Manitou MLT MLT-X 635 733 737 741 940 ST4 / ST3A S3 S2 S1 service manual

Description Manitou MLT MLT-X 635 733 737 741 940 ST4 / ST3A S3 S2 S1 service manual

Manitou Telescopic Handler MLT 635, MLT 733, MLT 737, MLT 741, MLT 940 ST4 Serie 2 & Serie 3 / MLT-X 737, MLT-X 741 ST3A Serie 1 pdf service & repair manual

Models covered:
MLT 635 130 PS D ST4 S2
MLT 733 105/115 D ST4 S2/S3
MLT 733 105/115 D ST4 S2/S3 TRACT
MLT 733 105/115 D ST4 S2/S3 TRACT LSU
MLT 737 130 PS D ST4 S2
MLT 635 140 V PLUS D ST4 S2
MLT 741 140 V PLUS D ST4 S2
MLT 940 140 V PLUS D ST4 S2
MLT-X 737 130 PS D ST3A S1
MLT-X 741 140 V PLUS D ST3A S1

MANUAL CONTENT:
GENERAL INSTRUCTIONS AND SAFETY NOTICE
SERVICING POSITION
EXPLANATION OF SYMBOLS
SERVICING RULES
GENERAL CHARACTERISTICS AND SPECIFICATIONS
LUBRICANTS AND FUEL
DIMENSIONS
GENERAL LOCATION
NAME AND IDENTIFICATION PLATE
GENERAL CONTROL AND ADJUSTMENT
METRIC - IMPERIAL UNIT CONVERSION

ENGINE CHARACTERISTICS AND SPECIFICATIONS
DIESEL EXHAUST FLUID (DEF)
INJECTION CYCLE
BOSCH CP4.1 HIGH PRESSURE PUMP
ENGINE SCHEMATIC DIAGRAMS
AIR INTAKE CIRCUIT AND EGR (EXHAUST GAS RECIRCULATION)
LUBRICATION CIRCUIT
COOLING CIRCUIT
FUEL CIRCUIT
DEF (DIESEL EXHAUST FLUID) CIRCUIT
ENGINE COMPONENTS LOCATION
ENGINE COMPONENTS
WATER AND AIR COOLING CIRCUIT
HYDRAULIC CIRCUIT
DIESEL CIRCUIT
FUEL INJECTION CIRCUIT
EGR (EXHAUST GAS RECIRCULATION) CIRCUIT
DEF (DIESEL EXHAUST FLUID) CIRCUIT
ENGINE CONTROLS AND ADJUSTMENTS
ENGINE START-UP AUTHORIZATION CONDITIONS
DEF REGENERATION
DEF PUMP CLEANING PROCEDURE
ENGINE LOAD LEVEL
VENTILATION REGULATION (MLT 733 AS OPTION)
A – FUNCTION
B – PRINCIPLE OF OPERATION
C – SCHEMATIC DIAGRAM
D – DESCRIPTION OF HYDRAULIC ENGINE WITH CONTROL
E – CONDITIONS OF FAN CONTROL-RELATED COMPONENTS
SILENT BLOCK TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
DIESEL FUEL CIRCUIT TIGHTENING TORQUES
EXHAUST CIRCUIT TIGHTENING TORQUES
COOLING CIRCUIT TIGHTENING TORQUES
HEATING CIRCUIT TIGHTENING TORQUES
ENGINE REMOVAL - REFITTING
ENGINE ECU REMOVAL - REFIT
AIR FILTER ASSEMBLY REMOVAL
STARTER MOTOR REMOVAL
DOC EXHAUST PIPE REMOVAL
REMOVE THE "SCR" PIPE
DEF INJECTOR REMOVAL
DEF TANK REMOVAL
DEF GAUGE REMOVAL
COOLER REMOVAL
REMOVING THE UPPER PART
SEPARATION OF COOLER FROM ENGINE
OPTION 1: REMOVAL OF PUMP
OPTION 2: REMOVAL OF COOLER ASSEMBLY
REMOVE THE ENGINE
ENGINE HOSE AND CONNECTOR REMOVAL
ENGINE/ANGLE GEAR BOX TRANSMISSION UNIVERSAL JOINT REMOVAL
ATTACHMENT BELT REMOVAL
ENGINE REFIT
ALTERNATOR REMOVAL
WATER PUMP REMOVAL
TURBO-COMPRESSOR REMOVAL
ENGINE TROUBLESHOOTING
SPECIFIC ENGINE TOOLING
SPECIAL ENGINE TOOLING
ELECTRONIC TENSION METER
DEF FLUSH KIT

