Description
Manitou MLT & MLT-X Telehandlers Service Manual — 647681EN, 2022 Edition
This is the complete Manitou service manual for the MLT and MLT-X range of telehandlers, published under document number 647681EN and last updated on 04/03/2022. It covers nine machine variants across the MLT 635, 733, 737, 741 and 940 families, plus the MLT-X 737 and 741 models. The manual is structured as an interactive repair manual, providing the full range of service, repair and diagnostic procedures needed to keep these machines working correctly — from engine and transmission overhauls down to brake bleeding, boom pad adjustment and electrical fault code lookup.
File Details
- Manual type: Service Manual (Interactive Repair Manual)
- Brand: Manitou
- Document number: 647681EN
- Publication date: 04/03/2022
- First edition: 09/01/2018
- Language: English
- Page count: 512
- File format: PDF
Models Covered
- MLT 635 130 PS D ST4 S2
- MLT 635 140 V PLUS D ST4 S2
- MLT 733 105 D ST4 S2 + TRACT + LSU
- MLT 733 115 D ST4 S3 + TRACT + LSU
- MLT 737 130 PS 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
Chapters Covered
The manual is organised into numbered groups, each with its own table of contents and cross-referenced procedures:
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Manitou MLT & MLT-X Telehandlers Service Manual 647681EN 2022 – PDF Download” are as follows:
Page de garde / Front pagep. 1
Sommaire général – General table of contentp. 3
00p. 9
+GENERAL, CHARACTERISTICS AND SAFETYp. 10
+00.1 GENERAL INSTRUCTIONS AND SAFETY NOTICEp. 10
00.1.1 FOREWORDp. 10
00.1.2 SERVICING POSITIONp. 10
00.1.3 EXPLANATION OF SYMBOLSp. 11
00.1.4 SERVICING RULESp. 12
+00.2 GENERAL CHARACTERISTICS AND SPECIFICATIONSp. 15
00.2.1 SPECIFICATIONSp. 15
00.2.2 LUBRICANTS AND FUELp. 15
+00.2.3 DIMENSIONSp. 16
MLT 635 / MLT+X 737p. 16
MLT 733 / MLT 733 TRACT / MLT 733 TRACT LSUp. 17
MLT+X 741 – 140 V PLUSp. 18
MLT 940 – 140 V PLUSp. 19
+00.3 GENERAL LOCATIONp. 20
00.3.1 NAME AND IDENTIFICATION PLATEp. 20
+00.4 GENERAL CONTROL AND ADJUSTMENTp. 21
00.4.1 STANDARD TIGHTENING TORQUESp. 21
00.4.2 METRIC – IMPERIAL UNIT CONVERSIONp. 22
10p. 23
+ENGINEp. 25
+10.1 Engine characteristics and specificationsp. 25
10.1.1 Featuresp. 25
10.1.2 Diesel exhaust fluid (DEF).p. 25
10.1.3 Injection cyclep. 26
10.1.4 Bosch CP4.1 high pressure pumpp. 27
+10.2 Engine Schematic Diagramsp. 28
10.2.1 Air intake circuit and EGR (Exhaust Gas Recirculation)p. 28
10.2.2 Lubrication systemp. 29
10.2.3 Cooling circuitp. 30
10.2.4 Fuel systemp. 31
10.2.5 DEF (Diesel Exhaust Fluid) circuitp. 32
+10.3 Engine components locationp. 33
10.3.1 Engine componentsp. 33
10.3.2 Water and air cooling circuitp. 35
10.3.3 Ventilation hydraulic circuitp. 36
10.3.4 Diesel circuitp. 37
10.3.5 Fuel injection circuitp. 38
10.3.6 EGR (Exhaust Gas Recirculation) circuitp. 39
10.3.7 DEF (Diesel Exhaust Fluid) circuitp. 40
+10.4 Engine controls and adjustmentsp. 41
10.4.1 Engine start-up authorization conditionsp. 41
10.4.2 Engine load levelp. 41
10.4.3 DEF regenerationp. 41
10.4.4 DEF pumpp. 41
10.4.5 DEF pump cleaning procedurep. 42
+10.4.6 Ventilation regulation (MLT 733 as option)p. 46
A – functionp. 46
B – principle of operationp. 46
C – schematic diagramp. 47
D – description of hydraulic engine with controlp. 47
E – conditions of fan control-related componentsp. 48
10.4.7 MLT 733 105 D engine suspension tightening torquesp. 49
10.4.8 MLT > 105 D engine suspension tightening torquesp. 50
10.4.9 V plus coupling tightening torquesp. 51
10.4.10 Gearbox coupling tightening torquesp. 52
10.4.11 Diesel fuel circuit tightening torquesp. 53
+10.4.12 Exhaust circuit tightening torquesp. 53
Assembly on MLT-Xp. 53
Assembly on MLTp. 54
10.4.13 Cooling circuit tightening torquesp. 55
10.4.14 Heating circuit tightening torquesp. 56
+10.5 Engine removal – refittingp. 56
10.5.1 Engine ECU removal – refitp. 56
10.5.2 Air filter assembly removalp. 57
10.5.3 Starter motor removalp. 59
10.5.4 DOC exhaust pipe removalp. 61
