Download Manitou Telehandler MLT-X 840 140 PS JD ST3A S2 to MLT 1040 145 PS L JD ST4 S2 Repair 647674EN (English) 

Get the Manitou Telehandler MLT-X 840 140 PS JD ST3A S2 to MLT 1040 145 PS L JD ST4 S2 Repair Manual (647674EN), a comprehensive technical guide designed to assist with maintenance, troubleshooting, servicing, and repairs. This manual provides essential technical information, repair procedures, inspection instructions, and maintenance guidelines to help technicians and equipment owners maintain optimal machine performance. Ideal for workshop professionals and operators, it supports accurate diagnostics, efficient repairs, and reliable servicing of Manitou telehandlers. Keep your equipment operating safely and efficiently with this detailed repair manual.

MODEL COVERED :
Manitou MLT-X 840 140 PS JD ST3A S2 to MLT 1040 145 PS L JD ST4 S2 Telehandler

CONTENTS INCLUDED :
Characteristics
Dimensionslocation 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 Timeengine 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 Parameterstightening Torque
Engine Suspension Assembly
Ventilation Control
Exhaustengine Ecu / Complete Engine Replacement Via Service Advisor
Preparation And Safety Instructions
Connection To The Website
Two Possible Situationsmachines Concerned
St3a
St4preparation And Safety Instructions
Specific Toolingbonnet 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 Removalstarter Removal
Cooler Removal
Engine Ecu Removal
Engine Removal
Disconnecting The Engine Harness
Air-conditioning Compressor Removal (Option)
Engine-gearbox Disassembly
Engine Extraction
Engine Replacementengine – Gearbox Assembly Removal
Engine – Gearbox Assembly Extraction
Engine / Gearbox / Converter Uncouplingmachines Concerned
St3a
St4preparation And Safety Instructions
Specific Toolingengine Refit
Engine / Gearbox Coupling
Air-conditioning Compressor Refit (Option)
Engine Harness Connectionengine-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
Overviewgearbox 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 Padgearbox Error Codes (Dtc)
Transmission Tightening Torques
Basic Kit
Digital Manometer Boxaxle 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 Conditionstrailer Brake Valve
Service Brake
Inching Adjustment Procedure
Bleeding Procedureparking Brake
Adjustment Procedure
Bleeding Proceduretowing Procedure
Tightening Torques
Parking Brake
Introduction
Brake Pads
Negative Brake Blockservice Brake
Preparation And Safety Instructionsparking Brake
Service Brake
Brake Fluid Bleeder
Parking Brake Bleeder Harnessduplex Booms Mlt 840
Triplex Booms Mlt 10408 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 Lubricationtriplex 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 Lubricationduplex Boom (Mlt 840)
Triplex Boom (Mlt 1040)
Duplex Boom (Mlt 840)
Triplex Boom (Mlt 1040)flare Nut Wrench
Magnetic Lifterpower 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 Operationtightening Torques
Main Distributor
Levelling Corrector (Mlt 1040 L)
Accumulator Block
Hydraulic Circuitsboom 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 (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 – A10technical 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 (Engine Harness)electrical Diagram Codification Example
Cable Identification On An Electrical Wiring Harness
Position Of Connectors By Diagram
Up To Machine Man00000 C01004587electrical 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 – Optionsposition Of Connectors By Diagram
From Machine Man00000 T01004588electrical 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 – Optionskeys
Connectors2d 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 Harness3d Location
Frame Harness
Cab Harnesses 1
St3a Engine Harness 1
St4 Engine 1 Harness
Engine Harness 2
CSS (Comfort Steering System) Option Harnessmenu 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 Procedurestrain Gauge
Location
Axle Preparation
Characteristics Of Products Used
Characteristics Of Fastening Screws
Assembly Precautions And Tightening Torque
Strain Gauge
Remove – Replace Jsm On Bmepinput/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 Descriptionerror Codes (Dtc)
Mc
Mp1
Mp2
Eng
Auxgearbox Error Codes (Dtc)
Diagnostic Tools
Version 1
Version 2electric Window And Engine Removal
Component Location
Preparation And Safety Instructions
Electric Window And Engine Removal
Cab Lower Trim Removalelectric Window And Engine Refit
Component Location
Preparation And Safety Instructions
Electric Window And Engine Refitstop Adjustment Fuel Tank And Oil Tank
110
Options – Attachments
110 Intelligent Hydraulics Option
110.1 Characteristics And Specifications
110.2 Location Of Components110 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 Smell110 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 Relay110 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

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