A L

INSTRUCTIONS FOR REMOVING AND REASSEMBLING THE BOOMS LINES - Connect these, tightening the connections without twisting the lines to ensure correct movement.

Position the lines correctly behind the boom.

(See Fig. 17)

Fig. 17

VENTING THE EXTENSION CYLINDER - For optimum operation of the telescopic extension, completely retract the boom using the control lever provided. Keep the lever in the same position to allow the cylinder to be filled. Slowly extend the telescopic extension, then retract it. Repeat the operation with the boom completely raised.

FIXING THE SKIDS - Tighten the bolts until fully down.

- Shim if necessary.

Torque : 205 N.m +/- 25%

FIXING THE OUTER BOOM BOTTOM SKIDS

FIXING THE INNER BOOM BOTTOM SKIDS

PERNI

PATTINO

SPESSORE

VITE

SPESSORE

FIXING THE INNER BOOM BOTTOM, TOP AND SIDE SKIDS INSERTO

SPESSORE

PATTINO

PATTINO

FIXING THE OUTER BOOM BOTTOM, TOP AND SIDE SKIDS VITE

SPESSORE

INSERTO

PATTINO

VITE Page

62

MVT 628 T

R E PA I R M A N U A L

ADJUSTING THE HANDBRAKE - Keep the brake levers on the axle open and then fit the cable (Ref. 1,2 - Fig. 14).

Fig. 14

1

2

- Position the brake lever in the released position, checking on the dashboard that the light is off (microswitch not excited) (Ref. A - Fig.15).

Fig. 15

B - Turn the handbrake knob clockwise or anti-clockwiseto adjust both the stroke of the brake lever and the tension of the cable (Ref. B - Fig. 15).

A

ADJUSTING THE BRAKE PUMP SHOE Fig. 16

- Adjust the shoe of the brake pump so that there is 1mm of clearance between the pump and the shoe (Ref. 1 - Fig.16).

1

Page

63

MVT 628 T

R E PA I R M A N U A L

REPLACING THE BOOM HYDRAULIC LINES REPLACING THE OPTIONAL AND SWING CIRCUIT LINES

- When replacing the lines inside the boom, lower the forks, engage the handbrake and fit the wheel stop chocks.

1) This operation must be carried out with the boom completely retracted.

Fig. 18 2) Remove the rear guard from the chassis by unscrewing the fixing screws 1,2,3,4 (see Fig. 18).

1

2

3) Remove pressure from the hydraulic circuit using the controls in the cab (see Fig. 19).

3 4) Remove the top collar of the hydraulic lines (Ref. 1 - Fig. 20).

4

Fig. 20 Fig. 19

1

Page

64

MVT 628 T

R E PA I R M A N U A L

5) Disconnect the hydraulic lines of the swing and optional circuit (Ref. 1,2,3,4-Fig. 21) and the relative fixing brackets (Ref. A,B,C-Fig. 21).

Fig. 21

6

5 A

1 2

B

3 4 C

Fig. 22

6) Disconnect the front hydraulic lines in the following order: 1st swing circuit (Ref. 1 - Fig. 22) 2nd o ptional circuit (Ref. 2 - Fig. 22).

1 2 1 2

Fig. 23

7) Remove the lines from the back of the machine (Ref. 1,2,3,4 - Fig. 23).

1 2 3 4

Page

65

MVT 628 T

R E PA I R M A N U A L

- Connect the hydraulic lines before inserting them inside the boom (Ref. 1,2 - Fig. 24).

Fig. 24

1

2

Fig. 25

- Extend the boom to allow removal of the front extension cylinder pin (Ref. 1 - Fig. 25).

- Disconnect the hydraulic lines of the extension circuit (Ref. 5,6-Fig. 21).

1

Fig. 26 - Then remove the rear pin of the extension cylinder and with the aid of a bridge crane extract the cylinder itself from the back of the machine (Fig. 26).

Page

66

MVT 628 T

R E PA I R M A N U A L

- Insert the swing hydraulic lines inside the raceway, keeping them on the left of the extension slide (Ref. 1,2 - Fig. 27).

