Manitou Telehandler MLT 845 120 S5 E3 MLT 845 120H S4 E3 MLT- X 845 120M ST3A S6 MLT- X 845 120M H ST3A S5 Repair Manual 647182EN – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Manitou Telehandler MLT 845 120 S5 E3 MLT 845 120H S4 E3 MLT- X 845 120M ST3A S6 MLT- X 845 120M H ST3A S5 Repair Manual 647182EN – PDF DOWNLOAD
PREAMBLE:
This chapter deals with the general instructions and safety notice during inspection and maintenance
work.
Other instructions and warnings are indicated in each chapter concerned.
In order to reduce accident risks, make sure to:
– Follow the instructions in the truck operating and maintenance manual.
⇒ This manual should be found in all trucks.
– Please follow all safety instructions.
– Use the appropriate tools for any work to be performed.
– Use original Manitou spare parts.
Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily
harm and even death.
An efficient, dependable and profitable combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.
TABLE OF CONTENTS:
Manitou Telehandler MLT 845 120 S5 E3 MLT 845 120H S4 E3 MLT- X 845 120M ST3A S6 MLT- X 845 120M H ST3A S5 Repair Manual 647182EN – PDF DOWNLOAD
Pdg647182EN 1
Page de garde / Front page 1
Som_647182EN 3
Group_00_MR647182EN 5
Som_Gr00M209EN 5
Group_00 7
00_00_M209EN 7
PREAMBLE 8
MAINTENANCE POSITION 9
RULES FOR MAINTENANCE 10
00_04_M209EN 13
STANDARD TIGHTENING TORQUES 14
Group_10_MR647182EN 15
Som_Gr10M209EN 15
Group_10 17
10_01_M209EN 17
ENGINE CHARACTERISTICS 18
FUEL CIRCUIT 18
ELECTRICAL SUPPLY AND PIN-OUT 20
ELECTRONIC CONTROL MODULE 22
ENGINE GROUND 22
10_03_M209EN 23
MERCEDES ENGINE 24
FUEL CIRCUIT 25
10_04_m209en 27
ENGINE TIGHTENING TORQUES 28
ENGINE ASSEMBLY 28
FUEL CIRCUIT – 120CV 28
ENGINE SILENTBLOCS 29
FUEL GAUGE ADJUSTMENT PROCEDURE 30
ALTERNATOR/CRANKSHAFT DRIVE BELT ADJUSTMENT 31
ENGINE COMPONENTS REMOVAL AND REFIT 32
PREPARATION AND SAFETY INSTRUCTIONS 32
A – ALTERNATOR DRIVE BELT CHANGE 33
B – ALTERNATOR REFIT 34
C – CHANGING THE OIL FILTER ASSEMBLY 35
D – CHANGING THE FUEL FILTER AND FUEL PUMP ASSEMBLY 36
E – WATER PUMP REMOVAL AND REFIT 37
F – REMOVAL AND REFIT OF STARTER MOTOR 38
FAN DRIVE 39
Graph showing Fan Drive operating cycle 42
10_06_M209EN 43
PREPARATION AND SAFETY INSTRUCTIONS 44
DISMANTLING ORDER 45
“HYDRAULIC MOTOR” REMOVAL 46
REMOVAL COOLER 47
“ENGINE” REMOVAL 51
10_07_M209EN 57
PREPARATION AND SAFETY INSTRUCTIONS 58
ORDER OF REASSEMBLY 59
REFIT “I C ENGINE” 60
REFIT COOLER 64
HYDRAULIC MOTOR REFIT 68
