Manitou Telehandler MRT 3050, MRT 2470,MRT-X 2470,MRT-X 3050 PRIVILEGE PLUS Repair Manual 647625EN – PDF DOWNLOAD

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Manitou Telehandler MRT 3050, MRT 2470,MRT-X 2470,MRT-X 3050 PRIVILEGE PLUS Repair Manual 647625EN – PDF DOWNLOAD

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Manitou Telehandler MRT 3050, MRT 2470,MRT-X 2470,MRT-X 3050 PRIVILEGE PLUS Repair Manual 647625EN – PDF DOWNLOAD

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Manitou Telehandler MRT 3050, MRT 2470,MRT-X 2470,MRT-X 3050 PRIVILEGE PLUS Repair Manual 647625EN – PDF DOWNLOAD

647625EN (20/01/2021)
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

GENERAL INSTRUCTIONS AND SAFETY NOTICE:
00.1.1 INTRODUCTION:
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 MRT 3050, MRT 2470,MRT-X 2470,MRT-X 3050 PRIVILEGE PLUS Repair Manual 647625EN – PDF DOWNLOAD

Page de garde / Front page………………………………………………………………………………. 1
Sommaire général – General table of content……………………………………………………………….. 3
00……………………………………………………………………………………………………. 5
GENERAL characteristics and safety……………………………………………………………………….. 6
00.1 GENERAL INSTRUCTIONS AND SAFETY NOTICE……………………………………………………………. 6
00.1.1 INTRODUCTION……………………………………………………………………………… 6
00.1.2 SERVICING POSITION………………………………………………………………………… 6
00.1.3 EXPLANATION OF SYMBOLS…………………………………………………………………….. 7
00.1.4 SERVICING RULES…………………………………………………………………………… 8
00.2 GENERAL CHARACTERISTICS AND SPECIFICATIONS………………………………………………………… 11
00.2.1 CHARACTERISTICS MRT 3050…………………………………………………………………… 11
00.2.2 CHARACTERISTICS MRT 2470…………………………………………………………………… 12
00.2.3 TECHNICAL SPECIFICATIONS…………………………………………………………………… 13
00.3 GENERAL LOCATION……………………………………………………………………………….. 17
00.3.1 IDENTIFICATION PLATEs……………………………………………………………………… 17
00.4 GENERAL CONTROL AND ADJUSTMENT…………………………………………………………………… 19
00.4.1 STANDARD TIGHTENING TORQUES………………………………………………………………… 19
00.4.2 Filtering elements and belts……………………………………………………………….. 20
00.4.3 LUBRICANTS AND FUEL……………………………………………………………………….. 24
RECOMMENDATION………………………………………………………………………………. 25
PACKAGING…………………………………………………………………………………… 26
10……………………………………………………………………………………………………. 27
10.1 ENGINE CHARACTERISTICS AND SPECIFICATIONS…………………………………………………………….. 31
10.1.1 MRT 2470/3050 Privilege Plus ST4 S1 – ENGINE CHARACTERISTICS………………………………………. 31
ENGINE SYSTEM General information…………………………………………………………………. 31
Networking – system overview………………………………………………………………….. 32
Identification of the Major Units……………………………………………………………… 33
EXAUST AFTERTREATMENT SYSTEM – SYSTEM DESCRIPTION……………………………………………….. 34
10.1.2 Inducement strategy (only with Engine version ST4)……………………………………………. 35
10.1.3 MRT-X 2470/3050 Privilege Plus ST3A – ENGINE CHARACTERISTICS…………………………………… 40
ENGINE General information……………………………………………………………………. 41
Identification of the engine………………………………………………………………….. 43
10.2 ENGINE COMPONENTS LOCATION………………………………………………………………………. 44
10.2.1 ENGINE SURROUNDINGS……………………………………………………………………….. 44
MRT 2470/3050 Privilege Plus ST4 S1……………………………………………………………. 44
MRT 2470/3050 Privilege Plus ST3A……………………………………………………………… 45
10.2.2 ENGINE MRT 2470/3050 Privilege Plus ST4 S1…………………………………………………… 46
AIR COOLING/COOLING LIQUID CIRCUIT…………………………………………………………….. 47
FAN MOTOR CIRCUIT……………………………………………………………………………. 48
