Manitou MRT MRT-X 3050 2470 Privilege Plus ST4 / ST3A Serie 1 service manual

Description Manitou MRT MRT-X 3050 2470 Privilege Plus ST4 / ST3A Serie 1 service manual

Manitou Telescopic Handler MRT MRT-X 3050, 2470 Privilege Plus ST4/ST3A Series 1 pdf service & repair manual

Models covered:
MRT 3050 PRIVILEGE PLUS ST4 S1
MRT-X 3050 PRIVILEGE PLUS ST3A S1
MRT 2470 PRIVILEGE PLUS ST4 S1
MRT-X 2470 PRIVILEGE PLUS ST3A S1

MANUAL CONTENT:
ENGINE CHARACTERISTICS AND SPECIFICATIONS
ENGINE SYSTEM GENERAL INFORMATION
NETWORKING - SYSTEM OVERVIEW
IDENTIFICATION OF THE MAJOR UNITS
EXHAUST AFTERTREATMENT SYSTEM - SYSTEM DESCRIPTION
INDUCEMENT STRATEGY (ONLY WITH ENGINE VERSION ST4)
ENGINE GENERAL INFORMATION
IDENTIFICATION OF THE ENGINE

ENGINE COMPONENTS LOCATION
ENGINE SURROUNDINGS
AIR COOLING/COOLING LIQUID CIRCUIT
FAN MOTOR CIRCUIT
FUEL COOLING CIRCUIT
FAN MOTOR CIRCUIT

ENGINE CONTROL AND ADJUSTMENT
FAN CONTROL OPERATION
SCHEMATIC DIAGRAM
TIGHTENING TORQUE
ENGINE SUSPENSION ASSEMBLY
FAN CONTROL AND AIR FILTER
EXHAUST
GETTING STARTED ENGINE PROGRAMMING AND DIAGNOSTICS
DIAGNOSTIC SOFTWARE PROCEDURES
PROGRAMMING PROCEDURES

ENGINE REMOVAL
ENGINE COMPONENTS
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
SPECIFIC TOOLING
REMOVING THE ENGINE COMPONENTS
DISASSEMBLY ORDER
REMOVING THE ENGINE RADIATOR
REMOVING THE RADIATOR HYDRAULIC MOTOR
REMOVING THE I.C. ENGINE
ENGINE COMPONENTS
REMOVING THE ENGINE COMPONENTS
DISASSEMBLY ORDER
REMOVING THE ENGINE RADIATOR
REMOVING THE RADIATOR HYDRAULIC MOTOR
REMOVING THE I.C. ENGINE
REFITTING PROCEDURE

ENGINE TROUBLESHOOTING
USE OF THE ONBOARD DIAGNOSTIC MERCEDES ENGINE ST4
FAULT CODES CPC4
FAULT CODES MCM2
FAULT CODES ACM
USE OF THE ONBOARD DIAGNOSTIC MERCEDES ST3A
FAULT CODES
SPECIFIC ENGINE TOOLING
XENTRY DIAGNOSTICS HARDWARE CASE
MINIDIAG  RECOVERY RELEASE

TRANSMISSION CHARACTERISTICS AND SPECIFICATIONS
PRINCIPLE OF OPERATION OF GEARBOX
OPERATION
OVERVIEW

TRANSMISSION SCHEMATIC DIAGRAMS
FORWARD GEAR SCHEMATIC DIAGRAM
REVERSE GEAR SCHEMATIC DIAGRAM

TRANSMISSION COMPONENTS LOCATION
HYDROSTATIC TRANSMISSION

TRANSMISSION CONTROL AND ADJUSTMENT
PRESSURE TAKE-OFF POINTS
PRESSURE TEST PORTS
LOCATION
VALUES
PUMP / MOTOR CONTROL AND ADJUSTMENT
TRANSMISSION ADJUSTMENT POINTS
PRE START-UP OR POST MAINTENANCE CHECKS
PUMP MECHANICAL "0" ADJUSTMENT
CHECKING PRESSURE CUT-OFF (DR)
PLACE THE TRUCK ON BLOCKS (WHEELS OFF THE GROUND) WITH THE BRAKES APPLIED
A6VM MOTOR CONTROL ADJUSTMENT
CHECKING MAXIMUM DISPLACEMENT (MAXIMUM TRACTION FORCE)
SEAL REPLACEMENT / TIGHTENING TORQUES
HYDROSTATIC SYSTEM TROUBLESHOOTING
A4VG-DA / A6VM-DA HYDROSTATIC TRANSMISSION SETTINGS SHEET
TRANSMISSION ASSEMBLY TIGHTENING TORQUES

