Manitou Telehandler MLT-X 840 140 PS JD ST3A S2 to MLT 1040 145 PS L JD ST4 S2 Repair Manual 647674EN

Hyundai · Jul 29, 2026

Manitou Telehandler MLT-X 840 140 PS JD ST3A S2 to MLT 1040 145 PS L JD ST4 S2 Repair Manual 647674EN
Size: 148.40 MB
Format: PDF
Language: English
Brand: Manitou
Type of Machine: Telehandler
Type of Manual: Repair Manual, Electric and Hydraulic Diagrams
Model: Manitou MLT-X 840 140 PS JD ST3A S2 to MLT 1040 145 PS L JD ST4 S2 Telehandler
Part Number: 647674EN
Publication Date: 2018
Number of Pages: 592 Pages

Contents:
Page de garde / Front page
CHARACTERISTICS

DIMENSIONS

LOCATION OF NAME AND IDENTIFICATION PLATE
STANDARD TIGHTENING TORQUES
LUBRICANTS AND FUEL
ENGINE ST3A CHARACTERISTICS

ENGINE ST3A OVERVIEW

ST3A AFTER-TREATMENT SYSTEM PROCESS

OPERATING PRINCIPLE

ENGINE ST4 CHARACTERISTICS

ENGINE ST4 OVERVIEW

OPERATION OF ST4 SELECTIVE CATALYTIC REDUCTION SYSTEM

CRYSTAL LEVELS AND SUBLIMATION

TYPES OF SUBLIMATION

SUBLIMATION FLOW DIAGRAM

DIESEL EXHAUST FLUID LEVEL (DEF or urea)

ERROR CODES

CLEAN-UP STRATEGY

TEMPERATURE THRESHOLDS

SCR SYSTEM BLEED TIME

ENGINE ST3A ENVIRONMENT
ENGINE ST4 ENVIRONMENT
ENGINE COMPONENT
AIR COOLING/COOLING LIQUID CIRCUITS
DIESEL CIRCUIT
VENTILATION CONTROL OPERATION

LOCATION

ROLE

SYSTEM DESCRIPTION

VENTILATION CONTROL AND REVERSAL PARAMETERS

TIGHTENING TORQUE

ENGINE SUSPENSION ASSEMBLY

VENTILATION CONTROL

EXHAUST

ENGINE ECU / COMPLETE ENGINE REPLACEMENT VIA SERVICE ADVISOR

PREPARATION AND SAFETY INSTRUCTIONS

CONNECTION TO THE WEBSITE

TWO POSSIBLE SITUATIONS

MACHINES CONCERNED

ST3A

ST4

PREPARATION AND SAFETY INSTRUCTIONS

SPECIFIC TOOLING

BONNET REMOVAL
ENGINE HOUSING REMOVAL
ST4 AFTER-TREATMENT SYSTEM REMOVAL

UREA TANK REMOVAL

UREA INJECTION SYSTEM REMOVAL

UREA INJECTOR REMOVAL

DECOMPOSITION PIPE REMOVAL

DOC TURBO PIPE REMOVAL

DOC REMOVAL

SCR + AOC REMOVAL

STARTER REMOVAL
COOLER REMOVAL
ENGINE ECU REMOVAL
ENGINE REMOVAL

DISCONNECTING THE ENGINE HARNESS

AIR-CONDITIONING COMPRESSOR REMOVAL (OPTION)

ENGINE-GEARBOX DISASSEMBLY

ENGINE EXTRACTION

ENGINE REPLACEMENT

ENGINE - GEARBOX ASSEMBLY REMOVAL

ENGINE – GEARBOX ASSEMBLY EXTRACTION

ENGINE / GEARBOX / CONVERTER UNCOUPLING

MACHINES CONCERNED

ST3A

ST4

PREPARATION AND SAFETY INSTRUCTIONS

SPECIFIC TOOLING

ENGINE REFIT

ENGINE / GEARBOX COUPLING

AIR-CONDITIONING COMPRESSOR REFIT (OPTION)

