Manitou Telehandler MLT 845 100D H ST4 S1 MLT 845 120D ST4 S1 Repair Manual 647819EN – PDF DOWNLOAD

Description

Manitou Telehandler MLT 845 100D H ST4 S1 MLT 845 120D ST4 S1 Repair Manual 647819EN – PDF DOWNLOAD

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DESCRIPTION:

Manitou Telehandler MLT 845 100D H ST4 S1 MLT 845 120D ST4 S1 Repair Manual 647819EN – 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 100D H ST4 S1 MLT 845 120D ST4 S1 Repair Manual 647819EN – PDF DOWNLOAD

Page de garde / Front page 1
Som_647819EN 3
Group_00_MR647819EN 5
Som_Gr00EN 5
Group_00 7
00_00_EN 7
PREAMBLE 8
MAINTENANCE POSITION 9
RULES FOR MAINTENANCE 10
00_01_EN 13
00_03_EN 17
IDENTIFICATION PLATES 18
LOCATION 19
00_04_EN 21
STANDARD TIGHTENING TORQUES 22
LUBRICANTS AND FUEL 23
Group_10_MR647819EN 25
Som_Gr10EN 25
Group_10 27
10_01_EN 27
CHARACTERISTICS 28
POLLUTION MANAGEMENT 28
10_02_EN 31
AIR INTAKE CIRCUIT AND EGR (Exhaust Gas Recirculation) 32
LUBRICATION CIRCUIT 33
COOLING SYSTEM 34
DIESEL FUEL CIRCUIT 35
DEF (Diesel Exhaust Fluid) circuit 36
10_03_EN 37
ENGINE ELEMENTS 38
WATER AND AIR COOLING CIRCUIT 40
MLT845 100D H ST4 S1 41
MLT845 120D ST4 S1 41
DIESEL FUEL CIRCUIT 42
FUEL INJECTION CIRCUIT 43
EGR (Exhaust Gas Recirculation) CIRCUIT 44
DEF (Diesel Exhaust Fluid) circuit 45
10_04_EN 47
PREPARATION AND SAFETY INSTRUCTIONS 49
COMPONENT REMOVAL / REFIT 49
A – BONNET REMOVAL 49
B – RADIATOR AND FAN MOTOR REMOVAL 49
C – RADIATOR AND FAN MOTOR REFIT 50
D – FAN HYDRAULIC MOTOR REMOVAL / REFIT 51
E – RADIATOR REMOVAL 52
F – VENTILATION PUMP REMOVAL / REFIT 53
G – ENGINE OIL DIPSTICK FITTING INSTRUCTIONS 53
H – FIXED ENGINE COVER REMOVAL 54
I – AIR FILTER ASSEMBLY REMOVAL 54
J – EXHAUST REMOVAL / REFIT 57
K – DEF INJECTOR REMOVAL 57
L – EXHAUST PIPE REMOVAL 58
M – DEF TANK REMOVAL 59
N – DEF GAUGE REMOVAL 60
O – COOLER REMOVAL 61
P – AIR-CONDITIONING BELT REMOVAL (option) 69
Q – AIR-CONDITIONING BELT REFIT (option) 70
R – DRIVE BELT REMOVAL 71
S – AIR-CONDITIONING COMPRESSOR REMOVAL 71
T – STARTER MOTOR REMOVAL 72
U – ALTERNATOR REMOVAL 73
V – WATER PUMP REMOVAL 73
W – TURBO REMOVAL 74
X – ENGINE SHOCK ABSORBER REPLACEMENT 74
INJECTION CYCLE 75
BOSCH CP4 1 HIGH PRESSURE PUMP 76
FAN DRIVE 77
A – FUNCTION 77
B – PRINCIPLE OF OPERATION 77
C – SCHEMATIC DIAGRAM 77
D – DESCRIPTION OF HYDRAULIC MOTORS 78
E – CONDITIONS OF FAN CONTROL-RELATED COMPONENTS 79
10_06_EN 81
GENERAL INFORMATION 82
PREPARATION AND SAFETY INSTRUCTIONS 82
SPECIFIC TOOLING 82
Remove the engine 83
STANDARD ENGINE REPLACEMENT 88
10_07_EN 89
PREPARATION AND SAFETY INSTRUCTIONS 90
ENGINE REFIT 90
