Manitou Telehandler MT-X 1440 100P ST3A S2 MT-X 1440 A 100P ST3A S2 MT-X 1840 100P ST3A S2 MT-X 1840 A 100P ST3A S2 Service Manual 647793EN-USM2 – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Manitou Telehandler MT-X 1440 100P ST3A S2 MT-X 1440 A 100P ST3A S2 MT-X 1840 100P ST3A S2 MT-X 1840 A 100P ST3A S2 Service Manual 647793EN-USM2 – PDF DOWNLOAD
GENERAL AND SAFETY CHARACTERISTICS:
00.1. FOREWORD:
This chapter deals with the general instructions and safety notice during servicing checks and work. The other instructions and warning texts are indicated in the chapters concerned.
In order to reduce the risk of accidents, please:
• Follow the instructions in the operator’s manual and
the truck servicing instructions.
• > This manual should be found in all trucks.
• Please follow the safety instructions.
• Use the appropriate tools for all work to be carried
out.
• Use original Manitou spare parts.
If these instructions are not followed there is a risk of accidents occurring, the severity of which could go as far as causing death. A person who follows the safety instructions and a wellserviced machine make a safe, effective and profitable combination.
TABLE OF CONTENTS:
Manitou Telehandler MT-X 1440 100P ST3A S2 MT-X 1440 A 100P ST3A S2 MT-X 1840 100P ST3A S2 MT-X 1840 A 100P ST3A S2 Service Manual 647793EN-USM2 – PDF DOWNLOAD
00 GENERAL AND SAFETY CHARACTERISTICS 13
00 1 FOREWORD 13
00 2 LIST OF ABBREVIATIONS 13
00 3 WORK DURING THE WARRANTY PERIOD 15
00 4 MAINTENANCE POSITION 15
00 5 EXPLANATION OF SYMBOLS 15
00 6 MAINTENANCE RULES 16
00 7 LIST OF SUPPLIER DOCUMENTATION 19
00 8 CHARACTERISTICS AND SPECIFICATIONS 19
00 8 1 Weights and forces 19
00 8 2 Lubricants and fuels 20
00 8 3 Dimensions 21
00 9 LOCATION 23
00 9 1 Location of name and identification plates 23
00 10 CONTROL AND ADJUSTMENT 23
00 10 1 Standard tightening torques 23
00 10 2 Metric – imperial unit conversion 25
10 ENGINE 27
10 1 CHARACTERISTICS AND SPECIFICATIONS 27
10 1 1 Supplier Documentation 27
10 2 LOCATION 27
10 2 1 Engine components 27
10 2 2 Diesel fuel circuit 28
10 2 3 Water + air cooling circuit 29
10 3 CONTROL AND ADJUSTMENT 29
10 3 1 Fan check points 29
10 3 2 Accelerator pedal and position sensor adjustment 30
10 3 3 Adjusting the accelerator solenoid 32
10 3 4 Engine suspension tightening torques 33
10 3 5 Engine/gearbox tightening torques 34
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TABLE OF CONTENTS
10 4 REFIT 34
10 4 1 Refitting exhaust muffler 34
10 5 TROUBLESHOOTING 35
10 5 1 Engine assembly error codes 35
10 5 2 Ignition switching test 35
10 5 3 Engine start-up authorization conditions 35
10 5 4 Lack of engine power 36
10 5 5 Fault table 36
10 6 SPECIFIC TOOLING 38
10 6 1 Electronic belt tensiometer 38
20 TRANSMISSION 39
20 1 CHARACTERISTICS AND SPECIFICATIONS 39
20 1 1 Supplier Documentation 39
20 2 DIAGRAMS AND SCHEMATICS 39
20 2 1 Mechanical transmission 39
20 3 LOCATION 44
20 3 1 Mechanical transmission 44
20 4 CONTROL AND ADJUSTMENT 46
20 4 1 Mechanical transmission 46
20 5 REMOVAL 48
20 5 1 Mechanical transmission 48
20 6 TROUBLESHOOTING 55
20 6 1 General authorization conditions for carriage movement 55
20 6 2 Transmission DTC error codes 55
20 7 SPECIFIC TOOLING 56
20 7 1 Basic manometer box 56
20 7 2 Digital manometer box 56
20 7 3 Machined 50 mm socket 56
TABLE OF CONTENTS
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30 AXLE 58
30 1 CHARACTERISTICS AND SPECIFICATIONS 58
30 1 1 Supplier Documentation 58
30 2 CONTROL AND ADJUSTMENT 58
30 2 1 Bleeding the axle locking cylinder 58
30 2 2 Adjusting the axle stops when installing wider tires 58
40 BRAKE 61
40 1 CHARACTERISTICS AND SPECIFICATIONS 61
40 1 1 Specifications of the master cylinder 61
40 1 2 Service brake specifications 61
40 1 3 Parking brake specifications 61
40 2 DIAGRAMS AND SCHEMATICS 63
40 2 1 Mechanical transmission 63
40 3 LOCATION 65
40 3 1 Location of service brake components 65
40 4 CONTROL AND ADJUSTMENT 66
40 4 1 Mechanical transmission 66
40 5 REMOVAL 72
40 5 1 Preparation and safety instructions before removal operations on the braking system 72
