Manitou Telehandler MT 1135,MT 1335 EASY 75D ST5 S1 Repair Manual 647802EN – PDF DOWNLOAD

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Manitou Telehandler MT 1135,MT 1335 EASY 75D ST5 S1 Repair Manual 647802EN – PDF DOWNLOAD

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Manitou Telehandler MT 1135,MT 1335 EASY 75D ST5 S1 Repair Manual 647802EN – PDF DOWNLOAD

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Manitou Telehandler MT 1135,MT 1335 EASY 75D ST5 S1 Repair Manual 647802EN – PDF DOWNLOAD

647802EN (21/10/2019)

MT 1135 EASY 75D ST5 S1
MT 1135 H EASY 75D ST5 S1
MT 1135 HA EASY 75D ST5 S1
MT 1335 EASY 75D ST5 S1
MT 1335 H EASY 75D ST5 S1
MT 1335 HA EASY 75D ST5 S1

GENERAL INSTRUCTIONS AND SAFETY NOTICE
00.2.1 FOREWORD
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 effi cient, dependable and profi table combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.

TABLE OF CONTENTS:

Manitou Telehandler MT 1135,MT 1335 EASY 75D ST5 S1 Repair Manual 647802EN – PDF DOWNLOAD

Page de garde / Front page………………………………………………….. 1
Sommaire général – General table of content…………………………………… 3
00……………………………………………………………………….. 9
GENERAL, CHARACTERISTICS AND SAFETY………………………………………….. 10
00.1 Work during the Warranty Period……………………………………… 10
00.2 GENERAL INSTRUCTIONS AND SAFETY NOTICE……………………………….. 10
00.2.1 FOREWORD…………………………………………………….. 10
00.2.2 SERVICING POSITION……………………………………………. 10
00.2.3 EXPLANATION OF SYMBOLS………………………………………… 11
00.2.4 SERVICING RULES………………………………………………. 12
00.3 GENERAL CHARACTERISTICS AND SPECIFICATIONS……………………………. 15
00.3.1 CHARACTERISTICS………………………………………………. 15
00.3.2 LUBRICANTS AND FUEL…………………………………………… 15
00.3.3 DIMENSIONS…………………………………………………… 16
00.4 GENERAL LOCATION…………………………………………………… 18
00.4.1 LOCATION OF NAME AND IDENTIFICATION PLATE……………………….. 18
00.5 GENERAL CONTROL AND ADJUSTMENT………………………………………. 19
00.5.1 STANDARD TIGHTENING TORQUES……………………………………. 19
00.5.2 METRIC – IMPERIAL UNIT CONVERSION………………………………. 20
10……………………………………………………………………….. 21
ENGINES…………………………………………………………………… 23
10.1 CHARACTERISTICS AND SPECIFICATIONS…………………………………… 23
10.1.1 CHARACTERISTICS………………………………………………. 23
10.2 Engine Schematic Diagrams…………………………………………… 24
10.2.1 Intake circuit and EGR………………………………………… 24
10.2.2 Lubrication circuit…………………………………………… 25
10.2.3 Cooling circuit………………………………………………. 26
10.2.4 Fuel circuit…………………………………………………. 27
10.3 Location………………………………………………………….. 28
10.3.1 Engine………………………………………………………. 28
10.3.2 Water cooling system………………………………………….. 30
10.3.3 Diesel fuel circuit…………………………………………… 31
10.3.4 Fuel injection circuit………………………………………… 32
10.3.5 EGR circuit………………………………………………….. 33
10.4 Control and adjustment……………………………………………… 34
10.4.1 Diesel fuel circuit tightening torques………………………….. 34
10.4.2 Exhaust circuit tightening torques……………………………… 34
10.4.3 Heating system tightening torques………………………………. 34
10.5 Removal – Refit……………………………………………………. 35
PREPARATION AND SAFETY INSTRUCTIONS…………………………………… 35
10.5.1 Removing the engine cover……………………………………… 35