Fig. 27 1

- Now insert the hydraulic lines of the optional in the raceway, keeping them on the right of the extension slide (Ref. 1,2 - Fig. 28).

2

Fig. 28 1

2

Fig. 29 - Put the extension cylinder back in place and fix it using the pins provided (Fig. 29).

Fig. 30 - Use a bracket to secure the swing and optional hydraulic lines both at the top and at the bottom (Ref. 1,2,3 - Fig. 30).

2 1

3

Page

67

MVT 628 T

R E PA I R M A N U A L

- Connect the hydraulic lines of the extension, optional and swing circuits (Ref. 1,2,3,4,5,6 Fig. 31).

Fig. 31

6

5

1

4

3

2

Fig. 32 - Fit the hydraulic line fixing bracket (Ref. 1 Fig. 32).

1

Fig. 33 1 - Fit the rear guard (Ref. 1,2,3,4 - Fig. 33).

3

4

2 Fig. 34

- Connect the hydraulic lines to the end of the boom, taking care that the curvature is correct when fitting the collars (Ref. 1,2,3,4 - Fig. 34).

2 3 1 4 Page

68

MVT 628 T

R E PA I R M A N U A L

REMOVING THE SWING CYLINDER

Fig. 35

- Place the machine on a flat surface and engage the parking brake.

- Operate the swing control, completely extending the cylinder rod.

- Place the snap connection on one or more supports in wood or other material (Ref. 1Fig. 35).

- Discharge the hydraulic pressure from the circuit.

2

- Disconnect the lines of the swing cylinder (take care to observe the marking).

- Protect the threads of the hydraulic connections on the swing cylinder valve.

1

1

- Remove the rod side swing cylinder pin (Ref. 2-Fig. 35).

- Secure the cylinder.

Fig. 36

1 - Remove the bottom end swing cylinder pin (Ref. 1-Fig. 36).

- Raise the boom, keeping the cylinder vertical.

Page

69

MVT 628 T

R E PA I R M A N U A L

REMOVING THE EXTENSION CYLINDER

Fig. 37

- Place the machine on a flat surface, engage the parking brake and place the stop chocks under the wheels.

- Position the boom horizontal.

1

- Extend the telescopic extension for access to the rod side pin (Fig. 37).

Fig. 38 1 - Remove the rod side extension cylinder pin (Ref. 1-Fig. 37).

4

- Stop the engine.

3 2 - Remove the rear guard from the chassis (Ref. 1,2,3,4 - Fig. 38).

Fig. 39

- Discharge the pressure from the hydraulic circuit usingthe controls in the cab (see Fig.39)

Page

70

MVT 628 T

R E PA I R M A N U A L

- Unscrew the line fixing support (Ref.A - Fig.40) and remove the hydraulic lines on the back of the boom (Ref.1,2,3,4,5,6 - Fig.40).

Fig. 40

A

☞ 6

5

4

2

3

1

Fig. 41

- Remove the boom side extension cylinder pin (Ref. 1 - Fig.41).

1

Page

71

R E PA I R M A N U A L

- Secure the extension cylinder and extract it from the back of the machine (Fig.42).

MVT 628 T Fig. 42

- After repairing or replacing the extension cylinder, put it back into the boom from the back of the machine.

- Reassemble, reversing the order of the removal procedure.

Page

72

MVT 628 T

R E PA I R M A N U A L

REMOVING THE TELESCOPIC EXTENSION - Place the boom horizontal.

Fig. 43

ANTERIORE

- Remove the extension cylinder (See procedure on previous pages).

1 - Remove the skids and the shims of the front side of the outside boom (Ref. 1 - Fig.43) taking care to observe the marking for recognition of the position and thickness (Ref. 1 - Fig.44).

Fig. 44

- Unscrew the screws fixing the swing and optional lines in the back of the machine (Ref. 1,2 - Fig.45).

- Remove the telescopic extension with the aid of a bridge crane or lift-truck (Fig.46).

Fig. 45

1

Fig. 46

2

Page

73

MVT 628 T

R E PA I R M A N U A L

REMOVING THE TELESCOPIC BOOM FROM THE MACHINE

Fig. 47

- Place the truck on a flat surface and remove the fork support equipment installed on the snap connection (Fig. 47).