POST REFIT ENGINE INSPECTION 90
10_08_EN 91
FAULT TABLE 92
Error indicator lamp 94
IGNITION SWITCHING TEST: 94
START-UP CONDITIONS 94
LACK OF POWER 94
INJECTION CODE 95
FAN DRIVE CHECK POINTS 95
10_09_EN 97
FAN BELT FITTING TOOL 98
ELECTRONIC TENSION METER 98
DEF FLUSH KIT 99
Group_20_MR647819EN 101
Som_Gr20EN 101
Group_20 103
20_02_EN 103
POWER FLOW DIAGRAM/GEAR RATIOS – MECHANICAL TRANSMISSION 105
POWER FLOW DIAGRAM/GEAR RATIOS – HYDROSTATIC TRANSMISSION 106
SCHEMATIC DIAGRAM HYDROSTATIC TRANSMISSION IN FORWARD GEAR 107
SCHEMATIC DIAGRAM HYDROSTATIC TRANSMISSION IN REVERSE GEAR 108
20_04_EN 109
TIGHTENING TORQUES, MECHANICAL TRANSMISSION 111
TIGHTENING TORQUES, HYDROSTATIC TRANSMISSION 112
PRESSURE TAKE-OFF POINTS 113
A4VG 71 DA PUMP PRESSURE MEASURING POINT 113
A6VM SERIES 63 MOTOR PRESSURE MEASURING POINT 114
TRANSMISSION CONTROL AND ADJUSTMENT 115
TRANSMISSION SETTING POINTS 115
PRE START-UP OR POST SERVICING CHECKS 116
BOOSTER PRESSURE SETTING AND MONITORING 117
PUMP MECHANICAL “0” SETTING 118
PUMP REGULATION START MONITORING AND SETTING 119
REGULATION END MONITORING AND SETTING 120
HP LIMITERS MONITORING AND ADJUSTMENT 121
UNBLOCKING HP LIMITERS FOR TOWING 121
A6VM MOTOR REGULATION SETTING 122
A4VG-DA/A6VM-DA HYDROSTATIC TRANSMISSIONS SETTING FILE 124
20_06_EN 125
MECHANICAL TRANSMISSION REMOVAL 126
PREPARATION AND SAFETY INSTRUCTIONS 126
ANGLE GEAR BOX 127
GEAR BOX 131
20_07_EN 137
MECHANICAL TRANSMISSION REFIT 138
GENERAL INFORMATION 138
PREPARATION AND SAFETY INSTRUCTIONS 138
SPECIFIC TOOLING 138
ANGLE GEAR BOX (NOT H) 139
GEAR BOX (NOT H) 142
HYDRAULIC TRANSMISSION REFIT 145
PUMPS REFIT (H) 145
GEARBOX AND HYDROSTATIC MOTOR REMOVAL 145
20_09_EN 147
BASIC BOX 148
Group_30_MR647819EN 151
Som_Gr30EN 151
Group_30 153
TIGHTENING TORQUE 156
AXLE 156
Group_40_MR647819EN 157
Som_Gr40EN 157
Group_40 159
40_01_EN 159
SERVICE BRAKE / PARKING BRAKE 161
40_04_EN 163
MLT 845 SERVICE BRAKE 164
SETTING BRAKE PEDAL HEIGHT 164
MLT 845 H SERVICE BRAKE 165
SETTING BRAKE PEDAL HEIGHT 165
PARKING BRAKE (CABLE OPERATED BRAKE) 166
HAND BRAKE CABLE ADJUSTMENT 166
40_09_EN 169
PURGEUR FREINS HYDRAULIQUE 170
Group_50_MR647819EN 171
Som_Gr50EN 171
Group_50 173
50_01_EN 173
DUPLEX (MLT 8 MÈTRES) : 174
50_03_EN 175
COMPONENT CODE INDEX 176
LOCATIONS OF THE MAIN COMPONENTS OF THE 8M BOOM 176
50_04_EN 177
DUPLEX BOOM COMPONENT DISMANTLING 178
PREPARATION AND SAFETY INSTRUCTIONS 178
T2 TELESCOPE REMOVAL 179
TELESCOPE CYLINDER REMOVAL 182
DUPLEX BOOM COMPONENTS REFIT 184
RECOMMENDATIONS FOR WEDGE ASSEMBLY AND GREASING AREAS 184
50_06_EN 185
DUPLEX BOOM 186