ENGINE HARNESS CONNECTION

ENGINE-GEARBOX ASSEMBLY REFIT

ENGINE / GEARBOX / CONVERTER COUPLING

ENGINE-GEARBOX ASSEMBLY REFIT

ENGINE HARNESS CONNECTION

ST4 EXHAUST FILTER REFIT 

COOLER REFIT
ENGINE BONNET AND HOUSING REFIT (o10 - ENGINE REMOVAL)
ELECTRONIC TENSION METER

ADDITIONAL ENGINE TOOLS

DEF RINSING KIT (ST4)

PRINCIPLE OF OPERATION OF GEARBOX PS09

OPERATION

OVERVIEW

GEARBOX PS09 TECHNOLOGIES

"OVERLAP"

"LOCKUP"

TRANSMISSION DRIVE CHAIN
CONTROL LOGIC
SCHEMATIC DIAGRAM
TRANSMISSION SYSTEM
PRESSURE TEST PORT LOCATION
GEARBOX/ HYDRAULIC OIL COOLING CIRCUITS

OPERATING PRINCIPLE FOR "THERMOSTAT REGULATOR"

PRESSURE TEST PORT VALUES
GEARBOX OIL LEVEL
GEARBOX ECU REPLACEMENT (APC 312)

CALIBRATION PROCEDURE WITH THE PAD

GEARBOX ERROR CODES (DTC)
TRANSMISSION TIGHTENING TORQUES
BASIC KIT

DIGITAL MANOMETER BOX

AXLE BUMP STOP ADJUSTMENT FOR "500/70R24 WIDE WHEEL" OPTION
REAR AXLE FRAME MOUNTING ADJUSTMENT
AXLE TIGHTENING TORQUES
SERVICE BRAKE
PARKING BRAKE

PARKING BRAKE RELEASE CONDITIONS

PARKING BRAKE APPLICATION CONDITIONS

TRAILER BRAKE VALVE
SERVICE BRAKE

INCHING ADJUSTMENT PROCEDURE

BLEEDING PROCEDURE

PARKING BRAKE

ADJUSTMENT PROCEDURE

BLEEDING PROCEDURE

TOWING PROCEDURE
TIGHTENING TORQUES
PARKING BRAKE

INTRODUCTION

BRAKE PADS

NEGATIVE BRAKE BLOCK

SERVICE BRAKE

PREPARATION AND SAFETY INSTRUCTIONS

PARKING BRAKE
SERVICE BRAKE
BRAKE FLUID BLEEDER

PARKING BRAKE BLEEDER HARNESS

DUPLEX BOOMS MLT 840

TRIPLEX BOOMS MLT 1040

8 METRE TELESCOPIC BOOM OPERATION (MLT 840)

10 METRE TELESCOPIC BOOM OPERATION (MLT 1040)

INDEX OF COMPONENT CODES
DUPLEX BOOMS MLT 840
TRIPLEX BOOMS MLT 1040
TELESCOPE BOOM EXTENSION AND RETRACTION ADJUSTMENT PROCEDURE
DUPLEX BOOM (MLT 840)

REMOVAL OF INTERNAL COMPONENTS

DUPLEX BOOM COMPONENT REFIT

RECOMMENDATION FOR FITTING SHIMS AND LUBRICATION AREAS

TIGHTENING TORQUE AND LUBRICATION

TRIPLEX BOOM (MLT 1040)

REMOVAL OF INTERNAL COMPONENTS

TRIPLEX BOOM COMPONENTS REFIT

RECOMMENDATION FOR FITTING SHIMS AND LUBRICATION AREAS

SLIDE PAD MOUNTING INSTRUCTIONS

TIGHTENING TORQUE AND LUBRICATION

DUPLEX BOOM (MLT 840)
TRIPLEX BOOM (MLT 1040)
DUPLEX BOOM (MLT 840)

TRIPLEX BOOM (MLT 1040)