Fig. 48 - Raise the boom until the lift cylinder pin is above the cab (Fig. 48).

Fig. 49

- Secure the cylinders with a sling connected to a bridge crane or lift-truck (Ref. A/B-Fig. 49).

- Switch off the engine.

A

B

Page

74

MVT 628 T

R E PA I R M A N U A L

- Support the telescopic boom with a bridge crane or lift-truck, using the eye-rings provided (Fig. 50).

Fig. 50

Fig. 51

- Unscrew the fixing screw and remove the pin of the lifting and compensation cylinder, rod side (Ref. 1-Fig. 51).

- Lower the lifting and compensation cylinders with the bridge crane until they are inside the chassis, making sure that the cylinders just lifted are resting inside the chassis.

1

Fig. 52 1 - Unscrew the guard covering the boom lines in the back of the machine (Ref. 1,2,3,4-Fig. 52).

4

- Discharge the hydraulic circuit using the controls in the cab (e.g. control lever).

- Unscrew the line retainer support (Ref. A-Fig. 53).

3 2

Page

75

MVT 628 T

R E PA I R M A N U A L

- Disconnect the lines in the back of the boom (Ref. 1, 2, 3, 4, 5, 6-Fig. 53).

Fig. 53

A

☞ 6

5

4

- Unscrew the retainer screws and remove the hinge pin connecting the boom to the chassis (Ref. 1-Fig. 54).

3

2

1

Fig. 54

1

Fig. 55 - The telescopic boom can now be removed with the aid of a bridge crane or lift-truck (Fig. 55).

Page

76

R E PA I R M A N U A L

MVT 628 T

REMOVING THE LIFT CYLINDER Fig. 56 - Once the telescopic boom has been removed, the lift cylinder can also be removed.

- Disconnect the cylinder supply hoses (Ref. 1,2Fig. 56).

- Fit a belt or sling in the eye-ring of the lift cylinder free from the fixing attachment and lift it vertically with a bridge crane or lift-truck.

1

2

Fig. 57

- Unscrew the pin retainer screw (Ref. 1-Fig. 57).

1

Fig. 58

- Remove the cylinder pin (Ref. 1-Fig. 58).

- The cylinder can now be removed.

1

Page

77

R E PA I R M A N U A L

MVT 628 T

REMOVING THE COMPENSATION CYLINDER Fig. 59 - After removal of the telescopic boom, the compensation cylinder can be removed.

1 - Disconnect the cylinder supply hoses (Ref. 1,2-Fig. 59).

2 - Fit a belt or sling around the eye-ring of the compensation cylinder free from the fixing attachment.

- Unscrew the pin retainer screw (Ref. 1-Fig. 60).

Fig. 60

1

- Remove the compensation cylinder pin (Ref. 1-Fig. 61).

- The cylinder can now be removed.

Fig. 61

Page

78

MVT 628 T

R E PA I R M A N U A L

DISMANTLING THE LIFT CYLINDER

12 13 15 16 11 11 17 2

3

14 10

2

3 9

2 4 2 8 5 6 5 7

DISMANTLING -

Unscrew the head Ref. 16 Extract the rod+piston assembly from the body of the cylinder Remove the Allen screw of the piston Ref.4 CAUTION the screw is fixed with Loctite.

Unscrew the cylinder piston .

Remove the cylinder piston.

Remove the gaskets Ref. 6/8 and the two rings Rif 5 of the piston.

Remove the gaskets Ref. 15/12/13, the anti-extrusion gasket Ref. 14 and the 2 airtight gaskets Ref. 11 and 17 of the head.

- Change the gaskets and components if necessary.

- TAKE CARE to reassemble facing in the correct direction.

REASSEMBLY Operazione inversa dello smontaggio.

N.B.: - The Allen screw must be fitted with thread-locking Loctite.

- Spread hydraulic fluid on the gaskets.

- When fitting the assembly of the gaskets Ref. 6 and the two rings Ref. 5 “take care not to align the cuts in the anti-extrusion gaskets."

