Manitou Forklift MT 1440 E3 MT 1440 A E3 MT 1840 E3 MT 1840 A E3 MT-X 1440 MT-X 1440 A MT-X 1840 MT-X 1840 A Repair Manual – PDF DOWNLOAD

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Manitou Forklift MT 1440 E3 MT 1440 A E3 MT 1840 E3 MT 1840 A E3 MT-X 1440 MT-X 1440 A MT-X 1840 MT-X 1840 A Repair Manual – PDF DOWNLOAD

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Manitou Forklift MT 1440 E3 MT 1440 A E3 MT 1840 E3 MT 1840 A E3 MT-X 1440 MT-X 1440 A MT-X 1840 MT-X 1840 A Repair Manual – PDF DOWNLOAD

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Manitou Forklift MT 1440 E3 MT 1440 A E3 MT 1840 E3 MT 1840 A E3 MT-X 1440 MT-X 1440 A MT-X 1840 MT-X 1840 A Repair Manual – 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 e cient, dependable and pro table combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.

TABLE OF CONTENTS:

Manitou Forklift MT 1440 E3 MT 1440 A E3 MT 1840 E3 MT 1840 A E3 MT-X 1440 MT-X 1440 A MT-X 1840 MT-X 1840 A Repair Manual – PDF DOWNLOAD

Page de garde / Front page………………………………………………………… 1
HOW TO USE THIS REPAIR MANUAL?…………………………………………………….. 3
Table of content ………………………………………………………………… 5
GR00 – GENERAL, CHARACTERISTICS AND SAFETY…………………………………………. 7
GENERAL INSTRUCTIONS AND SAFETY NOTICE………………………………………….. 9
GENERAL CHARACTERISTICS AND SPECIFICATIONS………………………………………. 15
CHARACTERISTICS…………………………………………………………… 16
MT 1440 / MT-X 1440 / MT 1440 A / MT-X 1440 A…………………………….. 17
MT 1840 / MT-X 1840 / MT 1840 A / MT-X 1840 A…………………………….. 18
DIMENSIONS……………………………………………………………….. 17
GENERAL LOCATION……………………………………………………………… 19
LOCATION…………………………………………………………………. 21
GENERAL CONTROL AND ADJUSTMENT…………………………………………………. 23
STANDARD TIGHTENING TORQUES………………………………………………… 24
GR10 – ENGINE…………………………………………………………………… 25
ENGINE COMPONENTS LOCATION…………………………………………………….. 27
ENGINE…………………………………………………………………… 28
COOLING SYSTEM……………………………………………………………. 29
ENGINE CONTROL AND ADJUSTMENT………………………………………………….. 31
ACCELERATOR PEDAL AND POSITION SENSOR ADJUSTMENT……………………………… 32
ACCELERATOR SOLENOID ADJUSTMENT…………………………………………….. 34
ENGINE SUSPENSION TIGHTENING TORQUES………………………………………… 35
ENGINE/GEARBOX TIGHTENING TORQUES…………………………………………… 36
GR20 – TRANSMISSION……………………………………………………………… 37
TRANSMISSION SCHEMATIC DIAGRAMS………………………………………………… 39
NEUTRAL (STANDARD) SCHEMATIC DIAGRAM………………………………………… 40
FORWARD GEAR (STANDARD) SCHEMATIC LAYOUT…………………………………….. 41
REVERSE GEAR (STANDARD) SCHEMATIC LAYOUT…………………………………….. 42
NEUTRAL GEAR (INCHING) SCHEMATIC LAYOUT……………………………………… 43
FORWARD GEAR (INCHING) SCHEMATIC DIAGRAM…………………………………….. 44
REVERSE GEAR (INCHING) SCHEMATIC DIAGRAM…………………………………….. 45
TRANSMISSION COMPONENTS LOCATION……………………………………………….. 47
TRANSMISSION SYSTEM……………………………………………………….. 48
COOLING SYSTEM……………………………………………………………. 49
TRANSMISSION CONTROL AND ADJUSTMENT…………………………………………….. 51
LOCATION: PRESSURE TEST PORTS………………………………………………. 52
PRESSURE TEST PORT VALUES………………………………………………….. 53
BLOCKING 4TH GEAR…………………………………………………………. 54
TRANSMISSION ASSEMBLY TIGHTENING TORQUES…………………………………….. 55
SPECIFIC TRANSMISSION TOOLING………………………………………………….. 57
BASIC MANOMETER BOX……………………………………………………….. 58
DIGITAL MANOMETER BOX……………………………………………………… 59
