Manitou MRT 3050 Privilege ST3A MRT-X 3050 Privilege ST3A REPAIR MANUAL – PDF DOWNLOAD
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Manitou MRT 3050 Privilege ST3A MRT-X 3050 Privilege ST3A REPAIR MANUAL – PDF DOWNLOAD
Language : English
Pages :476
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Manitou MRT 3050 Privilege ST3A MRT-X 3050 Privilege ST3A REPAIR MANUAL – PDF DOWNLOAD
Pdg_647396EN 1
Page de garde / Front page 1
Som_GeneM216EN 3
Group_00_MR647396 5
Som_Gr00M216EN 5
Group_00 7
00_00_m216en 7
PREAMBLE 8
MAINTENANCE POSITION 9
RULES FOR MAINTENANCE 10
00_01_m216en 13
CHARACTERISTICS 14
DIMENSIONS 14
00_03_m216en 15
IDENTIFICATION PLATES 16
LOCATION 17
00_04_m216en 19
STANDARD TIGHTENING TORQUES 20
Group_10_MR647396 21
Som_Gr10M216EN 21
Group_10 23
10_01_m216en 23
PERKINS 1106D EURO 3 ENGINE 24
GENERAL 24
INJECTION CIRCUIT 24
ELECTRONIC CONTROL MODULE (ECM) 25
PERKINS ENGINE ELECTRICAL DIAGRAM 26
PERKINS ENGINE ELECTRICAL COMPONENTS LOCATION 27
FUEL CIRCUITS LOCATION 28
COOLING CIRCUITS LOCATION 29
10_06_m216en 31
IC ENGINE 32
PREPARATION AND SAFETY INSTRUCTIONS 32
DISMANTLING ORDER 33
ENGINE BONNET REMOVAL 34
“HYDRAULIC PUMP + HYDROSTATIC PUMP” ASSEMBLY REMOVAL 35
AIR FILTER REMOVAL 37
IC ENGINE REMOVAL 38
IC ENGINE REFIT 44
10_08_m216en 45
PERKINS 1106D EURO 3 ENGINE ERROR CODES LIST 46
Group_20_MR647396 49
Som_Gr20M216EN 49
Group_20 51
20_02_m216en 51
FUNCTION OF HYDROSTATIC COMPONENTS 52
SCHEMATIC DIAGRAM HYDROSTATIC TRANSMISSION IN FORWARD GEAR 53
SCHEMATIC DIAGRAM HYDROSTATIC TRANSMISSION IN REVERSE GEAR 54
20_03_m216en 55
20_04_m216en 59
HYDROSTATIC PUMP AND MOTOR 60
OPERATION OVERVIEW 60
CALIBRATION 60
ERROR CODES 61
HYDROSTATIC TRANSMISSION PRESSURE TEST PORTS 62
CHECKS BEFORE INITIAL START-UP OR AFTER REPAIRS 64
GEAR BOX 65
OPERATION OVERVIEW 65
CHECKING THE TRANSFER CONDITIONS 65
ERROR CODES 65
TRANSMISSION TIGHTENING TORQUES 67
20_08_m216en 69
HYDROSTATIC SYSTEM TROUBLESHOOTING 70
PUMP / MOTOR 70
MACHINE 71
A4VG-DA / A6VM-DA HYDROSTATIC TRANSMISSION SETTINGS SHEET 72
TRANSMISSION ASSEMBLY FAULTS 73
RC4/4 HYDROSTATIC TRANSMISSION ECU 73
RC2/2 GEARBOX ECU 75
20_09_m216en 77
BASIC MANOMETER KIT 78
DIGITAL MANOMETER KIT 80
Group_30_MR647396 81
Som_Gr30M216EN 81
Group_30 83
SUSPENSION CYLINDER SENSOR SETTINGS 84
AXLE TIGHTENING TORQUES 85
Group_40_MR647396 87
Som_Gr40M216EN 87
Group_40 89
BRAKE COMPONENTS LOCATION 90
LOCATION 90
BRAKING CIRCUIT FLUID FLOW AND TURRET LOCKING 91
HYDRAULIC DIAGRAM 92
SERVICE BRAKE 93
CHARACTERISTICS 93
INCHING PEDAL 93
PURGING PROCEDURE 94
PARKING BRAKE 96
CHARACTERISTICS 96
PURGING PROCEDURE 96
FREEWHEEL AND TOWING 98
Group_50_MR647396101
Som_Gr50M216EN101
Group_50103
50_01_m216en103
FOUR EXTENSION ARM104
50_03_m216en105
LIST OF COMPONENT PART NOS 106
POSITION OF THE COMPONENTS OF THE PENTAGONAL FOUR EXTENSION ARM107
50_04_m216en109
PREPARATION AND SAFETY INSTRUCTIONS110