(Stagger by one third of the circumference).

Page

79

MVT 628 T

R E PA I R M A N U A L

DISMANTLING THE SWING CYLINDER

12 13 15 11 16 14 16 17 2 10

8

2 9

2

3 2

4 5

7

6 5

DISMANTLING -

Unscrew the head Ref. 11 Extract the rod+piston assembly from the body of the cylinder Remove the Allen screw of the piston Ref.3 CAUTION the screw is fixed with Loctite.

Unscrew the cylinder piston Ref. 4.

Remove the cylinder piston.

Remove the gasket Ref. 7 and the airtight gasket of the piston Ref. 5 and 6.

Remove the gaskets Ref. 12, 13 and 15 and the anti-extrusion gaskets Ref. 14/16/18 of the head.

- Change the gaskets and components if necessary.

- TAKE CARE to reassemble facing in the correct direction.

REASSEMBLY This operation is the reverse of the dismantling operation.

N.B.: - The Allen screw must be fitted with thread-locking Loctite.

- Spread hydraulic fluid on the gaskets.

- When fitting the assembly of the gaskets Ref. 6 “take care not to align the cuts in the anti-extrusion gaskets."

(Stagger by one third of the circumference)

Page

80

MVT 628 T

R E PA I R M A N U A L

DISMANTLING THE EXTENSION CYLINDER

16

8

13 15 14 11 12 10 2

5

9

6

7

3 4 3

DISMANTLING -

Unscrew the head Ref. 15 Extract the rod+piston assembly from the body of the cylinder Remove the Allen screw of the piston Ref.2 CAUTION the screw is fixed with Loctite.

Unscrew the cylinder piston Ref. 5.

Remove the cylinder piston.

Remove the gasket Ref. 5 and the two airtight gaskets of the piston Ref. 3 and 4.

Remove the gaskets Ref. 11/14 and the two anti-extrusion gaskets Ref. 13 and 16 of the head.

- Change the gaskets and components if necessary.

- TAKE CARE to reassemble facing in the correct direction.

REASSEMBLY This operation is the reverse of the dismantling operation.

N.B.: - The Allen screw must be fitted with thread-locking Loctite.

- Spread hydraulic fluid on the gaskets.

- When fitting the assembly of the gaskets Ref. 3/4 “take care not to align the cuts in the anti-extrusion gaskets."

(Stagger by one third of the circumference)

Page

81

MVT 628 T

R E PA I R M A N U A L

DISMANTLING THE COMPENSATION CYLINDER

10 14

11

15 12 12 2

13 8

2

16 9

17 18 3 18 7

17

5 6 5 4

DISMANTLING - Unscrew the head Ref. 15 - Extract the rod+piston assembly from the body of the cylinder - Remove the Allen screw Ref.3 - Remove the cylinder piston.

- Remove the gasket Ref. 7 and the airtight gasket of the piston Ref. 5/6.

- Remove the gaskets Ref. 10/11/14 and the anti-extrusion gasket Ref. 13 of the head.

- Change the gaskets and components if necessary.

- TAKE CARE to reassemble facing in the correct direction.

REASSEMBLY This operation is the reverse of the dismantling operation.

N.B.: - Spread hydraulic fluid on the gaskets.

- When fitting the assembly of the gaskets Ref. 5/6 “take care not to align the cuts in the anti-extrusion gaskets."

(Stagger by one third of the circumference)

Page

82

MVT 628 T

R E PA I R M A N U A L

REMOVING THE ENGINE Fig. 1 - Place the truck on a flat surface, the engine must be off.

- Lift the engine hood.

1 1

- Support the hood in the fully open position with a sling and remove the gas springs (Ref. 1-Fig. 1).

- Lower the hood and remove the screws which fix the hinges.

- Remove the hood.

- Remove the exhaust pipes from the manifold side on the engine and on the main exhaust pipe (Ref. 1,2-Fig. 2).

Fig. 2

1 2

Page

83

MVT 628 T

R E PA I R M A N U A L

Fig. 3

- Remove the metal pipes fitted on the engi ne fuel pre-filter (Ref. 1,2-Fig. 3).

