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7/25/2019 MLT625 XPRT Service Training.ppt
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XPRT MLT 625 Training
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MLT 625 75 H
MLT
6
25
= Manitou Loader Telescopic
= Max height: 6 meters
= Max load capacity: 2.5 tons
! = uro !
"enomination
#$ = #eries$
= ngine 75 H%75
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MLT 940 T-120 LSU
New Agricultural Range &urrent 'ange
Series 6 E3
Series 4 E3
Series 1 E3
MLT 625-75 H
MLT 735-120 LSU
MLT 625-75 H
MLT 735 T 120 LSU
MLT 845 T 120 LSU
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Unit Identification
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Specifications
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#peci(ications
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#peci(ications
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#peci(ications
# (
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#peci(ications
# i(i i
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#peci(ications
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Specifications
Load &harts are in pounds and
(eet so there is no need tocon)ert the *eight.
+hat is the capacity *here the
green dot is located,
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Instruents and !ontrols
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Instruments and Controls
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Instruments and Controls
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Instruments and Controls
-T: The location o( the s*itches may )arydepending on the options.
/ 0 +/'-1- L1HT#
3 0 '/' 4 L1HT#
& 0 'L1- L1HT
" 0 4'-T /-" '/' +'1- L1HT# %T1-
13 H/" L1HT#
0 %T1- '/' +1-"+ "01&1-
4 0 -8T'/L1#/T1- 4 H9"'/8L1&
MM-T#
0 /' #L&T1-. ears can e selected *hile dri)ing.
#L+ #%": 8se (or handling; s*itch in the up position; the indicator lamp is o((.
H1H #%": 8se on the road; s*itch in do*n position; the high speed indicator lamp comes on.
H 0 +HL /L1-M-T 1-"1&/T' L/M%#
1 0 %/'1- 3'/
/
3
&
"
4
H
1
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Instruments and Controls 0 "1#/3L1- TH
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#M oysticA
&ontrols
&ontrol
/ 0 Li(ting and tilting control le)er.
3 0 Telescoping control utton.& 0 /ttachment control utton.
L14T1- TH L/"
0 The le)er / acA*ards *hen li(ting.
0 The le)er / (or*ards *hen lo*ering.
T1LT 4 &/''1/
0 The le)er / to the le(t (or re)erse tilt.
0 The le)er / to the right (or (or*ard tilt.
TL#&%1-
0 3utton 3 (or*ards (or extending.
0 3utton 3 acA*ards (or retracting./TT/&HM-T
0 3utton & (or*ards or acA*ards.
/
3 &
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#M oysticA
&ontrols
"#R$AR%&N'UTRAL&R'('RS'GEAR
SELECTION
+hen operating this control; the li(t trucA
should e tra)elling at slo* speed and not
accelerating.
4'+/'": %ush the Ano (or*ard
>position /?.
''#: %ull the Ano acA*ard
>position 3?. >/n %T1-/L re)ersing light
and audile re)ersing alarm indicate that
the li(t trucA is tra)elling in re)erse?.
-8T'/L
2$
/
3&
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)*draulic !oponent Location and "unction
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P
DBA
BMHP
BCMA
PDD
PH2!
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Hydraulic %ump
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Hydraulic fan motor + inverse valve
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hydraulic valve Bank
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Supply block + Accumulator
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Hydraulic proportional manipulator block
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Aggravating cut o movements block
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!rbitrol
Double hydraulic pump
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11 cm3
31 cm3
Maximumtorque:
280 Nm
Double hydraulic pump
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One wayvalve
Flowregulation
TS/1!
Flowinver"ion
S#/20
Tan$
Su%%ly
Hydraulic fan motor + inverse valve
Compensating cylinder + Compensating
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Compensating cylinder + Compensatingisolation valve
One way valve"
&"olationvalve
'300()
Tig*tening
torque at+,/,0 Nm
Steering pump "!rbitrol#
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Steering pump "!rbitrol#
-ig*t "i.e
et "i.e
Su%%ly
Tan$
#alve an$S
Hydraulic proportional manipulator block
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Hydraulic proportional manipulator block
MN&TO-e
4u"co 5o.e
Su%%ly
Tan$
Tilt .own
Tilt u%
iting
owering
Aggravating cut o movements block
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1+'oweringcut o6 7#)
1, 'Tiltingcut o6 7#)
Tan$
Tilting.own
owering
Tilting u%iting
Su%%ly
Tilting.own
18 'itingcut o6 7#)
owering
iting
1+'owering
cut o6 7# )
Aggravating cut o movements block
Supply block + Accumulator
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10 'Tele"co%e%ro%ortional 7#)
11'ttac*ement%ro%ortional
7#)
12 '4y.raulic
cut o6 7#)
13 'ar$ing
(ra$e 7#)
8 'Tele"co%e"election 7#)
!
