Manitou not engaging gears

[Lithuanian]

Hello, I am new to this forum but when searching some information it is great place to get it and also to get some advice. So i got a issue with my Manitou MLT735-120 LSU PS. 2013 powershift. while working it started jerking and totally stopped. Does not engage gears just beeping sound. Checked oils all good even changed. Switched relays. that also did not helped. Also checked if there is any power to relay and looks all good. Fuse not blown up. Another thing what i noticed that is i remove relay and turn on 5th gear then no beeping moving fine, also same thing with the reverse that only in highest gear with is 3th is moving, in second or first gear it's start to jerk beeping sound . So now i dont even know where to start looking. All started suddenly. Thank you for your ideas and suggestions.

 

[davidroberts30]

@ACEngineering is your man

 

[ACEngineering]

@ACEngineering is your man

Got to love a customers description of the problem its like trying to interpret a whole new language! (yes i realise English probably isn't his first language!)

 

[davidroberts30]

Got to love a customers description of the problem its like trying to interpret a whole new language! (yes i realise English probably isn't his first language!)

its probably a better attempt than your or my Lithuanian!!

 

[ACEngineering]

Hello, I am new to this forum but when searching some information it is great place to get it and also to get some advice. So i got a issue with my Manitou MLT735-120 LSU PS. 2013 powershift. while working it started jerking and totally stopped. Does not engage gears just beeping sound. Checked oils all good even changed. Switched relays. that also did not helped. Also checked if there is any power to relay and looks all good. Fuse not blown up. Another thing what i noticed that is i remove relay and turn on 5th gear then no beeping moving fine, also same thing with the reverse that only in highest gear with is 3th is moving, in second or first gear it's start to jerk beeping sound . So now i dont even know where to start looking. All started suddenly. Thank you for your ideas and suggestions.

Okay!

the way your explaining the problem is too complicated!

So your getting drive in some gears but not others?

On the LED gear display, do any errors come up?

Turn on ignition, watch the display, if it flashes up E for a few seconds there is an error. There is a way to enter a diagnostic mode to check the error codes which i will email you later when i have more time.

If there are no errors then its likely you have a clutch pack piston leaking but to make 100% sure later i will send you the solenoid sequence for each gear so you can manually check each solenoid is working while in each gear, the solenoid plugs often get water in them and rust the connections which should be picked up on the display as an error but not always.

I think the beeping you have is for low oil pressure and should have a red light on the dash too, and when you press the cut off for 6th gear you would be disconnecting forward High clutch pack and using forward low instead which limits the machine to 5th gear, so at this point in time i would guess your problem is forward high clutch pack piston leaking badly, but as my comment earlier its often hard work to interpret a customers description of the problem! no matter if there from same county or not

Forwards high clutch is used in 2nd, 4th and 6th forward gears. so if i'm right 1st, 3rd and 5th should work a lot better.

 

[ACEngineering]

its probably a better attempt than your or my Lithuanian!!

his English seems no worse than any other English, welsh or Scot person IMO, some of the farmer descriptions i get are rather long winded and complicated sometimes your lucky if they know the model number of it

 

[ACEngineering]

Hello, I am new to this forum but when searching some information it is great place to get it and also to get some advice. So i got a issue with my Manitou MLT735-120 LSU PS. 2013 powershift. while working it started jerking and totally stopped. Does not engage gears just beeping sound. Checked oils all good even changed. Switched relays. that also did not helped. Also checked if there is any power to relay and looks all good. Fuse not blown up. Another thing what i noticed that is i remove relay and turn on 5th gear then no beeping moving fine, also same thing with the reverse that only in highest gear with is 3th is moving, in second or first gear it's start to jerk beeping sound . So now i dont even know where to start looking. All started suddenly. Thank you for your ideas and suggestions.

All started suddenly.
it's start to jerk

Your above 2 comments make me think theres nothing wrong with the machine!, on the dash is a orange rocker switch with a cog in it, make sure its turned OFF. this dumps the drive when you touch the brake pedal, with it turned on machine is awful to drive.

 

[Lithuanian]

Got to love a customers description of the problem its like trying to interpret a whole new language! (yes i realise English probably isn't his first language!)

Well english is not the problem but how i write down everything is it, that's why you have problem understanding what i am trying to say . I will write down every detail in parts.
1. after loading a trailer and heading home manitou started to jerking, like clutches were slipping and then stopped. After restarting machine nothing changed it could not move there was only sound of beeping in dash.
2. checked all the fuses there were non blown up and changed relays in places to see if the relay was bad but that also proven to be fruitless.
3 Checked if power was coming to relays, which was coming.
4. Checked oil level which was low. Then I just changed whole oil and poured to required level. Nothing changed. Old oil was good no burn smell or anything strange.
5. Removed gearbox relay and then it started to move but like clutches were slipping from 1th to 4th gear and dash continues to make beep sound. then when it is in 5th gear it runs smoothly like it should be. In reverse it got the same problem that 1th and 2th gears like slipping and third is all good.
6. Again putted relay in to check but still same results that it wont move even in 5th gear or 6th gear.
So right now i am out of option what to do. Also contacted the dealer but still i am interested to get some answers to this problem maybe someone had such issue.
I hope that right now you will understand what i wanted to say

 

[Lithuanian]

All started suddenly.
it's start to jerk

Your above 2 comments make me think theres nothing wrong with the machine!, on the dash is a orange rocker switch with a cog in it, make sure its turned OFF. this dumps the drive when you touch the brake pedal, with it turned on machine is awful to drive.

I thought the same thing but that is turned off and i have tested that rocker/button when machine was working fine. when that switch is toggled you need to press accelerator pedal almost to the floor to move but you wont get clutch slipping feeling from machine so this is out of option.