PREPARATION AND SAFETY INSTRUCTIONS 186
BOOM REMOVAL 187
50_07_EN 191
DUPLEX BOOM 192
PREPARATION AND SAFETY INSTRUCTIONS 192
BOOM REFIT 193
Group_70_MR647819EN 195
Som_Gr70EN 195
Group_70 197
70_01_EN 197
F70_3_0003EN 199
F70_3_0008EN 201
F70_3_0017EN 203
F70_3_0023EN 205
F70_3_0027EN 207
F70_3_0037EN 209
F70_3_0038EN 211
F70_3_0039EN 213
F70_3_0040EN 215
F70_3_0041EN 219
F70_3_0042EN 221
F70_3_0047EN 223
F70_3_0059EN 227
70_02_EN 233
MLT845 100D H ST4 S1 235
KEY 235
HYDRAULIC DIAGRAM 236
MLT845 120D ST4 S1 237
KEY 237
HYDRAULIC DIAGRAM 238
70_03_EN 239
KEY 240
HYDRAULIC CIRCUITS 241
1 – MAIN HYDRAULIC CIRCUIT 241
2 – HYDRAULIC LIFTING CIRCUIT 243
3 – HYDRAULIC BOOM CIRCUIT 244
4 – BOOM COMPENSATION HYDRAULIC CIRCUIT 245
5 – STEERING HYDRAULIC CIRCUIT 246
70_04_EN 247
PRESSURE TAKE-OFF POINTS 248
VALUES 248
LOCALIZATION 248
SX14 S CONTROL BLOCK CONTROL LOGIC 249
DANGEROUS MOVEMENTS CUT-OFF OPERATING PRINCIPLES 251
REMOVAL OF SX 14 S DISTRIBUTOR 252
1 – SAFETY INSTRUCTIONS 252
2 – TROUBLESHOOTING 253
3 – ESSENTIAL RULES 255
4 – REMOVAL AND RE-FITTING OF THE SX 14 S UNIT 256
5 – SX 14 S unit REPAIR PROCEDURES 257
6 – SPECIFIC TIGHTENING TORQUE 261
70_06_EN 263
DISTRIBUTOR 264
PREPARATION AND SAFETY INSTRUCTIONS 264
DISTRIBUTOR REMOVAL 265
70_07_EN 269
DISTRIBUTOR 270
PREPARATION AND SAFETY INSTRUCTIONS 270
DISTRIBUTOR REFIT 271
70_09_EN 275
COFFRET MANOMÈTRES DE BASE 276
COFFRET MANOMÈTRE DIGITAL 277
Group_80_MR647819EN 279
Som_Gr80EN 279
Group_80 281
80_01_A_EN 281
FUSES AND RELAYS IN THE CAB 282
FUSE POWERBOX IN BATTERY COMPARTMENT 283
FUSE AND RELAY POWERBOX IN THE ENGINE COMPARTMENT 283
ELECTRICAL CONNECTORS 284
CHASSIS/CAB LINE MLT845-100D H ST4 S1 284
ENGINE LINE MLT845-100D H ST4 S1 351
DISTRIBUTOR LINE MLT845-100D H ST4 S1 366
CAB LINE MLT845-100D H ST4 S1 368
CHASSIS/CAB LINE MLT845-120D LSU ST4 S1 370
ENGINE LINE MLT845-120D LSU ST4 S1 437
DISTRIBUTOR LINE MLT845-120D LSU ST4 S1 452
CAB LINE MLT845-120D LSU ST4 S1 454
80_01_B_EN 457
HYDRAULIC ECU INPUTS/OUTPUTS 460
ECU RC4-5/30 Rexroth (WITH CAN) 460
CASAPPA (CED100X) ECU 460
SPU INPUTS/OUTPUTS 461
SPU 25-15 (LSU) 461
80_01_C_EN 463
KEY KEY OPERATED STARTER SWITCH 465
X72 BRAKE FLUID LEVEL CONTACT 466
X226 AIR FILTER SWITCH 466
X08 TRANSMISSION OIL THERMOSWITCH 467
X73 STOP PRESSURE SWITCH 467
X22 RANSMISSION OIL THERMOSWITCH (NO H) 468
X114 EMERGENCY STOP 468
X313+X312 REVERSE+SLOW SPEED ELECTROVALVE (H) 469
X314 HIGH SPEED ELECTROVALVE (H) 469
Y6+Y7+Y8+Y9 PROPORTIONAL SOLENOID VALVE BOOM/ACCESSORY 470
Y14 HYD CUT-OFF VALVE/VS 470
Y15 PROPORTIONAL SOLENOID VALVE, BOOM DESCENT VRP 471
Y16 VCI TILT CUT-OFF 471
