Manitou MLT 635 733 737 741 940 105 D / 130 PS D / 140 V Plus D ST4 S1 service manual

Description Manitou MLT 635 733 737 741 940 105 D / 130 PS D / 140 V Plus D ST4 S1 service manual

Manitou Telescopic Handler MLT 635 733 737 741 940 105 D/130 PS D/140 V Plus D ST4 Series 1 pdf service & repair manual

Models covered:
MLT 635 130 PS D ST4 S1
MLT 733 105 D ST4 S1
MLT 733 105 D ST4 S1 TRACT
MLT 733 105 D ST4 S1 TRACT LSU
MLT 737 130 PS D ST4 S1
MLT 635 140 V PLUS D ST4 S1
MLT 741 140 V PLUS D ST4 S1
MLT 940 140 V PLUS D ST4 S1

MANUAL CONTENT:
ENGINE CHARACTERISTICS AND SPECIFICATION
DIESEL EXHAUST FLUID (DEF)
CHARACTERISTICS
LEVELS
WINTERING
INJECTION CYCLE
EFFECTS OF FUEL PRE-INJECTION
EFFECTS OF FUEL POST-INJECTION
BOSCH CP4.1 HIGH PRESSURE PUMP

ENGINE SCHEMATIC DIAGRAM
AIR INTAKE CIRCUIT AND EGR (EXHAUST GAS RECIRCULATION)
LUBRICATION CIRCUIT
COOLING SYSTEM
FUEL CIRCUIT
DEF (DIESEL EXHAUST FLUID) SYSTEM

ENGINE COMPONENTS LOCATION
ENGINE ELEMENTS
WATER AND AIR COOLING CIRCUIT
HYDRAULIC VENTILATION SYSTEM
DIESEL FUEL CIRCUIT
FUEL INJECTION CIRCUIT
EGR (EXHAUST GAS RECIRCULATION) CIRCUIT
DEF (DIESEL EXHAUST FLUID) SYSTEM

ENGINE CONTROL AND ADJUSTMENT
DEF REGENERATION
ENGINE LOAD LEVEL
FAN CONTROL
A - FUNCTION
B - PRINCIPLE OF OPERATION
C - SCHEMATIC DIAGRAM
D - DESCRIPTION OF HYDRAULIC MOTORS
E - CONDITIONS OF FAN CONTROL-RELATED COMPONENTS
SILENT BLOCK TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
DIESEL FUEL CIRCUIT TIGHTENING TORQUES
EXHAUST SYSTEM TIGHTENING TORQUES
COOLING SYSTEM TIGHTENING TORQUES
HEATING SYSTEM TIGHTENING TORQUES

ENGINE REMOVAL - REFIT
ENGINE ECU REMOVAL - REFIT
REFIT
AIR FILTER ASSEMBLY REMOVAL
STARTER REMOVAL
DOC EXHAUST PIPE REMOVAL
DEF INJECTION SYSTEM REMOVAL
DEF TANK REMOVAL
DEF GAUGE REMOVAL
COOLER REMOVAL
REMOVING THE UPPER PART
SEPARATION OF COOLER FROM ENGINE
OPTION 1: REMOVAL OF PUMP AND GRILL
OPTION 2: REMOVAL OF COOLER ASSEMBLY
ENGINE REMOVAL
SCR EXHAUST PIPE REMOVAL
ENGINE HOSE AND CONNECTOR REMOVAL
ENGINE/ANGLE GEAR BOX TRANSMISSION UNIVERSAL JOINT REMOVAL
ENGINE REFIT
ALTERNATOR REMOVAL
WATER PUMP REMOVAL
TURBO-COMPRESSOR REMOVAL

SPECIFIC TOOLING
ELECTRONIC TENSION METER

TRANSMISSION SCHEMATIC DIAGRAMS
COMPACT+ (C+) MANUAL GEAR BOX
C+ DRIVE TRAIN
C+ OPERATION OVERVIEWS
SUMMARY TABLE OF CONNECTORS CONCERNED BY FUNCTIONS (C+)
POWERSHIFT GEAR BOX
PS DRIVE TRAIN
PS OPERATION OVERVIEWS
SUMMARY TABLE OF CONNECTORS CONCERNED BY FUNCTIONS (PS)

TRANSMISSION COMPONENTS LOCATION
MECHANICAL TRANSMISSION AND GEAR BOX COOLING
POWERSHIFT GEAR BOX COMPONENTS

TRANSMISSION CONTROL AND ADJUSTMENT
CONDITIONS AUTHORISING LIFT TRUCK TRAVEL MOVEMENTS
CONDITIONS FOR OBTAINING AUTHORISATION
CONDITIONS FOR MAINTAINING AUTHORISATION
CONDITIONS FOR LOOSING AUTHORISATION
POWERSHIFT GEAR BOX
TRANSMISSION ECU (X322)
AUTOMATIC GEAR CHANGE MODE
TABLE OF MAXIMUM SPEED PER GEAR NUMBER
SHAFT AND CLUTCH
GEARS
DRIVE TRAIN
PRESSURE PORT LOCATIONS
TABLE OF PRESSURES
TRANSMISSION TIGHTENING TORQUES

TRANSMISSION REMOVAL - REFIT
GEAR BOX REMOVAL
PREPARATION AND SAFETY INSTRUCTIONS
SPECIFIC TOOLS
GEAR BOX - ANGLE DRIVE ASSEMBLY REMOVAL
PREPARATION AND SAFETY INSTRUCTIONS
SPECIFIC TOOLS