'attac*ement "election
7#)
7F 9lter
ar$ing(ra$e
connection
pp y
5oil" re"i"tance
8 o*m" or 8;!; 12; 13
2;2 o*m" or 10et 11
Supply block + Accumulator
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pp y
re""urete"t %ort
'in)
re""urete"t %ort
'%)
ar$ing(ra$e
%re""ureSwitc*'"a*r)
Su%%lyTan$
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Main relief
valve
(235b)
Flow
divide r
element
Liftingelem
ent
Tiltingelem
ent
Atta
cheme
ntelement
Tele
scope
element
Tank
!ppl"
teering
L
teerings!ppl"
Anti#shockrod side(2$5b)
Anti#shock%arrel
side(2$5b)
Anti#shock
(&'b)
Anti#shock(2$5b)
)
elemen
t
y
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Compensating isolation valve
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T+e purpose of t+e copensation ,al,e-
eep the toolBucAet position le)el *ith the mo)ement o( up
B do*n (unction o( the oom.
&ompensation
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Compensating isolation valve
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&ounteralance )al)e
The aim: #upports the cylinder in case o( hose reaAage. &ylinder mo)ement reCuires the starting o( the
engine Limits maximum pressure due to impacts.
& l l
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ChargeCharge
effectiveeffective
L
3ulletin 1T 7D6
&ounteralance )al)e
a.a. adita/le 0 153 & inuteadita/le 0 153 & inute
a. L adita/le 0 451 & 41 inutesa. L adita/le 0 451 & 41 inutes
Reffe
ring
PrEn
1!"
#1""$
norm
e
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#chematic:
C1 C2
V1 V2
Max pressureadEustment
/nti return )al)eTemporisation
scre*
#pool
&ounteralance )al)e
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#ectional )ie*
4lo* &ontrol
#cre*
/nti return )al)e
#poolMax pressure
adEustment
&ounteralance )al)e
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"escription
%iston side 'od side
4lo* control scre*
locA nutMax pressure
adEustment
&ounteralance )al)e
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/dEustment and checAing
1( the mo)ements are sharp >too (ast B EerAy? or too slo* >delay in
comparison to the control?; the adEustment o( the scre* 3 is reCuired
.
The distance / is a re(erence = optimum setting (rom (actory.
A= $7mm
!
&ounteralance )al)e
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$arning t+e setting of t+is ,al,e engages *our ci,il and criinal lia/ilit* in
case of accident7 T+is ,al,e ust necessaril* /e sealed
$ARRANT8 $ILL ' (#I% I" TAMP'R'% $IT)
&ounteralance )al)e
To e ale to adEust a counter alance )al)e; a test ench is reCuired..
The procedure is descried in the
Safet*
cartridge
Technical in(ormation nr 6FD
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A= $7mm
!
1t is possile to G unlocA the conter alance )al)e in order to release the pressure to e
ale to disconnect the it (rom the cylinder.
$0'emo)e the time delay scre* 3
20'emo)e the locA nut >&? (rom the time delay scre*>3?.
!0Tighten the time delay scre* >3? manually up to the end o( stroAe.
I0 Tighten the time delay scre* >3? o( $ rotation *ith a tool.
&ounteralance )al)e
IMP#RTANT-
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!*lindersIMP#RTANT-
+hen replacing or *orAing on a cylinder (or *arranty
purpose record the #/HL -umer
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)*draulic Testing
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Hydraulic Circuit
Hydraulic Test &ircuit
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Hydraulic Test &ircuit
Hydraulic Test &ircuit
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Hydraulic Test &ircuit
3oost pressure is adEusted on the
hydrostatic pump
Main pressure is adEusted on themain )al)e
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)*dostatic %ri,e !oponent Location and "unction
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)*drostatic Transission
&haracteristics
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&haracteristics
/xial piston pump H$ B I5 (or MLT 625J Proportional EV pilot
J I5 cm!J H% against pressure (lo* regulation
%ressureJ Boost at 25b
J HP at 400b for MLT 625
/xial piston motor H$ B KF (or MLT 625J Proportional EV pilot capacity regulation
J 80 c!
