Manitou MRT 1440 1640 1840 Easy 400 / 360 ST3B S1 service manual

Description Manitou MRT 1440 1640 1840 Easy 400 / 360 ST3B S1 service manual

Manitou Telescopic Handler MRT 1440 1640 1840 EASY 400 / 360 ST3B Serie 1 pdf service & repair manual

Models covered:
MRT 1440 EASY 400 ST3B S1
MRT 1640 EASY 400 ST3B S1
MRT 1840 EASY 400 ST3B S1
MRT 1840 EASY 360 ST3B S1

MANUAL CONTENT:
POSITION OF THE ENGINE COMPONENTS
ENGINE COMPONENTS
WATER + AIR COOLING CIRCUIT
INTAKE AND EXHAUST
HYDRAULIC OIL COOLING CIRCUIT
FUEL CIRCUIT

CHECKING AND ADJUSTING THE ENGINE
POSITION OF THE COMPONENTS
PREPARATION AND SAFETY INSTRUCTIONS
A - REMOVING THE ALTERNATOR BELT
B - REMOVING THE ALTERNATOR
C - REMOVING THE STARTER MOTOR
D - REMOVING THE EGR VALVE
E - REMOVING THE INJECTORS
F - REMOVING THE ENGINE COOLING WATER PUMP
ENGINE TIGHTENING TORQUE
ASSEMBLING THE ENGINE

REMOVING THE ENGINE
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
SPECIFIC TOOLING

FEATURES AND TECHNICAL SPECIFICATIONS OF THE TRANSMISSION
REXROTH HYDROSTATIC TRANSMISSION
SPECIFIC ADVANTAGES OF HYDROMATIC TRANSMISSIONS
MAIN CIRCUIT OF HYDROSTATIC TRANSMISSIONS
DESCRIPTION OF THE WORKING OF THE A4 VG..DA/A6 VM..DA HYDROMATIC TRANSMISSION
GENERAL INFORMATION
TRANSMISSION KINEMATIC CHAIN
HYDROSTATIC TRANSMISSION
TRANSMISSION HYDRAULIC SYSTEM
A4 VG / 56 DA / 18 PUMP
A4 VG / DA PUMP SECTION
WORKING OF THE “DA” CONTROL CARTRIDGE
INCHING CIRCUIT
DR VALVE
ROLE
OPERATION
CROSS-SECTION VIEW OF DR VALVE
A6 VM / DA ENGINE

TRANSMISSION LAYOUTS
HYDROSTATIC TRANSMISSION LAYOUT - FORWARD MOVEMENT
HYDROSTATIC TRANSMISSION LAYOUT - REVERSING MOVEMENT

POSITION OF THE TRANSMISSION COMPONENTS
HYDROSTATIC TRANSMISSION CIRCUIT

CHECKING AND ADJUSTING THE TRANSMISSION
A 4 VG - A 6 VM TRANSMISSION
CHECKS BEFORE STARTING UP THE TRANSMISSION OR AFTER A REPAIR

TRANSMISSION ADJUSTMENT POINTS
A 4VG PUMP
A 6VM ENGINE
CHECKING AND ADJUSTING THE TRANSMISSION
CHECKING AND ADJUSTING THE BOOST PRESSURE
ADJUSTING THE PUMP MECHANICAL
CHECKING AND ADJUSTING THE BEGINNING OF THE CONTROL
CHECKING AND RECORDING THE END OF ADJUSTMENT
CHECKING AND ADJUSTING THE HP LIMITERS
ADJUSTING THE HP LIMITERS
PRESSURE CONTROL POINTS ON PUMP A 4 VG
A6 VM 80 ENGINEBPRESSURE CONTROL POINTS
REGULATION OF ENGINE
TROUBLESHOOTING
PUMP/MOTOR
HYDROSTATIC TRANSMISSION REGULATION CHART