FUEL COOLING CIRCUIT…………………………………………………………………………. 49
10.2.3 ENGINE MRT-X 2470/3050 Privilege Plus ST3A…………………………………………………… 50
AIR COOLING/COOLING LIQUID CIRCUIT…………………………………………………………….. 51
FAN MOTOR CIRCUIT……………………………………………………………………………. 52
FUEL COOLING CIRCUIT…………………………………………………………………………. 53
10.3 ENGINE CONTROL AND ADJUSTMENT……………………………………………………………………. 54
10.3.1 FAN CONTROL OPERATION……………………………………………………………………… 54
SCHEMATIC DIAGRAM……………………………………………………………………………. 55
10.3.2 MRT 2470/3050 Privilege Plus ST4 S1 – TIGHTENING TORQUE……………………………………….. 57
ENGINE SUSPENSION ASSEMBLY……………………………………………………………………. 57
FAN CONTROL AND AIR FILTER……………………………………………………………………. 58
EXHAUST…………………………………………………………………………………….. 59
10.3.3 MRT-X 2470/3050 Privilege Plus ST3A- TIGHTENING TORQUE………………………………………… 60
ENGINE SUSPENSION ASSEMBLY……………………………………………………………………. 60
FAN CONTROL AND AIR FILTER……………………………………………………………………. 61
EXHAUST…………………………………………………………………………………….. 62
10.3.4 MRT 2470/3050 Privilege Plus ST4 S1 – ENGINE CONTROL AND ADJUSTMENT……………………………. 63
GETTING STARTED ENGINE PROGRAMMING AND DIAGNOSTICS………………………………………………. 64
Downloading the XENTRY StartKey onlinE…………………………………………………………. 65
DIAGNOSTIC SOFTWARE PROCEDURES………………………………………………………………… 67
10.3.5 MRT-X 2470/3050 Privilege Plus ST43A – ENGINE CONTROL AND ADJUSTMENT…………………………… 71
GETTING STARTED ENGINE PROGRAMMING AND DIAGNOSTICS………………………………………………. 72
PROGRAMMING procedures……………………………………………………………………….. 73
DIAGNOSTIC SOFTWARE PROCEDURES………………………………………………………………… 79
10.4 ENGINE REMOVAL…………………………………………………………………………………. 82
10.4.1 MRT 2470/3050 Privilege Plus ST4 S1…………………………………………………………. 82
ENGINE COMPONENTS……………………………………………………………………………. 82
GENERAL INFORMATION………………………………………………………………………….. 82
PREPARATION AND SAFETY INSTRUCTIONS……………………………………………………………. 82
SPECIFIC TOOLING…………………………………………………………………………….. 82
REMOVING THE ENGINE COMPONENTS………………………………………………………………… 83
10.4.2 MRT 2470/3050 Privilege Plus ST4 S1 – REMOVING ENGINE AND RADIATOR……………………………… 85
DISASSEMBLY ORDER……………………………………………………………………………. 85
REMOVING THE ENGINE RADIATOR………………………………………………………………….. 86
REMOVING THE RADIATOR HYDRAULIC MOTOR………………………………………………………….. 87
REMOVING THE I.C. ENGINE……………………………………………………………………… 88
10.4.3 MRT-X 2470/3050 Privilege Plus ST3A…………………………………………………………. 91
ENGINE COMPONENTS……………………………………………………………………………. 91
REMOVING THE ENGINE COMPONENTS………………………………………………………………… 92
10.4.4 MRT-X 2470/3050 Privilege Plus ST3A – REMOVING ENGINE AND RADIATOR………………………………100
DISASSEMBLY ORDER…………………………………………………………………………….100
REMOVING THE ENGINE RADIATOR…………………………………………………………………..101
REMOVING THE RADIATOR HYDRAULIC MOTOR…………………………………………………………..102
REMOVING THE I.C. ENGINE………………………………………………………………………103
REFITTING PROCEDURE…………………………………………………………………………..105
10.5 ENGINE TROUBLESHOOTING…………………………………………………………………………..106
10.5.1 Use of the Onboard Diagnostic Mercedes Engine ST4……………………………………………..106
Fault Codes CPC4……………………………………………………………………………..106
Fault Codes MCM2……………………………………………………………………………..128
Fault Codes ACM………………………………………………………………………………146
10.5.2 Use of the Onboard Diagnostic Mercedes ST3A…………………………………………………..161
Fault Codes………………………………………………………………………………….161
10.6 SPECIFIC ENGINE TOOLING………………………………………………………………………….181
10.6.1 XENTRY DIAGNOSTICS HARDWARE CASE…………………………………………………………….181