TRANSMISSION SCHEMATIC DIAGRAMS
COMPACT+ (C+) MANUAL GEARBOX
C+ DRIVE TRAIN
C+ OPERATION OVERVIEWS
SUMMARY TABLE OF CONNECTORS CONCERNED BY FUNCTIONS (C+)
POWERSHIFT (PS - PG 115) GEARBOX
PS DRIVE TRAIN
PS OPERATION OVERVIEWS
SUMMARY TABLE OF CONNECTORS CONCERNED BY FUNCTIONS (PS)
HYDROSTATIC GEARBOX (ZF 2 HC 85)
DRIVE TRAIN
OPERATION OVERVIEWS (ZF 2 HC 85)
PRESSURE CONNECTORS
TRANSMISSION LOCATIONS
MECHANICAL TRANSMISSION AND GEARBOX COOLING
POWERSHIFT (PG 115) GEARBOX COMPONENTS
HYDROSTATIC TRANSMISSION (ZF 2 HC 85)
TRANSMISSION CONTROLS AND ADJUSTMENTS
HYDROSTATIC AUTO-CALIBRATION
VERIFICATION OF MACHINE CONFIGURATIONS
GENERAL AUTHORISATION CONDITIONS FOR CARRIAGE MOVEMENT
ACQUISITION CONDITIONS
UPKEEP CONDITIONS
LOSS CONDITIONS
POWERSHIFT - PG115 GEARBOX
ECU TRANSMISSION (X322)
AUTOMATIC GEAR CHANGE MODE
TABLE OF MAXIMUM SPEEDS PER GEAR
SHAFT AND CLUTCH
GEAR SET
DRIVE TRAIN
TABLE OF PRESSURES
PRESSURE TEST PORT LOCATIONS
HYDROSTATIC GEARBOX (ZF 2 HC 85)
KEY FOR HYDROSTATIC CIRCUITS
DIAGRAM NEUTRAL
TRANSMISSION TIGHTENING TORQUES
CHANGING TO FREEWHEEL MODE (MECHANICAL TRANSMISSION)
CHANGING TO FREEWHEEL MODE (HYDROSTATIC TRANSMISSION)
AFTER TOWING
TRANSMISSION REMOVAL - REFIT
REMOVE THE POWERSHIFT GEAR BOX
REMOVAL OF THE MANUAL GEARBOX ASSEMBLY - ANGLE TRANSMISSION
REMOVE THE HYDROSTATIC GEARBOX (ZF 2 HC 85)
REMOVE THE HYDROSTATIC PUMP
REMOVE THE HYDRAULIC PUMP
REMOVE THE HYDROSTATIC PUMP
SPECIFIC TRANSMISSION TOOLING
BASIC MANOMETER BOX
MANOMETER BOX
ARBOX REMOVAL TOOL

AXLE CONTROLS AND ADJUSTMENTS
TIGHTENING TORQUES

BRAKE CHARACTERISTICS AND SPECIFICATIONS
SERVICE BRAKE
ASSEMBLY WITH MASTER CYLINDER
ASSEMBLY WITH HYDRAULIC VALVE
TRAILER BRAKE VALVE
ACCUMULATOR LOAD VALVE
SERVICE BRAKE VALVE
SERVICE BRAKE SCHEMATIC DIAGRAMS
BRAKE VALVE (VAFS) OPERATING PRINCIPLE
ENGINE ON, PUMP RUNNING, PEDAL AT REST
ENGINE ON, PUMP RUNNING, PEDAL ACTIVATED
ENGINE OFF, PUMP SHUT DOWN, PEDAL ACTIVATED
BRAKE LOCATIONS
BRAKE LOCATIONS - MECHANICAL TRANSMISSION
BRAKE SYSTEM LOCATION
BRAKE LOCATIONS - HYDROSTATIC TRANSMISSION
BRAKE CONTROLS AND ADJUSTMENT
TRAILER BRAKE VALVE TIGHTENING TORQUE
ADJUSTMENT OF PARKING BRAKE ON GEARBOX
FOR MACHINES BEFORE TRACTOR STANDARD
ADJUSTMENT OF PARKING BRAKE ON FRONT AXLE
FOR TRACTOR STANDARD 167-2013 MACHINES
ADJUSTING THE BRAKE PEDAL
CALIBRATE THE INCHING PEDAL
BLEED THE BRAKES
TAKING BRAKE PRESSURE ON MLT 140 V PLUS
TOWING THE LIFT TRUCK
MECHANICAL TRANSMISSION
HYDROSTATIC TRANSMISSION
BRAKE REMOVAL - REFIT
BRAKE MASTER CYLINDER ON MLT PS
SPECIFIC BRAKE TOOLING
BRAKE FLUID BLEEDER