50 MM MACHINED SOCKET……………………………………………………… 60
GR30 – AXLE…………………………………………………………………….. 61
GR40 – BRAKE……………………………………………………………………. 63
BRAKE CHARACTERISTICS AND SPECIFICATIONS………………………………………… 65
SERVICE BRAKE…………………………………………………………….. 66
PARKING BRAKE…………………………………………………………….. 67
BRAKE CONTROL AND ADJUSTMENT…………………………………………………… 69
SERVICE BRAKE…………………………………………………………….. 70
PEDAL SYSTEM STOP ADJUSTMENT……………………………………………. 70
PRESSURE CONNECTOR…………………………………………………….. 71
BLEEDING PROCEDURE…………………………………………………….. 72
PARKING BRAKE…………………………………………………………….. 74
SETTINGS……………………………………………………………… 74
PRESSURE CONNECTOR…………………………………………………….. 75
BLEEDING PROCEDURE…………………………………………………….. 76
FREEWHEEL AND TOWING…………………………………………………… 77
BRAKE REMOVAL………………………………………………………………… 79
PARKING BRAKE…………………………………………………………….. 80
BRAKE PADS……………………………………………………………. 81
NEGATIVE BRAKE BLOCK…………………………………………………… 82
SPECIFIC BRAKE TOOLING………………………………………………………… 83
HYDRAULIC BRAKE BLEED VALVE………………………………………………… 84
PARKING BRAKE BLEEDER HARNESS………………………………………………. 84
GR50 – BOOM…………………………………………………………………….. 85
BOOM CHARACTERISTICS AND SPECIFICATIONS…………………………………………. 87
TRIPLEX (MT 14 METERS)…………………………………………………….. 88
QUADRUPLEX (MT 18 METERS)………………………………………………….. 89
BOOM SCHEMATIC DIAGRAMS……………………………………………………….. 91
CHAIN BOOM OPERATING MECHANISM……………………………………………… 93
BOOM COMPONENTS LOCATION………………………………………………………. 95
INDEX OF COMPONENT CODES…………………………………………………… 96
TX BOOM MAIN COMPONENT LOCATION (3 ELEMENTS)…………………………………. 97
QX BOOM MAIN COMPONENT LOCATION (4 ELEMENTS)…………………………………. 98
BOOM CONTROL AND ADJUSTMENT……………………………………………………. 99
PREPARATION AND SAFETY INSTRUCTIONS………………………………………….100
IMPORTANT INFORMATION………………………………………………………101
CHECKING BOOM CHAIN WEAR……………………………………………………102
OUTER CHAINS…………………………………………………………..102
INNER CHAINS…………………………………………………………..104
DISMANTLING CHAIN BOOM COMPONENTS……………………………………………106
GENERAL INFORMATION…………………………………………………….106
STAGES INVOLVED FOR CHANGING CHAINS………………………………………107
“HYDRAULIC KIT” REMOVAL…………………………………………………108
“TELESCOPE T2 + T3 ASSEMBLY” REMOVAL……………………………………..114
“TELESCOPE T3” REMOVAL………………………………………………….120
REASSEMBLING CHAIN BOOM COMPONENTS…………………………………………..123
GENERAL INFORMATION…………………………………………………….123
“TELESCOPE T3” REFIT……………………………………………………124
“TELESCOPE T2 + T3 ASSEMBLY” REFIT……………………………………….127
CHAIN TENSION PRESETS DURING REASSEMBLY…………………………………..134
CHECKING AND SETTING CHAIN TENSIONS………………………………………136
“HYDRAULIC KIT” REFIT…………………………………………………..139
SPECIFIC BOOM TOOLING………………………………………………………….143
CHANNEL LEVER……………………………………………………………..144
HOSE ROUTING SUPPORT TOOL…………………………………………………..145
HOSE TENSION ADJUSTMENT GAUGE……………………………………………….146
CHAIN CHECKING GAUGE……………………………………………………….146
GR70 – HYDRAULICS………………………………………………………………..147
HYDRAULIC CHARACTERISTICSAND SPECIFICATIONS (HYDRAULIC COMPONENT SHEETS) ……………149
PRIORITY FLOW DIVIDER (DPP)…………………………………………………150
POWER ASSISTED BRAKE MASTER CYLINDER…………………………………………152
STEERING UNIT OSPC 200 LS…………………………………………………..154
PVG 100 VALVE BANK (INLET ELEMENT)…………………………………………..156
PVG 100 VALVE BANK (TELESCOPING ELEMENT)……………………………………..158
PVG 100 VALVE BANK (OUTLET ELEMENT)………………………………………….160