3 - Remove the pipe on the engine air intake manifold (Ref. 3-Fig. 3).

2

1

- Unscrew the lid of the air filter.

(Ref. 1-Fig. 4).

Fig. 4

1 - Disconnect the positive and negative wires on the battery (Ref. 2,3-Fig. 4).

3

2

5

- Remove the battery retainer (Ref. 4-Fig. 4),

4

- Remove the battery (Ref. 5-Fig. 4).

Fig. 5

- Remove the battery support ((Ref. 1-Fig.5).

1

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- Remove the side casing and front casing which enclose the engine compartment (Ref. 1,2-Fig. 6).

Fig. 6

1

1

2

Fig. 7

- Remove the bottom casing of the engine compartment. (Ref. 1-Fig. 7).

1

Fig. 8 - Remove the collars which connect the cooling lines on the engine to the cooling lines fixed to the right-hand side of the chassis (Ref. 1-Fig. 8).

1

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- Disconnect the hydraulic lines fitted on the steering feeder pump and fan on the engine (Ref. 1,2Fig. 9) and (Ref. 1,2-Fig. 10).

Fig. 9

1

2

Fig. 10

2 1 - Disconnect the hoses mounted on the hydraulic system pump (Ref. 1,2,3,4,5,6-Fig. 11).

Fig. 11

6

1

2 3

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Fig. 12

- Disconnect the hoses mounted on the hydrostatic pump on the engine REF. 1-2-3-4-5-6-7-8 (Fig. 12)).

1 3

2

8

4 5 7 6 Fig. 13

- Disconnect the lines of the heating system and the throttle cable on the engine (Ref. 1,2,-Fig. 13).

2 1

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- Disconnect the electrical wiring on the alternator (Ref. 1-Fig. 14).

Fig. 14

1

Fig. 15 - Disconnect the electrical wiring on the starter motor (Ref. 1-Fig. 15).

1

Fig. 16 - Disconnect the electrical wiring on the preheating plug and the respective water return line (Ref. 1,2-Fig. 16).

1 2

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- Disconnect the electrical wiring on the injection pump solenoid (Ref. 1-Fig. 17).

Fig. 17

1

Fig. 18

- Disconnect the electrical wiring of the thermostatic valve water line (Ref. 1-Fig. 18).

1

Fig. 19 - Disconnect the chassis ground wire (Ref. 1-Fig. 19).

1

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Fig. 20

- Connect the engine to the supports by means of a device connected to a bridge crane or a lift-truck (Fig. 20).

- Unscrew the screws fixing the internal supports of the engine to the chassis (Ref. 1-Fig. 21).

- Remove the hydraulic line support bracket (Ref. 1-Fig. 22).

- Unscrew the screws fixing the external supports of the engine to the chassis (Ref. 1-Fig. 23 and Ref. 1-Fig. 24).

Fig. 21

- The complete engine can be removed.

1

- Reassemble, reversing the order followed for dismantling.

CAUTION Once assembly is complete: Fill the cooling circuit.

Top up the hydraulic circuit levels.

Remember to pressurise the hydrostatic circuit, checking its pressures.

Fig. 22

1

Fig. 24

Fig. 23

1

1

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R E PA I R M A N U A L

REMOVING THE WHEELS - Place the truck on a flat surface, the engine must be switched off.

- With the aid of a bridge crane or lift-truck, connect to the holes “A” on the right and left of the chassis (Fig. 25).

- Raise the front of the truck and unscrew the fixing bolts with a 30 mm socket wrench.

- Remove the wheels.

- Perform the same operation for the rear wheels, raising the chassis by point “B” (Fig. 25).

- Remove the wheels.

CAUTION : When replacing the wheels, tighten the fixing nuts to the torque of 343/364 Nm.

Fig. 25

B A

A

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REMOVING THE FRONT AND REAR DIFFERENTIAL AXLE REMOVING THE FRONT DIFFERENTIAL AXLE AND HYDROSTATIC MOTOR Fig. 26 - After removing the front wheels, the front axle and the hydrostatic motor fixed to the axle can be removed.

