Manitou MRT 3255 PRIVILEGE PLUS ST4/T4F \MRT-X 3255 PRIVILEGE PLUS ST3A Repair Manual – PDF DOWNLOAD
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Manitou MRT 3255 PRIVILEGE PLUS ST4/T4F \MRT-X 3255 PRIVILEGE PLUS ST3A Repair Manual – PDF DOWNLOAD
Language : English
Pages :902
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Manitou MRT 3255 PRIVILEGE PLUS ST4/T4F \MRT-X 3255 PRIVILEGE PLUS ST3A Repair Manual – PDF DOWNLOAD
Pdg_647488EN 1
Page de garde / Front page 1
Som_GeneM235EN 3
Group_00_MR647488EN 5
Som_Gr00M235EN 5
Group_00 7
00_00_M235EN 7
PREAMBLE 8
MAINTENANCE POSITION 9
RULES FOR MAINTENANCE 10
00_01_M235EN 13
CHARACTERISTICS 14
DIMENSIONS 14
00_03_M235EN 15
IDENTIFICATION PLATES 16
LOCATION 17
00_04_M235EN 19
STANDARD TIGHTENING TORQUES 20
LUBRICANTS AND FUEL 21
Group_10_MR647488EN 25
Som_Gr10M235EN 25
Group_10 27
10_01_M235EN 27
MRT3255 – ENGINE CHARACTERISTICS 28
ENGINE SYSTEM General information 28
Networking – system overview 29
Identification of the Major Units 30
EXAUST AFTERTREATMENT SYSTEM – SYSTEM DESCRIPTION 31
Inducement strategy (only MRT3255 Model) 34
MRT3255-X – ENGINE CHARACTERISTICS 38
ENGINE General information 39
Identification of the engine 41
10_03_M235EN 43
ENGINE SURROUNDINGS 44
MRT 3255 PLUS PRIVILEGE EURO4 44
MRT-X 3255 PLUS PRIVILEGE SP3FINAL 45
MRT 3255PLUS PRIVILEGE EURO4 46
AIR COOLING/COOLING LIQUID CIRCUIT 47
FAN MOTOR CIRCUIT 48
FUEL COOLING CIRCUIT 49
MRT-X 3255 PLUS PRIVILEGE SP3FINAL 50
AIR COOLING/COOLING LIQUID CIRCUIT 51
FAN MOTOR CIRCUIT 52
FUEL COOLING CIRCUIT 53
10_04_M235EN 55
FAN CONTROL OPERATION 56
SCHEMATIC DIAGRAM 57
MRT3255 – TIGHTENING TORQUE 59
ENGINE SUSPENSION ASSEMBLY 59
FAN CONTROL AND AIR FILTER 60
EXHAUST 61
MRT3255-X – TIGHTENING TORQUE 63
ENGINE SUSPENSION ASSEMBLY 63
FAN CONTROL AND AIR FILTER 64
EXHAUST 65
MRT3255 – ENGINE CONTROL AND ADJUSTMENT 66
GETTING STARTED ENGINE PROGRAMMING AND DIAGNOSTICS 67
Downloading the XENTRY StartKey onlinE 68
DIAGNOSTIC SOFTWARE PROCEDURES 70
Fault Codes MCM2 97
Fault Codes ACM116
MRT3255-X – ENGINE CONTROL AND ADJUSTMENT130
GETTING STARTED ENGINE PROGRAMMING AND DIAGNOSTICS131
PROGRAMMING procedures132
DIAGNOSTIC SOFTWARE PROCEDURES138
Use of the Onboard Diagnostic Mercedes DeTier141
10_06_M235EN161
MRT3255 162
ENGINE COMPONENTS162
GENERAL INFORMATION162
PREPARATION AND SAFETY INSTRUCTIONS162
REMOVING THE ENGINE COMPONENTS163
MRT3255 – REMOVING THE ENGINE AND RADIATOR165
DISASSEMBLY ORDER165
REMOVING THE ENGINE RADIATOR166