Hydrostatic Pump
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*everse pilot line
Forward pilotline
%oost press!re+ase press!re
,igh -ress!re-ort
,igh -ress!re-ort
Tank ret!rn
Hydrostatic Pump
!ction
Components location
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Forward pilotline (M$)
,- (%)
,- (A)
Tank *et!rn (L&)
!ction ()
*everse pilot line(M5)
+ase press!re(L2)
Components location
Components location
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*et!rn tank(M&$ bleeding)
Forward ,- (M%)
%oost press!re(M3)
*everse ,- (MA)
,ole to e.ternalfilter
Components location
96 t*o speed solenoid
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Tank ret!rn
*everse ,-
Forward,-
,-
*eg!lationpress!re
)*drostatic Motor
+ase press!re
960t*o speed solenoid
970%ump control (rom raAe pedal
Components location
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,- (M5)
*everse ,- (MA)
-ress!rereg!lation (M$)
p
Components location
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*everse ,- (A)Forward ,- (%)
Forward ,- (M%)
Tank ret!rn
+ase press!re
p
/lectronic transmission +ontrol
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FN-
-oller"
&nc*ing%otentiometer
75 S7-
4y.ro"tatic%um%
75 > @@@ A
Transmission Can-Bus
75 lig*t ault
Negative(ra$e
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)*dostatic S*ste Testing
)*dostatic S*ste Testing
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%ressure test port >%%? is
located on the dri)e motor
on the (ront axle and isaccess )ia the top co)er.
%ressure is tested at idle
and (ull throttle
)*dostatic S*ste Testing
)*dostatic S*ste Testing
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* * g
1n order to stall the
hydraulic system
you must remo)e
the connectors on
the raAe pressure
>%sahr? signal
s*itch.
) d t ti S t T ti
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)*dostatic S*ste Testing
There are t*ohigh pressure
relie( )al)es
located on the
pump.
The relie( )al)es
are non0
adEustale.
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'lectrical S*sten oard Tec+nologies
#n oard
Tec+nologies
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Tec+nologies
Here are the
areas that
maAe the MLT
625 a )ery
uniCue
machine .
+e *ill talA
aout each o(
the systems
that maAe this
a )ersatile
machine.
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#M
C!$$%C&!' P($ &ension
*,
- . / 0round
1 -2 / supply
, Signal
3neutral ./ out of
$eutral -2 /
4neutral ./ out of
$eutral -2 /
Signal
5
neutral ./ out of
$eutral -2 /
2neutral ./ out of
$eutral -2 /
lectrical &omponent
# d T + l i
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Strain gauge
M&
#eat sensor>normallyo(( ?
#M 'oller '$ '2 B0
4-'
)erride
T1-
sensor
3oom
angle
sensor
HYD-ECU
P"#
BCMA
Mo)ement B #tailty
#n oard Tec+nologies
BA
#
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T1- sensor
$!I
3oom angle sensor
C!$$%C&%! P($ &ension
*-54
- -2 /
2 -2 /
5 Signal
4 Signal
C!$$%C&!' P($ &ension
*-..
- . /
2 -2 /
5 Signal
4 . /
3 -2 /
Signal
lectrical - $5FFF M"L#
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/lectronic transmissionTransmission Can-Bus
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FN-
-oller"
&nc*ing%otentiomete
r
75 S7-
4y.ro"tatic%um%
75 > @@@ A
Transmission Can Bus
75 lig*t ault
Negativera$e
lectrical architecture
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lectrical architecture
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lectrical architecture
lectrical architecture
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lectrical architecture
lectrical architecture
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lectrical architecture
Man0Machine 1nter(ace >MM1?
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Man0Machine 1nter(ace >MM1?
Man0Machine 1nter(ace >MM1?
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Man0Machine 1nter(ace >MM1?
Man0Machine 1nter(ace >MM1?
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Man0Machine 1nter(ace >MM1?
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#creen "isplay on the MM1
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#creen "isplay on the MM1
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#creen "isplay on the MM1
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#creen "isplay on the MM1
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#creen "isplay on the MM1
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rror &odes as Listed in the #er)ice Manual
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9u/ota 'ngine !+aracteristics
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The -+ uota F7 #eries engines ha)e een designed to comply *ith
%/ 1nterim Tier I ption emissions regulations.