10.5.5 Remove the “SCR” pipep. 62
10.5.6 DEF injector removalp. 63
+10.5.7 DEF tank removalp. 63
+10.5.8 Cooler removalp. 65
Removing the upper part.p. 65
Separation of cooler from engine.p. 67
Option 1: removal of pump and grill.p. 70
Option 2: removal of cooler assembly.p. 71
+10.5.9 Remove the enginep. 72
Engine hose and connector removalp. 74
Engine/Angle gear box transmission universal joint removalp. 76
10.5.10 ATTACHMENT BELT REMOVALp. 78
10.5.11 Engine refitp. 78
10.5.12 Alternator removalp. 78
10.5.13 Water pump removalp. 78
10.5.14 Turbo-compressor removal.p. 78
10.6 Engine troubleshootingp. 78
+10.7 Specific engine toolingp. 79
10.7.1 Special engine toolingp. 79
10.7.2 Electronic tension meterp. 79
10.7.3 DEF flush kitp. 79
20p. 81
+TRANSMISSIONp. 83
+20.1 Transmission characteristicsp. 83
+20.1.1 Hydrostatic gearbox (zf 2 HC 85)p. 83
Operating mode – 2 HC 85p. 84
+20.2 Transmission schematic diagramsp. 86
+20.2.1 Compact+ (C+) manual gearboxp. 86
C+ DRIVE TRAINp. 86
C+ OPERATION OVERVIEWSp. 87
Summary table of connectors concerned by functions (C+)p. 88
+20.2.2 POWERSHIFT (PS – PG 115) gearboxp. 88
PS DRIVE TRAINp. 88
PS OPERATION OVERVIEWSp. 89
Summary table of connectors concerned by functions (PS)p. 90
DRIVE TRAINp. 91
+20.2.3 Hydrostatic gearbox (zf 2 HC 85)p. 93
DRIVE TRAINp. 93
OPERATION OVERVIEWS (ZF 2 hc 85)p. 94
Key for HYDROSTATIC CIRCUITS 2 HC-85p. 95
Diagram: Neutral and pressure connectorp. 96
Diagram: drive range 1p. 97
Diagram: drive range 2p. 98
Diagram: drive range 3p. 99
+20.3 Transmission locationsp. 100
20.3.1 MECHANICAL TRANSMISSION AND GEARBOX COOLINGp. 100
+20.3.2 POWERSHIFT (PG 115) GEARBOX COMPONENTSp. 101
PRESSURE TEST PORT LOCATIONSp. 102
SHAFT AND CLUTCHp. 103
GEARINGp. 103
+20.3.3 Hydrostatic TRANSMISSION (ZF 2 HC 85)p. 104
Transmission assemblyp. 104
Hydrostatic pumpp. 105
Gearboxp. 106
+20.4 Transmission controls and adjustmentsp. 108
+20.4.1 General authorization conditions for carriage movementp. 108
Acquisition conditionsp. 108
Upkeep conditionsp. 108
Loss conditionsp. 109
20.4.2 Verification of machine configurationsp. 109
+20.4.3 Powershift – PG115 gearboxp. 109
ECU Transmission (X322)p. 109
Automatic gear change modep. 110
Table of maximum speeds per gearp. 110
TABLE OF PRESSURESp. 110
+20.4.4 Hydrostatic transmission (zf 2 HC 85)p. 110
Hydrostatic auto-calibrationp. 110
Check of hydrostatic pump with the iV diagnostic toolp. 111
Hydrostatic pump pressure connector procedurep. 112
Check of the high pressure hydrostatic circuitp. 112
Check of hydrostatic gearbox with the iV diagnostic toolp. 113
Hydrostatic gearbox pressure connector procedurep. 113
+20.4.5 TRANSMISSION TIGHTENING TORQUESp. 114
MLT 635 – 737 PSp. 114
MLT 733p. 115
MLT 635 – 741 – 940 V PLUSp. 116
Hydrostatic pump A4VG90p. 117
20.4.6 Changing to freewheel mode (Mechanical transmission)p. 118
20.4.7 Changing to freewheel mode (Hydrostatic transmission)p. 118
20.4.8 Freewheel (axle with negative brake)p. 118
+20.5 Transmission removal – refitp. 119
20.5.1 Remove the Powershift gear boxp. 119
20.5.2 Removal of the manual gearbox assembly – angle transmissionp. 122
+20.5.3 Remove the hydrostatic gearbox (zf 2 HC 85)p. 127
Pull out the valve spoolsp. 129
+20.5.4 Remove the hydrostatic pumpp. 130
Remove the hydraulic pumpp. 130
Remove the hydrostatic pumpp. 131
Refitp. 132
+20.6 Specific transmission toolingp. 133
20.6.1 BASIC MANOMETER BOXp. 133
20.6.2 DIGITAL MANOMETER BOXp. 134
20.6.3 Hydrostatic gearbox removal toolp. 135
30p. 137
+AXLEp. 138
+30.1 Axle controls and adjustmentsp. 138
30.1.1 Adjusting the axle stopsp. 138
30.1.2 Rear axle pin adjustment clearancep. 138
30.1.3 Tightening torquesp. 138
40p. 139
+BRAKEp. 141
+40.1 Brake characteristics and specificationsp. 141
+40.1.1 Service brakep. 141
Assembly with master cylinder.p. 141
Assembly with hydraulic valve.p. 142
40.1.2 Trailer brake valvep. 143
40.1.3 Accumulator load valvep. 144
40.1.4 Service brake valve 55 bp. 145
40.1.5 Automatic parking brake OPTIONp. 146