REMOVING THE RADIATOR HYDRAULIC MOTOR167
REMOVING THE IC ENGINE168
MRT3255-X 172
ENGINE COMPONENTS172
REMOVING THE ENGINE COMPONENTS173
MRT3255 – X – REMOVING THE ENGINE AND RADIATOR181
DISASSEMBLY ORDER181
REMOVING THE ENGINE RADIATOR182
REMOVING THE RADIATOR HYDRAULIC MOTOR183
REMOVING THE IC ENGINE184
REFITTING PROCEDURE186
Group_20_MR647488EN187
Som_Gr20M235EN187
Group_20189
20_01_M235EN189
PRINCIPLE OF OPERATION OF GEARBOX190
OPERATION190
OVERVIEW191
CRUISE CONTROL SWITCH192
20_02_M235EN193
FUNCTION OF HYDROSTATIC COMPONENTS194
FORWARD GEAR SCHEMATIC DIAGRAM195
REVERSE GEAR SCHEMATIC DIAGRAM196
20_03_M235EN197
TRANSMISSION SYSTEM198
20_04_M235EN199
MRT3255 – TRANSMISSION CONTROL AND ADJUSTMENT200
EQUIPMENT REQUIRED200
USE OF BODAS-SERVICE SOFTWARE200
PRESSURE TAKE-OFF POINTS202
A4VG 145 DA SERIES 40 PUMP202
A11VO DA SERIES 95 PUMP203
A6VM 115 EP1 DA SERIES 71 MOTOR203
PRESSURE TEST PORTS204
LOCATION204
VALUES204
PUMP / MOTOR CONTROL AND ADJUSTMENT205
1 – TRANSMISSION ADJUSTMENT POINTS205
2 – PRE START-UP OR POST MAINTENANCE CHECKS207
3 – PUMP MECHANICAL “0” ADJUSTMENT208
4 – CHECKING PRESSURE CUT-OFF (DR)209
5 – A6VM MOTOR CONTROL ADJUSTMENT210
6 – SEAL REPLACEMENT / TIGHTENING TORQUES211
HYDROSTATIC SYSTEM TROUBLESHOOTING212
A4VG-DA / A6VM-DA HYDROSTATIC TRANSMISSION SETTINGS SHEET214
TRANSMISSION ASSEMBLY TIGHTENING TORQUES215
20_06_M235EN217
GENERAL INFORMATION218
PREPARATION AND SAFETY INSTRUCTIONS 218
REMOVING THE HYDROSTATIC TRANSMISSION219
REMOVING THE UNIVERSAL SHAFTS219
REMOVING THE HYDRAULIC MOTORS220
REMOVING THE GEAR222
REMOVING THE HYDROSTATIC PUMP224
20_07_M235EN227
GENERAL INFORMATION228
PREPARATION AND SAFETY INSTRUCTIONS 228
REFITTING THE GEAR229
REFITTING THE HYDRAULIC MOTORS232
REFITTING THE HYDROSTATIC PUMP233
20_08_M235EN235
USE OF THE ONBOARD DIAGNOSTIC BOSCH ELECTRONIC TRANSMISSION236
REXROTH TRANSMISSION ECU252
SYSTEM INTERNAL ERROR252
20_09_M235EN277
BASIS GAUGE KIT278
DIGITAL GAUGE KIT279
Group_30_MR647488EN281
Som_Gr30M235EN281
Group_30283
SUSPENSION CYLINDER SENSOR SETTINGS284
AXLE TIGHTENING TORQUES285
Group_40_MR647488EN287
Som_Gr40M235EN287
Group_40289
40_04_M235EN289
BRAKE COMPONENTS LOCATION290
LOCATION290
BRAKING CIRCUIT FLUID FLOW AND TURRET LOCKING291
BRAKING CIRCUIT FLUID FLO: BRAKE VALVE, PEDAL AND ACCUMULATORS292
BRAKING/STEERING HYDRAULIC DIAGRAM293
STEERING CIRCUIT FLUID FLO294
SERVICE BRAKE295
CHARACTERISTICS295
INCHING PEDAL295
PURGING PROCEDURE296
PARKING BRAKE298
CHARACTERISTICS298
PURGING PROCEDURE298