10.5.2 Removing the starter motor…………………………………….. 35
10.5.3 Removing the belt casing………………………………………. 36
10.5.4 Removing the attachment belt ………………………………….. 36
Refitting the attachment belt…………………………………….. 36
10.5.5 Removing THE AIR CONDITIONING BELT……………………………… 37
Refitting the air conditioning belt……………………………….. 37
10.5.6 Remove the alternator…………………………………………. 37
10.5.7 Removing the water pump……………………………………….. 37
10.5.8 Removing the fuel filter ……………………………………… 38
10.5.9 Remove the engine ECU…………………………………………. 38
10.5.10 Removing the AIR CONDITIONING COMPRESSOR……………………….. 38
10.5.11 Removing the exhaust line…………………………………….. 40
Refitting the exhaust line ………………………………………. 40
10.5.12 Removing the turbo…………………………………………… 41
10.5.13 Remove the expansion tank…………………………………….. 41
10.5.14 Removing the radiator………………………………………… 41
10.5.15 Removing the hydraulic engine-fan assembly……………………… 42
REFITTING the hydraulic motor-fan assembly…………………………. 44
10.5.16 REMOVING THE FUEL TANK……………………………………….. 44
10.5.17 Removing the engine………………………………………….. 46
Removing the wiring harness………………………………………. 46
Removing the engine housing………………………………………. 47
Disconnecting the gearbox………………………………………… 50
ENGINE REFIT……………………………………………………. 51
10.6 TROUBLESHOOTING……………………………………………………. 52
10.6.1 ENGINE ERROR CODES……………………………………………. 52
10.6.2 IGNITION SWITCHING TEST……………………………………….. 52
10.6.3 START-UP CONDITIONS…………………………………………… 52
10.6.4 LACK OF POWER………………………………………………… 52
10.6.5 Error table………………………………………………….. 53
10.7 SPECIFIC TOOLING…………………………………………………… 55
10.7.1 Special engine tooling………………………………………… 55
10.7.2 ELECTRONIC TENSION METER………………………………………. 55
20……………………………………………………………………….. 57
TRANSMISSION………………………………………………………………. 59
20.1 Schematic diagrams…………………………………………………. 59
20.1.1 MECHANICAL TRANSMISSION……………………………………….. 59
DRIVE TRAIN…………………………………………………….. 59
OPERATION OVERVIEWS……………………………………………… 60
NEUTRAL GEAR SCHEMATIC DIAGRAM……………………………………. 61
FORWARD GEAR SCHEMATIC DIAGRAM……………………………………. 62
REVERSE GEAR SCHEMATIC DIAGRAM……………………………………. 63
20.1.2 HYDROSTATIC TRANSMISSION………………………………………. 64
DRIVE TRAIN…………………………………………………….. 64
OPERATION OVERVIEWS……………………………………………… 65
FORWARD GEAR SCHEMATIC DIAGRAM……………………………………. 67
FORWARD GEAR FLUID FLOW DISPLAY…………………………………… 68
REVERSE GEAR SCHEMATIC DIAGRAM……………………………………. 69
REVERSE GEAR FLUID FLOW DISPLAY…………………………………… 70
20.2 Location………………………………………………………….. 71
20.2.1 MECHANICAL GEARBOX PORTS………………………………………. 71
20.2.2 HYDROSTATIC TRANSMISSION………………………………………. 72
Pump PORTS……………………………………………………… 72
Engine PORTS……………………………………………………. 72
PRESSURE TEST PORTS……………………………………………… 73
20.3 Control and adjustment……………………………………………… 74
20.3.1 General authorisation conditions for carriage movement……………. 74
Acquisition conditions…………………………………………… 74
Upkeep conditions……………………………………………….. 74
Loss conditions…………………………………………………. 74
20.3.2 Verification of hydrostatic carriage configurations………………. 74
20.3.3 Eco Mode on hydrostatic carriages………………………………. 74
20.3.4 TIGHTENING TORQUES……………………………………………. 75