40.1.6 Pneumatic trailer braking OPTIONp. 146
+40.2 Service brake schematic diagramsp. 147
+40.2.1 Brake valve (VAFS) operating principlep. 147
Engine on, pump running, pedal at restp. 147
Engine on, pump running, pedal activatedp. 147
Engine off, pump shut down, pedal activatedp. 148
40.2.2 Automatic parking brake OPTIONp. 148
40.2.3 Pneumatic trailer braking OPTIONp. 148
+40.3 Brake locationsp. 149
+40.3.1 Brake locations – Mechanical transmissionp. 149
MLt 635/737 – MLT 733 S2/S3 Tract+LSU (Up to machine no. MAN00000K01007220)p. 149
MLt 635/737 – MLT 733 S3 Tract+LSU (from machine no. MAN00000K01007221)p. 149
Brake system location – MLT 733 S2/S3p. 150
+40.3.2 Brake locations – Hydrostatic transmissionp. 150
MLT-X 741 140 V PLUS ST3A S2p. 151
40.3.3 Automatic parking brake OPTIONp. 151
40.3.4 Pneumatic trailer braking OPTIONp. 151
+40.4 Brake controls and adjustmentp. 152
40.4.1 TRAILER BRAKE VALVE TIGHTENING TORQUEp. 152
+40.4.2 Adjustment of parking brake on gearboxp. 152
For machines before tractor standard 167-2013p. 152
+40.4.3 Adjustment of parking brake on front axlep. 155
For tractor standard 167-2013 machinesp. 155
+40.4.4 Adjusting the brake pedalp. 160
MLT 733 105 Dp. 160
MLT 635/737 130 PS – MLT 733 105 D Tract (up to machine no. MAN00000K01007220)p. 161
MLT 635/737 130 PS – MLT 733 115 D Tract (from machine no. MAN00000K01007221)p. 162
MLT 635/741/940 140 v plusp. 163
40.4.5 Calibrate the inching pedalp. 163
40.4.6 Bleed the brakesp. 164
40.4.7 Taking brake pressure on MLT 140 V PLUSp. 165
+40.4.8 Towing the lift truckp. 165
Mechanical transmissionp. 165
Hydrostatic transmissionp. 165
40.4.9 Automatic parking brake OPTIONp. 165
+40.5 Brake removal – refitp. 165
40.5.1 Brake master cylinder on mlt psp. 165
+40.6 Specific brake toolingp. 167
40.6.1 BRAKE FLUID BLEEDERp. 167
50p. 169
+BOOMp. 170
+50.1 BOOM CHARACTERISTICS AND SPECIFICATIONSp. 170
50.1.1 DUPLEX BOOMSp. 170
50.1.2 TRIPLEX BOOMSp. 170
+50.2 BOOM locationp. 171
50.2.1 DUPLEX BOOM (6 and 7 m)p. 171
50.2.2 TRIPLEX BOOM (9 m)p. 172
+50.3 BOOM CONTROL AND ADJUSTMENTp. 173
+50.3.1 TELESCOPE EXTENSION AND RETRACTION ADJUSTMENT PROCEDUREp. 173
TELESCOPE EXTENSION SPEED ADJUSTMENT (TRIPLEX BOOM).p. 173
TELESCOPE RETRACTION SPEED ADJUSTMENT (DUPLEX AND TRIPLEX BOOM).p. 173
INNER TELESCOPE RETRACTION DE-SYNCHRONISATION (TRIPLEX BOOM).p. 173
50.3.2 RECOMMENDATION FOR FITTING SHIMS AND LUBRICATIONp. 175
50.3.3 Duplex TIGHTENING TORQUE AND LUBRICATIONp. 176
50.3.4 Triplex TIGHTENING TORQUE AND LUBRICATIONp. 177
+50.4 Removal – refitp. 178
+50.4.1 duplex boomp. 178
Telescope removalp. 178
Telescope removalp. 180
Telescopic Cylinder Removalp. 181
Refit:p. 183
+50.4.2 triplex boomp. 184
PREPARATION AND SAFETY INSTRUCTIONSp. 184
Telescoping circuit removalp. 184
BOOM HEAD TELESCOPE T2 REMOVALp. 188
INTERMEDIATE TELESCOPE T1 REMOVALp. 189
+50.5 Special boom toolsp. 190
50.5.1 PIPE END PIECESp. 190
50.5.2 MAGNETIC LIFTERp. 190
70p. 191
+HYDRAULICSp. 193
+70.1 Hydraulic characteristics and specificationsp. 193
70.1.1 Dynamic steering operationp. 193
+70.1.2 Hydraulic component sheetsp. 195
Accumulator blockp. 195
OSPC 200 LS steering blockp. 197
Pilot safety valvep. 199
Pilot safety valvep. 201
Distributor RS 14p. 203
Distributor SDS 140p. 209
FAN REGULATOR MOTOR (FAN DRIVE)p. 210
Casappa MVP 60 – 63 pumpp. 214
Hydraulic pump LA10V072EK1DS/53Rp. 217
Steering selectorp. 219
Automatic steering selectorp. 220
+70.2 Hydraulic schematic diagramsp. 221
70.2.1 Key MLT-X S1 & MLT S2p. 221
70.2.2 Key MLT-X S2 & MLT S3p. 222
70.2.3 Diagram MLT 635-737 130 PS D ST4 S2 (1st fit)p. 224
70.2.4 Diagram MLT 635-737 130 PS D ST4 S2 (2nd fit) + mlt-x 737 130 ps d st3a s1p. 225
70.2.5 Diagram MLT 733 105 D ST4 S2p. 226
70.2.6 Diagram MLT 733 105 D ST4 S2 TRACTp. 227
70.2.7 Diagram MLT 733 105 D ST4 S2 TRACT LSUp. 228
70.2.8 Diagram MLT 635/741/940 140 V Plus D ST4 S2 + MLT-X 741 140 V Plus D ST3A S1p. 229
70.2.9 Diagram MLT 733 115 D ST4 S3p. 230
70.2.10 Diagram MLT 733 115 D ST4 S3 TRACTp. 231