10.6.2 MINIDIAG 2 – RECOVERY RELEASE 2_5.02.69………………………………………………………182
20…………………………………………………………………………………………………….183
20.1 TRANSMISSION CHARACTERISTICS AND SPECIFICATIONS………………………………………………………..185
20.1.1 PRINCIPLE OF OPERATION OF GEARBOX……………………………………………………………….185
OPERATION……………………………………………………………………………………….185
OVERVIEW…………………………………………………………………………………….186
20.2 TRANSMISSION SCHEMATIC DIAGRAMS…………………………………………………………………..187
20.2.1 FORWARD GEAR SCHEMATIC DIAGRAM………………………………………………………………187
20.2.2 REVERSE GEAR SCHEMATIC DIAGRAM………………………………………………………………188
20.3 TRANSMISSION COMPONENTS LOCATION………………………………………………………………….189
20.3.1 MRT 2470/3050 Privilege Plus ST4 S1 / MRT-X 2470/3050 Privilege Plus ST3A HYDROSTATIC TRANSMISSION….189
20.4 TRANSMISSION CONTROL AND ADJUSTMENT ………………………………………………………………191
20.4.1 PRESSURE TAKE-OFF POINTS……………………………………………………………………191
A4VG 110 ET PUMP……………………………………………………………………………..191
MVP60.84D+KP20.16 PUMP………………………………………………………………………..192
A6VM 115 EP2 MOTOR……………………………………………………………………………192
20.4.2 PRESSURE TEST PORTS………………………………………………………………………..193
LOCATION…………………………………………………………………………………….193
VALUES………………………………………………………………………………………193
20.4.3 PUMP / MOTOR CONTROL AND ADJUSTMENT………………………………………………………….194
1 – TRANSMISSION ADJUSTMENT POINTS……………………………………………………………..194
2 – PRE START-UP OR POST MAINTENANCE CHECKS……………………………………………………..196
3 – PUMP MECHANICAL “0” ADJUSTMENT……………………………………………………………..197
4 – CHECKING PRESSURE CUT-OFF (DR)……………………………………………………………..198
5 – A6VM MOTOR CONTROL ADJUSTMENT………………………………………………………………199
6 – SEAL REPLACEMENT / TIGHTENING TORQUES……………………………………………………….200
HYDROSTATIC SYSTEM TROUBLESHOOTING……………………………………………………………..201
20.4.4 A4VG-DA / A6VM-DA HYDROSTATIC TRANSMISSION SETTINGS SHEET………………………………………203
20.4.5 TRANSMISSION ASSEMBLY TIGHTENING TORQUES……………………………………………………..205
20.5 TRANSMISSION REMOVAL…………………………………………………………………………….207
20.5.1 REMOVING THE HYDROSTATIC TRANSMISSION………………………………………………………..207
GENERAL INFORMATION…………………………………………………………………………..207
PREPARATION AND SAFETY INSTRUCTIONS ……………………………………………………………207
REMOVING THE UNIVERSAL SHAFTS………………………………………………………………….208
REMOVING THE HYDRAULIC MOTOR…………………………………………………………………..209
REMOVING THE PUMPS……………………………………………………………………………210
20.6 TRANSMISSION REFIT………………………………………………………………………………212
20.6.1 REFITTING THE HYDROSTATIC TRANSMISSION……………………………………………………….212
GENERAL INFORMATION…………………………………………………………………………..212
PREPARATION AND SAFETY INSTRUCTIONS ……………………………………………………………212
REFITTING THE PUMPS…………………………………………………………………………..213
REFITTING THE HYDRAULIC MOTOR………………………………………………………………….214
REFITTING THE UNIVERSAL SHAFTS…………………………………………………………………215
20.7 SPECIFIC TRANSMISSION TOOLING…………………………………………………………………….216
20.7.1 BASIS GAUGE KIT……………………………………………………………………………216
20.7.2 DIGITAL GAUGE KIT………………………………………………………………………….217
30…………………………………………………………………………………………………….219
30.1 REMOVING THE AXLE…………………………………………………………………………………..221
GENERAL INFORMATION………………………………………………………………………………….221
PREPARATION AND SAFETY INSTRUCTIONS ……………………………………………………………….221
30.1.1 REMOVING THE FRONT AXLE AND HYDROSTATIC MOTOR…………………………………………………222
30.1.2 REMOVING THE REAR AXLE……………………………………………………………………..225
30.2 REINSERTING THE AXLES……………………………………………………………………………227
GENERAL INFORMATION………………………………………………………………………………227