PVG 32 VALVE BANK (ATTACHMENT ELEMENT)……………………………………….161
PILOT SAFETY VALVE…………………………………………………………163
DUMP CORRECTION VALVE………………………………………………………165
HYDRAULIC DISTRIBUTOR………………………………………………………166
STABILISER COUNTERBALANCE VALVE……………………………………………..167
DOUBLE TELESCOPE COUNTERBALANCE VALVE………………………………………..168
“ACCESS” DISCHARGE VALVE……………………………………………………169
COMPLETE ELECTROVALVE (OPTION)………………………………………………171
COMPENSATING ISOLATION VALVE………………………………………………..172
CONTROL HEAD………………………………………………………………173
CONTROL HEAD………………………………………………………………175
TX TELESCOPE DOUBLE COUNTERBALANCE VALVE……………………………………..177
FLOW DISTRIBUTOR…………………………………………………………..178
SD 8/8 DISTRIBUTOR…………………………………………………………180
HYDRAULIC SCHEMATIC DIAGRAMS……………………………………………………189
MT 1440…………………………………………………………………..191
KEY…………………………………………………………………..193
HYDRAULIC DIAGRAM (MT 1440 _ MT-X 1440)…………………………………..195
MT 1840 _ MT-X 1840………………………………………………………..197
KEY…………………………………………………………………..199
HYDRAULIC DIAGRAM (MT 1840 _ MT-X 1840)…………………………………..201
MT 1440 A _ MT-X 1440 A…………………………………………………….203
KEY…………………………………………………………………..205
HYDRAULIC DIAGRAM (MT 1440 A _ MT-X 1440 A)……………………………….207
MT 1840 A _ MT-X 1840 A…………………………………………………….209
KEY…………………………………………………………………..211
HYDRAULIC DIAGRAM (MT 1840 A _ MT-X 1840 A)……………………………….213
HYDRAULIC COMPONENTS LOCATION…………………………………………………..215
MT 1440 / MT-X 1440………………………………………………………..217
KEY…………………………………………………………………..218
LOCATION (MT 1440 / MT-X 1440)…………………………………………..219
MT 1840 / MT-X 1840………………………………………………………..221
KEY…………………………………………………………………..222
LOCATION (MT 1840 / MT-X 1840)…………………………………………..223
MT 1440 A / MT-X 1440 A…………………………………………………….225
KEY…………………………………………………………………..226
LOCATION (MT 1440 A / MT-X 1440 A)……………………………………….227
MT 1840 A / MT-X 1840 A…………………………………………………….229
KEY…………………………………………………………………..230
LOCATION (MT 1840 A / MT-X 1840 A)……………………………………….231
HYDRAULIC CONTROL AND ADJUSTMENT………………………………………………..233
PRESSURE TEST PORTS………………………………………………………..234
VALUES………………………………………………………………..234
PRESSURE TEST PORT LOCATION……………………………………………..235
BLEEDING PROCEDURES………………………………………………………..237
REAR AXLE LOCKING CYLINDERS……………………………………………..237
COMPENSATING, TILTING CIRCUIT……………………………………………238
COMPENSATING ISOLATION VALVE (VIC)…………………………………………..239
HYDRAULIC DIAGRAM:……………………………………………………..239
COMPENSATING ISOLATION VALVE (VIC) OPERATION………………………………240
TIGHTENING TORQUES…………………………………………………………241
MAIN DISTRIBUTOR (MT 1440 – MT-X 1440)……………………………………241
MAIN DISTRIBUTOR (MT 1840 – MT-X 1840)……………………………………241
MAIN DISTRIBUTOR (MT 1440 A / MT-X 1440 A / MT 1840 A / MT-X 1840 A)…………242
LEVELLING / STABILISER DISTRIBUTOR……………………………………….242
COUNTERBALANCE VALVE TEST PROCEDURE………………………………………….243
PREPARATION……………………………………………………………243
TESTING THE LIFTING AND TILTING CYLINDER VALVES……………………………244
TESTING THE TELESCOPE CYLINDER VALVES…………………………………….245
TESTING THE STABILISER CYLINDER VALVES……………………………………247
TESTING THE LEVELLING CYLINDER VALVE……………………………………..248
HYDRAULIC COMPONENT REMOVAL…………………………………………………….249
OIL TANK………………………………………………………………….250
MECHANICALLY CONTROLLED DISTRIBUTOR………………………………………….254
HYDRAULIC COMPONENTS REFIT……………………………………………………..257