TRANSMISSION REMOVAL
REMOVING THE HYDROSTATIC TRANSMISSION
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING THE UNIVERSAL SHAFTS
REMOVING THE HYDRAULIC MOTOR
REMOVING THE PUMPS
TRANSMISSION REFIT
REFITTING THE HYDROSTATIC TRANSMISSION
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REFITTING THE PUMPS
REFITTING THE HYDRAULIC MOTOR
REFITTING THE UNIVERSAL SHAFTS

SPECIFIC TRANSMISSION TOOLING
BASIS GAUGE KIT
DIGITAL GAUGE KIT

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

POSITION OF THE BRAKE COMPONENTS
THE BRAKES COMPONENTS
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)
BRAKING CIRCUIT FLUID FLOW: BRAKE VALVE, PEDAL AND ACCUMULATORS
BRAKES SYSTEM LAYOUT
BRAKE REMOVAL
SERVICE BRAKE
PREPARATION AND SAFETY INSTRUCTIONS
BRAKE PUMP REMOVAL
BRAKE REMOVAL
SERVICE BRAKE
SPECIAL TOOLS FOR THE BRAKES
HYDRAULIC BRAKE VENTING VALVE

BOOM CHARACTERISTICS AND SPECIFICATIONS
FOUR EXTENSION BOOM
COMPRISING FIVE PARTS
TRUCKS FITTED WITH FOUR-EXTENSION BOOM
WEIGHT OF THE BOOM

BOOM COMPONENTS LOCATION
LIST OF COMPONENT
POSITION OF THE COMPONENTS OF THE PENTAGONAL FOUR EXTENSION BOOM

BOOM CONTROL AND ADJUSTMENT
ADJUSTING THE PENTAGONAL TELESCOPIC BOOM
PREPARATION AND SAFETY INSTRUCTIONS
REPLACING THE SLIDING BLOCKS
REPLACING THE FRONT SLIDING BLOCKS
REPLACING THE REAR SLIDING BLOCKS
ADJUSTING THE SLIDING BLOCKS
BOOM ASSEMBLY OVERVIEW
CHECK AND ADJUSTMENT OF THE BOOM CHAIN TENSION
CHECK THE TENSION OF THE BOOM UPPER CHAIN
CHECKING THE EXTERNAL CHAINS FOR WEAR
CHAIN ELONGATION
SIDE WEAR OF PLATES
EXTENDED PIN WEAR
ALIGNMENT OF EXTENDED PIN FLATS

BOOM REMOVAL
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING THE TELESCOPIC BOOM FROM THE TRUCK
REMOVING THE RAMS FROM THE BOOM
REMOVING THE TRAVERSE RAM
REMOVING THE EXTENSION RAM
REMOVING THE BOOM COMPONENTS
REMOVING THE HYDRAULIC SYSTEM AND ELECTRICAL SYSTEM OF THE BOOM
REMOVING THE IST, IIND, IIIRD AND IVTH BOOMS FROM THE EXTERNAL BOOM
REMOVING THE IIND, IIIRD AND IVTH BOOMS FROM THE IST EXTENSION BOOM
REMOVING THE IIIRD AND IVTH BOOMS FROM THE IIND EXTENSION BOOM
REMOVING THE IVTH BOOM FROM THE IIIRD EXTENSION BOOM
REMOVING THE QUICK COUPLING
BOOM REFIT
GENERAL INFORMATION
PRELIMINARY OPERATIONS
PREPARATION AND SAFETY INSTRUCTIONS
REFITTING THE BOOM COMPONENTS
REFITTING THE IVTH BOOM INTO THE IIIRD EXTENSION BOOM
REFITTING THE IIIRD AND IVTH BOOMS INTO THE IIND EXTENSION BOOM
REFITTING THE IIND, IIIRD AND IVTH BOOMS INTO THE IST EXTENSION BOOM
REFITTING THE IST, IIND, IIIRD AND IVTH BOOMS INTO THE EXTERNAL BOOM
REFITTING THE QUICK COUPLING
FITTING THE HYDRAULIC AND ELECTRICAL SYSTEMS OF THE BOOM
REFITTING THE RAM TO THE BOOM
REFITTING THE EXTENSION RAM
REFITTING THE TRAVERSE RAM
REFITTING THE TELESCOPIC BOOM TO THE TRUCK

