Printed by Manitou under document number 647541EN, this 527-page Manitou MLT 840 repair manual PDF is the factory workshop book for the MLT 840 115 PS, 840 137 PS and 1040 L 137 PS JD ST4 S1 telehandlers. Hydraulics and electrics fill nearly half the book: hydraulic schematics follow the circuits through the boom, leveling and counterbalance valves, while wiring diagrams and fault code tables point you to the circuit behind the problem. Engine, boom and brake chapters run from specifications through removal and refit, and the boom and brake sections name the specific tooling each job calls for. Set the counterbalance valve timing delay screw to 17.5 +0/-0.5 mm, and check the transmission safety valve at 9 bar. A parked telehandler costs you every hour it waits. Text-searchable pages and chapter bookmarks take you straight to the right procedure, and the machine back to lifting.
What's Inside This Repair Manual
| System | Pages | Key Topics |
|---|
| General Instructions and Safety Notice | 5-26 | Preamble, Maintenance Position, Rules for Maintenance |
| Engine | 27-96 | Engine Characteristics and Specifications, Engine Components Location, Engine Control and Adjustment, Engine Removal, Engine Refit |
| Transmission | 97-134 | Transmission Characteristics and Specifications, Transmission Schematic Diagrams, Transmission Components Location, Transmission Control and Adjustment |
| Axle Assembly - Axle | 135-140 | Axle Control and Adjustment |
| Brake | 141-178 | Brake Characteristics and Specifications, Brake Control and Adjustment, Brake Removal, Brake Refit, Specific Brake Tooling |
| Telescopic Boom | 179-264 | Boom Characteristics and Specifications, Boom Schematic Diagrams, Boom Components Location, Boom Control and Adjustment, Boom Removal, Boom Refit, Specific Boom Tooling |
| Hydraulic | 265-376 | Hydraulic Characteristics and Specifications, Hydraulic Schematic Diagrams, Hydraulic Components Location, Hydraulic Control and Adjustment, Hydraulic Components Refit |
| Electricity | 377-500 | Electrical Characteristics and Specifications, Electrical Schematic Diagrams, Electrical Components Location, Electrical Control and Adjustment, Electrical Troubleshooting |
| Driver Cab | 501-518 | Driver Cab Components Location, Driver Cab Control and Adjustment, Driver Cab Removal, Driver Cab Refit |
| Frame - Body | 519-522 | Frame - Body Control and Adjustment |
| Options - Accessories | 523-527 | Options - Attachments Characteristics and Specifications |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Fuel tank capacity | 145 l | p. 25 |
| DOC turbo pipe clamp (Item 45) tightening torque | 20 N.m ±10% | p. 92 |
| DOC turbo pipe clamp (Item 46) tightening torque | 6.8 N.m ±10% | p. 92 |
| Counterbalance valve timing delay screw adjustment clearance | 17.5 +0/-0.5 mm | p. 346 |
| Leveling cylinder mounting bracket screws tightening torque | 190 Nm ± 28.5 N.m | p. 349 |
| Valve By-pass pressure | 3.44 - 3.94 bar | p. 107 |
| Safety valve pressure | 9 bar | p. 107 |
| Main pressure regulator pressure | 18-21 bar | p. 114 |
| Converter inlet pressure | 2-5 bar | p. 114 |
| Nominal pressure | 140 bar | p. 284 |
| Nominal flowrate | 25 liters/minute | p. 284 |
| B5207 EGR Temperature Sensor Resistance at 40°C | 26065 Ω | p. 410 |