FREEWHEEL AND TOWING300
40_06_M235EN303
SERVICE BRAKE304
PREPARATION AND SAFETY INSTRUCTIONS305
BRAKE PUMP REMOVAL305
40_07_M235EN307
SERVICE BRAKE308
PREPARATION AND SAFETY INSTRUCTIONS309
BRAKE PUMP REFIT309
Group_50_MR647488EN311
Som_Gr50M235EN311
Group_50313
50_01_M235EN313
FOUR EXTENSION BOOM314
50_03_M235EN315
LIST OF COMPONENT PART NOS 316
POSITION OF THE COMPONENTS OF THE PENTAGONAL FOUR EXTENSION BOOM317
50_04_M235EN321
PREPARATION AND SAFETY INSTRUCTIONS322
REPLACING THE SLIDING BLOCKS323
REPLACING THE FRONT SLIDING BLOCKS323
REPLACING THE REAR SLIDING BLOCKS325
ADJUSTING THE SLIDING BLOCKS326
BOOM ASSEMBLY OVERVIEW327
CHECK AND ADJUSTMENT OF THE BOOM CHAIN TENSION328
CHECK THE TENSION OF THE BOOM UPPER CHAIN328
CHECKING THE EXTERNAL CHAINS FOR WEAR329
CHAIN ELONGATION329
SIDE WEAR OF PLATES330
EXTENDED PIN WEAR330
ALIGNMENT OF EXTENDED PIN FLATS330
50_06_M235EN333
GENERAL INFORMATION334
PREPARATION AND SAFETY INSTRUCTIONS 334
REMOVING THE TELESCOPIC BOOM FROM THE TRUCK335
REMOVING THE RAMS FROM THE BOOM 340
REMOVING THE TRAVERSE RAM340
REMOVING THE EXTENSION RAM341
REMOVING THE BOOM COMPONENTS345
REMOVING THE HYDRAULIC SYSTEM AND ELECTRICAL SYSTEM OF THE BOOM345
REMOVING THE Ist, IInd, IIIrd AND IVth BOOMS FROM THE EXTERNAL BOOM349
REMOVING THE IInd, IIIrd AND IVth BOOMS FROM THE Ist EXTENSION BOOM351
REMOVING THE IIIrd AND IVth BOOMS FROM THE IIND EXTENSION BOOM352
REMOVING THE IVth BOOM FROM THE IIIrd EXTENSION BOOM353
REMOVING THE QUICK COUPLING354
50_07_M235EN357
GENERAL INFORMATION358
PRELIMINARY OPERATIONS358
PREPARATION AND SAFETY INSTRUCTIONS 358
REFITTING THE BOOM COMPONENTS359
REFITTING THE IVth BOOM INTO THE iiird EXTENSION BOOM359
REFITTING THE IIIrd AND IVth BOOMS INTO THE IInd EXTENSION BOOM360
REFITTING THE IInd, IIIrd AND IVth BOOMS INTO THE Ist EXTENSION BOOM362
REFITTING THE Ist, IInd, IIIrd AND IVth BOOMS INTO THE EXTERNAL BOOM363
REFITTING THE QUICK-RELEASE COUPLING366
FITTING THE HYDRAULIC AND ELECTRICAL SYSTEMS OF THE BOOM368
REFITTING THE RAM TO THE BOOM372
REFITTING THE EXTENSION RAM372
REFITTING THE TRAVERSE RAM 374
REFITTING THE TELESCOPIC BOOM TO THE TRUCK376
50_09_M235EN381
SAFETY LOCK FOR THE LIFTING PISTON382
TOOL FOR REMOVING THE EXTENSION RAM382
FLARE NUT WRENCH382
MAGNETIC LIFTER382
Group_70_MR647488EN383
Som_Gr70M235EN383
Group_70385
70_01_M235EN385
F70_3_0015EN387
70_02_M235EN389
1 – MOVEMENTS HYDRAULIC SYSTEM LEGEND390
1 – MOVEMENTS HYDRAULIC SYSTEM391
2 – STEERING/BRAKES HYDRAULIC SYSTEM LEGEND392