PREPARATION AND SAFETY INSTRUCTIONS ……………………………………………………………227
30.2.1 REINSERTING THE REAR AXLE…………………………………………………………………..228
30.2.2 REINSERTING THE FRONT AXLE AND HYDROSTATIC MOTOR………………………………………………230
40…………………………………………………………………………………………………….233
40.1 POSITION OF THE BRAKE COMPONENTS……………………………………………………………………..235
40.1.1 THE BRAKES COMPONENTS………………………………………………………………………….235
40.2 BLEEDING THE BRAKES AND ADJUSTING THE INCHING………………………………………………………236
40.2.1 PREPARATION AND SAFETY INSTRUCTIONS …………………………………………………………236
40.2.2 BRAKES BLEEDING PROCEDURE…………………………………………………………………..237
40.2.3 DEACTIVATE THE NEGATIVE BRAKE……………………………………………………………….238
40.2.4 SETTING THE GEAR IN NEUTRAL (FOR TOWING)……………………………………………………..238
40.2.5 BRAKING CIRCUIT FLUID FLOW: BRAKE VALVE, PEDAL AND ACCUMULATORS…………………………………239
40.2.6 BRAKES SYSTEM LAYOUT……………………………………………………………………….240
40.3 BRAKE REMOVAL…………………………………………………………………………………..241
40.3.1 SERVICE BRAKE……………………………………………………………………………..241
PREPARATION AND SAFETY INSTRUCTIONS…………………………………………………………….241
BRAKE PUMP REMOVAL……………………………………………………………………………241
40.4 BRAKE REMOVAL…………………………………………………………………………………..243
40.4.1 SERVICE BRAKE……………………………………………………………………………..243
40.5 SPECIAL TOOLS FOR THE BRAKES……………………………………………………………………..245
40.5.1 HYDRAULIC BRAKE VENTING VALVE……………………………………………………………….245
50…………………………………………………………………………………………………….247
50.1 BOOM CHARACTERISTICS AND SPECIFICATIONS……………………………………………………………….250
50.1.1 THREE EXTENSION BOOM…………………………………………………………………………..250
50.1.2 FOUR EXTENSION BOOM………………………………………………………………………..251
50.2 BOOM COMPONENTS LOCATION…………………………………………………………………………252
50.2.1 three extension boom LIST OF COMPONENT PART NOS……………………………………………….252
50.2.2 POSITION OF THE COMPONENTS OF THE PENTAGONAL THREE EXTENSION BOOM……………………………….253
50.2.3 FOUR extension boom LIST OF COMPONENT PART NOS………………………………………………..254
50.2.4 POSITION OF THE COMPONENTS OF THE PENTAGONAL FOUR EXTENSION BOOM………………………………..255
50.3 BOOM CONTROL AND ADJUSTMENT………………………………………………………………………256
50.3.1 ADJUSTING THE PENTAGONAL TELESCOPIC BOOM……………………………………………………..256
50.3.2 PREPARATION AND SAFETY INSTRUCTIONS………………………………………………………….256
50.3.3 REPLACING THE SLIDING BLOCKS………………………………………………………………..257
REPLACING THE FRONT SLIDING BLOCKS……………………………………………………………..257
REPLACING THE REAR SLIDING BLOCKS………………………………………………………………259
ADJUSTING THE SLIDING BLOCKS…………………………………………………………………..260
three extension BOOM ASSEMBLY OVERVIEW………………………………………………………….261
four extension BOOM ASSEMBLY OVERVIEW…………………………………………………………..262
50.3.4 CHECK AND ADJUSTMENT OF THE THREE EXTENSION BOOM CHAIN TENSION………………………………….263
CHECK THE TENSION OF THE BOOM UPPER CHAIN……………………………………………………….263
50.3.5 CHECK AND ADJUSTMENT OF THE FOUR EXTENSION BOOM CHAIN TENSION…………………………………..265
CHECK THE TENSION OF THE BOOM UPPER CHAIN……………………………………………………….265
CHECKING THE EXTERNAL CHAINS FOR WEAR…………………………………………………………..267
CHAIN ELONGATION……………………………………………………………………………..267
SIDE WEAR OF PLATES…………………………………………………………………………..268
EXTENDED PIN WEAR…………………………………………………………………………….268
ALIGNMENT OF EXTENDED PIN FLATS………………………………………………………………..268
50.4 BOOM REMOVAL……………………………………………………………………………………269
50.4.1 GENERAL INFORMATION………………………………………………………………………..269
50.4.2 PREPARATION AND SAFETY INSTRUCTIONS …………………………………………………………269