SPECIFIC BOOM TOOLING
SAFETY LOCK FOR THE LIFTING PISTON
TOOL FOR REMOVING THE EXTENSION RAM
FLARE NUT WRENCH
MAGNETIC LIFTER

HYDRAULIC CHARACTERISTICS AND SPECIFICATION
HYDRAULIC COMPONENT SHEETS
DOUBLE EXTENSION BALANCING VALVE
HYDRAULIC SCHEMATIC DIAGRAMS
PRIVILEGE PLUS LEGEND
PRIVILEGE PLUS SYSTEM
HYDRAULIC COMPONENTS LOCATION
KEY POSITION FOR HYDRAULIC COMPONENTS - SCHEMATIC DIAGRAM 1
SCHEMATIC DIAGRAM 1 - HYDRAULIC COMPONENTS POSITION (FRAME)
KEY POSITION FOR HYDRAULIC COMPONENTS - SCHEMATIC DIAGRAM 2
SCHEMATIC DIAGRAM 2 - HYDRAULIC COMPONENTS POSITION (FRAME)
KEY POSITION FOR HYDRAULIC COMPONENTS - SCHEMATIC DIAGRAM 3
SCHEMATIC DIAGRAM 3 - HYDRAULIC COMPONENTS POSITION (TURRET)

HYDRAULIC CONTROL AND ADJUSTMENT
PRESSURE TEST PORTS
VALUES
PRESSURE TEST PORT LOCATION
TIGHTENING TORQUES
MAIN DISTRIBUTOR
HYDRAULIC CIRCUITS

HYDRAULIC COMPONENTS REMOVAL
HYDRAULIC CYLINDER REMOVAL
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING THE LIFT CYLINDER
REMOVING THE COMPENSATION CYLINDER
REMOVING THE LOCKING REAR CYLINDER
STABILISER HYDRAULIC CYLINDER
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING HYDRAULIC CYLINDER
STABILISER DEPLOYMENT CYLINDER
HYDRAULIC DISTRIBUTOR REMOVAL
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING THE DISTRIBUTOR
REMOVING STABILISERS ELECTROVALVE GROUP

HYDRAULIC COMPONENTS REFIT
HYDRAULIC DISTRIBUTOR REFIT
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REFIT STABILISERS ELECTROVALVE GROUP
REFIT THE DISTRIBUTOR
STABILISER HYDRAULIC CYLINDER
PREPARATION AND SAFETY INSTRUCTIONS
REFIT HYDRAULIC CYLINDER
HYDRAULIC CYLINDER REFIT
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REFIT THE LOCKING REAR CYLINDER
REFIT THE COMPENSATION CYLINDER
REFIT THE LIFT CYLINDER

HYDRAULIC SPECIFIC TOOLING
BASIC MANOMETER KIT
DIGITAL MANOMETER KIT

ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS
SOFTWARE VERSION
MACHINE OPERATING LOGIC
MACHINE WITH FORKS
MACHINE WITH FORKS ON WHEELS OR OUTRIGGERS
MACHINE WITH FORKS ON WHEELS OR OUTRIGGERS IN TILTING CONDITION
MACHINE ON OUTRIGGERS WITH BASKET
MACHINE WITH FIXED BASKET / ORH
MACHINE ON OUTRIGGERS WITH FIXED BASKET / ORH IN TILTING CONDITION
MACHINE ON WHEELS WITH FIXED BASKET / ORH IN TILTING CONDITION
MACHINE ON WHEELS WITH FIXED BASKET / ORH
MACHINE WITH PENDULUM BASKET
MACHINE ON WHEELS WITH PENDULUM BASKET IN TILTING CONDITION
MACHINE ON WHEELS WITH PENDULUM BASKET
MACHINE ON OUTRIGGERS WITH PENDULUM BASKET IN TILTING CONDITION
MACHINE ON OUTRIGGERS WITH PENDULUM BASKET
MACHINE WITH RADIOCONTROL
MACHINE ON OUTRIGGERS WITH RADIOCONTROL IN TILTING CONDITION
MACHINE ON OUTRIGGERS WITH RADIOCONTROL