FLARE NUT WRENCH

MAGNETIC LIFTER

POWER ASSISTED BRAKE MASTER CYLINDER
FEED BLOCK + ACCUMULATOR
HYDRAULIC PUMP A10VO EK1
DISTRIBUTOR AR1506-239
3-POSITION STEERING SELECTOR
PILOT SAFETY VALVE (LIFTING CYLINDER)
PILOT SAFETY VALVE (LIFTING CYLINDER)
COMPENSATING ISOLATION VALVE
LEVELLING CORRECTOR CONTROL VALVE
NEGATIVE BRAKE LEVER
LEVELLING CONTROL VALVE
LAGU 250/125 STEERING PUMP
PILOT SAFETY VALVE
DOUBLE PILOT SAFETY VALVE
FAN REGULATOR MOTOR (FAN DRIVE)
BOOM SUSPENSION ELECTROVALVE/SUSPENSION + REGENERATION / REGENERATION ON LIFTING CIRCUIT (OPTIONS)
BOOM SUSPENSION ELECTROVALVE (OPTION)
BOOM SUSPENSION ELECTROVALVE WITH OR WITHOUT REGENERATION (OPTION)
OSPEDF 125/250 LS STEERING PUMP
KEY
SCHEMATIC DIAGRAMS
KEY

LOCATION (MLT 840)

LOCATION (MLT 1040)

PRESSURE TEST PORT LOCATION
COMPENSATING ISOLATION VALVE (VIC)

LOCATION

HYDRAULIC DIAGRAM

VIC OPERATION

TIGHTENING TORQUES

MAIN DISTRIBUTOR

LEVELLING CORRECTOR (MLT 1040 L)

ACCUMULATOR BLOCK

HYDRAULIC CIRCUITS

BOOM SUSPENSION OPTION
DISTRIBUTOR
HYDRAULIC PUMP
COMPENSATING CYLINDER
LIFTING CYLINDER
LEVELLING CYLINDER
DISTRIBUTOR
HYDRAULIC PUMP
COMPENSATING CYLINDER
LIFTING CYLINDER
LEVELLING CYLINDER
BASIC MANOMETER BOX
DIGITAL MANOMETER BOX
CONNECTORS (FRAME, CAB, ENGINE 1 HARNESSES)
CONNECTORS (John Deere ENGINE HARNESS)
OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM
ECU INPUTS/OUTPUTS