70.2.11 Diagram MLT 733 115 D ST4 S3 TRACT LSUp. 232
+70.3 Hydraulic locationsp. 233
+70.4 Hydraulic controls and adjustmentsp. 234
70.4.1 Flush the MLT 733 distributor (initial fitting)p. 234
70.4.2 Accumulator tightening torquep. 234
70.4.3 Hydraulic pump tightening torquep. 235
+70.5 Hydraulics removal – refitp. 236
70.5.1 Removing the hydraulic pumpp. 236
70.5.2 Lifting cylinder removalp. 238
70.5.3 Remove the distributorp. 240
+70.6 Hydraulic specific toolingp. 242
70.6.1 Square bracketp. 242
70.6.2 Distributor lifting devicep. 242
70.6.3 DIGITAL MANOMETER BOXp. 243
70.6.4 BASIC MANOMETER BOXp. 244
70.6.5 INFLATION KIT BOXp. 245
80p. 247
+ELECTRICITYp. 251
+80.1 Electricity characteristics and specificationsp. 251
80.1.1 Location of relays and fusesp. 251
80.1.2 Screen menusp. 252
80.1.3 Electrical network architecturep. 255
80.1.4 Electrical network architecture detailsp. 256
+80.1.5 ECU Inputs/Outputsp. 257
X13/X25 – screen (A9)p. 257
X14 – Navigator (A4)p. 258
X39-C10 – Air-conditioning ECU (A17)p. 258
X80 – Main ECU SPU 40-26 (A2)p. 259
X81 – Main ECU SPU 40-26 (A2)p. 260
X82 – Main ECU SPU 40-26 (A2)p. 261
X274 – Engine ECU EDC17CV52 (A19)p. 262
X275 – Engine ECU EDC17CV52 (A19)p. 263
X322 – Powershift gearbox ECU PG115 (A10)p. 264
X356 – Auxiliary ECU SPU 25-15 (A3)p. 265
X357 – Auxiliary ECU SPU 25-15 (A3)p. 266
X400 – Gearbox ECU ZF – 2HC85 _ CVT Box (A10)p. 267
X401 – Gearbox ECU ZF – 2HC85 _ Box CVT (A10)p. 268
+80.1.6 Technical sheets for electrical componentsp. 269
X1/X2 – starter ignition switch (A12)p. 269
X10 – lighting commutator switch (S5)p. 269
X11 / 12 – windscreen wiper commutator switch (S4)p. 270
X34 – Outside air temperature sensorp. 270
X56 – Rotating beacon light (e15)p. 271
X72 – Brake fluid level switch (S11)p. 271
X74 – Accelerator potentiometer (B18)p. 272
X75 / X76 / X98 – JSM (A12)p. 273
X77 – BMEP (A11)p. 274
X78 – Manual acceleratorp. 275
X79 – stop pressure switch (B8)p. 275
X90 to X94 – DSB (Double Switch Board) (S61 to S76)p. 276
X121 – Brake pedal angular sensor (PS) (B47)p. 277
X225 – DEF tank gauge (B53)p. 278
X225 – DEF tank analog gauge (US) (B53)p. 279
X245 – Supercharged air cooler temperature sensorp. 280
X246 – Transmission oil cooler temperature sensorp. 280
X247 – Hydraulic fluid cooler temperature sensorp. 281
X252 – VENTILATION CONTROL ELECTROVALVEp. 281
X253 – VENTILATION inversion ELECTROVALVEp. 282
X265 – Fuel level sensor (R2)p. 282
X300 – boom angle potentiometer (B23)p. 283
X334 – telescope retracted position sensor (S34)p. 284
X382 – Brake circuit pressure switch (B30)p. 284
X453 / X454 – Hydrostatic motor speed sensor ()p. 285
X461 / X267 – Hydrostatic oil temperature sensor ()p. 285
+80.2 Wiring diagramsp. 286
80.2.1 Examples of coding on wiring diagramsp. 286
80.2.2 Cable marking on an electrical wiring harnessp. 287
+80.2.3 MLT 635/737 130 PS D ST4 S2 – MLT-X 737 130 ps d st3a s1p. 288
Positions of connectors by diagramp. 288
Diagram 1 – Startingp. 290
Diagram 2 – Networks (CAN & lin)p. 292
Diagram 3 – Transmissionp. 294
Diagram 4 – Hydraulicsp. 296
Diagram 5 – Sensorp. 298
Diagram 6 – Ventilation, wipers and air conditioningp. 300
Automatic air conditioning optionp. 300
Diagram 7 – Optionsp. 302
Diagram 8 – Lights and signalsp. 304
+80.2.4 MLT 733 105 D ST4 S2+ S3 + TRACT + LSUp. 306
Positions of connectors by diagramp. 306
Diagram 1 – Startingp. 308
Diagram 2 – Networks (CAN & lin)p. 310
Diagram 3 – Transmissionp. 312
Diagram 4 – Hydraulicsp. 314
Diagram 5 – Sensorp. 316
Diagram 6 – Ventilation, wipers and air conditioningp. 318
Automatic air conditioning optionp. 318
Diagram 7 – Optionsp. 320
Diagram 8 – Lights and signalsp. 322
+80.2.5 MLT 635/741/940 140 V plus d ST4 S2 – MLT-X 741 140 V plus d ST3a S1p. 324
Positions of connectors by diagramp. 324
Diagram 1 – Startingp. 326
Diagram 2 – CAN & lin networksp. 328
Diagram 3 – Transmissionp. 330
Diagram 4 – Hydraulicsp. 332
Diagram 5 – Sensorp. 334
Diagram 6 – Ventilation, wipers and air conditioningp. 336
Automatic air conditioning optionp. 336