AXLE CONTROL AND ADJUSTMENT
TIGHTENING TORQUE

CONTROL AND ADJUSTMENT
BRAKE PEDAL ON MLT
BRAKE BLEEDING PROCEDURE

REMOVAL BRAKE MASTER CYLINDER ON MLT PS

SPECIFIC BRAKE TOOLING
HYDRAULIC BRAKE BLEEDER

BOOM COMPONENT REMOVAL - REFIT
BOOM HEAD REMOVAL
FITTING OF BOOM SLIDE INSERTS
TELESCOPE CYLINDER REMOVAL

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
DYNAMOMETRIC STEERING OPERATION
HYDRAULIC COMPONENT SHEETS
ACCUMULATOR BLOCK
STEERING UNIT OSPC
COUNTERBALANCE VALVE
DISTRIBUTOR RS
DISTRIBUTOR SDS
CASAPPA MVP
STEERING SELECTOR
AUTOMATIC STEERING SELECTOR

HYDRAULIC DIAGRAM
PARTS LIST
DIAGRAM MLT

HYDRAULIC COMPONENTS LOCATION
PARTS LIST

HYDRAULIC COMPONENTS REMOVAL - REFIT
HYDRAULIC OIL PUMP REMOVAL
LIFTING CYLINDER REMOVAL

ELECTRICAL CHARACTERISTICS
LOCATION OF RELAYS AND FUSES
SCREEN MENUS
ELECTRICAL NETWORK ARCHITECTURE
DETAILED ELECTRICAL NETWORK ARCHITECTURE
ECU INPUTS / OUTPUTS
SCREEN (A9)
NAVIGATOR (A4)
POWERSHIFT PG115 GEARBOX ECU
TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS
STARTER IGNITION SWITCH (A12)
LIGHTING COMMUTATOR SWITCH (S5)
WINDSCREEN WIPER COMMUTATOR SWITCH (S4)
ROTATING BEACON LIGHT (E15)
BRAKE FLUID LEVEL SWITCH (S11)
ACCELERATOR POTENTIOMETER (B18)
BRAKE PEDAL ANGULAR SENSOR (PS) (B47)
DEF TANK ANALOG GAUGE (B53)
FUEL LEVEL SENSOR (R2)
TELESCOPE RETRACTED POSITION SENSOR
BRAKE CIRCUIT PRESSURE SWITCH

ELECTRICAL DIAGRAMS
ELECTRICAL DIAGRAM CODIFICATION EXAMPLE
POSITIONS BY DIAGRAM
DIAGRAM 1 - STARTER
DIAGRAM 2 - CAN
DIAGRAM 3 - TRANSMISSION
DIAGRAM 4 - HYDRAULICS
DIAGRAM 5 - SENSOR
DIAGRAM 6 - FAN, WIPERS AND AIR-CONDITIONING
DIAGRAM 7 - OPTIONS
DIAGRAM 8 - LIGHTS AND SIGNALS

ELECTRICAL LOCATION
PARTS LIST
FRAME 3D PS HARNESS
FRAME 3D MECHANICAL HARNESS
CAB 3D HARNESS
ENGINE 3D HARNESS
DEUTZ ENGINE 3D HARNESS
FRAME 2D PS HARNESS
FRAME 2D MECHANICAL HARNESS
CAB 2D PS HARNESS
CAB 2D MECHANICAL HARNESS
ENGINE 2D HARNESS
DISTRIBUTOR 2D HARNESS

ELECTRICAL COMPONENTS REMOVAL - REFIT
BATTERY REMOVAL
ENGINE ECU REMOVAL
DASHBOARD DISPLAY SCREEN REMOVAL

ELECTRICAL TROUBLESHOOTING
ERROR CODES (DTC)
AUXILIARY ECU
PS+ TRANSMISSION ECU
CVT TRANSMISSION ECU
ENGINE ECU

DRIVERS CAB CONTROL AND ADJUSTMENT
TIGHTENING TORQUES

DRIVERS CAB COMPONENTS REMOVAL/REFIT
CAB REMOVAL
DOOR WINDER REMOVAL
DOOR TRIM PANEL REMOVAL
REMOVAL OF INNER DOOR FITTINGS
CAB DOOR REMOVAL
WINDSCREEN WIPER ENGINE REMOVAL
CAB INTERIOR TRIM REMOVAL
HEATING BLOCK REMOVAL
DRIVERS SEAT REMOVAL
ARMREST REMOVAL
DASHBOARD SWITCH REMOVAL

REMOVAL - REFIT
ENGINE BONNET REMOVAL

AIR-CONDITIONING
OPERATION DESCRIPTION
OPERATING PRINCIPLE
DESCRIPTION OF COMPONENTS
COMPRESSOR
CONDENSER
DRIER FILTER
THE "BINARY" PRESSURE SWITCH
PRESSURE REDUCING VALVE
EVAPORATOR
ANTI-FROST THERMOSTAT
AIR-CONDITIONING COMPONENT LOCATION AND TIGHTENING TORQUES
INTERNAL AIR-CONDITIONING COMPONENTS
EXTERNAL AIR-CONDITIONING COMPONENTS
CONDENSER COMPONENTS
GENERAL CHECK POINTS
AIR-CONDITIONING ELECTRICAL SYSTEM CHECK POINTS
ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT
SAFETY MEASURES FOR HANDLING
REFRIGERANT FLUID LOAD FOR THE AIR-CONDITIONING CIRCUIT
AIR-CONDITIONING BELT REMOVAL (OPTION)
AIR-CONDITIONING BELT REFIT (OPTION

SPECIFIC TOOLING
FAN BELT FITTING TOOL
TROUBLESHOOTING
PRESSURE TROUBLESHOOTING
ABNORMAL NOISE ON A/C SYSTEM