ADJUSTING THE FEET111
ADJUSTING THE BOOM FEET IST EXTENSION111
ADJUSTING THE BOOM FEET IIND EXTENSION112
ADJUSTING THE BOOM FEET IIIRD EXTENSION113
ADJUSTING THE BOOM FEET IVTH EXTENSION114
ADJUSTING THE BOOM CHAIN TIE RODS115
50_06_m216en119
GENERAL INFORMATION120
PREPARATION AND SAFETY INSTRUCTIONS 120
REMOVING THE TELESCOPIC BOOM FROM THE TRUCK121
REMOVING THE RAMS FROM THE BOOM 126
REMOVING THE TRAVERSE RAM126
REMOVING THE IST EXTENSION RAM127
REMOVING THE IIND EXTENSION RAM129
REMOVING THE BOOM COMPONENTS131
REMOVING THE HYDRAULIC SYSTEM AND ELECTRICAL SYSTEM OF THE BOOM131
REMOVING THE Ist, IInd, IIIrd AND IVth BOOMS FROM THE EXTERNAL BOOM135
REMOVING THE IInd, IIIrd AND IVth BOOMS FROM THE Ist EXTENSION BOOM137
REMOVING THE IIIrd AND IVth BOOMS FROM THE IIND EXTENSION BOOM138
REMOVING THE IVth BOOM FROM THE IIIrd EXTENSION BOOM139
50_07_m216en141
GENERAL INFORMATION142
PRELIMINARY OPERATIONS142
PREPARATION AND SAFETY INSTRUCTIONS 142
REFITTING THE BOOM COMPONENTS143
REFITTING THE IVth BOOM INTO THE iiird EXTENSION BOOM143
REFITTING THE IIIrd AND IVth BOOMS INTO THE IInd EXTENSION BOOM144
REFITTING THE IInd, IIIrd AND IVth BOOMS INTO THE Ist EXTENSION BOOM146
REFITTING THE Ist, IInd, IIIrd AND IVth BOOMS INTO THE EXTERNAL BOOM147
FITTING THE HYDRAULIC AND ELECTRICAL SYSTEMS OF THE BOOM150
REFITTING THE RAMS TO THE BOOM154
REFITTING THE IIND EXTENSION RAM154
REFITTING THE IST EXTENSION RAM155
REFITTING THE TRAVERSE RAM 156
REFITTING THE TELESCOPIC BOOM TO THE TRUCK158
50_09_m216en163
SAFETY LOCK FOR THE LIFTING PISTON164
TOOL FOR REMOVING THE EXTENSION RAM 164
Group_70_MR647396165
Som_Gr70M216EN165
Group_70167
70_01_m216en167
F70_3_0022EN169
f70_3_0075en173
F70_3_0076EN177
70_02_m216en181
KEY182
1 – HYDRAULIC MOVEMENTS SCHEMATIC DIAGRAM185
2 – STABILISERS – SUSPENSION SCHEMATIC DIAGRAM186
3 – DIRECTION – BRAKES SCHEMATIC DIAGRAM187
4 – HYDROSTATIC TRANSMISSION SCHEMATIC DIAGRAM188
70_03_m216en189
KEY POSITION FOR HYDRAULIC COMPONENTS190
SCHEMATIC DIAGRAM 1 – HYDRAULIC COMPONENTS POSITION (FRAME) 0
SCHEMATIC DIAGRAM 2 – HYDRAULIC COMPONENTS POSITION (FRAME) 0
SCHEMATIC DIAGRAM 3 – HYDRAULIC COMPONENTS POSITION (TURRET) 0
70_04_m216en195
PRESSURE TEST PORTS196
ADJUSTING THE TURRET ROTATION BRAKE199
COUNTERBALANCE VALVE TEST PROCEDURE200
LOCATION 2D/3D200
TESTING LIFTING AND TILTING CYLINDER VALVES201
TESTING TELESCOPE CYLINDER VALVES202
TIGHTENING TORQUES204
MAIN DISTRIBUTOR (D)204
70_06_m216en205
STABILISER HYDRAULIC CYLINDER + CHAINS206
SCHEMATIC DIAGRAM OF OPERATION 206
PREPARATION AND SAFETY INSTRUCTIONS206
HYDRAULIC CYLINDER REMOVAL207
CHAIN REMOVAL210
CHAIN AND HYDRAULIC CYLINDER REFIT210
70_09_m216en211
BASIC MANOMETER KIT212
DIGITAL MANOMETER KIT213
Group_80_MR647396215
Som_Gr80M216EN215
Group_80217
80_01_m216en217
OPERATING CONDITIONS218
MACHINE WITH FORKS218
MACHINE ON STABILISERS WITH PLATFORM220