20.3.5 MECHANICAL TRANSMISSION PRESSURE TEST PORT values………………… 76
20.3.6 4TH GEAR LOCKING……………………………………………… 77
20.3.7 HYDROSTATIC TRANSMISSION PRESSURE TEST PORT values……………….. 78
TRANSMISSION ADJUSTMENT POINTS……………………………………. 79
PRE-OPERATION OR POST-REPAIR CHECKS……………………………….. 80
PUMP MECHANICAL “0” ADJUSTMENT……………………………………. 81
CHECKING PRESSURE CUT-OFF (DR)……………………………………. 82
CHECKING THE CONTROL CARTRIDGE (DA)……………………………….. 83
SETTING A6VM ENGINE CONTROL………………………………………. 84
SEAL REPLACEMENT / TIGHTENING TORQUES……………………………… 85
BRAKE PEDAL AND TH7 VALVE SETTING…………………………………. 85
20.4 REMOVAL…………………………………………………………… 87
20.4.1 PREPARATION AND SAFETY INSTRUCTIONS…………………………….. 87
20.4.2 MECHANICAL GEARBOX REMOVAL…………………………………….. 88
20.4.3 HYDROSTATIC TRANSMISSION REMOVAL……………………………….. 90
FLEXIBLE COUPLING REMOVAL………………………………………… 90
HYDROSTATIC PUMP REMOVAL…………………………………………. 91
20.5 TROUBLESHOOTING……………………………………………………. 96
20.5.1 HYDROSTATIC SYSTEM……………………………………………. 96
PUMP / ENGINE…………………………………………………… 96
MACHINE………………………………………………………… 97
20.6 SPECIFIC TOOLING…………………………………………………… 98
20.6.1 BASIC MANOMETER BOX…………………………………………… 98
20.6.2 DIGITAL MANOMETER BOX…………………………………………. 99
20.6.3 HYDROMATIK KIT (Replacement – A 4 VG – DA pump/A 6 VM – DA engine)….100
20.6.4 50 MM MACHINED SOCKET………………………………………….100
40………………………………………………………………………..103
BRAKE……………………………………………………………………..105
40.1 CHARACTERISTICS AND SPECIFICATIONS……………………………………105
40.1.1 SERVICE BRAKE (MECHANICAL AND HYDROSTATIC)……………………….105
40.1.2 PARKING BRAKE…………………………………………………106
MECHANICAL TRANSMISSION…………………………………………..106
HYDROSTATIC TRANSMISSION………………………………………….106
40.2 CONTROL AND ADJUSTMENT………………………………………………107
40.2.1 SERVICE BRAKE…………………………………………………107
MECHANICAL TRANSMISSION ADJUSTMENT PROCEDURE………………………..107
HYDROSTATIC TRANSMISSION ADJUSTMENT PROCEDURE……………………….108
BLEEDING PROCEDURE……………………………………………….109
40.2.2 PARKING BRAKE…………………………………………………111
ADJUSTMENT PROCEDURE……………………………………………..111
BLEEDING PROCEDURE……………………………………………….112
40.2.3 FREEWHEEL AND TOWING…………………………………………..113
RELEASING THE PARKING BRAKE……………………………………….113
PUTTING THE REDUCTION GEARBOX IN NEUTRAL (HYDROSTATIC TRANSMISSION)……113
40.3 Removal……………………………………………………………114
40.3.1 PREPARATION AND SAFETY INSTRUCTIONS……………………………..114
40.3.2 MASTER CYLINDER REMOVAL ……………………………………….114
40.3.3 PARKING BRAKE REMOVAL………………………………………….116
40.4 SPECIFIC TOOLING……………………………………………………117
40.4.1 BRAKE FLUID BLEEDER……………………………………………117
40.4.2 PARKING BRAKE BLEEDER HARNESS…………………………………..117
50………………………………………………………………………..119
BOOM………………………………………………………………………120
50.1 CHARACTERISTICS AND SPECIFICATIONS……………………………………120
50.1.1 TRIPLEX (MT 11/13 METRES)………………………………………120
50.2 Location…………………………………………………………..121
50.2.1 LOCATION OF MAIN TRIPLEX BOOM COMPONENTS…………………………121
50.3 CONTROL AND ADJUSTMENT………………………………………………122
50.3.1 TELESCOPE EXTENSION AND RETRACTION ADJUSTMENT PROCEDURE……………122
BOOM EXTENSION TIME ADJUSTMENT…………………………………….122
BOOM RETRACTATION TIME ADJUSTMENT………………………………….122
INNER TELESCOPE RETRACTION DE-SYNCHRONISATION……………………….122