REMOVING THE HYDROSTATIC TRANSMISSION
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING THE HYDROSTATIC TRANSMISSION

REINSERTING THE HYDROSTATIC TRANSMISSION
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS

REINSERTING THE HYDROSTATIC TRANSMISSION
SPECIAL TOOLS FOR THE TRANSMISSION
STANDARD BOX

REMOVING THE AXLE
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING THE AXLE
REMOVING THE REAR AXLE
REINSERTING THE FRONT AND REAR AXLES
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REINSERTING THE REAR AXLE
REINSERTING THE FRONT AXLE AND HYDROSTATIC MOTOR

BRAKE
FEATURES AND TECHNICAL SPECIFICATIONS OF THE BRAKES
SERVICE BRAKE
PARKING BRAKE

POSITION OF THE BRAKES COMPONENTS
BRAKES COMPONENTS

CHECKING AND ADJUSTING THE BRAKES
BLEEDING THE BRAKES AND ADJUSTING THE INCHING
PREPARATION AND SAFETY INSTRUCTIONS
BRAKES BLEEDING PROCEDURE
DEACTIVATE THE NEGATIVE BRAKE
SETTING THE GEAR IN NEUTRAL (FOR TOWING)
INCHING CONTROL
BRAKES SYSTEM LAYOUT

SPECIAL TOOLS FOR THE BRAKES
HYDRAULIC BRAKE VENTING VALVE

BOOM
BOOM CHARACTERISTICS AND SPECIFICATIONS
BOOM WITH TWO EXTENSIONS
BOOM WITH THREE EXTENSIONS

BOOM COMPONENTS LOCATION
POSITION OF COMPONENTS OF BOOM WITH TWO EXTENSIONS
POSITION OF COMPONENTS OF PENTAGONAL BOOM WITH THREE EXTENSIONS

BOOM CONTROL AND ADJUSTMENT
PREPARATION AND SAFETY INSTRUCTIONS
ADJUSTING THE SLIDING BLOCKS OF THE BOOM WITH TWO EXTENSIONS
ADJUSTING THE I EXTENSION BOOM/OUTER BOOM SLIDING BLOCKS
ADJUSTING THE I EXTENSION BOOM/II EXTENSION BOOM SLIDING BLOCKS
ADJUSTING THE SLIDING BLOCKS OF THE BOOM WITH THREE EXTENSIONS
ADJUSTING THE II EXTENSION BOOM/III EXTENSION BOOM SLIDING BLOCKS
ADJUSTING THE II EXTENSION BOOM/II EXTENSION BOOM SLIDING BLOCKS
ADJUSTING THE I EXTENSION BOOM/OUTER BOOM SLIDING
ADJUSTING THE CHAINS OF THE BOOM WITH THREE EXTENSIONS

BOOM REMOVAL
REMOVING THE ENTIRE TELESCOPIC BOOM
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING THE TELESCOPIC BOOM WITH TWO EXTENSIONS FROM THE VEHICLE
REMOVING THE COMPONENTS OF THE BOOM WITH TWO EXTENSIONS
REMOVING THE BOOM HYDRAULIC SYSTEM AND ELECTRICAL SYSTEM
REMOVING THE II EXTENSION BOOM FROM THE I EXTENSION
REMOVING THE I EXTENSION BOOM FROM THE OUTER BOOM
REMOVING THE TELESCOPIC BOOM WITH THREE EXTENSIONS FROM THE VEHICLE
REMOVING THE COMPONENTS OF THE BOOM WITH THREE EXTENSIONS
REMOVING THE BOOM HYDRAULIC SYSTEM AND ELECTRICAL SYSTEM
REMOVING THE CYLINDERS FROM THE BOOM
REMOVING THE I, II AND III EXTENSIONS FROM THE OUTER BOOM
REMOVING THE I EXTENSION BOOM FROM THE II EXTENSION BOOM