 

[Lithuanian]

Well english as a language is complicated ir self due to word having a lot of meaning

 

[Lithuanian]

Okay!

the way your explaining the problem is too complicated!

So your getting drive in some gears but not others?

On the LED gear display, do any errors come up?

Turn on ignition, watch the display, if it flashes up E for a few seconds there is an error. There is a way to enter a diagnostic mode to check the error codes which i will email you later when i have more time.

If there are no errors then its likely you have a clutch pack piston leaking but to make 100% sure later i will send you the solenoid sequence for each gear so you can manually check each solenoid is working while in each gear, the solenoid plugs often get water in them and rust the connections which should be picked up on the display as an error but not always.

I think the beeping you have is for low oil pressure and should have a red light on the dash too, and when you press the cut off for 6th gear you would be disconnecting forward High clutch pack and using forward low instead which limits the machine to 5th gear, so at this point in time i would guess your problem is forward high clutch pack piston leaking badly, but as my comment earlier its often hard work to interpret a customers description of the problem! no matter if there from same county or not

Forwards high clutch is used in 2nd, 4th and 6th forward gears. so if i'm right 1st, 3rd and 5th should work a lot better.

I can send you a video to your email

 

[ACEngineering]

Well english as a language is complicated ir self due to word having a lot of meaning

I know its not a dig at you directly, most customers are the same some times vague complicated description for simple problems

 

[Lithuanian]

I know its not a dig at you directly, most customers are the same some times vague complicated description for simple problems

Totally agree to that

 

[ACEngineering]

Well english is not the problem but how i write down everything is it, that's why you have problem understanding what i am trying to say . I will write down every detail in parts.
1. after loading a trailer and heading home manitou started to jerking, like clutches were slipping and then stopped. After restarting machine nothing changed it could not move there was only sound of beeping in dash.
2. checked all the fuses there were non blown up and changed relays in places to see if the relay was bad but that also proven to be fruitless.
3 Checked if power was coming to relays, which was coming.
4. Checked oil level which was low. Then I just changed whole oil and poured to required level. Nothing changed. Old oil was good no burn smell or anything strange.
5. Removed gearbox relay and then it started to move but like clutches were slipping from 1th to 4th gear and dash continues to make beep sound. then when it is in 5th gear it runs smoothly like it should be. In reverse it got the same problem that 1th and 2th gears like slipping and third is all good.
6. Again putted relay in to check but still same results that it wont move even in 5th gear or 6th gear.
So right now i am out of option what to do. Also contacted the dealer but still i am interested to get some answers to this problem maybe someone had such issue.
I hope that right now you will understand what i wanted to say

I think your clutches are knackered. The fact they are engaging at all is a good sign the electrics are okay, but do the test on the display for errors and check the solenoids manually in each gear to be sure, otherwise its internal fault almost certain clutch pack pistons.

 

[Lithuanian]

I think your clutches are knackered. The fact they are engaging at all is a good sign the electrics are okay, but do the test on the display for errors and check the solenoids manually in each gear to be sure, otherwise its internal fault almost certain clutch pack pistons.

Maybe you can send me how to test selenoid? you said earlier that you have such information. That would be great. Also as i was changing oil i saw only one selenoid on the top. Is there any other or only that one the top? And i guess this join is quite demanding to change clutch pack pistons?

 

[ACEngineering]

Totally agree to that

See the attached PDF, and the drawing labeling the solenoid clutches. (that same drawing in the PDF is different although not wrong, for solenoid sequence and what solenoid i what clutch use the separate attached drawing along with the chart in the PDF also attached.

Your last post now saying its not moving in 5th is contradicting your first post saying it does move in 5th. Ignore taking any relays out not sure why you think that is helping cause your just complicating the problem, there are only 3 relays that have any effect on transmission, a dump relay which if faulty you loose all drive totally in all gears and directions (actually in your case of a powershift i think this relay i replaced with a red jumper wire?), a forwards relay and a reverse relay. The rest is all done via the transmission ECU.

 

[Lithuanian]

Maybe you can send me how to test selenoid? you said earlier that you have such information. That would be great. Also as i was changing oil i saw only one selenoid on the top. Is there any other or only that one the top? And i guess this join is quite demanding to change clutch pack pistons?

Also it just started suddenly with gearbox jerking

 

[ACEngineering]

Maybe you can send me how to test selenoid? you said earlier that you have such information. That would be great. Also as i was changing oil i saw only one selenoid on the top. Is there any other or only that one the top? And i guess this join is quite demanding to change clutch pack pistons?

Was already finding info, yes 6 solenoids total and different combination for each gear.

 

[Lithuanian]

See the attached PDF, and the drawing labeling the solenoid clutches. (that same drawing in the PDF is different although not wrong, for solenoid sequence and what solenoid i what clutch use the separate attached drawing along with the chart in the PDF also attached.

Your last post now saying its not moving in 5th is contradicting your first post saying it does move in 5th. Ignore taking any relays out not sure why you think that is helping cause your just complicating the problem, there are only 3 relays that have any effect on transmission, a dump relay which if faulty you loose all drive totally in all gears and directions (actually in your case of a powershift i think this relay i replaced with a red jumper wire?), a forwards relay and a reverse relay. The rest is all done via the transmission ECU.

View attachment 976646

What i wanted to say that if gearbox relay is installed it wont engage any of gears but if i remove it then it is trying to move but moves likes clutches are slipping. This symptom happens from 1th to4th gear. In 5gear ir drives fine of relay is removed. Same happening also in reverse.

 

[Lithuanian]

Was already finding info, yes 6 solenoids total and different combination for each gear.

Okey i will try to check them.