50.3.2 RECOMMENDATION FOR FITTING SHIMS AND LUBRICATION AREAS…………….123
50.3.3 TIGHTENING TORQUE AND LUBRICATION AREA…………………………..124
50.4 REMOVAL – Refit…………………………………………………….125
50.4.1 PREPARATION AND SAFETY INSTRUCTIONS……………………………..125
50.4.2 COMPLETE BOOM REMOVAL………………………………………….126
50.4.3 TELESCOPING CIRCUIT REMOVAL…………………………………….129
50.4.4 REMOVAL OF TELESCOPES T1+T2…………………………………….133
50.4.5 COMPLETE BOOM REFIT……………………………………………134
50.4.6 INTERMEDIATE TELESCOPE T1 REFIT…………………………………135
50.4.7 BOOM HEAD TELESCOPE T2 REFIT …………………………………..138
50.4.8 TELESCOPING CIRCUIT REFIT………………………………………141
50.5 SPECIFIC TOOLING……………………………………………………145
50.5.1 PIPE END PIECES……………………………………………….145
50.5.2 MAGNETIC LIFTER……………………………………………….145
70………………………………………………………………………..147
HYDRAULICS…………………………………………………………………149
70.1 Characteristics and specifications……………………………………149
70.1.1 Hydraulic sheets………………………………………………149
ACCUMULATOR BLOCK………………………………………………..149
DUMP CORRECTION VALVE…………………………………………….154
STABILISER COUNTERBALANCE VALVE……………………………………155
DOUBLE TELESCOPE COUNTERBALANCE VALVE………………………………156
“ACCESS” DISCHARGE VALVE …………………………………………157
HYDRAULIC PUMP LOAD DETECTION PRIORITY VALVE………………………..159
LAGU 250/125 STEERING PUMP………………………………………..161
POWER ASSISTED BRAKE MASTER CYLINDER……………………………….163
FLOW DISTRIBUTOR…………………………………………………165
DISCHARGE VALVE………………………………………………….167
3-POSITION STEERING SELECTOR………………………………………168
SD 8/7 VALVE BANK………………………………………………..169
PVG 100 VALVE BANK (ELEMENT)………………………………………176
PVG 100 VALVE BANK (INLET ELEMENT) ………………………………..178
PVG 100 VALVE BANK (TELESCOPING ELEMENT) …………………………..180
PVG 100 VALVE BANK (OUTLET ELEMENT) ……………………………….182
PVG 32 VALVE BANK (ATTACHMENT ELEMENT)……………………………..183
CONTROL HEAD…………………………………………………….185
CONTROL HEAD…………………………………………………….187
70.2 SCHEMATIC DIAGRAMS………………………………………………….189
70.2.1 KEY………………………………………………………….189
70.2.2 MT 1135 + 1335………………………………………………..191
70.2.3 MT 1135 + 1335 H………………………………………………192
70.2.4 MT 1135 + 1335 HA……………………………………………..193
70.3 LOCATION…………………………………………………………..194
70.3.1 KEY………………………………………………………….194
70.3.2 MT 1135 – 1335………………………………………………..194
70.3.3 MT 1135 H A / MT 1335 + H +A……………………………………195
70.4 CONTROL AND ADJUSTMENT………………………………………………196
70.4.1 OPERATION OF COMPENSATING ISOLATION VALVES (VIC)………………….196
70.4.2 ACCUMULATION OF THE FLOW RATES OF THE “ACCESS” DISCHARGE VALVE……..196
70.4.3 PRESSURE TEST PORTS……………………………………………196
Theoretical values in normal operation……………………………..196
PRESSURE TEST PORT LOCATION……………………………………….197
70.4.4 PROCEDURES FOR PURGING REAR AXLE LOCKING CYLINDERS………………..198
70.4.5 TIGHTENING TORQUES…………………………………………….198
MAIN DISTRIBUTOR (MT 1135/1335 +H)…………………………………198
MAIN DISTRIBUTOR (MT 1135/1335 H A)………………………………..199
ACCUMULATOR BLOCK………………………………………………..199
FRAME LEVELLING/STABILISER DISTRIBUTOR……………………………..200
70.4.6 COUNTERBALANCE VALVE TEST PROCEDURE (MT 1135/1335 HA)……………..201
PREPARATION……………………………………………………..201
70.4.7 TESTING THE LIFTING AND TILTING CYLINDER VALVES…………………..202