BOOM CHARACTERISTICS AND SPECIFICATIONS
DUPLEX BOOMS
TRIPLEX BOOMS
BOOM LOCATION
DUPLEX BOOM (6 AND 7 M)
TRIPLEX BOOM (9 M)
BOOM CONTROL AND ADJUSTMENT
TELESCOPE EXTENSION AND RETRACTION ADJUSTMENT PROCEDURE
TELESCOPE EXTENSION SPEED ADJUSTMENT (TRIPLEX BOOM)
TELESCOPE RETRACTION SPEED ADJUSTMENT (DUPLEX AND TRIPLEX BOOM)
INNER TELESCOPE RETRACTION DE-SYNCHRONISATION (TRIPLEX BOOM)
RECOMMENDATION FOR FITTING SHIMS AND LUBRICATION
DUPLEX TIGHTENING TORQUE AND LUBRICATION
TRIPLEX TIGHTENING TORQUE AND LUBRICATION
REMOVAL - REFIT
DUPLEX BOOM
TELESCOPE REMOVAL
TELESCOPIC CYLINDER REMOVAL
TRIPLEX BOOM
PREPARATION AND SAFETY INSTRUCTIONS
TELESCOPING CIRCUIT REMOVAL
BOOM HEAD TELESCOPE T2 REMOVAL
INTERMEDIATE TELESCOPE T1 REMOVAL
SPECIAL BOOM TOOLS
FLARE NUT WRENCHES
MAGNETIC LIFTER

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
DYNAMIC STEERING OPERATION
HYDRAULIC COMPONENT SHEETS
ACCUMULATOR BLOCK
OSPC 200 LS STEERING BLOCK
PILOT SAFETY VALVE
DISTRIBUTOR RS
DISTRIBUTOR SDS
FAN REGULATOR MOTOR (FAN DRIVE)
CASAPPA MVP 60 - 63 PUMP
HYDROSTATIC PUMP LA10V072EK1DS/53R
HYDRAULIC SCHEMATIC DIAGRAMS
HYDRAULIC LOCATIONS
KEY
HYDRAULIC CONTROLS AND ADJUSTMENTS
FLUSH THE MLT 733 DISTRIBUTOR (INITIAL FITTING)
HYDRAULICS REMOVAL - REFIT
REMOVE THE HYDRAULIC PUMP
LIFTING CYLINDER REMOVAL
REMOVE THE DISTRIBUTOR
HYDRAULIC SPECIFIC TOOLING
SQUARE BRACKET
DISTRIBUTOR LIFTING DEVICE
DIGITAL MANOMETER BOX
BASIC MANOMETER BOX
INFLATION KIT BOX