Diagram 7 – Optionsp. 338
Diagram 8 – Lights and signalsp. 340
+80.3 Electricity locationsp. 342
+80.3.1 MLT mechanical transmissionp. 342
Keyp. 342
Frame 3D PS Harnessp. 345
Frame 3D Mechanical Harnessp. 346
Cab 3D mechanical & PS harnessp. 347
Engine 3D MLT mechanical & PS harnessp. 348
Deutz engine 3D harnessp. 349
Frame 2D PS Harnessp. 350
Frame 2D Mechanical Harnessp. 351
Cab 2D harnessp. 352
Engine harness 2Dp. 353
2D control valve harnessp. 354
+80.3.2 MLT V plusp. 355
Keyp. 355
Frame 3D V plus harnessp. 358
Cab 3D v plus harnessp. 359
Engine 3D MLT V plus harnessp. 360
Deutz engine 3D harnessp. 361
Frame 2D V plus harnessp. 362
Cab 2D V PLUS harnessp. 363
Engine harness 2Dp. 364
2D control valve harnessp. 365
+80.3.3 Options harnessesp. 366
3D option ECU harnessp. 366
2D option ECU harness (1/2)p. 367
2D option ECU harness(2/2)p. 368
3D semi-auto wheel alignment harnessp. 369
2D semi-auto wheel alignment harnessp. 370
+80.4 Electrical control and adjustmentp. 370
80.4.1 Resetting the codesp. 370
80.4.2 Adjusting the boom angle sensorp. 371
+80.5 Electrical removal – refitp. 372
80.5.1 Remove the battery.p. 372
+80.5.2 Removing the engine ECUp. 373
80.5.3 Remove the main ECU “SPU 40-26”p. 374
+80.5.4 Remove the transmission ECUp. 374
powershift "pg115"p. 374
Hydrostatic "ZF EC2 B"p. 374
80.5.5 Remove the auxiliary ECU “SPU 25-15”p. 374
80.5.6 Remove the dashboard screenp. 374
80.5.7 Removing – Refitting the JSM on BMEPp. 376
+80.5.8 Refitting the strain gagep. 377
Locationp. 377
Axle preparationp. 378
Characteristics of products usedp. 378
Characteristics of fastening screwsp. 379
Assembly precautions and tightening torquep. 379
+80.6 Electrical troubleshootingp. 382
+80.6.1 Error codes (DTC)p. 382
DTC ECU HARMONY screen (X13)p. 382
Air Conditioning ECU DTC (X39-C10)p. 382
Main ECU DTC SPU 40-26 (X80 – X81 – X82)p. 383
Engine ECU DTC EDC17CV52 (X274 – X275)p. 388
Transmission ECU DTC PS+ PowershifT PG115 (X322)p. 404
Auxiliary ECU DTC SPU 25-15 (X356 – X357)p. 405
Transmission ECU DTC CVT 2 HC85 (X400 – X401)p. 408
+80.7 Specific electric toolingp. 411
80.7.1 Breakout boxesp. 411
80.7.2 Electrovalve adapterp. 411
+80.7.3 Diagnostic toolsp. 412
DIAGNOSTICS CASEp. 412
CONNECTIONS TO THE LIFT TRUCKp. 413
ENGINE ADAPTATION KITp. 413
85p. 415
+DRIVER'S CABp. 416
+85.1 Driver's cab control and adjustmentp. 416
+85.1.1 Tightening torquesp. 416
Cab silent blockp. 416
Air conditionerp. 416
85.1.2 Adjusting the door opening/closing controlp. 417
+85.2 Removal – refitting driver's cabp. 420
85.2.1 Removing the cabp. 420
+85.2.2 Remove the windshieldp. 423
Procedure for opening the protective grille.p. 423
+85.2.3 Removing the door window winderp. 425
Removing the door trimp. 425
Removing the door liningp. 426
Refitp. 428
85.2.4 Remove the cab doorp. 431
85.2.5 Removing the windshield wiper motorp. 432
85.2.6 Removing the cab lower trimp. 434
85.2.7 Removing the upper dashboardp. 435
85.2.8 Removing the heating unitp. 437
85.2.9 Driver’s seat removalp. 440
85.2.10 Armrest removalp. 441
85.2.11 Dashboard switch removalp. 442
+85.3 Specific cab toolingp. 442
85.3.1 Cab grille hinge kitp. 442
90p. 443
+CHASSIS – BODYWORKp. 444
+90.1 Chassis – bodywork removal – refittingp. 444
90.1.1 Removing the engine hoodp. 444
110p. 445
OPTIONS – ATTACHMENTSp. 448
+110 Intelligent hydraulics OPTIONp. 448
110.1 Characteristics and specificationsp. 448
+110.2 Location of componentsp. 449
110.2.1 Assembly on 6 or 7 metre boomp. 449
110.2.2 Assembly on 9 metre boomp. 450
+110 Regenerative hydraulics optionp. 451
+110 Boom suspension optionp. 452
+110 Automatic parking brake OPTIONp. 453
+110.1 Characteristics and specificationsp. 453
110.1.1 Functional electrical architecturep. 453
+110.1.2 Technical sheets for electrical componentsp. 454
Y13 – Automatic parking brake electrovalvep. 454
X442 – Analogue pressure transmitter (OPTION) (B29)p. 454
+110.1.3 operating modes: 2 possibilities (manual and automatic).p. 455
Manual mode parking brake/p. 455