AUXILIARY ECU - SPU 25-15 - A18

MANIMUX POWER MP1 ECU

MANIMUX POWER MP2 ECU

MANIMUX CLUSTER MC ECU

TRANSMISSION ECU - APC 312 - A10

TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS

X1/X2 - STARTER IGNITION SWITCH

X6 - ROTATING BEACON LIGHT

X11/X12 - WIPER COMMUTATOR SWITCH

X14 - LIGHTING COMMUTATOR SWITCH

X21 - HYDRAULIC FILTER PRESSURE SWITCH

X22 - BRAKE FLUID LEVEL SWITCH

X38 - REVERSING BUZZER

X39 - HORN

X45 - NF DOOR OPENING SWITCH

X46/X47 - CIGARETTE LIGHTER

X52 - NO DOOR OPENING SWITCH

X55/X56 - FORWARD/REVERSE GEAR SENSOR ON GEAR BOX

X63 - FUEL LEVEL GAUGE

X64 - MASTER CYLINDER PRESSURE SWITCH

X65/X66 - WHEEL ALIGNMENT SENSOR

X70 - BRAKING ASSISTANCE CIRCUIT PRESSURE SWITCH

X73 - FORWARD/REVERSE GEAR SENSOR ON GEAR BOX

X75 - MOVEMENT SAFETY EV

X67/X74 - JSM

X89/X90 - DISTRIBUTOR PROPORTIONAL EV

X98/X99 - DISTRIBUTOR PROPORTIONAL EV

X100 - BOOM ANGLE SENSOR

X118 - GAROS DIGICODE

X133 - ON/OFF NEGATIVE BRAKE PRESSURE SWITCH

X134 - BOOM RETRACTION SWITCH

X152 - BMEP JOYSTICK

X155 - AIR-CONDITIONING HIGH PRESSURE SENSOR

X180 - BRAKE PEDAL ANGLE SENSOR

X181 - ACCELERATOR PEDAL ANGLE SENSOR

X207 TO X212 - HYDRAULIC ELECTROVALVE ON GEARBOX

X213 - GEARBOX OIL PRESSURE SENSOR

X214/X215 - SPEED SENSORS

X218 - GEARBOX OIL TEMPERATURE SENSOR

X258 -RADIATOR MINIMUM WATER LEVEL SENSOR

X263 - STRAIN GAUGE

X269 - HYDRAULIC ELECTROVALVE ON GEARBOX

X278/X281 - DISTRIBUTOR PROPORTIONAL EV

X286 - MANUAL THROTTLE SENSOR

X289 - HYDRAULIC OIL TEMPERATURE SENSOR

X312 - REGULATED PRESSURE VALVE

X316 - PVED-CLS controller steering pump OSPEDF 125/250 LS

X317 - SASA sensor

X318 - ELECTROVALVE CUT-OFF STEERING PUMP OSPEDF 125/250 LS

X319 - STEERING ANGLE SENSOR

X320 - Speed sensor

X322 TO X324 - DSB (Double Switch Board)

B5205/B5206 - AIR TEMPERATURE SENSORS

B5207 - EGR TEMPERATURE SENSORS

B5208/B5209 - COOLANT AND FUEL TEMPERATURE SENSORS

CONNECTORS (John Deere ENGINE HARNESS)

ELECTRICAL DIAGRAM CODIFICATION EXAMPLE
CABLE IDENTIFICATION ON AN ELECTRICAL WIRING HARNESS
POSITION OF CONNECTORS BY DIAGRAM

Up to machine MAN00000 C01004587

ELECTRICAL DIAGRAMS BY FUNCTION

Up to machine MAN00000 C01004587

1A (ST3A)– STARTER / CUSTOMER DIGICODE

1B (ST4)– STARTING/CUSTOMER DIGICODE

2 – CAN / ECU

3 – SENSORS + TRANSMISSION

4 – HYDRAULICS

5 – EXHAUST AND ENGINE SENSORS

6 – LIGHTING / SIGNALLING / HEATING / VENTILATION

7 – OPTIONS

POSITION OF CONNECTORS BY DIAGRAM

From machine MAN00000 T01004588

ELECTRICAL DIAGRAMS BY FUNCTION

From machine MAN00000 T01004588

1A (ST3A)– STARTER / CUSTOMER DIGICODE

1B (ST4)– STARTING/CUSTOMER DIGICODE

2 – CAN / ECU

3 – SENSORS + TRANSMISSION

4 – HYDRAULICS

5 – EXHAUST AND ENGINE SENSORS

6 – LIGHTING / SIGNALLING / HEATING / VENTILATION

7 – OPTIONS

KEYS

CONNECTORS

2D LOCATION

HARNESS ASSEMBLY

FRAME HARNESS

CAB HARNESSES 1 AND 2

ENGINE ST3A HARNESS

ST4 ENGINE HARNESS

ST4 (DEF) ENGINE HARNESS

HYDRAULIC REGENERATION AND DSB

CSS (COMFORT STEERING SYSTEM) OPTION HARNESS

3D LOCATION

FRAME HARNESS

CAB HARNESSES 1

ST3A ENGINE HARNESS 1

ST4 ENGINE 1 HARNESS

ENGINE HARNESS 2

CSS (COMFORT STEERING SYSTEM) OPTION HARNESS

MENU CLUSTER ARCHITECTURE
MACHINE COMPUTER (MANIMUX POWER)
LED ILLUMINATION AS A FUNCTION OF THE CHANGING GAUGE SIGNAL
WARNING DEVICE / LONGITUDINAL STABILITY LIMITER TEST

"SECU" MENU (BOOM ANGLE AND STRAIN GAUGE CALIBRATION)

"GAUGE" MENU (WARNING DEVICE / LONGITUDINAL STABILITY LIMITER RESET)

"BOOM" MENU (BOOM ANGLE CALIBRATION)