MACHINE WITH FIXED BASKET / ORH222
MACHINE WITH PENDULAR PLATFORM230
MACHINE WITH RADIO CONTROL238
ECU INPUTS/OUTPUTS243
80_02_m216_a_en247
CODES ON THE ELECTRICAL DIAGRAMS250
DISTRIBUTION OF SCHEMATIC DIAGRAMS ON MACHINE251
80_02_m216_b_en253
KEY / POSITION OF CONNECTORS BY DIAGRAM 255
1 – BATTERIES, ALTERNATOR, STARTER, BACK-UP PUMP263
2 – IOMODE_C1/J2 CONTROL UNIT INPUT/OUTPUT264
3 – MACHINE LIGHTING265
4 – IOMODE_C1/J3 CONTROL UNIT INPUT/OUTPUT266
5 – MIDAC_C1 CONTROL UNIT INPUT/OUTPUT267
6 – FUSE OPTIONS AND START-UP RELAYS268
7 – CONNECTORS OPTION AND PROGRAMME CONNECTOR 3B6269
8 – RC2-2 GEARBOX CONTROL BOX270
9 – ENGINE CONNECTOR271
10 – RC4-4 TRANSMISSION CONTROL BOX272
11 – HYDROSTATIC PUMP AND HYDRAULIC ENGINE SENSORS273
12 – ARM_C1 CONTROL UNIT INPUT/OUTPUT274
13 – STABILISERS AND SUSPENSION ELECTROVALVES275
14 – ARM_C2 CONTROL UNIT INPUT/OUTPUT276
15 – STABILISERS AND SUSPENSION ELECTROVALVES277
16 – ROTATING MANIFOLD, ACCELERATOR PEDAL, INCHING PEDAL278
17 – BATTERIES, ALTERNATOR, STARTER, BACK-UP PUMP279
18 – IOMODE_B2/J2 CONTROL UNIT INPUT/OUTPUT280
19 – RADIO CONTROL/WINDSCREEN WIPER CONTROL SWITCH281
20 – IOMODE_B2/J3 CONTROL UNIT INPUT/OUTPUT282
21 – IOMODE_B1/J3 CONTROL UNIT INPUT/OUTPUT283
22 – MIXER BUCKET OPTION284
23 – HEATING AND RADIO285
24 – SCREEN CONNECTOR286
25 – IOMODE_B1/J2 CONTROL UNIT INPUT/OUTPUT287
26 – BASKET RADIO CONTROL CONNECTOR OPTION288
27 – MIDAC_T1 CONTROL UNIT INPUT/OUTPUT289
28 – ARM_T1 CONTROL UNIT INPUT/OUTPUT290
29 – DOOR CONTACT, TURRET ROTATION AND JIB CONTACTS, CYLINDER PRESSURE SENSITIVE SWITCHES291
30 – DANFOSS DISTRIBUTOR ELECTROVALVES, ROTATION POTENTIOMETER292
31 – DANFOSS JOYSTICK CONNECTOR293
32 – WORKING LIGHT, ROOF WINDSCREEN WIPER, SEAT SWITCHES294
33 – REAR WINDSCREEN WIPER, DEFROST, ELECTRIC WINDOW SWITCH, CAB LIGHTING295
80_02_m216_c_en297
KEY / POSITION OF CONNECTORS BY DIAGRAM299
1A – BATTERIES, ALTERNATOR, STARTER, BACK-UP PUMP307
1B – BATTERIES, ALTERNATOR, STARTER, BACK-UP PUMP308
2 – IOMODE_C1/J2 CONTROL UNIT INPUT/OUTPUT309
3 – MACHINE LIGHTING310
4 – IOMODE_C1/J3 CONTROL UNIT INPUT/OUTPUT 311
5 – MIDAC_C1 CONTROL UNIT INPUT/OUTPUT312
6 – FUSE OPTIONS AND START-UP RELAYS313
7 – CONNECTORS OPTION AND PROGRAMME CONNECTOR 3B6314
8 – RC2-2 GEARBOX CONTROL BOX 315
9 – ENGINE CONNECTOR316
10 – RC4-4 TRANSMISSION CONTROL BOX 317
11 – HYDROSTATIC PUMP AND HYDRAULIC ENGINE SENSORS318
12 – ARM_C1 CONTROL UNIT INPUT/OUTPUT319
13 – STABILISERS AND SUSPENSION ELECTROVALVES320
14 – ARM_C2 CONTROL UNIT INPUT/OUTPUT321
15 – STABILISERS AND SUSPENSION ELECTROVALVES322
16 – ROTATING MANIFOLD, ACCELERATOR PEDAL, INCHING PEDAL323
17 – BATTERIES, ALTERNATOR, STARTER, BACK-UP PUMP324
18 – IOMODE_B2/J2 CONTROL UNIT INPUT/OUTPUT325
19 – RADIO CONTROL/WINDSCREEN WIPER CONTROL SWITCH326
20 – IOMODE_B2/J3 CONTROL UNIT INPUT/OUTPUT327
21 – IOMODE_B1/J3 CONTROL UNIT INPUT/OUTPUT328