OIL TANK………………………………………………………………….258
MECHANICALLY CONTROLLED DISTRIBUTOR………………………………………….262
SPECIFIC HYDRAULIC TOOLING……………………………………………………..265
BASIC MANOMETER BOX………………………………………………………..266
DIGITAL MANOMETER BOX………………………………………………………267
GR80 – ELECTRICITY……………………………………………………………….269
ELECTRICAL CHARACTERISTICS ANDSPECIFICATIONS……………………………………..271
FUSES AND RELAYS (ENGINE HOOD)………………………………………………273
FUSES AND RELAYS (CAB)……………………………………………………..274
ELECTRICAL CONNECTORS………………………………………………………275
COMPUTER/TRUCK ALLOCATION…………………………………………………..280
MANIMUX CLUSTER MC ECU……………………………………………………..281
MANIMUX POWER MP1 ECU………………………………………………………282
MANIMUX POWER MP2 ECU………………………………………………………284
TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS……………………………………286
– Anti-theft output……………………………………………………286
A11 – BMEP Joystick…………………………………………………….286
A12 – Joystick JSM…………………………………………………….287
B1 – Reversing buzzer…………………………………………………..287
B2 – Horn……………………………………………………………..288
B3 – Engine oil pressure switch………………………………………….288
B5 – Engine water temperature sensor……………………………………..289
B6 – Air filter switch………………………………………………….290
B7 – Hydraulic filter switch…………………………………………….290
B8 – Master cylinder pressure switch……………………………………..291
B9 + B10 – Wheel alignment sensor………………………………………..291
B11 + B12 – Valve position sensor (BV pressure)……………………………292
B13 – Transmission oil pressure switch (mechanical version)…………………292
B13 – Transmission oil pressure switch (inching version)……………………293
B14 – Transmission speed sensor………………………………………….293
B22 – Mechanical distributor pressure switch contact……………………….294
B23 – Telescope Angle Potentiometer………………………………………295
B24 – Transmission oil thermoswitch………………………………………296
B34 – Water in fuel filter sensor………………………………………..296
B35 to B44 – Walvoil slide position………………………………………297
B47 + B48 – Angular sensor………………………………………………297
B74 – Radiator minimum water level sensor…………………………………298
D+ – Alternator input…………………………………………………..298
W – Alternator rotation sensor…………………………………………..299
E15 – Rotating beacon light……………………………………………..299
R2 – Fuel level gauge…………………………………………………..300
S2 – Ignition key switch………………………………………………..300
S9 – NC door opening switch……………………………………………..301
S10 – NO door opening switch…………………………………………….301
S11 – Brake fluid switch………………………………………………..302
S14 – DECLUTCH push button………………………………………………302
S34 – Boom retracted switch……………………………………………..303
S46 – Accelerator switch………………………………………………..303
Y3+Y4 – Forward and reverse electrovalve………………………………….304
Y9+Y16 – VS electrovalve (Mechanical version)……………………………..304
Y40+Y41 – Stabiliser deflector electrovalve……………………………….305
Y42 – Levelling deflector electrovalve……………………………………305
Y47 – PVEA electrovalve…………………………………………………306
Y44+Y45+Y46 – PVEH electrovalve………………………………………….306
Y50 – VRD electrovalve (Mechanical version)……………………………….307
– Inductive sensor…………………………………………………….307
ELECTRICAL SCHEMATIC DIAGRAMS…………………………………………………..309
Up to machine –>| no. 971080……………………………………………….313
MT 1440 A / MT-X 1440 A / MT 1840 A / MT-X 1840 A………………………….337
POSITION OF CONNECTORS BY DIAGRAM…………………………………….339
ELECTRICAL DIAGRAMS BY FUNCTION………………………………………342