BOOM REFIT
REFITTING THE ENTIRE TELESCOPIC BOOM
GENERAL INFORMATION
PRELIMINARY OPERATIONS
PREPARATION AND SAFETY INSTRUCTIONS
REFITTING THE COMPONENTS OF THE BOOM WITH TWO EXTENSIONS
REFITTING THE I EXTENSION BOOM IN THE OUTER BOOM
REFITTING THE II EXTENSION BOOM IN THE I EXTENSION
REFITTING THE BOOM HYDRAULIC SYSTEM AND ELECTRICAL SYSTEM
REFITTING THE TELESCOPIC BOOM WITH TWO EXTENSIONS ON THE VEHICLE
REFITTING THE COMPONENTS OF THE BOOM WITH THREE EXTENSIONS
PRELIMINARY OPERATIONS
PREASSEMBLY OF THE III EXTENSION BOOM
PREASSEMBLY OF THE II EXTENSION BOOM
REINSERTING THE III EXTENSION BOOM IN THE II EXTENSION BOOM
PREASSEMBLY OF THE I EXTENSION BOOM
REFITTING THE II AND III EXTENSION BOOMS IN THE I EXTENSION BOOM
OUTER BOOM PREASSEMBLY
REFITTING THE I, II AND III EXTENSION BOOMS IN THE OUTER BOOM
REFITTING THE CYLINDERS ON THE BOOM
REFITTING THE BOOM HYDRAULIC SYSTEM AND ELECTRICAL SYSTEM
REFITTING THE TELESCOPIC BOOM WITH THREE EXTENSIONS ON THE VEHICLE

HYDRAULIC
HYDRAULIC SCHEMATIC DIAGRAMS
1 - MOVEMENTS HYDRAULIC DIAGRAM
2 - STABILIZERS AND REAR AXLE BLOCK HYDRAULIC DIAGRAM
3 - HYDROSTATIC TRANSMISSION HYDRAULIC DIAGRAM
4 - STEERING BRAKES HYDRAULIC DIAGRAM

HYDRAULIC COMPONENTS LOCATION
DIAGRAM 1 - HYDRAULIC COMPONENTS LOCATION
DIAGRAM 2 - HYDRAULIC COMPONENTS LOCATION

HYDRAULIC CONTOL AND ADJUSTMENT
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
LOCATION OF THE PRESSURE PLUGS
CHECKING THE PRESSURES
BOOM MOVEMENTS
COMPENSATION CYLINDER BOTTOM PLATE MOVEMENT
STABILIZERS MOVEMENTS
FAN MOTOR
BOOST PUMP ON HYDROSTATIC TRANSMISSION
GENERAL RULES FOR DISMANTLING THE CYLINDERS
PISTON AND LOCKING NUT
PISTON GASKETS
GASKETS OF THE LOCKING RING NUT
APPLICATION OF THREADLOCKERS
LIFT CYLINDER
SLEWING CYLINDER
COMPENSATION CYLINDER
STABILIZER INCLINATION CYLINDER
REAR AXLE BLOCKING CYLINER
LEVELLING CYLINDER
ADJUSTING THE TURRET ROTATION BRAKE

HYDRAULIC COMPONENTS REMOVAL
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING THE DIRECTIONAL CONTROL VALVE
REMOVING THE LIFT CYLINDER
REMOVING THE COMPENSATION CYLINDER
REMOVING THE STABILIZERS ASCENT AND DESCENT CYLINDERS
ROTARY HYDRAULIC CONNECTOR
REMOVING THE TANK
REMOVING THE HYDRAULIC FLUID TANK AND FUEL TANK

REFITTING THE HYDRAULIC COMPONENTS
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REFITTING THE TANK
REFITTING THE HYDRAULIC FLUID AND FUEL TANK
REFITTING THE COMPENSATION CYLINDER
REFITTING THE LIFT CYLINDER
REINSERTING THE STABILIZERS ASCENT AND DESCENT CYLINDER
REFITTING THE DIRECTIONAL CONTROL VALVE