50.4.3 REMOVING THE TELESCOPIC BOOM FROM THE TRUCK…………………………………………………..270
50.4.4 REMOVING THE RAMS FROM THE BOOM …………………………………………………………….274
REMOVING THE TRAVERSE RAM……………………………………………………………………..274
REMOVING THE EXTENSION RAM…………………………………………………………………….275
50.4.5 REMOVING THE BOOM COMPONENTS………………………………………………………………..278
REMOVING THE HYDRAULIC SYSTEM AND ELECTRICAL SYSTEM OF THE BOOM……………………………………278
REMOVING THE boom extensions FROM THE EXTERNAL BOOM………………………………………………281
REMOVING THE boom extensions FROM THE 1st boom EXTENSION………………………………………….284
REMOVING THE boom extensions FROM THE 2ND boom EXTENSION………………………………………….284
50.4.6 REMOVING THE QUICK COUPLING…………………………………………………………………286
50.5 BOOM REFIT……………………………………………………………………………………..288
50.5.1 GENERAL INFORMATION………………………………………………………………………..288
50.5.2 PRELIMINARY OPERATIONS……………………………………………………………………..288
50.5.3 PREPARATION AND SAFETY INSTRUCTIONS …………………………………………………………288
50.5.4 REFITTING THE BOOM COMPONENTS……………………………………………………………….289
REFITTING THE 4th BOOM INTO THE 3rd EXTENSION BOOM (MRT 3050)……………………………………..289
REFITTING THE boom extensions INTO THE 2nd boom EXTENSION…………………………………………290
REFITTING THE Boom extensions INTO THE 1st boom EXTENSION…………………………………………292
REFITTING THE boom extensions INTO THE EXTERNAL BOOM……………………………………………..293
REFITTING THE QUICK COUPLING…………………………………………………………………..295
FITTING THE HYDRAULIC AND ELECTRICAL SYSTEMS OF THE BOOM………………………………………….296
50.5.5 REFITTING THE RAM TO THE BOOM……………………………………………………………….300
REFITTING THE EXTENSION RAM……………………………………………………………………300
REFITTING THE TRAVERSE RAM…………………………………………………………………….302
50.5.6 REFITTING THE TELESCOPIC BOOM TO THE TRUCK……………………………………………………303
50.6 SPECIFIC BOOM TOOLING……………………………………………………………………………306
50.6.1 SAFETY LOCK FOR THE LIFTING PISTON…………………………………………………………..306
50.6.2 TOOL FOR REMOVING THE EXTENSION RAM………………………………………………………….306
50.6.3 FLARE NUT WRENCH…………………………………………………………………………..306
50.6.4 MAGNETIC LIFTER……………………………………………………………………………306
70…………………………………………………………………………………………………….307
70.1 HYDRAULIC CHARACTERISTICS AND SPECIFICATION……………………………………………………………309
70.1.1 HYDRAULIC COMPONENT SHEETS……………………………………………………………………..309
DOUBLE EXTENSION BALANCING VALVE…………………………………………………………………..309
70.2 HYDRAULIC SCHEMATIC DIAGRAMS……………………………………………………………………..311
70.2.1 MRT 2470/3050 Privilege Plus LEGEND………………………………………………………….311
70.2.2 MRT 2470/3050 Privilege Plus SYSTEM………………………………………………………….312
70.3 HYDRAULIC COMPONENTS LOCATION…………………………………………………………………….313
70.3.1 KEY POSITION FOR HYDRAULIC COMPONENTS – SCHEMATIC DIAGRAM 1…………………………………….313
70.3.2 SCHEMATIC DIAGRAM 1 – HYDRAULIC COMPONENTS POSITION (FRAME)…………………………………….314
70.3.3 KEY POSITION FOR HYDRAULIC COMPONENTS – SCHEMATIC DIAGRAM 2…………………………………….315
70.3.4 SCHEMATIC DIAGRAM 2 – HYDRAULIC COMPONENTS POSITION (FRAME)…………………………………….316
70.3.5 KEY POSITION FOR HYDRAULIC COMPONENTS – SCHEMATIC DIAGRAM 3…………………………………….317
70.3.6 SCHEMATIC DIAGRAM 3 – HYDRAULIC COMPONENTS POSITION (TURRET)……………………………………318
70.4 HYDRAULIC CONTROL AND ADJUSTMENT………………………………………………………………….319
70.4.1 PRESSURE TEST PORTS………………………………………………………………………..319
VALUES………………………………………………………………………………………319
PRESSURE TEST PORT LOCATION……………………………………………………………………320
70.4.2 TIGHTENING TORQUES…………………………………………………………………………321