40 5 2 Removing the parking brake 72
40 5 3 Removing the master cylinder 73
40 6 SPECIFIC TOOLING 74
40 6 1 Hydraulic brake bleed valve 74
40 6 2 Parking brake bleeder harness 74
50 LIFT STRUCTURE 75
50 1 CHARACTERISTICS AND SPECIFICATIONS 75
50 1 1 Triplex boom MT 14 75
50 1 2 Quadruplex boom MT 18 75
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TABLE OF CONTENTS
50 2 DIAGRAMS AND SCHEMATICS 75
50 2 1 Triplex 14 m boom kinematics 77
50 2 2 Quadruplex 18 m boom kinematics 79
50 3 LOCATION 81
50 3 1 Location of components of 14 m triplex boom 83
50 3 2 Location of 18 m quadruplex boom components 85
50 4 CONTROL AND ADJUSTMENT 87
50 4 1 Triplex boom 87
50 4 2 Quadruplex boom 93
50 5 REMOVAL 100
50 5 1 Triplex boom 100
50 5 2 Quadruplex boom 110
50 6 REFIT 126
50 6 1 Triplex boom 126
50 6 2 Quadruplex boom 134
50 7 SPECIFIC TOOLING 147
50 7 1 Pipe end pieces 147
50 7 2 Channel lever 147
50 7 3 Hose routing support 148
50 7 4 Hose tension adjustment gage 149
50 7 5 Chain checking gage 149
70 HYDRAULICS 150
70 1 CHARACTERISTICS AND SPECIFICATIONS 150
70 1 1 List of hydraulic sheets 151
70 1 2 FP HP feed block + accumulator 153
70 1 3 SD 8/8 9-component distributor 157
70 1 4 4-component electro-proportional distributor PVG100/32 163
70 1 5 3-component deflector distributor 175
70 1 6 Power-assisted brake master cylinder 176
70 1 7 Hydraulic pump KP30 43 178
70 1 8 Backup pump EP-45 180
70 1 9 Steering pump 181
70 1 10 3-position steering selector 183
TABLE OF CONTENTS
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70 1 11 Double safety valve 184
70 1 12 Double safety valve 184
70 1 13 Double safety valve 185
70 1 14 Double safety valve 186
70 1 15 Single pilot safety valve 186
70 1 16 Single pilot safety valve 188
70 1 17 Discharge valve VMS 189
70 1 18 Discharge block valve 191
70 1 19 Compensating isolation valve 191
70 1 20 Operation of the compensating isolation valve 193
70 1 21 Flow rate control valve 194
70 1 22 Dynamic selection valve 195
70 2 DIAGRAMS AND SCHEMATICS 195
70 2 1 Hydraulic diagram – MT-X 1440 197
70 2 2 Hydraulic diagram – MT-X 1840 203
70 2 3 Hydraulic diagram – MT(-X) A 1440 209
70 2 4 Hydraulic diagram – MT(-X) A 1840 215
70 3 LOCATION 221
70 3 1 Location of hydraulic components – MT-X 1440 100P ST3A 221
70 3 2 Location of hydraulic components – MT-X 1440 A 100P ST3A 222
70 3 3 Location of hydraulic components – MT-X 1840 100P ST3A 224
70 3 4 Location of hydraulic components – MT-X 1840 A 100P ST3A 225
70 3 5 Location of central greasing system lubricators 227
70 4 CONTROL AND ADJUSTMENT 227
70 4 1 Accumulation of the flow rates of the discharge valve (Access versions) 227
70 4 2 Adjustment of the hydraulic circuit pressure connectors (non-Access versions) 228
70 4 3 Adjustment of the hydraulic circuit pressure connectors (Access versions) 229
70 4 4 Bleed the compensation/tilting circuit 229
70 4 5 Test the load holding capacity of the counterbalance valves of the cylinders (Access versions
only) 230
70 4 6 Check the service brake hydraulic circuit on the FP HP feed block 235
70 4 7 9-component main hydraulic distributor tightening torques (14 m non-Access versions) 236
70 4 8 9-component main hydraulic distributor tightening torques (18 m non-Access versions) 237
70 4 9 4-component electro-proportional main hydraulic distributor tightening torques (Access
versions) 238
70 4 10 Leveling/stabilizer 3-component hydraulic distributor tightening torques (Access versions) 239
70 4 11 Hydraulic pump tightening torques 239
70 4 12 Hydraulic suction assembly tightening torques 240
70 4 13 Hydraulic return filter tightening torque 240
70 4 14 Breather plug tightening torque 240
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70 4 15 Hydraulic tank sealing plug tightening torque 240
70 4 16 Backup hydraulic circuit tightening torques (Access versions) 241
70 4 17 Braking/steering hydraulic unit tightening torques 241
70 4 18 Return manifold tightening torques (mechanical transmission) 241
70 4 19 Parking brake hydraulic components tightening torques (mechanical transmission) 241