A

A

- Lift the front of the truck by means of the holes “A” on the right and left of the chassis with the aid of a bridge crane or a lift-truck (Fig. 26).

Fig. 27 - Unscrew the screws which secure the drive shaft flange (Ref. 1-Fig. 27).

1

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- Disconnect the hoses 1-2-3-4-5-6 (Fig. 29) installed on the hydrostatic motor.

Fig. 29

1 2 6

3

5

4

Fig. 30 - Disconnect the hoses on the steering cylinder (Ref. 1-Fig. 30).

1

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Fig. 31 - Disconnect the hose from the service brake control device (Ref. 1-Fig. 31) and disconnect the lines on the steering cylinder (Ref. 2-Fig. 31).

1

1 - Unscrew the bracket supporting the hydraulic lines.

(Ref. 1-Fig. 32).

2

2

- Place a pallet truck underneath the differential axle.

Fig. 32

1

- Unscrew the screws which secure the front axle to the chassis (Ref. 1-Fig. 33).

- Lift the chassis with a bridge crane, turning the axle slightly anti-clockwise, pushing it towards the cab side.

Fig. 33

1 - The front differential axle with the hydrostatic motor can be removed.

Page

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R E PA I R M A N U A L

REMOVING THE HYDROSTATIC MOTOR ONLY Fig. 34

- Place the truck on a flat surface with the engine switched off.

1 - Disconnect the hoses 1-2-3-4-5-6 (Fig. 34) installed on the hydrostatic motor.

2 6

3

5 4

- Support the hydrostatic motor with a sling or a support and unscrew the fixing screws (Ref. 1-Fig. 35).

Fig. 35

- The hydrostatic motor can be removed

1 1

1 1

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R E PA I R M A N U A L

REMOVING THE REAR DIFFERENTIAL AXLE - Once the rear wheels have been removed, the rear axle can also be removed.

Fig. 37 A

- Remove the side casings from the tank (Ref. B-Fig. 37).

A

B

- Remove the tank roll-bar.

Fig. 38 B - Remove the guard protecting the boom lines (Ref. A -Fig. 37).

- Unscrew the tank fixing screws and the relative fuel lines.

Fig. 39

- Raise the rear of the truck using point "B" (Fig. 38).

1

- Unscrew the fixing screws of the drive shaft flange (Ref. 1-Fig. 39).

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Fig. 40 - Disconnect the hoses, left and right-hand sides, of the steering cylinder (Ref. 1-Fig. 40).

1

- Place a pallet truck underneath the differential axle.

Fig. 41

- Unscrew the screws which fix the front and rear support of the axle (Ref. 1-Fig. 41).

- Raise the chassis with a bridge crane.

1

The rear differential axle can be removed.

N.B.: Once installation of the rear axle has been completed, a check must be made on venting of the fuel lines to remove any air inside them.

Page

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R E PA I R M A N U A L

REMOVING THE HYDRAULIC FLUID AND WATER RADIATOR

Fig. 42

- Place the truck on a flat surface with the engine off.

- Place a container underneath the radiator and use the cock provided to drain it of the cooling liquid (Ref. 1-Fig. 42).

1

Fig. 43 - Position a container underneath the radiator and drain it of the hydraulic fluid by disconnecting the hoses (Ref. 1,2-ILL. 43).

1

2

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Fig. 45 - Remove the top and bottom radiator delivery line collars (Ref. 1-Fig. 45 and Ref. 1-Fig. 46).

1 - Remove the cooling circuit vent line (Ref. 1Fig. 47).

Fig. 46

Fig. 47

1 1

Fig. 48 - Disconnect the hydraulic lines leading to the cooling circuit fan (Ref. 1-Fig. 48).

1 1

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R E PA I R M A N U A L

- Unscrew the side and bottom radiator fixing screws (Ref. 1,2,3-ILL. 49).

- The radiator is free from all fixing devices; it can be lifted off the chassis, connecting it to a bridge crane.

Fig. 49

2

3 1

Page

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R E PA I R M A N U A L

Fig. 52

REMOVING THE DIRECTIONAL CONTROL VALVE - Place the truck on a flat surface.