MAIN DISTRIBUTOR……………………………………………………………………………..321
HYDRAULIC CIRCUITS……………………………………………………………………………322
70.5 HYDRAULIC COMPONENTS REMOVAL …………………………………………………………………….323
70.5.1 HYDRAULIC CYLINDER REMOVAL………………………………………………………………….323
GENERAL INFORMATION…………………………………………………………………………..323
PREPARATION AND SAFETY INSTRUCTIONS…………………………………………………………….323
REMOVING THE LIFT CYLINDER…………………………………………………………………….324
REMOVING THE COMPENSATION CYLINDER……………………………………………………………..326
REMOVING THE LOCKING REAR CYLINDER……………………………………………………………..328
70.5.2 STABILISER HYDRAULIC CYLINDER……………………………………………………………….330
PREPARATION AND SAFETY INSTRUCTIONS…………………………………………………………….330
REMOVING HYDRAULIC CYLINDER……………………………………………………………………331
STABILISER DEPLOYMENT CYLINDER…………………………………………………………………332
70.5.3 HYDRAULIC DISTRIBUTOR REMOVAL……………………………………………………………….334
GENERAL INFORMATION…………………………………………………………………………..334
PREPARATION AND SAFETY INSTRUCTIONS…………………………………………………………….334
REMOVING THE DISTRIBUTOR………………………………………………………………………335
REMOVING STABILISERS ELECTROVALVE GROUP…………………………………………………………337
70.6 HYDRAULIC COMPONENTS REFIT……………………………………………………………………….340
70.6.1 HYDRAULIC DISTRIBUTOR REFIT…………………………………………………………………340
GENERAL INFORMATION…………………………………………………………………………..340
PREPARATION AND SAFETY INSTRUCTIONS…………………………………………………………….340
REFIT STABILISERS ELECTROVALVE GROUP……………………………………………………………341
REFIT THE DISTRIBUTOR…………………………………………………………………………344
70.6.2 STABILISER HYDRAULIC CYLINDER……………………………………………………………….346
PREPARATION AND SAFETY INSTRUCTIONS…………………………………………………………….346
REFIT HYDRAULIC CYLINDER………………………………………………………………………347
70.6.3 HYDRAULIC CYLINDER REFIT……………………………………………………………………350
GENERAL INFORMATION…………………………………………………………………………..350
PREPARATION AND SAFETY INSTRUCTIONS…………………………………………………………….350
REFIT THE LOCKING REAR CYLINDER………………………………………………………………..351
REFIT THE COMPENSATION CYLINDER………………………………………………………………..352
REFIT THE LIFT CYLINDER……………………………………………………………………….353
70.7 HYDRAULIC SPECIFIC TOOLING……………………………………………………………………….355
70.7.1 BASIC MANOMETER KIT………………………………………………………………………..355
70.7.2 DIGITAL MANOMETER KIT………………………………………………………………………356
80…………………………………………………………………………………………………….357
80.1 ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS………………………………………………………….360
80.1.1 SOFTWARE VERSION………………………………………………………………………………360
80.1.2 MACHINE OPERATING LOGIC…………………………………………………………………….361
80.1.3 MACHINE WITH FORKS…………………………………………………………………………362
MACHINE WITH FORKS ON WHEELS OR OUTRIGGERS………………………………………………………362
MACHINE WITH FORKS ON WHEELS OR OUTRIGGERS IN TILTING CONDITION……………………………………363
80.1.4 MACHINE ON OUTRIGGERS WITH BASKET……………………………………………………………364
80.1.5 MACHINE WITH FIXED BASKET / ORH……………………………………………………………..366
MACHINE ON OUTRIGGERS WITH FIXED BASKET / ORH……………………………………………………366
MACHINE ON OUTRIGGERS WITH FIXED BASKET / ORH IN TILTING CONDITION…………………………………367
MACHINE ON WHEELS WITH FIXED BASKET / ORH IN TILTING CONDITION…………………………………….369
MACHINE ON WHEELS WITH FIXED BASKET / ORH……………………………………………………….370
80.1.6 MACHINE WITH PENDULUM BASKET………………………………………………………………..372
MACHINE ON WHEELS WITH PENDULUM BASKET IN TILTING CONDITION……………………………………….372
MACHINE ON WHEELS WITH PENDULUM BASKET………………………………………………………….373
MACHINE ON OUTRIGGERS WITH PENDULUM BASKET IN TILTING CONDITION……………………………………375