Group_20_MR647182EN 69
Som_Gr20M209EN 69
Group_20 71
20_02_M209EN 71
POWER FLOW DIAGRAM/GEAR RATIOS – MECHANICAL TRANSMISSION 73
POWER FLOW DIAGRAM/GEAR RATIOS – HYDROSTATIC TRANSMISSION 74
SCHEMATIC DIAGRAM HYDROSTATIC TRANSMISSION IN FORWARD GEAR 75
SCHEMATIC DIAGRAM HYDROSTATIC TRANSMISSION IN REVERSE GEAR 76
20_04_M209EN 77
TIGHTENING TORQUES, MECHANICAL TRANSMISSION 79
TIGHTENING TORQUES, HYDROSTATIC TRANSMISSION 80
PRESSURE TAKE-OFF POINTS 81
A4VG 71 DA PUMP PRESSURE MEASURING POINT 81
A6VM SERIES 63 MOTOR PRESSURE MEASURING POINT 82
TRANSMISSION CONTROL AND ADJUSTMENT 83
TRANSMISSION SETTING POINTS 83
PRE START-UP OR POST SERVICING CHECKS 84
BOOSTER PRESSURE SETTING AND MONITORING 85
PUMP MECHANICAL “0” SETTING 86
PUMP REGULATION START MONITORING AND SETTING 87
REGULATION END MONITORING AND SETTING 88
HP LIMITERS MONITORING AND ADJUSTMENT 89
UNBLOCKING HP LIMITERS FOR TOWING 89
A6VM MOTOR REGULATION SETTING 90
A4VG-DA/A6VM-DA HYDROSTATIC TRANSMISSIONS SETTING FILE 92
20_06_m209en 93
MECHANICAL TRANSMISSION REMOVAL 94
PREPARATION AND SAFETY INSTRUCTIONS 94
ANGLE GEAR BOX 95
GEAR BOX 99
20_07_m209en 103
MECHANICAL TRANSMISSION REFIT 104
PREPARATION AND SAFETY INSTRUCTIONS 104
ANGLE GEAR BOX 105
GEAR BOX 108
20_09_M209EN 111
BASIC BOX 112
Group_30_MR647182EN 115
Som_Gr30M209EN 115
Group_30 117
TIGHTENING TORQUE 118
AXLE 118
Group_40_MR647182EN 121
Som_Gr40M209EN 121
Group_40 123
40_01_M209EN 123
SERVICE BRAKE / PARKING BRAKE 125
40_04_M209EN 127
MLT 845 SERVICE BRAKE 128
SETTING BRAKE PEDAL HEIGHT 128
MLT 845 H SERVICE BRAKE 129
SETTING BRAKE PEDAL HEIGHT 129
PARKING BRAKE (CABLE OPERATED BRAKE) 130
HAND BRAKE CABLE ADJUSTMENT 130
40_09_M209EN 131
PURGEUR FREINS HYDRAULIQUE 132
Group_50_MR647182EN 133
Som_Gr50M209EN 133
Group_50 135
50_01_M209EN 135
DUPLEX (MLT 8 MÈTRES) : 136
50_03_M209EN 137
COMPONENT CODE INDEX 138
LOCATIONS OF THE MAIN COMPONENTS OF THE 8M BOOM 138
50_04_m209en 139
DUPLEX BOOM COMPONENT DISMANTLING 140
PREPARATION AND SAFETY INSTRUCTIONS 140
T2 TELESCOPE REMOVAL 141
TELESCOPE CYLINDER REMOVAL 144
DUPLEX BOOM COMPONENTS REFIT 146
RECOMMENDATIONS FOR WEDGE ASSEMBLY AND GREASING AREAS 146
50_06_m209en 147
DUPLEX BOOM 148
PREPARATION AND SAFETY INSTRUCTIONS 148
BOOM REMOVAL 149
50_07_m209en 153
DUPLEX BOOM 154
PREPARATION AND SAFETY INSTRUCTIONS 154
BOOM REFIT 155
Group_70_MR647182EN 157
Som_Gr70M209EN 157
Group_70 159
70_01_m209en 159
70_02_m209en 161
MLT 845 120 H Series 4-E3 / MLT- X 845 120M H ST3A Series 5 164