1

- Raise the telescopic boom to the maximum height.

- Stop the engine.

- Disconnect the hydraulic delivery, drain and control lines of the directional control valve (Ref. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 ILL. 53).

- Disconnect the cylinder intake lines (Ref. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 Fig. 52)

3

7

4

8

5

9

6

10

2

.

Fig. 53

3 4

5 6 1 2

10

9

8

7

Page

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SAFETY SYSTEM UNIT

OPERATOR

VISUAL DISPLAY

Switch the machine on Engine turning over

AUDIO SIGNAL

All the LEDS are on

Start of setting

To position "0", machine : - Stable (no movement) - On level ground - With no attachments - Jib raised to max., telescope retracted Press for 2 s the adjust button located at the back of the unit (see diagram 2)

2 yellow LEDS and 2 green LEDS in the middle flash alternately

Enter set mode Press the "STOP BUZZER" button

2 green LEDS at the bottom remain on

5 beeps indicate that the setting has been saved

"O" setting saved

2 red LEDS at the top remain on

To position "MAX": Take the machine's rated load, position it at max. startup as per truck's load chart

2 yellow LEDS and 2 green LEDS in the middle flash alternately

Press the "TEST" button

5 beeps indicate that the setting has been saved

"MAX" setting saved

setting conforms consistency "MAX" and "0"

NO

The unit returns to the "locked" position All the LEDS are on, with no buzzer ignition on

A continuous 2s beep indicates to the operator that the settings have been taken into account and that the unit is passing automatically into the normal operation position

YES

The unit automatically leaves the set position the LEDS stop coming on Check the setting against the load chart : put the rated load at max. startup

setting conforms to load chart YES

Operator starts setting over again

End of setting

NO

Operator starts setting over again The LEDS come on up to the first red LED

Stick on the other part of the "SESALY" sticker to seal the setting (see diagram 2)

The operator can put the truck in the desired position

Page

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WARNING 1 - This setting must be made with the rear axle assembly at a stable temperature. Do not carry out after braking tests as the temperature difference between the axle assembly and the gauge would disturb the setting.

2 - Before setting the unit, it is important to operate the machine for placing the strain gauge (for example, when testing the machine, in which case make sure to comply with point N° 1).

3 - Last checking of setting must be done before forwarding the machine

DIAGRAM1

1 red LED

DIAGRAM 2 Place the sticker after setting and conformity checks

2 red LEDS 2 yellow LEDS 4 green LEDS

Set button clearance hole (tool Ø 2, min. length 40)

Page

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P 150 SAFETY SYSTEM

2 red LEDS Test switch

Sound alarm signal light off

2 yellow LEDS

Sound alarm off switch

4 green LEDS

Power supply connector + aggravating movements cut-off signal output

Connection to the strain gauge

adjustment microswitch (accessible with a 6 mm male hexagonal wrench)

Page

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INSPECTION PROCEDURE FOR THE SAFETY SYSTEM STRAIN GAUGE Connector engineering : + power supply - power supply and PT 100 + measurement - measurement PT 100 Shielding

brown wire / contact N° 1 white wire / contact N° 2 green wire / contact N° 3 yellow wire / contact N° 4 grey wire / contact N° 5 braid / contact N° 6

Prior to any electrical inspection, carry out a visual check on the state of the gauge and its connections Electrical Inspection Disconnect the gauge from the electrical circuit.

Use a multimeter to take the following measurements : - Measure the impedance between A+(m) and A-(bc) = Z power (power supply impedance) Values : 300Ω ≤ Z power ≤ 400Ω - Measure the impedance between M+(v) and M-(j) = Z meas. (measuring system impedance) Values : 300Ω ≤ Z power ≤ 400Ω - Measure the impedance between A- (bc) and PT 100(g) = Z PT100 Values : 101Ω + 0.39xT T corresponds to the gauge temperature.