1 – START-UP / CUSTOMER DIGICODE………………………………….342
2 – CAN H-L / OBD PLUG (DIAGNOSTIC)……………………………….344
3 – TRANSMISSION………………………………………………..346
4 – HYDRAULIC MOVEMENT…………………………………………..348
5 – RC (RADIO CONTROL) ORH……………………………………….350
6 – CAB SENSORS / EMERGENCY STOP………………………………….353
7 – LIGHTING AND SIGNALLING………………………………………356
8 – LIGHTING AND SIGNALING / CAR RADIO OPTIONS……………………..358
9 – AIR CONDITIONING + HEATING OPTIONS…………………………….360
10 – CRC / BOOM HEAD EV / PNEUMATIC SEAT OPTION…………………….364
11 – REAR HYDRAULIC TWO WAY EV / BOOM HEAD ELECTRICAL CONNECTOR………366
MT 1440 / MT-X 1440 / MT 1840 / MT-X 1840…………………………………313
POSITION OF CONNECTORS BY DIAGRAM…………………………………….314
ELECTRICAL DIAGRAMS BY FUNCTION………………………………………316
1 – START-UP / CUSTOMER DIGICODE………………………………….316
2 – CAN H-L / OBD PLUG (DIAGNOSTIC)……………………………….318
3 – TRANSMISSION………………………………………………..320
4 – HYDRAULIC MOVEMENT…………………………………………..321
5 – CAB SENSORS / EMERGENCY STOP………………………………….323
6 – LIGHTING AND SIGNALING……………………………………….326
7 – LIGHTING AND SIGNALING / CAR RADIO OPTIONS……………………..328
8 – AIR CONDITIONING + HEATING OPTIONS…………………………….330
9 – CRC / BOOM HEAD EV / PNEUMATIC SEAT OPTION……………………..333
10 – REAR HYDRAULIC TWO WAY EV / BOOM HEAD ELECTRICAL CONNECTOR………334
From machineNo.: 971081…………………………………………………….369
MT 1440 / MT-X 1440 / MT 1840 / MT-X 1840…………………………………369
POSITION OF CONNECTORS BY DIAGRAM…………………………………….370
ELECTRICAL DIAGRAMS BY FUNCTION………………………………………372
1 – START-UP / CUSTOMER DIGICODE………………………………….372
2 – CAN H-L / OBD PLUG (DIAGNOSTIC)……………………………….374
3 – HYDRAULIC MOVEMENT AND TRANSMISSION……………………………376
4 – CAB SENSORS / EMERGENCY STOP………………………………….378
5 – LIGHTING AND SIGNALLING………………………………………380
6 – LIGHTING AND SIGNALING / CAR RADIO OPTIONS……………………..382
7 – AIR CONDITIONING + HEATING OPTIONS…………………………….384
8 – REAR HYDRAULIC TWO WAY EV / BOOM HEAD ELECTRICAL CONNECTOR……….386
MT 1440 A / MT-X 1440 A / MT 1840 A / MT-X 1840 A………………………….389
POSITION OF CONNECTORS BY DIAGRAM…………………………………….391
ELECTRICAL DIAGRAMS BY FUNCTION………………………………………394
1 – START-UP / CUSTOMER DIGICODE………………………………….394
2 – CAN H-L / OBD PLUG (DIAGNOSTIC)……………………………….396
3 – TRANSMISSION………………………………………………..398
4 – HYDRAULIC MOVEMENT…………………………………………..400
5 – RC (RADIO CONTROL) ORH……………………………………….402
6 – CAB SENSORS / EMERGENCY STOP………………………………….404
7 – LIGHTING AND SIGNALING……………………………………….406
8 – LIGHTING AND SIGNALING / CAR RADIO OPTIONS……………………..408
9 – AIR CONDITIONING + HEATING OPTIONS…………………………….410
10 – CRC / BOOM HEAD EV / PNEUMATIC SEAT OPTION…………………….412
11 – REAR HYDRAULIC TWO WAY EV / BOOM HEAD ELECTRICAL CONNECTOR………414
ELECTRICAL COMPONENTS LOCATION………………………………………………….417
MT 1440 /MT-X 1440 / MT 1840 / MT-X 1840……………………………………..419
MT 1440 A /MT-X 1440 A / MT 1840 A / MT-X 1840 A………………………………433
ELECTRICAL CONTROL AND ADJUSTMENT……………………………………………….449
CLUSTER MENU ARCHITECTURE…………………………………………………..451
CALIBRATION MENU…………………………………………………………..452
STEP 1………………………………………………………………..452
STEP 2………………………………………………………………..452
STEP 3………………………………………………………………..452
STEP 4………………………………………………………………..452
STEP 5………………………………………………………………..453
STEP 6………………………………………………………………..453