#peci(ications
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#peci(ications
'ngine "eatures
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The -+ uota F7 #eries engines ha)e een
designed to comply *ith %/ 1nterim Tier I ption
emissions regulations.The F7 series "1 engine are the )ertical type I0cycle
diesel engine (eaturing the ad)anced per(ormances
uota@s original 0&"1# >&enter "irect
1nEection
#ystem? comustion system; reno*ned (or
clean
comustion in the uota ! >"1? #eries;
has een
reno)ated. The (uel inEection pressure *as
increased
and the comustion chamer *as
redesigned to
achie)e a 25 N lo*er particulate matter
>%M? le)el
'ngine "eatures
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xternal ' system
*ith ' cooler
The engine (eatures
indi)idual glo* plugs
The engine uses a
separated (uel inEection
%ump *ith external (uel
shuto(( solenoid and
external shuto(( le)er
'ngine "eatures
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ngine coolant temp hot light
sender located on the thermostathousing
ngine coolant temp gage sender
located near the rear o( the engine
'ngine "eatures
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il pressure s*itch located on the
right hand side o( the engine on theoutside
The ' system taAes exhaust gas
(rom the (ront o( the engine andcomines the cooled exhaust gas
*ith the intaAe air near the rear.
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!ooling !ircuit
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ngine &ooling #ystem
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3ottom ypass system is designed (or impro)ing the
cooling per(ormance o( the radiator.
+hile the temperature o( coolant in the engine is
lo*; the thermostat >$? is held closed and the
coolant is allo*ed to (lo* through the ypass pipe
and to circulate in the engine.
+hen the temperature exceeds the thermostat >$?
)al)e opening le)el; the thermostat >$? (ully opens
itsel( to pre)ent the hot coolant (rom (lo*ing through
the ypass into the engine.
1n this *ay; the radiator can increase its cooling
per(ormance.
>$? Thermostat
>2? 'adiator
>!? ngine
>/? 3ypass pened
>3? 3ypass &losed
ngine &ooling #ystem
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ngine cooling radiator is
located on the (ront o( the
engine to the le(t o( the
hydraulic oil cooler
Mounted to the right o( the
radiator is the hydraulic oil
cooler
g g y
Hydostatic oil cooling system
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ngine oil cooling system
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The engine has a coolant0cooled oil cooler
that not only cools hot oil; ut also *arms
the cool engine oil shortly a(ter start up.
/s sho*n in the (igure; the oil (lo*s inside
the connected cooler plate; *here the
coolant is Aept circulating outside the
cooler plate; therey cooling do*n or
*arming the oil.
>/? il 1nlet %ort
>3? il utlet %ort
>a? &oolant 1nlet %ort
>? &oolant utlet %ort
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Steering !ircuit
#teering circuit
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T+e ai -
"irect and dose the (lo* in order to supply the
steering circuit 1t is a rotating )al)e
#teering circuit
#teering circuit
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ORBITROL
Antishock Valve
Relief valve
Steering selector
L#
"escription
# ee g c cu
#teering circuit
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Relief valve
Antishock Valve
"escription
g
#teering circuit
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peration
g
-o rotation o(
steering
Turn on le(t side
Turn on right side
#teering circuit
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#n MANIS!#PI! truc:s t+ere are ; steering odes
2 w+eel steer S+ort steering !ra/wise
position
g
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#teering circuit
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!ra/ position
g
#teering circuit
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S+ort steering
g
#teering circuit
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nd o( steering cylinder
g
#teering circuit
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/ntishocA (unction
g
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3raAe &ircuit
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3raAe &ircuit
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%arA 3raAe &ircuit
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3raAe &ircuit0 1nching %edal /dEustment
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8se a gauge or other
template to checA the 7 mm
dimension et*een pushutton *asher >1tem /?
contact (ace and shell >1tem
3? contact (ace.
'elease ruer pad >1tem &?
up to contact *ith pedalsystem support >1tem ?
Tighten locAnut >1tem "? on
raAe pedal arm.
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1-&H1-B3'/1-
#/8' M"8L/"8#TM-T
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Power Train&A.les
/xle
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%ANA SPI!'R%ANA SPI!'R
&haracteristics
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'ear axle >22$?
J "irectionalJ "i((erential *ithout limited slip *ithout locA
J +heels alignment sensor
4ront axle >2$$?J "irectional
J "i((erential *ith limited slip >I5N?
J #er)ice raAe in ath o( oil >only one side?
J -egati)e parAing raAe >y the ser)ice raAe?J +heels alignment sensor >only MLT?
Components location
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ervice brake-arking brake
0ifferential lock (not!sed)
ervice brakebleeding
-arking brakebleeding
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Planetar*
Reducer
Steering c*linder
%ifferential
$+at oil to use
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$+at oil to use