Example : T=20°C then Z PT 100 = 101Ω + 7.8Ω = 109Ω - Measure the impedance between A+ (m) and shielding : Zbl Zbl > 30 MΩ (infinite resistance or open circuit) - Measure the impedance between A+ and the machine frame : Z frame Z frame > 30 MΩ (infinite resistance or open circuit)

Description of the connectors placed behind the overcharge indicator + power supply 1

Shielding 6

- power supply 2

PT 100 5

Measurement + 3

+ Battery

- Battery

Measurement - 4 Movement cut-out signal output

Page

105

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R E PA I R M A N U A L

6

13

9 11 12

8

1

10

7

2

3

14

16

15

13

5

13

4

PARKING BRAKE

Page

106

30

3

16

14

13

12

11

15

3

15

30

14 13

35

12 11

29

36

31

33

37

39

16

40

34

28 38

32

3 2

22 20

32 38

17

18

38

3

20

38

32

30

30 2

22

21

19

32

3

20

24

23

5

41

25

5

3

26

18

6

1 20 17

2 3

10

27

11

8

7

2 3

9

11

28

29

10

9

7

8

4

6 3 5

R E PA I R M A N U A L

MVT 628 T

HYDRAULICS (HYDROSTATIC TRANSMISSION)

107

Page

41

37

5

34

35

39

20

37

18 21

36

38

19

47

52 51

37

5

40

26

27

28

33

29

4

44

42

55

43

58 59

54

16

57

53

15

49 48

4

56 50

14

11

10

37

5

17

60

21

8

12

40

20

23

41

38

37

10

37

32

13

22

5

1

4

3

9

46

30

46

9

2

12

8

7

13

8

7

32

30

31

25

24

6

8

7

R E PA I R M A N U A L

MVT 628 T

HYDRAULICS (MAIN CIRCUIT)

108

Page

MVT 628 T

R E PA I R M A N U A L

25 5

10

2

4

10

1

1

9

22

8

16 17

12

26

24

16

18

22

13

23

9

7

6

20

9

6

19

7

21

9

8

11

7

20

19

HYDRAULICS (MAIN CIRCUIT)

Page

109

10

11

16

9

17

12

11

18

14

11

13

12

11

15

11

13

5

17

19

11

6

8

10

20

7

21

3

11

2

11

4

9

24

19

23

4

1

26

11

13

25

22 14

1

25

11

11

13

15 11

26 27

R E PA I R M A N U A L

MVT 628 T

HYDRAULICS (SWING AND OPTIONALS CIRCUIT)

110

Page

MVT 628 T

R E PA I R M A N U A L

17

16

8

9

15

12

8

9

11

10

9

9

10

9

14

13

7

4

11

8

3

9

6

8

5

3

1

3

2

HYDRAULICS (COMPENSATION AND SWING CIRCUIT)

Page

111

28

25

25

15

10

8

3

21

26

16

17 14

20 8

3

27

33

31 32 21 8

19

8

22

23

9

20 1 4

3

6 8 9

18

2

7

7

24

11

10

8

5

30

7

8

34

7

29

13

14

12

34 30

R E PA I R M A N U A L

MVT 628 T

HYDRAULICS (LIFTINGS AND EXTENSION CIRCUIT)

112

Page

13

10

2

1

32

12

11

7 6 14

6

3

5

4

15

7 6 14

34

17

29

28

32 6

16

5

34

18

19

20

6

21

33

22

28

22

9 28

7

29

27

26

25

26

23

24 31 28 27

30

R E PA I R M A N U A L

MVT 628 T

HYDRAULICS (FAN CIRCUIT)

113

Page

MVT 628 T

R E PA I R M A N U A L

HYDRAULICS (STEERING CIRCUIT)

Page

114

R E PA I R M A N U A L

MVT 628 T

HYDRAULICS (SERVOCONTROLS CIRCUIT)

Page

115

36

37

25

19

33

36

25

34

23 15

28

37

21

36

22

20

35

16 15

16 15

35

26

24

49

47

45

32

18

40

27

38

27

26

51

44 39

29

17

16

50

8

15

15

46

16 15

15

48 42 43

30

41

31

6

11

7

9

5 4

1

8

3

2

16

15

13

14

10

12

R E PA I R M A N U A L

MVT 628 T

PEDALS (BRAKE AND ACCELLERATOR)

116

Page