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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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​