22 – MIXER BUCKET OPTION329
23 – HEATING AND RADIO330
24 – SCREEN CONNECTOR331
25 – IOMODE_B1/J2 CONTROL UNIT INPUT/OUTPUT332
26 – BASKET RADIO CONTROL CONNECTOR OPTION333
27 – MIDAC_T1 CONTROL UNIT INPUT/OUTPUT334
28 – ARM_T1 CONTROL UNIT INPUT/OUTPUT 335
29 – DOOR CONTACT, TURRET ROTATION AND JIB CONTACTS, CYLINDER PRESSURE SENSITIVE SWITCHES336
30 – DANFOSS DISTRIBUTOR ELECTROVALVES, ROTATION POTENTIOMETER 337
31 – DANFOSS JOYSTICK CONNECTOR338
32 – WORKING LIGHT, ROOF WINDSCREEN WIPER, SEAT SWITCHES 339
33 – REAR WINDSCREEN WIPER, DEFROST, ELECTRIC WINDOW SWITCH, CAB LIGHTING340
80_02_m216_d_en341
CODES ON SCHEMATIC DIAGRAMS342
KEY342
CAN FLOW DIAGRAM344
ECU POWER SUPPLY345
EMERGENCY STOPS AND ECM POWER SUPPLY346
80_03_m216en347
KEY / POSITION OF CONNECTORS348
2D LOCATION357
A – POSITION OF COMPONENTS AND CONNECTORS ON MACHINE357
B – FRAME AND TURRET HARNESS ASSEMBLY358
C – CAB HARNESS ASSEMBLY359
HARNESS DETAILS360
1 – FRONT FRAME HARNESS360
2 – REAR FRAME HARNESS361
3 – TURRET HARNESS362
4 – DASHBOARD HARNESS363
5 – CAB HARNESS364
6 – SEAT HARNESS365
7 – DISTRIBUTOR HARNESS366
8 – FRAME FUSE BOX AND RELAY367
9 – CAB FUSE BOX AND RELAY368
10 – ENGINE FUSE BOX AND RELAY369
11 – MOVEMENT LOCKING SYSTEM370
80_04_m216en371
3B6 ELECTRONIC SYSTEM372
Assembly view372
DISPLAYS OF VIEW373
Automatic diagnostic and warning messages377
Diagnostics pages378
Calibration of machine sensors379
Warning codes380
Alarm codes381
WINSCOPE395
CONNECTION TO TRUCK395
FIRST USE395
DIAGNOSTIC PLUG395
80_09_m216en399
TRUCK SPECIFIC CONNECTIONS400
CAS N°1400
CAS N°2400
CAS N°3401
CAS N°4401
DOCKING STATION404
WORKSHOP TROLLEY404
BREAKOUT BOX KIT405
ELECTROVALVE ADAPTER405
Group_85_MR647396407
Som_Gr85M216EN407
Group_85409
85_01_m216en409
HEATING TECHNICAL DATA410
85_02_m216en411
HEATING ELECTRICAL SCHEMATIC DIAGRAM412
85_03_m216en413
HEATING COMPONENTS LOCATION 415
CROSS-SECTION VIEW OF HEATING SYSTEM416
85_04_m216en417
METERING PUMP ASSEMBLY POSITIONS418
85_08_m216en419
HEATING CONTROL AND SAFETY SYSTEMS420
PROCEDURE TO ADOPT IN THE EVENT OF HEATING FAILURE420
85_09_m216en421
AIRTRONIC HEATING DIAGNOSTIC DEVICE422
Group_90_MR647396423
Som_Gr90M216FR423
Group_90425
90_06_m216en425
90_07_m216en441
Group_110_MR647396457
Som_Gr110M216EN457
Group_110459
110_02_m216en459
AIR CONDITIONING SCHEMATIC DIAGRAMS460
KEY460
1 – CONDENSER WIRING461
2 – CAB REAR UNIT WIRING462
3 – CAB INTERIOR WIRING463
4 – FUSE BOX AND RELAY464
PLATFORM SCHEMATIC DIAGRAM465
RADIO CONTROL SCHEMATIC DIAGRAM466
110_03_m216en467
AIR CONDITIONING COMPONENTS OVERVIEW468
AIR-CONDITIONING COMPONENTS LOCATION469
POSITION OF AIR CONDITIONING CONNECTORS470
KEY470
DIAGRAM 1: CONDENSER WIRING471
DIAGRAM 2: CAB REAR UNIT WIRING472
DIAGRAM 3: CAB INTERIOR WIRING473
DIAGRAM 4: FUSE BOX AND RELAYS474
110_04_m216en475
AIR CONDITIONING CHECKS AND CONTROLS476
S.M 11/24