2 – STEERING/BRAKES HYDRAULIC SYSTEM393
3 – OUTTRIGGER AND SUSPENSIONS HYDRAULICS SYSTEM LEGEND394
3 – OUTTRIGGER AND SUSPENSIONS HYDRAULICS SYSTEM LEGEND395
4 – TRANSMISSION HYDRAULIC SYSTEM LEGEND396
4 – TRANSMISSION HYDRAULIC SYSTEM397
70_03_M235EN399
KEY POSITION FOR HYDRAULIC COMPONENTS400
SCHEMATIC DIAGRAM 1 – HYDRAULIC COMPONENTS POSITION (FRAME)401
SCHEMATIC DIAGRAM 2 – HYDRAULIC COMPONENTS POSITION (FRAME)402
SCHEMATIC DIAGRAM 3 – HYDRAULIC COMPONENTS POSITION (TURRET)403
70_04_M235EN405
PRESSURE TEST PORTS406
VALUES406
PRESSURE TEST PORT LOCATION407
TIGHTENING TORQUES409
MAIN DISTRIBUTOR409
HYDRAULIC CIRCUITS410
70_06_M235EN411
HYDRAULIC CYLINDER REMOVAL412
GENERAL INFORMATION412
PREPARATION AND SAFETY INSTRUCTIONS412
REMOVING THE LIFT CYLINDER413
REMOVING THE COMPENSATION CYLINDER415
REMOVING THE SUSPENSION CYLINDER417
STABILISER HYDRAULIC CYLINDER + CHAINS418
SCHEMATIC DIAGRAM OF OPERATION418
PREPARATION AND SAFETY INSTRUCTIONS418
REMOVING HYDRAULIC CYLINDER419
CHAIN REMOVAL423
HYDRAULIC DISTRIBUTOR REMOVAL424
GENERAL INFORMATION424
PREPARATION AND SAFETY INSTRUCTIONS424
REMOVING THE DISTRIBUTOR425
REMOVING PRIORITY MODULE426
REMOVING STABILISERS ELECTROVALVE GROUP427
70_07_M235EN431
HYDRAULIC DISTRIBUTOR REFIT432
GENERAL INFORMATION432
PREPARATION AND SAFETY INSTRUCTIONS432
REFIT STABILISERS ELECTROVALVE GROUP433
REFIT PRIORITY MODULE435
REFIT THE DISTRIBUTOR436
STABILISER HYDRAULIC CYLINDER + CHAINS438
SCHEMATIC DIAGRAM OF OPERATION438
PREPARATION AND SAFETY INSTRUCTIONS438
CHAIN REFIT439
REFIT HYDRAULIC CYLINDER439
HYDRAULIC CYLINDER REFIT443
GENERAL INFORMATION443
PREPARATION AND SAFETY INSTRUCTIONS443
REFIT THE SUSPENSION CYLINDER444
REFIT THE COMPENSATION CYLINDER445
REFIT THE LIFT CYLINDER446
70_09_M235EN449
BASIC MANOMETER KIT450
DIGITAL MANOMETER KIT451
Group_80_MR647488EN453
Som_Gr80M235EN453
Group_80455
80_01_M235_A_EN455
CONNECTORS, FUSES AND RELAYS458
BOOM HEAD BOX 462
recognition accessory BOOM HEAD BOX – WITHOUT PLATFORM463
FRONT CARRIAGE LINE464
REAR CARRIAGE LINE (TIER4)482
FUSE AND RELAYS BOX CARRIAGE496
3B6 WIRING TRANSDUCTORS512
DASHBOARD TRANSDUCTORS WIRING514
DRIVING PLACE WIRING576
WIRING DASHBOARD582
ENGINE LINE WIRING – TIER 4F620
TURRET REAR LINE WIRING 624
PLATFORM INTERMEDIATE WIRING639
CABLE ON PLATFORM641
ENGINE LINE WIRING – TIER 3A642
REAR CARRIAGE LINE WIRING – T3A644
ADAPTOR WIRING CPC4-ADM2655
MICRO WIRING FOR BREAKING CHAINS 658
FUSE AND RELAYS BOX FOR A/C 659
A/C NORDICA WIRING667