CHANGING THE MACHINE (MANIMUX POWER) ECU……………………………………..453
“BOOM ANGLE” ANGULAR SENSOR ADJUSTMENT……………………………………….454
OPERATION……………………………………………………………..454
ON-TRUCK ADJUSTMENT PROCEDURE……………………………………………454
ELECTRICAL COMPONENTS REFIT…………………………………………………….457
STRAIN GAUGE………………………………………………………………458
ELECTRICAL TROUBLESHOOTING……………………………………………………..463
INPUT/OUTPUT STATES………………………………………………………..464
CODE READING PRINCIPLE (Example for OUTOR and INTOR)……………………….464
CODE READING PRINCIPLE (Example for OUTANA and INANA)………………………464
“OUTOR” CODE DESCRIPTION………………………………………………..465
“INTOR” CODES DESCRIPTION……………………………………………….468
“OUTANA” CODES DESCRIPTION………………………………………………472
“INANA” CODES DESCRIPTION……………………………………………….475
ERROR CODES (DTC)………………………………………………………….477
ELECTRICAL SPECIFIC TOOLING…………………………………………………….485
DIAGNOSTIC TOOLS…………………………………………………………..486
BREAKOUT BOXES…………………………………………………………….488
ELECTROVALVE ADAPTER……………………………………………………….488
GR85 – DRIVER’S CAB………………………………………………………………489
DRIVER’S CAB REFIT…………………………………………………………….491
CAB………………………………………………………………………492
LOCATION OF COMPONENTS………………………………………………….492
MOUNTING THE CAB ON SILENT BLOCKS………………………………………..493
ELECTRICAL CONNECTION…………………………………………………..495
HYDRAULIC CONNECTION……………………………………………………496
GR110 – OPTIONS – ATTACHMENTS……………………………………………………..499
A – INCHING OPTION ……………………………………………………………….501
CHARACTERISTICS AND SPECIFICATIONS………………………………………………502
DIAGRAM………………………………………………………………………505
MT 1440 INCHING / MT-X 1440 INCHING / MT 1840 INCHING / MT-X 1840INCHING…………505
POSITION OF CONNECTORS BY DIAGRAM………………………………………..506
ELECTRICAL DIAGRAMS BY FUNCTION………………………………………….508
1 – START-UP / CUSTOMER DIGICODE……………………………………..508
2 – CAN H-L / OBD PLUG (DIAGNOSTIC)…………………………………..510
3 – TRANSMISSION……………………………………………………512
4 – HYDRAULIC MOVEMENT………………………………………………513
5 – CAB SENSORS / EMERGENCY STOP……………………………………..515
6 – LIGHTING AND SIGNALING…………………………………………..518
7 – LIGHTING AND SIGNALING / CAR RADIO OPTIONS…………………………520
8 – AIR CONDITIONING + HEATING OPTIONS………………………………..522
9 – CRC / BOOM HEAD EV / PNEUMATIC SEAT OPTION…………………………525
10 – REAR HYDRAULIC TWO WAY EV / BOOM HEAD ELECTRICAL CONNECTOR………….526
MT 1440 A INCHING / MT-X 1440 A INCHING / MT 1840 A INCHING / MT-X1840 A INCHING….529
POSITION OF CONNECTORS BY DIAGRAM………………………………………..531
ELECTRICAL DIAGRAMS BY FUNCTION………………………………………….534
1 – START-UP / CUSTOMER DIGICODE……………………………………..534
2 – CAN H-L / OBD PLUG (DIAGNOSTIC)…………………………………..536
3 – TRANSMISSION……………………………………………………538
4 – HYDRAULIC MOVEMENT………………………………………………540
5 – RC (RADIO CONTROL) ORH…………………………………………..542
6 – CAB SENSORS / EMERGENCY STOP……………………………………..545
7 – LIGHTING AND SIGNALING…………………………………………..548
8 – LIGHTING AND SIGNALING / CAR RADIO OPTIONS…………………………550
9 – AIR CONDITIONING + HEATING OPTIONS………………………………..552
10 – CRC / BOOM HEAD EV / PNEUMATIC SEAT OPTION………………………..555
11 – REAR HYDRAULIC TWO WAY EV / BOOM HEAD ELECTRICAL CONNECTOR………….556
LOCATION……………………………………………………………………..559
MT 1440 INCHING / MT-X 1440 INCHING / MT 1840 INCHING / MT-X 1840INCHING…………559
CONNECTOR KEY………………………………………………………….560
GROUND CONNECTIONS KEY………………………………………………….562