70.4.8 TESTING THE TELESCOPE CYLINDER VALVES……………………………203
70.4.9 TESTING THE STABILISER CYLINDER VALVES…………………………..205
70.4.10 TESTING THE LEVELLING CYLINDER VALVE……………………………206
70.5 REMOVAL……………………………………………………………207
70.5.1 PREPARATION AND SAFETY INSTRUCTIONS……………………………..207
70.5.2 REMOVING THE DISTRIBUTOR……………………………………….208
MT 1135 /1335 + H………………………………………………..208
MT 1135/1335 HA………………………………………………….210
70.5.3 HYDRAULIC PUMP REMOVAL…………………………………………214
70.5.4 ACCUMULATOR UNIT REMOVAL……………………………………….215
70.5.5 AXLE LOCKING CYLINDER REMOVAL…………………………………..215
Refit…………………………………………………………..215
70.5.6 STABILISER CYLINDER REMOVAL…………………………………….216
70.5.7 LEVELLING CYLINDER REMOVAL (MT 1135/1335 +H +A)…………………..217
70.6 SPECIFIC TOOLING……………………………………………………218
70.6.1 BASIC MANOMETER BOX……………………………………………218
70.6.2 DIGITAL MANOMETER BOX………………………………………….219
80………………………………………………………………………..221
ELECTRICITY………………………………………………………………..225
80.1 CHARACTERISTICS AND SPECIFICATIONS……………………………………225
80.1.1 FUSES AND RELAYS………………………………………………225
IN THE CAB………………………………………………………225
IN the engine housing…………………………………………….228
80.1.2 ECU INPUTS/OUTPUTS…………………………………………….230
HARMONY SCREEN…………………………………………………..230
MT 1135 / 1335…………………………………………………..231
MT 1135 / 1335 H…………………………………………………236
MT 1135 / 1335 HA………………………………………………..241
ENGINE ECU………………………………………………………247
80.1.3 TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS……………………….252
X1/X2 – STARTER IGNITION SWITCH……………………………………252
X6 – ROTATING BEACON LIGHT………………………………………..252
X20 – AIR FILTER CLOGGING SWITCH…………………………………..253
X24 – LIGHTING STALK……………………………………………..254
X38 – Reverse gear warning………………………………………..254
X39 – Audible alarm………………………………………………255
X41 / X42 – DSB dashboard…………………………………………256
X45 / X52 – NC DOOR OPENING SWITCH…………………………………257
X46 / X47 – CIGARETTE LIGHTER……………………………………..257
X53 / X54 – H pump + H motor electrovalve…………………………..258
X57 – Transmission oil pressure switch……………………………..258
X58 – Transmission oil thermocontact……………………………….259
X61 – Water in fuel filter sensor …………………………………259
X62 – TRANSMISSION SPEED SENSOR……………………………………260
X63 – FUEL LEVEL GAUGE……………………………………………260
X67 / X74 / X98 – JSM…………………………………………….261
X76 – MECH DISTRIBUTOR PRESSURE SWITCH CONTACT………………………262
X98 – See X67 / X74 / X98 – JSM……………………………………262
X100 – BOOM ANGLE SENSOR………………………………………….263
X116 / X117 – DSB right console and fuse box………………………..264
X134 – Boom retracted switch………………………………………265
X138 – EMERGENCY STOP…………………………………………….265
X144 / X145 – 1 or 2 speed electrovalve (EVCV)………………………266
X147 – Forward or reverse electrovalve……………………………..266
X152 – BMEP JOYSTICK……………………………………………..267
X181 – ACCELERATOR PEDAL ANGLE SENSOR………………………………267
X188 – Ventilation discharge valve…………………………………268
X258 -RADIATOR MINIMUM WATER LEVEL SENSOR…………………………..268
X263 – STRAIN GAUGE………………………………………………269
X311 – VRD electrovalve (Mech version)……………………………..269
80.2 SCHEMATIC DIAGRAMS………………………………………………….270
80.2.1 ELECTRICAL DIAGRAM CODIFICATION EXAMPLE………………………….270
80.2.2 MARKING OF CABLES ON A WIRING HARNESS……………………………271