70 4 20 Stabilizer cylinder valve tightening torque 242
70 4 21 Lifting cylinder valve tightening torque 242
70 4 22 Telescopic boom cylinder valve tightening torque (all versions apart from A) 242
70 4 23 Telescopic boom cylinder valve tightening torque (A versions only) 242
70 5 REMOVAL 243
70 5 1 Preparing and securing the machine before removal of hydraulic components 243
70 5 2 Removing the hydraulic oil tank 244
70 5 3 Remove the 9-component hydraulic distributor with mechanical controls (non-Access versions) 246
70 5 4 Remove the 4-component electro-proportional hydraulic distributor (Access versions) 248
70 6 SPECIFIC TOOLING 249
70 6 1 Basic manometer box 249
70 6 2 Digital manometer box 249
80 ELECTRICITY 250
80 1 CHARACTERISTICS AND SPECIFICATIONS 250
80 1 1 Fuses and relays 250
80 1 2 ECU Inputs/Outputs 252
80 1 3 Technical sheets for electrical components 268
80 2 DIAGRAMS AND SCHEMATICS 290
80 2 1 CAN and LIN operating diagram – mechanical transmission 290
80 2 2 Examples of coding on the wiring diagrams 291
80 2 3 Cable marking on an electrical wiring harness 292
80 2 4 Position by diagram – MT-X 100P 292
80 2 5 Electrical diagrams – MT-X 100P 305
80 2 6 Position by diagram – MT-X A 100D 327
80 2 7 Electrical diagrams – MT-X A 100P 341
80 3 LOCATION 363
80 3 1 Location of electrical components – MT-X 100P 365
80 3 2 Location of electrical components – MT-X A 100P 385
TABLE OF CONTENTS
647793EN-USM2(A-03/2021) 9
80 4 CONTROL AND ADJUSTMENT 403
80 4 1 Checking aggravating hydraulic movement cut-off 403
80 4 2 Adjust the longitudinal stability limiter and warning device 403
80 4 3 Adjust the boom angular sensor 404
80 5 REMOVAL 404
80 5 1 Remove cab fuse and relay access panel 404
80 5 2 Remove engine fuse and relay access cover 405
80 5 3 Removing the cab ECU 405
80 5 4 Removing the instrument panel 406
80 5 5 Removing the strain gage 406
80 5 6 Removing the BMEP JSM 406
80 6 REFIT 406
80 6 1 Refitting the strain gage 406
80 6 2 Refit the JSM on BMEP 409
80 7 TROUBLESHOOTING 410
80 7 1 DTC Main ECU (SPU 40-26) 410
80 7 2 DTC auxiliary ECU (SPU 25-15-STD2) or (SPU 40-26 PWM) 419
80 7 3 DTC Perkins engine ECU (SPU 25-15) 425
80 7 4 Automatic air conditioning error codes 426
80 8 SPECIFIC TOOLING 426
80 8 1 Electrovalve adapter 426
80 8 2 Breakout boxes 427
85 OPERATOR STATION 428
85 1 CHARACTERISTICS AND SPECIFICATIONS 428
85 1 1 Description of air conditioning operation 428
85 1 2 Safety measures for handling R134a 428
85 2 DIAGRAMS AND SCHEMATICS 429
85 2 1 Schematic diagrams 429
85 3 LOCATION 431
85 3 1 HVAC components 431
85 3 2 Automatic air conditioning location 433
85 3 3 Condenser component 434
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85 4 CONTROL AND ADJUSTMENT 434
85 4 1 General checkpoints 434
85 4 2 Air conditioning assembly instructions 435
85 4 3 Safety measures for handling R134a 435
85 4 4 Check the evaporator temperature sensor 435
85 4 5 Cab air conditioning tightening torques 438
85 4 6 Cab suspension silent block tightening torques 439
85 5 REMOVAL 439
85 5 1 Removing the lower dashboard trim panel 439
85 5 2 Removing the front cab casing 440
85 5 3 Removing the rear cab casing 440
85 5 4 Removing the air conditioning heating unit 440
85 5 5 Removing the cab 441
85 5 6 Removing the condenser 447
85 5 7 Removing the motor and electric window 447
85 6 REFIT 449
85 6 1 Refitting the motor and electric window 449
85 7 TROUBLESHOOTING 450
85 7 1 Automatic air conditioning error codes 450
85 7 2 Temperature fault 450
85 7 3 Unusual noise 451
85 7 4 Unpleasant smell 451
90 CHASSIS 452
90 1 CONTROL AND ADJUSTMENT 452
90 1 1 Counterweight tightening torque 452
90 2 REMOVAL 452
90 2 1 Remove the engine hood 452
TABLE OF CONTENTS
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110 ADDITIONAL EQUIPMENT 454
120 DIAGNOSTIC TOOLS AND SOFTWARE 455
120 1 DIAGNOSTICS CASE KIT 455
120 2 USB LINK 2 BOX 456
120 3 COMPONENT DIAGNOSTICS BOX 457
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VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V