ELECTRICAL SCHEMATIC DIAGRAMS
WIRING DIAGRAMS: MRT
POSITION OF THE CONNECTOR ON THE DIAGRAMS
WIRING DIAGRAMS BY FUNCTION
POWER DISTRIBUTION
CRANKING-STOP FROM CAB NO BASKET PRED
CRANKING-STOP FROM CAB WITH BASKET PRED
CRANKING-STOP FROM BASKET OR REMOTE
CAN OPEN NETWORK
CAN J1939 NETWORK
CAN K-LINE - CAN TRANSMISSION DIAG - RFID NETWORK

HYDRAULIC - TRANSMISSION
HYDRAULIC - TRANSMISSION
HYDRAULIC - OUTTRIGGER; CHASSIS LEVELLING
HYDRAULIC - OUTTRIGGER SENSORS; CHASSIS SENSORS
HYDRAULIC - BOOM
HYDRAULIC - BOOM SENSORS; TOWER SENSORS
ROAD LIGHT
CABIN - WINDSCREEN; BEACON; DOOR WINDOW
CABIN - HEATER; USB PLUG; NAVI ENCODER
SAFETY - OVERRIDE
CABIN - OPTION_AIR COND; OPTION WATER HEATER
OPTION - CABIN
OPTION - CABIN
OPTION - BOOM
OPTION - REMOTE CONTROL
OPTION - BASKET
OPTION - BASKET 3D
OPTION - MAGNETIC RETARDER - EASY MANAGER
OPTION - ELECTRIC LADDER; REMOTE WINDOW; ELECTRIC DOOR
OPTION - TRILER BRAKE; AVAILABLE SUPPLY; SPARE WIRE

ELECTRICAL CONTROL AND ADJUSTMENT
DISPLAY
START-UP PAGE
PASSWORD PAGE
ENGINE PAGE
PAGE SELECTION PAGE (MENU KEY)
DIAGRAM PAGE (DIAGRAM KEY)
STABILITY PAGE (OPTIONAL KEY)
SLOWING-DOWN PAGE
CALIBRATION PAGE
CONFIGURATION 507
CALIBRATION

ELECTRICAL TROUBLESHOOTING
ALARM CODES
WARNING CODES
USE OF THE ONBOARD DIAGNOSTIC VEHICLE

ELECTRICAL SPECIFIC TOOLING
CONNECTION TO TRUCK

DRIVERS CAB CHARACTERISTICS AND SPECIFICATIONS
HEATING TECHNICAL DATA

DRIVERS CAB REMOVAL
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REMOVING THE CAB
REMOVING THE CAB HOUSING
DISCONNECT THE CAB ELECTRICAL SYSTEM
DISCONNECT THE CAB HYDRAULIC SYSTEM
REMOVING THE CAB FROM THE FRAME
COMPONENT LOCATION
PREPARATION AND SAFETY INSTRUCTIONS
ELECTRIC WINDOW AND MOTOR REMOVAL

DRIVERS CAB REFIT
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REFITTING THE CAB
REFITTING THE CAB TO THE FRAME
RECONNECT THE CAB HYDRAULIC SYSTEM
RECONNECT THE CAB ELECTRICAL SYSTEM
REFITTING THE CAB HOUSING
COMPONENT CAB REFIT
COMPONENT LOCATION
PREPARATION AND SAFETY INSTRUCTIONS
ELECTRIC WINDOW AND MOTOR REFIT

FRAME - BODY REMOVAL
GENERAL INFORMATION
REMOVING THE TURRET FROM THE FRAME
REMOVING THE TURRET ROTATION MOTOR
REMOVING THE TURRET THRUST RING

FRAME - BODY REFIT
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
REFITTING THE THRUST RING
REFITTING THE TURRET
REFITTING THE TURRET ROTATION MOTOR
ADJUSTING THE TURRET ROTATION BRAKE

ELECTROMECHANICAL LADDER
GENERAL INFORMATION
PREPARATION AND SAFETY INSTRUCTIONS
ELECTROMECHANICAL LADDER DISASSEMBLY
ELECTROMECHANICAL LADDER REASSEMBLY

AIR CONDITIONER
OPERATING PRINCIPLE
AIR CONDITIONER ASSEMBLY
ADJUSTING THE AIR CONDITIONING PRESSURES