80.2.3 MT 1135 1335………………………………………………….273
POSITION OF CONNECTORS BY DIAGRAM………………………………….273
Diagram 1 – Starting……………………………………………..276
Diagram 2 – CAN………………………………………………….278
Diagram 3 – TRANSMISSION………………………………………….280
Diagram 4 – HYDRAULIC MOVEMENTS……………………………………282
Diagram 5 – Sensors………………………………………………284
Diagram 6 – Ventilation, air conditioning and wipers…………………286
Diagram 7 – Options………………………………………………288
Diagram 8 – lights and signalling………………………………….290
80.2.4 MT 1135 1335 H………………………………………………..293
POSITION OF CONNECTORS BY DIAGRAM………………………………….293
Diagram 1 – Starting……………………………………………..296
Diagram 2 – CAN………………………………………………….298
Diagram 3 – TRANSMISSION………………………………………….300
Diagram 4 – HYDRAULIC MOVEMENTS……………………………………302
Diagram 5 – Sensors………………………………………………304
Diagram 6 – Ventilation, air conditioning and wipers…………………306
Diagram 7 – Options………………………………………………308
Diagram 8 – lights and signalling………………………………….310
80.2.5 MT 1135 1335 HA……………………………………………….313
POSITION OF CONNECTORS BY DIAGRAM………………………………….313
Diagram 1 – Starting……………………………………………..316
Diagram 2 – CAN………………………………………………….318
Diagram 3 – TRANSMISSION………………………………………….320
Diagram 4 – HYDRAULIC MOVEMENTS……………………………………322
Diagram 5 – Sensors………………………………………………324
Diagram 6 – Ventilation, air conditioning and wipers…………………326
Diagram 7 – Options………………………………………………328
Diagram 8 – lights and signalling………………………………….330
80.3 LOCATIONS………………………………………………………….332
80.3.1 MT 1135 & 1335………………………………………………..332
3D Assemblies key………………………………………………..332
ENGINE 3D Location MT 1135 & 1335………………………………….336
Frame 3D Location MT 1135 & 1335 ………………………………….337
CAB 3D Location MT 1135 & 1335 ……………………………………338
Key for 2D Harnesses MT 1135 & 1335………………………………..339
Distributor harness 2D Location……………………………………343
Frame 2D Location MT 1135 & 1335…………………………………..344
ENGINE 2D Location MT 1135 & 1335………………………………….345
CAB 2D Location MT 1135 & 1335…………………………………….346
80.3.2 MT 1135 & 1335 H………………………………………………347
3D Assemblies key………………………………………………..347
ENGINE 3D Location MT 1135 & 1335 H………………………………..351
Frame 3D Location MT 1135 & 1335 H…………………………………352
CAB 3D Location MT 1135 & 1335 H…………………………………..353
Key for 2D Harnesses MT 1135 & 1335 H………………………………354
Distributor harness 2D Location……………………………………358
Frame 2D Location MT 1135 & 1335 H…………………………………359
ENGINE 2D Location MT 1135 & 1335 H………………………………..360
Cab 2D Location MT 1135 & 1335 H…………………………………..361
80.3.3 MT 1135 & 1335 HA……………………………………………..362
3D Assemblies key………………………………………………..362
Engine 3D Location MT 1135 & 1335 HA……………………………….366
Frame 3D Location MT 1135 & 1335 HA………………………………..367
CAB 3D Location MT 1135 & 1335 HA………………………………….368
Key for 2D Harnesses MT 1135 & 1335 HA……………………………..369
ENGINE 2D Location MT 1135 & 1335 HA……………………………….373
Cab 2D Location MT 1135 & 1335 HA………………………………….374
Frame 2D Location MT 1135 & 1335 HA………………………………..375
80.4 CONTROL AND ADJUSTMENT………………………………………………376
80.4.1 ADJUSTMENT OF INDUCTIVE SENSOR ON BOOM…………………………..376
80.4.2 Longitudinal stability limiter and warning device…………………376