KEY 164
HYDRAULIC DIAGRAM 165
MLT 845 120 Series 5-E3 / MLT- X 845 120M ST3A Series 6 166
KEY 166
HYDRAULIC DIAGRAM 167
70_03_m209en 169
KEY 170
HYDRAULIC CIRCUITS 171
1 – MAIN HYDRAULIC CIRCUIT 171
2 – HYDRAULIC LIFTING CIRCUIT 173
3 – HYDRAULIC BOOM CIRCUIT 174
4 – BOOM COMPENSATION HYDRAULIC CIRCUIT 175
5 – STEERING HYDRAULIC CIRCUIT 176
70_04_M209EN 177
PRESSURE TAKE-OFF POINTS 178
VALUES 178
LOCALIZATION 178
SX14 S CONTROL BLOCK CONTROL LOGIC 179
DANGEROUS MOVEMENTS CUT-OFF OPERATING PRINCIPLES 181
REMOVAL OF SX 14 S DISTRIBUTOR 182
1 – SAFETY INSTRUCTIONS 182
2 – TROUBLESHOOTING 183
3 – ESSENTIAL RULES 185
4 – REMOVAL AND RE-FITTING OF THE SX 14 S UNIT 186
5 – SX 14 S unit REPAIR PROCEDURES 187
6 – SPECIFIC TIGHTENING TORQUE 191
70_06_m209en 193
DISTRIBUTOR 194
PREPARATION AND SAFETY INSTRUCTIONS 194
DISTRIBUTOR REMOVAL 195
70_07_m209en 199
DISTRIBUTOR 200
PREPARATION AND SAFETY INSTRUCTIONS 200
DISTRIBUTOR REFIT 201
70_09_M209EN 205
COFFRET MANOMÈTRES DE BASE 206
COFFRET MANOMÈTRE DIGITAL 207
Group_80_MR647182EN 209
Som_Gr80M209EN 209
Group_80 211
80_01_M209EN 211
80_01_M209_A_EN 213
OPERATION 214
SYSTEM OVERVIEW 215
80_01_m209_b_en 217
HYDRAULIC ECU INPUTS/OUTPUTS 219
ECU RC2-2/20 Rexroth (WITH CAN) 219
CASAPPA (CED100X) ECU 219
SPU INPUTS/OUTPUTS 220
SPU 25-15 (LSU) 220
ADM INPUTS/OUTPUTS 222
ADM 2 222
PLD INPUTS/OUTPUTS 224
PLD 224
80_01_M209_C_EN 227
KEY KEY OPERATED STARTER SWITCH 228
S4 BRAKE FLUID LEVEL CONTACT 229
S5 AIR FILTER SWITCH 229
S12 TRANSMISSION OIL THERMOSWITCH 230
S16+S37 STOP PRESSURE SWITCH 230
S17 RANSMISSION OIL THERMOSWITCH (NO H) 231
S52 EMERGENCY STOP 231
Y1+Y4 REVERSE+SLOW SPEED ELECTROVALVE (H) 232
Y10 HIGH SPEED ELECTROVALVE (H) 232
Y6+Y7+Y8+Y9 PROPORTIONAL SOLENOID VALVE BOOM/ACCESSORY 233
Y14 HYD CUT-OFF VALVE/VS 233
Y15 PROPORTIONAL SOLENOID VALVE, BOOM DESCENT VRP 234
Y16 VCI TILT CUT-OFF 234
Y18 SOLENOID VALVE 235
Y30 PEC (PRESSURE ELECTRONIC CONTROL) ON CASAPPA PUMP 236
XTP ACCELERATOR POTENTIOMETER 237
X01 DECLUTCH PUSH BUTTON (No H) 237
X14 HORN 238
X15+X21 WHEEL ALIGNMENT SENSOR 238
X36 JSM JOYSTICK 239
INDICATOR LIGHT PANEL 240
X68 FUEL LEVEL AND HOUR METER 240
X77 FRONT WINDSCREEN WIPER MOTOR 241
X89 WATER TEMPERATURE INDICATOR 241
X99 STRAIN GAUGE 242
X100 BOOM ANGLE ANGULAR SENSOR 242
X134 RETRACTED BOOM SWITCH 243
X165 FUEL GAUGE 243
X188 LIGHTING STALK SWITCH 244
X503 TRANSMISSION OIL TEMPERATURE SENSOR (NO H) 245
X504 HYDRAULIC OIL TEMPERATURE SENSOR 245
B18 ENGINE COOLANT TEMPERATURE SENSOR 246