Automatic mode parking brakep. 455
110.2 Schematic diagramp. 456
110.3 Locationp. 457
110.4 Automatic parking brake control and adjustmentp. 457
+110 Pneumatic trailer braking OPTIONp. 458
+110.1 Characteristics and specificationsp. 458
110.1.1 Operationp. 458
+110.1.2 Component sheetsp. 459
Electrovalvep. 459
Secondary pressure relief valvep. 459
Main pressure relief valvep. 460
Circuit selectorp. 460
Unidirectional flow restrictorp. 461
Hydraulic trailer control valvep. 461
Compressorp. 462
Trailer control valvep. 462
+110.2 Schematic diagramp. 463
110.2.1 Machine offp. 463
110.2.2 Machine on and parking brake appliedp. 464
110.2.3 Machine on unbrakedp. 464
110.2.4 Machine on and brake pedal pressedp. 465
110.2.5 Machine on and parking brake testp. 465
110.3 Locationp. 466
+110 Optional automatic central greasingp. 467
+110.1 Characteristics and specificationsp. 467
110.1.1 The auto greasing systemp. 467
+110.1.2 The pumpp. 468
Composition of the TriPlus pump unitp. 469
X434 – Greasing pumpp. 470
110.1.3 The distributorsp. 471
110.1.4 Monitoring/storage of datap. 472
110.2 Distributor schematic diagramsp. 472
110.3 Locationp. 473
+110.4 Control and adjustmentp. 474
110.4.1 The cab warning lightp. 474
110.4.2 The test buttonp. 474
110.4.3 System filling and bleedingp. 474
110.4.4 Maintenancep. 474
+110.4.5 Checksp. 474
+110.5 Troubleshootingp. 475
110.5.1 Detecting faultsp. 475
110.5.2 Faults tablep. 476
110.5.3 Error codes tablep. 477
+110 Camera optionp. 478
+110.1 Characteristics and specificationsp. 478
110.1.1 Front, rear and boom head camera systemp. 478
+110.1.2 Operationp. 478
Component sheetsp. 480
Video source selector boxp. 480
Boom head Wi-Fi camerap. 481
Wi-Fi boxp. 482
Front or rear camerap. 483
110.2 Diagramp. 484
110.3 Locationp. 484
+110.4 Control and adjustmentp. 485
110.4.1 Dashboard adjustments.p. 485
110.4.2 Boom head camera support.p. 486
+110 Engine ECO-STOP optionp. 487
+110.1 Characteristics and specificationsp. 487
110.1.1 Operating modesp. 487
110.2 Engine ECO-STOP schematic diagramp. 488
110.3 Engine ECO-STOP locationp. 488
110.4 Eco-stop control and adjustmentp. 488
+110 AIR CONDITIONING OPTIONp. 489
+110.1 Air conditioning characteristics and specificationsp. 489
110.1.1 Description of operationp. 489
110.1.2 Operating principlep. 490
110.1.3 Automatic air conditioning ECU Inputs/Outputsp. 492
110.1.4 Evaporator temperature sensor specificationsp. 493
+110.2 Air conditioning locationp. 494
110.2.1 Location and tightening torquesp. 494
110.2.2 HVAC interior componentsp. 495
110.2.3 HVAC exterior componentsp. 495
+110.2.4 Automatic air conditioning locationsp. 496
KEY TO AUTOMATIC AIR CONDITIONING LOCATIONSp. 497
110.2.5 Condenser componentsp. 497
+110.3 Air conditioning controls and adjustmentsp. 498
110.3.1 General checkpointsp. 498
110.3.2 ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUITp. 498
110.3.3 Safety measures for handling the r134ap. 499
110.3.4 Refrigerant charging of the air conditioning circuitp. 499
110.3.5 Check the evaporator temperature sensorp. 500
+110.4 Air conditioning removal – refitp. 502
110.4.1 Air conditioning belt removalp. 502
110.4.2 Air conditioning belt refitp. 503
110.4.3 Manual air conditioning sensor removalp. 504
110.4.4 Automatic air conditioning sensor removalp. 506
110.4.5 Manual air conditioning sensor refitp. 508
110.4.6 Automatic air conditioning sensor refitp. 509
+110.5 Air conditioning troubleshootingp. 510
110.5.1 Temperature troubleshootingp. 510
110.5.2 ABNORMAL NOISE ON A/C SYSTEMp. 510
110.5.3 UNPLEASANT SMELLp. 510
110.5.4 Automatic air conditioning error codes (DTC) – X39 (C10)p. 511
+110.6 Specific air conditioning toolingp. 511
110.6.1 Fitting wedge for elastic drive beltp. 511
- 00 — General: safety instructions, servicing position and rules, specifications, lubricants and fuel, dimensions, identification plates, standard tightening torques, metric-imperial conversion