MACHINE ON OUTRIGGERS WITH PENDULUM BASKET………………………………………………………376
80.1.7 MACHINE WITH RADIOCONTROL…………………………………………………………………..378
MACHINE ON OUTRIGGERS WITH RADIOCONTROL IN TILTING CONDITION………………………………………380
MACHINE ON OUTRIGGERS WITH RADIOCONTROL…………………………………………………………382
80.2 Electrical schematic diagrams…………………………………………………………………….394
80.2.1 WIRING DIAGRAMS: MRT ………………………………………………………………………394
POSITION OF THE CONNECTOR ON THE DIAGRAMS……………………………………………………….394
WIRING DIAGRAMS BY FUNCTION……………………………………………………………………402
1 – Power Distribution………………………………………………………………………..402
2 – Cranking-STOP from cab no basket pred……………………………………………………….404
3 – Cranking-STOP from cab with basket pred……………………………………………………..406
4 – Cranking-STOP from basket or Remote…………………………………………………………408
5 – CAN Open Network………………………………………………………………………….410
6 – CAN J1939 Network…………………………………………………………………………412
7 – CAN K-Line – CAN Transmission diag – RFID Network…………………………………………….414
8.1 – Engine FT4……………………………………………………………………………..416
8.2 – Engine FT4……………………………………………………………………………..418
9 – Engine T3a – X version…………………………………………………………………….420
10.1 – Hydraulic – Transmission………………………………………………………………..422
10.2 – Hydraulic – Transmission………………………………………………………………..424
11 – Hydraulic – Outtrigger; Chassis levelling…………………………………………………..426
12 – Hydraulic – Outtrigger sensors; Chassis sensors……………………………………………..428
13 – Hydraulic – Boom ………………………………………………………………………..430
14 – Hydraulic – Boom sensors; Tower sensors…………………………………………………….432
15 – Road Light………………………………………………………………………………434
16 – Cabin – Windscreen; beacon; door window…………………………………………………….436
17 – Cabin – Heater; USB plug; Navi Encoder …………………………………………………….438
18 – Safety – Override ……………………………………………………………………….440
19 – Cabin – Option_air cond; Option water heater………………………………………………..442
20.1 – Option – Cabin…………………………………………………………………………444
20.2 – Option – Cabin…………………………………………………………………………446
21 – Option – Boom……………………………………………………………………………448
22 – OPTION – REMOTE CONTROL…………………………………………………………………..450
23 – Option – Basket………………………………………………………………………….452
24 – Option – Basket 3D……………………………………………………………………….454
25 – Option – Magnetic retarder – Easy Manager…………………………………………………..456
26 – Option – Electric ladder; remote window; electric door……………………………………….458
27 – Option – triler brake; available supply; spare wire………………………………………….460
80.3 Electrical control and adjustment…………………………………………………………………509
80.3.1 Navigator…………………………………………………………………………………509
80.3.2 Display…………………………………………………………………………………..509
80.3.3 Start-up page……………………………………………………………………………..509
80.3.4 Password page……………………………………………………………………………..510
80.3.5 Engine page……………………………………………………………………………….511
80.3.6 Page selection page (Menu key)………………………………………………………………518
80.3.7 Diagram page (Diagram key)………………………………………………………………….519
80.3.8 Stability page (optional key)……………………………………………………………….520
80.3.9 Slowing-down page………………………………………………………………………….522
80.3.10 Calibration page………………………………………………………………………….523
Configuration………………………………………………………………………………..525
Calibration………………………………………………………………………………….526
80.4 ELECTRICAL troubleshooting……………………………………………………………………….539
ALARM CODES……………………………………………………………………………………..539
WARNING CODES………………………………………………………………………………..553