B19 ENGINE AIR TEMPERATURE SENSOR 247
CODES ON THE ELECTRICAL DIAGRAMS 250
CABLE MARKING ON AN ELECTRICAL WIRING HARNESS 252
80_02_m209_a_en 253
POSITION OF CONNECTORS ON DIAGRAMS 254
ELECTRICAL DIAGRAMS 260
1 – STARTER 260
2 – TRANSMISSION AND SENSORS 262
3 – CAN BUS AND DIAGNOSTICS 264
4 – LIGHTING/SIGNALING 266
5 – HYDRAULIC MOVEMENT 268
6 – OPTIONS 270
7 – HEATER AND A/C 272
80_02_m209_b_en 275
POSITION OF CONNECTORS ON DIAGRAMS 276
ELECTRICAL DIAGRAMS 282
1 – STARTER 282
2 – TRANSMISSION AND SENSORS 284
3 – CAN BUS AND DIAGNOSTICS 286
4 – LIGHTING/SIGNALING 288
5 – HYDRAULIC MOVEMENT 290
6 – OPTIONS 292
7 – HEATER AND A/C 294
80_03_m209en 297
KEY 299
CONNECTORS 299
GROUNDS 302
FUSES AND RELAYS 302
2D LOCATION 304
HARNESS ASSEMBLY 304
CABIN/CHASSIS HARNESS 305
ENGINE HARNESS 306
CONTROL VALVE HARNESS 307
FAN HARNESS 308
ADM CPC4-ECAN HARNESS 309
CABIN ROOF HARNESS 310
ELECTRIC FUSE PLATE AND RELAYS 311
CAN-BUS INTERFACE HARNESS 312
A/C HARNESS 313
80_04_M209EN 315
LONGITUDINAL STABILITY INDICATOR (LLMI) 316
ERROR CODES 316
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE 317
CALIBRATION OF THE STRAIN GAUGE AND THE ANGLE SENSOR (DEALER PROCEDURE) 318
RECALIBRATION OF STRAIN GAUGE (OWNER PROCEDURE) 320
GENERIC REGULATION LAW EN15000 321
LED ILLUMINATION AS A FUNCTION OF THE CHANGING GAUGE SIGNAL 322
80_07_M209EN 323
STRAIN GAUGE 324
LOCATION 324
CHARACTERISTICS OF THE AXLE SURFACE IN CONTACT WITH THE STRAIN GAUGE 325
CHARACTERISTICS OF PRODUCTS USED 325
CHARACTERISTICS OF THE ATTACHMENT SCREWS 326
PRECAUTIONS FOR ASSEMBLY AND TIGHTENING TORQUE 326
80_08_M209EN 329
DESCRIPTION ENGINE FAULTS CODES (MR2-PLD) 330
FAULT PRIORITY 330
FAULT PATH 331
FAULT TYPE 333
FAULTS CODES – ENGINE (MR2-PLD) 335
FAULTS CODES – TRUCK (SPU 25-15) 352
FAULTS CODES – LONGITUDINAL STABILITY INDICATOR (LLMI) 354
80_09_M209EN 355
DIAGNOSTIC TOOLKIT 356
RECEPTION STATION 358
WORKSHOP AREA 358
BREAKOUT BOX KIT 359
SOLENOID ADAPTER 359
Group_110_MR647182EN 361
Som_Gr110M209EN 361
Group_110 363
OPERATING PRINCIPLE 364
DESCRIPTION OF OPERATION 365
DESCRIPTION OF COMPONENTS 366
LOCALISATION CLIMATISATION 367
ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT 368
SECURITY MEASURES FOR THE MANIPULATION OF R134a 368
REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT 368
LOADING METHOD 369
OPERATING CONTROL 370
MONITORING ANTI-ICING SAFETY 372
AIR CONDITIONING MONITORING FORM 373
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