- 10 — Engine: engine characteristics, DEF (Diesel Exhaust Fluid), injection cycle, Bosch CP4.1 high pressure pump, air intake and EGR circuits, lubrication, cooling, fuel system, DEF circuit, component locations, engine start-up conditions, DEF regeneration, fan regulation, tightening torques for engine suspension and couplings, engine removal and refit, ECU removal, air filter, starter motor, DOC/SCR pipes, DEF injector and tank, cooler removal, alternator, water pump, turbo-compressor, troubleshooting, special engine tooling
- 20 — Transmission: ZF 2 HC 85 hydrostatic gearbox characteristics and operation, Compact+ manual gearbox, Powershift PG 115 gearbox, drive train schematics, transmission locations, authorisation conditions for carriage movement, hydrostatic auto-calibration, pressure testing, transmission tightening torques, freewheel mode, Powershift and hydrostatic gearbox removal, manual gearbox assembly removal, hydrostatic pump removal, specific transmission tooling
- 30 — Axle: axle stops adjustment, rear axle pin adjustment clearance, tightening torques
- 40 — Brakes: service brake specifications, trailer brake valve, accumulator load valve, service brake valve 55 B, automatic parking brake option, pneumatic trailer braking option, brake valve operating principle, brake locations, trailer brake valve tightening torque, parking brake adjustment on gearbox and front axle, brake pedal adjustment, inching pedal calibration, brake bleeding, towing, master cylinder removal, brake fluid bleeder
- 50 — Boom: duplex and triplex boom characteristics, boom locations, telescope extension and retraction adjustment, shim fitting and lubrication recommendations, duplex and triplex tightening torques and lubrication, duplex boom telescope and telescopic cylinder removal, triplex boom telescoping circuit removal, boom head telescope T2 and intermediate telescope T1 removal, special boom tools
- 70 — Hydraulics: dynamic steering operation, hydraulic component sheets (accumulator block, OSPC 200 LS steering block, pilot safety valve, RS 14 distributor, SDS 140 distributor, fan regulator motor, Casappa MVP 60-63 pump, LA10V072EK1DS/53R pump, steering selector, automatic steering selector), hydraulic schematic diagrams for each MLT/MLT-X model, hydraulic locations, controls and adjustments, hydraulic pump, lifting cylinder and distributor removal, hydraulic specific tooling
- 80 — Electricity: relay and fuse locations, screen menus, electrical network architecture, ECU inputs/outputs (screen, navigator, air-conditioning ECU, main ECU SPU 40-26, engine ECU EDC17CV52, Powershift ECU, auxiliary ECU SPU 25-15, CVT ECU), technical sheets for electrical components, wiring diagrams by model and function, electricity locations, electrical control and adjustment, battery and ECU removal, strain gage refitting, electrical troubleshooting, DTC error codes, specific electric tooling
- 85 — Driver’s Cab: tightening torques, door opening/closing control adjustment, cab removal, windshield removal, window winder removal, cab door removal, windshield wiper motor removal, cab lower trim removal, upper dashboard removal, heating unit removal, driver’s seat removal, armrest removal, dashboard switch removal, cab grille hinge kit
- 90 — Chassis-Bodywork: engine hood removal
- 110 — Options-Attachments: intelligent hydraulics option, regenerative hydraulics option, boom suspension option, automatic parking brake option, pneumatic trailer braking option, optional automatic central greasing, camera option, engine Eco-Stop option, air conditioning option, troubleshooting for each option
Across these groups, the manual gives a technician the complete working reference for the MLT and MLT-X telehandler platforms — not just a list of procedures, but the underlying specifications, tightening torques, pressure values, electrical pinouts and diagnostic code tables that make those procedures safe and repeatable. Engine work on the Deutz TCD 3.6 L4 and TD 3.6 L4 power units, hydrostatic and Powershift transmission service, boom telescoping adjustment, hydraulic distributor overhaul and full electrical diagnostics are all supported in depth.