Use of the Onboard Diagnostic vehicle…………………………………………………………..558
80.5 ELECTRICAL SPECIFIC TOOLING………………………………………………………………………559
CONNECTION TO TRUCK………………………………………………………………………………560
85…………………………………………………………………………………………………….561
85.1 DRIVER’S CAB CHARACTERISTICS AND SPECIFICATIONS………………………………………………………..563
85.1.1 HEATING TECHNICAL DATA…………………………………………………………………………563
85.2 DRIVER’S CAB REMOVAL…………………………………………………………………………….565
85.3 GENERAL INFORMATION……………………………………………………………………………..565
85.3.1 PREPARATION AND SAFETY INSTRUCTIONS………………………………………………………….565
85.3.2 REMOVING THE CAB…………………………………………………………………………..566
REMOVING THE CAB HOUSING………………………………………………………………………566
DISCONNECT THE CAB ELECTRICAL SYSTEM……………………………………………………………567
DISCONNECT THE CAB HYDRAULIC SYSTEM…………………………………………………………….568
REMOVING THE CAB FROM THE FRAME………………………………………………………………..568
COMPONENT LOCATION……………………………………………………………………………571
PREPARATION AND SAFETY INSTRUCTIONS…………………………………………………………….571
ELECTRIC WINDOW AND MOTOR REMOVAL………………………………………………………………572
85.4 DRIVER’S CAB REFIT………………………………………………………………………………573
85.4.1 GENERAL INFORMATION………………………………………………………………………..573
85.4.2 PREPARATION AND SAFETY INSTRUCTIONS………………………………………………………….573
85.4.3 REFITTING THE CAB………………………………………………………………………….574
REFITTING THE CAB TO THE FRAME…………………………………………………………………574
RECONNECT THE CAB HYDRAULIC SYSTEM……………………………………………………………..575
RECONNECT THE CAB ELECTRICAL SYSTEM…………………………………………………………….576
REFITTING THE CAB HOUSING……………………………………………………………………..577
85.4.4 COMPONENT CAB REFIT………………………………………………………………………..579
COMPONENT LOCATION……………………………………………………………………………579
PREPARATION AND SAFETY INSTRUCTIONS…………………………………………………………….579
ELECTRIC WINDOW AND MOTOR REFIT………………………………………………………………..580
90…………………………………………………………………………………………………….583
90.1 FRAME – BODY REMOVAL………………………………………………………………………………..585
90.1.1 GENERAL INFORMATION……………………………………………………………………………585
90.1.2 PREPARATION AND SAFETY INSTRUCTIONS………………………………………………………….585
90.1.3 REMOVING THE TURRET FROM THE FRAME ………………………………………………………….586
REMOVING THE TURRET ROTATION MOTOR …………………………………………………………….588
90.1.4 REMOVING THE TURRET THRUST RING……………………………………………………………..589
90.2 FRAME – BODY REFIT………………………………………………………………………………590
90.2.1 GENERAL INFORMATION………………………………………………………………………..590
90.2.2 PREPARATION AND SAFETY INSTRUCTIONS………………………………………………………….590
90.2.3 REFITTING THE THRUST RING…………………………………………………………………..591
90.2.4 REFITTING THE TURRET……………………………………………………………………….592
90.2.5 REFITTING THE TURRET ROTATION MOTOR …………………………………………………………594
ADJUSTING THE TURRET ROTATION BRAKE…………………………………………………………….594
110……………………………………………………………………………………………………595
Options – Attachments……………………………………………………………………………………597
110.1 ELECTROMECHANICAL LADDER………………………………………………………………………..597
GENERAL INFORMATION………………………………………………………………………………597
PREPARATION AND SAFETY INSTRUCTIONS ……………………………………………………………597
110.1.1 ELECTROMECHANICAL LADDER DISASSEMBLY………………………………………………………..598
110.1.2 ELECTROMECHANICAL LADDER REASSEMBLY…………………………………………………………600
110.2 AIR CONDITIONER………………………………………………………………………………..602
110.2.1 OPERATING PRINCIPLE……………………………………………………………………….602
110.2.2 AIR CONDITIONER ASSEMBLY…………………………………………………………………..603
ADJUSTING THE AIR CONDITIONING PRESSURES………………………………………………………..614

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V