Y18 SOLENOID VALVE 472
Y9 PEC (PRESSURE ELECTRONIC CONTROL) ON CASAPPA PUMP 473
X201 ACCELERATOR POTENTIOMETER 474
X01 DECLUTCH PUSH BUTTON (No H) 474
X14 HORN 475
X15+X21 WHEEL ALIGNMENT SENSOR 475
X36 JSM JOYSTICK 476
STR1 SMARTVIEW 1 477
STR2 SMARTVIEW 2 478
X77 FRONT WINDSCREEN WIPER MOTOR 479
X99 STRAIN GAUGE 480
X100 BOOM ANGLE ANGULAR SENSOR 480
X134 RETRACTED BOOM SWITCH 481
X165 FUEL GAUGE 481
X188 LIGHTING STALK SWITCH 482
X246 TRANSMISSION OIL TEMPERATURE SENSOR (NO H) 483
X247 HYDRAULIC OIL TEMPERATURE SENSOR 483
X245 ENGINE COOLANT TEMPERATURE SENSOR 484
X264 ENGINE AIR TEMPERATURE SENSOR 485
80_01_EN 487
80_02_A_EN 489
POSITION OF CONNECTORS ON DIAGRAMS 490
ELECTRICAL DIAGRAMS 496
1 – START-UP 496
2 – SENSORS 498
3 – CAN BUS 500
4 – HYDRAULIC MOVEMENTS 502
5 – TRANSMISSION 504
6 – LIGHTS AND CAB SERVICES 506
7 – OPTIONS 508
80_02_B_EN 511
POSITION OF CONNECTORS ON DIAGRAMS 512
ELECTRICAL DIAGRAMS 518
1 – START-UP 518
2 – SENSORS 520
3 – CAN BUS 522
4 – HYDRAULIC MOVEMENTS 524
5 – TRANSMISSION 526
6 – LIGHTS AND CAB SERVICES 528
7 – OPTIONS 530
80_02_EN 533
CODES ON THE ELECTRICAL DIAGRAMS 536
CABLE MARKING ON AN ELECTRICAL WIRING HARNESS 535
80_03_EN 537
KEY 538
CONNECTORS 538
GROUNDS 541
2D LOCATION 542
HARNESS ASSEMBLY 542
DISTRIBUTOR 543
MAIN HARNESS 545
ENGINE HARNESS 546
80_04_EN 547
LONGITUDINAL STABILITY INDICATOR (LLMI) 548
ERROR CODES 548
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE 549
CALIBRATION OF THE STRAIN GAUGE AND THE ANGLE SENSOR (DEALER PROCEDURE) 550
LED ILLUMINATION AS A FUNCTION OF THE CHANGING GAUGE SIGNAL 552
RECALIBRATION OF STRAIN GAUGE (OWNER PROCEDURE) 553
80_07_EN 555
STRAIN GAUGE 556
LOCATION 556
CHARACTERISTICS OF THE AXLE SURFACE IN CONTACT WITH THE STRAIN GAUGE 557
CHARACTERISTICS OF PRODUCTS USED 557
CHARACTERISTICS OF THE ATTACHMENT SCREWS 558
PRECAUTIONS FOR ASSEMBLY AND TIGHTENING TORQUE 558
80_08_EN 561
SPU 25-15 – A3 ERROR CODES LIST 562
ENGINE ECU ERROR CODES LIST (DTC) 565
HYDRAULIC PUMP ERROR CODES LIST 584
LONGITUDINAL STABILITY INDICATOR (LLMI) ERROR CODE LIST 584
80_09_EN 585
Group_110_MR647819EN 593
Som_Gr110EN 593
Group_110 595
OPERATING PRINCIPLE 596
DESCRIPTION OF OPERATION 597
DESCRIPTION OF COMPONENTS 598
LOCALISATION CLIMATISATION 599
ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT 600
SECURITY MEASURES FOR THE MANIPULATION OF R134a 600
REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT 600
LOADING METHOD 601
OPERATING CONTROL 602
MONITORING ANTI-ICING SAFETY 604
AIR CONDITIONING MONITORING FORM 605

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