"M THR" MENU (MANUAL ACCELERATOR CALIBRATION)

"BRAKE" MENU (BRAKE PEDAL CALIBRATION)

"TILT" MENU (CARRIAGE ANGLE CALIBRATION)

"BOOM ANGLE" ANGULAR SENSOR ADJUSTMENT

OPERATION

ON-TRUCK ADJUSTMENT PROCEDURE

STRAIN GAUGE

LOCATION

AXLE PREPARATION

CHARACTERISTICS OF PRODUCTS USED

CHARACTERISTICS OF FASTENING SCREWS

ASSEMBLY PRECAUTIONS AND TIGHTENING TORQUE

STRAIN GAUGE

Remove - Replace JSM on BMEP

INPUT/OUTPUT STATES

CODE READING PRINCIPLE (Example for OUTOR and INTOR)

CODE READING PRINCIPLE (Example for OUTANA and INANA)

"OUTOR" CODE DESCRIPTION

"INTOR" CODES DESCRIPTION

"OUTANA" CODES DESCRIPTION

"INANA" CODES DESCRIPTION

ERROR CODES (DTC)

MC

MP1

MP2

ENG

AUX

GEARBOX ERROR CODES (DTC)
DIAGNOSTIC TOOLS

VERSION 1

VERSION 2

ELECTRIC WINDOW AND ENGINE REMOVAL

COMPONENT LOCATION

PREPARATION AND SAFETY INSTRUCTIONS

ELECTRIC WINDOW AND ENGINE REMOVAL

CAB LOWER TRIM REMOVAL

ELECTRIC WINDOW AND ENGINE REFIT

COMPONENT LOCATION

PREPARATION AND SAFETY INSTRUCTIONS

ELECTRIC WINDOW AND ENGINE REFIT

STOP ADJUSTMENT FUEL TANK AND OIL TANK
110
OPTIONS - ATTACHMENTS
110 INTELLIGENT HYDRAULICS OPTION

110.1 CHARACTERISTICS AND SPECIFICATIONS

110.2 LOCATION OF COMPONENTS

110 WHEEL ALIGNMENT OPTION
110 COMFORT STEERING SYSTEM OPTION (CSS)
110 AIR CONDITIONING OPTION

110.3 Air conditioning characteristics and specifications

110.3.1 Description of operation

110.3.2 Operating principle

110.3.3 Evaporator temperature sensor specifications

110.4 Air conditioning location

110.4.1 Location and tightening torques

110.4.2 HVAC interior components

110.4.3 HVAC exterior components

110.4.4 Condenser components

110.5 Air conditioning controls and adjustments

110.5.1 General check points

110.5.2 ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT

110.5.3 Safety measures for handling r134a

110.5.4 Refrigerant fluid load for the air conditioning circuit

110.5.5 Check the evaporator temperature sensor

110.6 Air conditioning removal - refit

110.6.1 Air conditioning belt removal

110.6.2 AIR-CONDITIONING BELT REFIT

110.7 Air conditioning troubleshooting

110.7.1 Pressure troubleshooting

110.7.2 ABNORMAL NOISE ON A/C SYSTEM

110.7.3 UNPLEASANT SMELL

110 Engine eco stop OPTION

110.1 Engine eco stop characteristics and specifications

110.2 Engine ECO STOP schematic diagram

110.3 Engine ECO STOP location

110.4 Engine ECO STOP removal and refitting

110.4.1 Replace Eco Stop relay

110 Pneumatic trailer brake OPTION

110.1 Pneumatic trailer brake schematic diagram

110.2 Pneumatic trailer brake location

110.3 Pneumatic trailer brake removal and refitting

110.3.1 Preparation and safety instructions

110.3.2 Remove the pneumatic pressure control assembly

110.3.3 Remove the air controller assembly

110.3.4 Remove the brake compressor

110.3.5 Test pneumatic trailer braking operation

Manitou Telehandler MLT-X 840 140 PS JD ST3A S2 to MLT 1040 145 PS L JD ST4 S2 Repair Manual 647674EN

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