HYDRAULIC SPECIFIC TOOLING
PRESSURE GAUGES STANDARD BOX
DIGITAL PRESSURE GAUGE BOX

ELECTRICITY
ELECTRICAL FEATURES AND SPECIFICATIONS
VEHICLE WITH FORKS
VEHICLE WITH FORKS ON TYRES OR STABILIZERS
VEHICLE WITH FORKS ON TYRES OR STABILIZERS IN TILTING CONDITION
VEHICLE ON STABILIZERS WITH PLATFORM
MACHINE WITH FIXED/ORH PLATFORM
MACHINE ON ILIZERS WITH FIXED/ORH PLATFORM
VEHICLE ON STABILIZERS WITH FIXED/ORH PLATFORM IN TILTING CONDITION
VEHICLE WITH OSCILLATING PLATFORM
VEHICLE ON TYRES WITH OSCILLATING/ORH PLATFORM IN TILTING CONDITION
VEHICLE ON TYRES WITH OSCILLATING PLATFORM
VEHICLE ON STABILIZERS WITH OSCILLATING PLATFORM IN TILTING CONDITION
VEHICLE ON STABILIZERS WITH OSCILLATING PLATFORM
VEHICLE WITH RADIO CONTROL
VEHICLE ON STABILIZERS WITH RADIO CONTROL IN TILTING CONDITION
VEHICLE ON STABILIZERS WITH RADIO CONTROL
FUSES AND RELAYS
FUSES AND RELAYS CHARIOT
FUSES AND RELAYS IN THE CAB
FUSES AND RELAYS A/C
CONNECTORS WIRING
FRONT CARRIAGE WIRING
REAR CARRIAGE WIRING
CARRIAGE CONNECTION BOX
SWITCHES LINE WIRING
DRIVE SEAT WIRING
DASHBOARD WIRING
ENGINE WIRING
REAR TURRET WIRING
LIMITED ROTATION CABLE
BOOM WINDER CABLE
PLATFORM INTERFACE WIRING
3B6 SENSORS WIRING
BOOM CABLE
CONNECTION BOX
JOYSTICK WIRING
OPTION SWITCH CABLE
DRIVE SEAT CABLE

WIRING DIAGRAMS
IDENTIFICATION MARKINGS REGARDING THE WIRING DIAGRAMS
IDENTIFICATION OF CONNECTORS AND CONDUCTORS OF THE ELECTRIC WIRING
POSITION OF CONNECTORS BY DIAGRAM
WIRING DIAGRAMS BY FUNCTION
START-UP 1
START-UP 2
CAN-BUS
TRANSMISSION
HYDRAULIC MOVEMENTS 2
HYDRAULIC MOVEMENT
SENSORS
LIGHTS
OPTIONAL LIGHTS - VEHICLE RADIO - WINDSCREEN WIPER
AIR CONDITIONING - HEATING
OPTIONS
EMERGENCIES

POSITION OF CONNECTORS BY DIAGRAM
WIRING DIAGRAMS BY FUNCTION

CAN-BUS
TRANSMISSION
HYDRAULIC MOVEMENTS
HYDRAULIC MOVEMENTS SENSORS LIGHTS
OPTIONAL LIGHTS - VEHICLE RADIO - WINDSCREEN WIPER
AIR CONDITIONING - HEATING
OPTIONS
EMERGENCIES
ELECTRICITY

POSITION OF THE ELECTRICAL COMPONENTS
POSITION OF CONNECTORS ON THE VEHICLE
ASSEMBLY 1 WIRING
ASSEMBLY 2 WIRING
CHASSIS WIRING
TURRET WIRING
CAB WIRING
ENGINE WIRING