“AGGRAVATING” HYDRAULIC MOVEMENTS CUT-OFF…………………………..377
80.4.3 “BOOM ANGLE” ANGULAR SENSOR ADJUSTMENT ………………………….378
OPERATION……………………………………………………….378
ON-TRUCK ADJUSTMENT PROCEDURE……………………………………..378
80.5 Removal – refit…………………………………………………….380
80.5.1 REFITTING THE STRAIN GAUGE……………………………………..380
LOCATION………………………………………………………..380
AXLE PREPARATION…………………………………………………381
CHARACTERISTICS OF PRODUCTS USED…………………………………..381
CHARACTERISTICS OF FASTENING SCREWS………………………………..382
ASSEMBLY PRECAUTIONS AND TIGHTENING TORQUE………………………….382
STRAIN GAUGE…………………………………………………….383
80.5.2 Remove – Replace JSM on BMEP……………………………………385
80.6 TROUBLESHOOTING…………………………………………………….386
80.6.1 Engine ECU DTC………………………………………………..386
80.6.2 Harmony screen DTC…………………………………………….393
80.6.3 Main ECU DTC – SPU 40-26……………………………………….394
80.6.4 Auxiliary ECU DTC – SPU 25-15 – SPU 40-26………………………..399
80.7 SPECIFIC TOOLING……………………………………………………403
80.7.1 DIAGNOSTIC TOOLS………………………………………………403
ENGINE ADAPTATION KIT…………………………………………….404
80.7.2 BREAKOUT BOXES………………………………………………..405
80.7.3 ELECTROVALVE ADAPTER…………………………………………..405
85………………………………………………………………………..407
DRIVER’S CAB……………………………………………………………….408
85.1 REMOVAL – Refit…………………………………………………….408
85.1.1 CAB LOWER TRIM REMOVAL…………………………………………408
85.1.2 ELECTRIC WINDOW AND ENGINE REMOVAL………………………………409
COMPONENT LOCATION……………………………………………….409
PREPARATION AND SAFETY INSTRUCTIONS………………………………..409
85.1.3 ELECTRIC WINDOW AND ENGINE REFIT………………………………..411
90………………………………………………………………………..413
FRAME – BODYWORK……………………………………………………………414
90.1 CONTROL AND ADJUSTMENT………………………………………………414
90.1.1 FUEL TANK AND OIL TANK STOP ADJUSTMENT…………………………..414
110……………………………………………………………………….415
OPTIONS – ATTACHMENTS……………………………………………………….417
110 AIR CONDITIONING OPTION………………………………………………….417
110.1 Characteristics and specifications…………………………………..417
110.1.1 Description of operation………………………………………417
110.1.2 Evaporator temperature sensor specifications…………………….418
110.2 SCHEMATIC DIAGRAMS…………………………………………………419
110.3 Locations…………………………………………………………421
110.3.1 Components AND TIGHTENING TORQUES………………………………421
110.3.2 HVAC interior components………………………………………422
110.3.3 HVAC exterior components………………………………………422
110.3.4 Condenser components………………………………………….423
110.4 Control and adjustment……………………………………………..423
110.4.1 General check points………………………………………….423
110.4.2 Refrigerant fluid load………………………………………..424
110.5 Removal – refit……………………………………………………424
110.5.1 SAFETY MEASURES FOR HANDLING R134A……………………………..424
110.5.2 ASSEMBLY INSTRUCTION………………………………………….424
110.5.3 AIR CONDITIONING BELT REMOVAL………………………………….425
110.5.4 AIR CONDITIONING BELT REFIT……………………………………425
110.5.5 Check the evaporator temperature sensor…………………………426
110.6 Troubleshooting……………………………………………………428
110.6.1 Temperature Fault…………………………………………….428
110.6.2 Unusual noise………………………………………………..428
110.6.3 Unpleasant smell……………………………………………..428

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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