SPLICES KEY……………………………………………………………562
FRAME 2D HARNESS……………………………………………………….563
FRAME 3D HARNESS……………………………………………………….564
CAB HARNESS ASSEMBLY……………………………………………………565
MT 1440 A INCHING / MT-X 1440 A INCHING / MT 1840 A INCHING / MT-X1840 A INCHING….567
CONNECTOR KEY………………………………………………………….568
GROUND CONNECTIONS KEY………………………………………………….570
SPLICES KEY……………………………………………………………570
FRAME 2D HARNESS……………………………………………………….571
FRAME 3D HARNESS……………………………………………………….572
CAB HARNESS ASSEMBLY……………………………………………………573
RC + A ASSEMBLY………………………………………………………..574
B – AIR CONDITIONING OPTION UP TO MACHINE NO. 971080………………………………….577
LOCATION……………………………………………………………………..578
KEY………………………………………………………………………578
AIR-CONDITIONING ASSEMBLY…………………………………………………..579
COMPONENT DATA SHEETS………………………………………………………….580
THE COMPRESSOR…………………………………………………………….580
THE CONDENSER……………………………………………………………..581
THE DRIER FILTER…………………………………………………………..582
THE REDUCING VALVE…………………………………………………………583
THE EVAPORATOR…………………………………………………………….584
PRESSURE SWITCH SAFETY……………………………………………………..585
THE THERMOSTAT…………………………………………………………….586
THE FLEXIBLE LINES…………………………………………………………587
TEST BEFORE CHARGING……………………………………………………….587
R134A COOLANT CHARACTERISTICS……………………………………………….588
SAFETY MEASURES FOR HANDLING R134A…………………………………………..588
REFRIGERANT LOAD…………………………………………………………..588
REGULATION CONTROL…………………………………………………………589
AFTER SALES SERVICE PRODUCTS SHEET………………………………………………591
THE COMPRESSOR…………………………………………………………….591
THE CONDENSER……………………………………………………………..593
THE DRIER FILTER…………………………………………………………..594
REDUCING VALVE…………………………………………………………….595
THE EVAPORATOR…………………………………………………………….596
PRESSURE SWITCH SAFETY……………………………………………………..597
THE THERMOSTAT…………………………………………………………….598
THE FLEXIBLE LINES…………………………………………………………598
C – AIR-CONDITIONING OPTION FROM MACHINE NO. 971081…………………………………..599
110.1 Air conditioning characteristics and specifications………………………….600
110.1.1 Description of operation…………………………………………….600
110.1.2 Operating principle…………………………………………………601
110.1.3 Evaporator temperature sensor specifications…………………………..603
110.2 Air conditioning location…………………………………………………604
110.2.1 Location and tightening torques………………………………………604
110.2.2 HVAC interior components…………………………………………….605
110.2.3 HVAC exterior components…………………………………………….605
110.2.4 Condenser components………………………………………………..606
110.3 Air conditioning controls and adjustments…………………………………..607
110.3.1 General check points………………………………………………..607
110.3.2 ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT……………………..607
110.3.3 Safety measures for handling r134a……………………………………608
110.3.4 Refrigerant fluid load for the air conditioning circuit…………………608
110.3.5 Check the evaporator temperature sensor……………………………….609
110.4 Air conditioning removal – refit…………………………………………..611
110.4.1 Air conditioning belt removal………………………………………..611
110.4.2 AIR-CONDITIONING BELT REFIT………………………………………….611
110.5 Air conditioning troubleshooting…………………………………………..612
110.5.1 Pressure troubleshooting…………………………………………….612
110.5.2 ABNORMAL NOISE ON A/C SYSTEM…………………………………………612
110.5.3 UNPLEASANT SMELL……………………………………………………612

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V