ELECTRICAL CONTROL AND ADJUSTMENT
OVERVIEW
VEHICLE LAYOUT
FUNCTIONS
OPERATOR PANEL
ROAD TRAVEL PAGE (ADVANCEMENT MODE)
LOAD LIMITER PAGE
ISAAC PAGE (WORK SPACE LIMITER)
SLOWDOWN PAGE
DIAGNOSTICS PAGE
ERROR MESSAGES RECORD PAGE
ELECTRONIC CONTROL
SPEED CONTROL FROM CAB
SPEED CONTROL FROM PLATFORM
SPEED CONTROL FROM REMOTE RADIO CONTROL
MOVEMENT CONTROL
RAMPS
SUMMARY OF MOVEMENT
SLOW MOVEMENTS
DIAGNOSTICS AND TROUBLESHOOTING
WARNING MESSAGES
ALARM MESSAGES
ALARMS DESCRIPTION
MC2M ALARM
PRESSURE TRANSDUCERS ALARMS
POTENTIOMETRIC TRANSDUCER ALARMS
DIGITAL SIGNAL CONGRUENCE ALARM
CRC LOAD CHARTS DATA INTEGRITY ALARM
CRC PROGRAM ALARM
CAN BUS DEVICES ALARMS
THE DISPLAY IS BACKLIT BUT DOES NOT SHOW ANY INDICATION (EMPTY)
CHECKING THE SERIAL LINE BETWEEN THE IDR TYPE DISPLAY AND HEAD TYPE MAIN UNIT
CHECKING THE CAN BUS LINE
DIAGNOSTICS PROCEDURES WITH TEXT DISPLAY
DIAGNOSTICS PAGES
STATUS PAGES
CALIBRATION PROCEDURES WITH TEXT DISPLAY
CALIBRATION MENU
CALIBRATION OF TRANSDUCERS
STABILIZERS CALIBRATION
ENCODER CALIBRATION
CHASSIS LEVELLING SENSOR CALIBRATION
ANGLE AND LENGTH CALIBRATION
LMI CALIBRATION PROCEDURE
MECHANICAL ALIGNMENT OF ANGLE AND EXTENSION SENSORS
EXTENSION AND ANGLE CALIBRATION
SENSORS SELF-CALIBRATION IN VEHICLE CLOSED CONDITIONS
SENSORS SELF-CALIBRATION IN VEHICLE OPEN CONDITIONS
INITIALIZATION OF CALIBRATION PROCEDURE
WEIGHT CALIBRATION WITHOUT LOAD (NO-LOAD MODE)
WEIGHT CALIBRATION WITH LOAD APPLIED
DYNAMIC CORRECTIONS WITHOUT LOAD APPLIED

SPECIAL TOOLS FOR THE ELECTRICAL SYSTEM
DIAGNOSTICS CASE
BOX FITNESS
CONNECTIONS TO FORKLIFT TRUCK
DOCKING STATION
WORKSHOP TROLLEY

DRIVERS CAB
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING THE CAB GUARD
DISCONNECT THE CAB HYDRAULIC SYSTEM
DISCONNECT THE ELECTRICAL SYSTEM
REMOVING THE CAB FROM THE FRAME

DRIVERS CAB REFIT
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REFITTING THE CAB ON THE FRAME
RECONNECT THE ELECTRICAL SYSTEM
RECONNECT THE CAB HYDRAULIC SYSTEM
REFIT THE GUARD ON THE CAB

FRAME - BODY
REMOVING THE TURRET
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING TURRET FROM THE FRAME
REMOVING LIFT CYLINDER FROM TURRET
REMOVING COMPENSATION CYLINDER FROM TURRET
REMOVING THE TURRET FROM THE FRAME
REMOVING THE SLEWING RING BEARING

REFITTING THE TURRET
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REFITTING THE SLEWING RING BEARING
REFITTING THE TURRET ON THE FRAME
REFITTING THE TURRET ON THE FRAME
REFITTING THE LIFT CYLINDER ON THE TURRET
REFITTING THE COMPENSATION CYLINDER ON THE TURRET