ELECTRICITY CHARACTERISTICS AND SPECIFICATIONS
LOCATION OF RELAYS AND FUSES
SCREEN MENUS
ELECTRICAL NETWORK ARCHITECTURE
ECU INPUTS/OUTPUTS
X13/X25 - SCREEN
X14 - NAVIGATOR
X39-C10 - AIR-CONDITIONING ECU
X80 - MAIN ECU SPU
X275 - ENGINE ECU EDC17CV52
X322 - POWERSHIFT GEARBOX ECU PG115
X357 - AUXILIARY ECU SPU
X401 - GEARBOX ECU ZF - 2HC85 _ BOX CVT
80.1.6 TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS
X1/X2 - STARTER IGNITION SWITCH
X10 - LIGHTING COMMUTATOR SWITCH
X11 / 12 - WINDSCREEN WIPER COMMUTATOR SWITCH
X34 - OUTSIDE AIR TEMPERATURE SENSOR
X56 - ROTATING BEACON LIGHT
X72 - BRAKE FLUID LEVEL SWITCH
X74 - ACCELERATOR POTENTIOMETER
X75/X76 - JSM
X77 - BMEP
X78 - MANUAL ACCELERATOR
X79 - STOP PRESSURE SWITCH
X121 - BRAKE PEDAL ANGULAR SENSOR (PS)
X225 - DEF TANK GAUGE
X225 - DEF TANK ANALOG GAUGE
X245 - SUPERCHARGED AIR COOLER TEMPERATURE SENSOR
X246 - TRANSMISSION OIL COOLER TEMPERATURE SENSOR
X247 - HYDRAULIC FLUID COOLER TEMPERATURE SENSOR
X252 - VENTILATION CONTROL ELECTROVALVE
X253 - VENTILATION INVERSION ELECTROVALVE
X265 - FUEL LEVEL SENSOR
X300 - ANGLE BOOM POTENTIOMETER
X334 - TELESCOPE RETRACTED POSITION SENSOR
X382 - BRAKE CIRCUIT PRESSURE SWITCH
WIRING DIAGRAMS
EXAMPLES OF CODING ON THE WIRING DIAGRAMS
CABLE MARKING ON AN ELECTRICAL WIRING HARNESS
POSITIONS OF CONNECTORS BY DIAGRAM
AUTOMATIC AIR CONDITIONING OPTION
POSITIONS OF CONNECTORS BY DIAGRAM
DIAGRAM 1 - STARTING
DIAGRAM 2 - CAN & LIN NETWORKS
DIAGRAM 3 - TRANSMISSION
DIAGRAM 4 - HYDRAULICS
DIAGRAM 5 - SENSOR
DIAGRAM 6 - VENTILATION, WIPERS AND AIR CONDITIONING AUTOMATIC AIR CONDITIONING OPTION
DIAGRAM 7 - OPTIONS
DIAGRAM 8 - LIGHTS
ELECTRICITY LOCATIONS
MLT MECHANICAL TRANSMISSION
FRAME 3D PS HARNESS
FRAME 3D MECHANICAL HARNESS
CAB 3D MECHANICAL & PS HARNESS
ENGINE 3D MLT MECHANICAL & PS HARNESS
DEUTZ ENGINE 3D HARNESS
FRAME 2D PS HARNESS
FRAME 2D MECHANICAL HARNESS
CAB 2D HARNESS
ENGINE 2D HARNESS
VALVE BANK 2D HARNESS
MLT V PLUS
FRAME 3D V PLUS HARNESS
CAB 3D V PLUS HARNESS
ENGINE 3D MLT V PLUS HARNESS
DEUTZ ENGINE 3D HARNESS
FRAME 2D V PLUS HARNESS
CAB 2D V PLUS HARNESS
ENGINE 2D HARNESS
VALVE BANK 2D HARNESS
ELECTRICAL REMOVAL - REFIT
REMOVE THE BATTERY
REMOVE THE ENGINE ECU
REFIT
REMOVE THE MAIN ECU SPU
REMOVE THE TRANSMISSION ECU
POWERSHIFT "PG115"
HYDROSTATIC "ZF EC2 B"
REMOVE THE AUXILIARY ECU SPU
REMOVE THE DASHBOARD SCREEN
REMOVE - REPLACE JSM ON BMEP
REPLACE THE STRAIN GAUGE
LOCATION
AXLE PREPARATION
CHARACTERISTICS OF PRODUCTS USED
CHARACTERISTICS OF FASTENING SCREWS
ASSEMBLY PRECAUTIONS AND TIGHTENING TORQUE
ELECTRICAL TROUBLESHOOTING
ERROR CODES (DTC)
DTC ECU HARMONY SCREEN (X13) 360
AIR CONDITIONING ECU DTC (X39-C10) 360
MAIN ECU DTC SPU 40-26 (X80 - X81 - X82)
ENGINE ECU DTC EDC17CV52 (X274 - X275)
TRANSMISSION ECU DTC PS+ POWERSHIFT PG115 (X322)
AUXILIARY ECU DTC SPU 25-15 (X356 - X357)
TRANSMISSION ECU DTC CVT 2 HC85 (X400 - X401)
SPECIFIC ELECTRIC TOOLING
BREAKOUT BOXES
ELECTROVALVE ADAPTER
DIAGNOSTIC TOOLS
DIAGNOSTICS CASE
CONNECTIONS TO THE LIFT TRUCK
ENGINE ADAPTATION KIT