Engine and Powertrain Coverage in Detail
The engine section begins with the Deutz 3.6-litre four-cylinder unit used across the range, listing the compression ratio of 17.2, maximum power output of 100 kW (136 hp), maximum torque of 500 N.m at 1,600 rpm, and the minimum, nominal laden and maximum unladen engine speeds. The after-treatment system is fully described, including the DOC, DPF, SCR and AOC components, the DEF circuit and pump, regeneration conditions and the degraded-mode torque and speed reduction logic that applies if DEF quality or level is not maintained. The Bosch CP4.1 high pressure pump is covered with its MPROP valve, cam follower wear points and pressure relief valve behaviour. The manual also documents the EGR circuit, the turbocharger and air cooler, the lubrication and cooling systems and the diesel fuel circuit, with tightening torques for every major joint.
Transmission and Hydraulics
Three transmission types are covered: the ZF 2 HC 85 hydrostatic (CVT) gearbox with its two radial hydrostatic motors and gear train, the Powershift PG 115 automatic gearbox and the Compact+ manual gearbox. The hydrostatic section explains the two driving modes (comfort and dynamic), the auto-calibration procedure, and the pressure connector readings a technician needs to diagnose pump and motor problems. The hydraulic section is similarly thorough, with component sheets for the RS 14 and SDS 140 distributors, the Casappa MVP 60-63 and LA10V072EK1DS/53R pumps, the OSPC 200 LS steering block and the pilot safety valves, plus schematic diagrams for each machine variant.
Electrical and Diagnostic Content
The electrical group documents the SPU 40-26 main ECU, SPU 25-15 auxiliary ECU, EDC17CV52 engine ECU, PG115 Powershift ECU and ZF 2HC85 CVT ECU, with full pinout tables, fuse and relay positions, wiring diagrams arranged by model and function, and a comprehensive DTC error code listing with SPN/FMI designations and fault descriptions. This makes the manual a working diagnostic tool as well as a repair guide — you can trace a fault from the dashboard code to the affected circuit and component.
What This Service Manual Enables You to Do
With this manual, you can carry out scheduled maintenance, diagnose faults, remove and refit major assemblies, overhaul components, adjust and calibrate systems, and verify your work against the manufacturer’s own figures. It covers engine removal, transmission removal and refit, brake adjustment and bleeding, boom telescope adjustment, hydraulic pump and distributor removal, cab removal and refitting, air conditioning service, central greasing system fault-finding, and much more. For anyone maintaining a Manitou MLT or MLT-X telehandler, it is the difference between guessing at a procedure and following the exact sequence and torque values the machine was designed around.
Why the Correct Procedures and Specifications Matter
Telehandlers are lifting machines, and incorrect assembly or adjustment can create real safety risks — whether that is an incorrectly adjusted parking brake, a boom telescope pad set with the wrong clearance, or a hydraulic pressure left outside specification. Using the correct tightening torques, pressure values and adjustment dimensions matters for more than reliability; it is part of keeping the machine safe to operate. This manual provides those values in a structured, searchable document rather than scattered notes.
Instant PDF Delivery
The manual is delivered as a PDF download immediately after purchase — no shipping, no waiting. It can be read on any device, printed for use in the workshop, and kept as a permanent reference. Whether you are a technician, a fleet operator or an owner maintaining your own machine, this Manitou MLT and MLT-X service manual gives you the full factory-level content in a convenient, portable format.
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