INTERMEDIATE CABLE FOR ACCESSORY SEARCH – WITHOUT PLATFORM675
INTERMEDIATE CABLE FOR ACCESSORY SEARCH – WITHOUT PLATFORM676
SWITCH WIRING FOR OPT EXCLUSION676
A-B-C SWITCH WIRING FOR PLATFORM677
INTERMEDIATE CABLE WIRING FOR OPTIONAL678
CAB WIRING680
OPTIONAL X10A691
EXAMPLE OF CODES ON ELECTRICAL DIAGRAMS704
CABLE IDENTIFICATION ON A WIRING HARNESS705
POSITION OF CONNECTORS BY DIAGRAM707
ELECTRICAL DIAGRAMS BY FUNCTION716
11 – START-UP (Engine Mercedes Tier 4 final)716
12 – START-UP (Engine Mercedes Tier 3A)718
21 – CAN-BUS AND DIAGNOSTIC OUTLET (Engine Mercedes Tier 4 final)720
22 – CAN-BUS AND DIAGNOSTIC OUTLET (Engine Mercedes Tier 3A)722
3 – TRANSMISSION724
41 – HYDRAULIC MOVEMENTS (No platform version)726
42 – HYDRAULIC MOVEMENTS (Platform version)728
43 – HYDRAULIC MOVEMENTS (Platform version)730
44 – HYDRAULIC MOVEMENTS (Platform version)732
5 – SENSORS734
6 – lighting736
7 – OPTIONAL LIGHTS / WINDSCREEN WIPERS/ CAR RADIO738
81 – AIR CONDITIONING / HEATING SYSTEM740
82 – AIR CONDITIONING / HEATING SYSTEM742
9 – OPTIONAL744
10 – EMERGENCY746
11 – CAB748
12 – SUSPENSIONS750
80_03_M235EN753
KEYS755
CONNECTORS755
FRONT FRAME HARNESS 762
REAR FRAME MRT 3255 HARNESS763
REAR FRAME MRT-X 3255 HARNESS764
TURRET 1 HARNESS765
TURRET 2 HARNESS766
ENGINE MRT 3255 HARNESS767
ENGINE MRT-X 3255 HARNESS768
CAB 1 HARNESS769
CAB 2 HARNESS770
CAB 3 HARNESS771
CAB 4 HARNESS772
FUSE AND RELAY CHARIOT HARNESS773
FUSE AND RELAY CABINE HARNESS774
3D LOCATIONS775
FRONT FRAME HARNESS775
ENGINE HARNESS775
REAR FRAME MRT 3255 HARNESS776
REAR FRAME MRT-X 3255 HARNESS777
TURRET HARNESS778
ENGINE MRT 3255 HARNESS779
ENGINE MRT-X 3255 HARNESS780
CAB HARNESS781
80_04_M235EN783
ELECTRONIC SYSTEM OVERVIEW784
principle of operation784
electronic architecture LAYOUT785
3b6 supplying:785
CAN FLOW DIAGRAM786
components location787
Functional description 788
operator panel790
Software update procedure792
80_08_M235EN797
Use of the Onboard Diagnostic vehicle803
80_09_M235EN807
SPECIFIC TOOLING808
CONNECTION TO TRUCK809
Group_85_MR647488EN811
Som_Gr85M235EN811
Group_85813
85_01_M235EN813
HEATING TECHNICAL DATA814
85_02_M235EN815
HEATING ELECTRICAL SCHEMATIC DIAGRAM816
85_03_M235EN817
HEATING COMPONENTS LOCATION 819
CROSS-SECTION VIEW OF HEATING SYSTEM820
85_04_M235EN821
METERING PUMP ASSEMBLY POSITIONS822
85_06_M235EN823
85_07_M235EN833
85_08_M235EN843
HEATING CONTROL AND SAFETY SYSTEMS844
PROCEDURE TO ADOPT IN THE EVENT OF HEATING FAILURE844
85_09_M235EN845
AIRTRONIC HEATING DIAGNOSTIC DEVICE846
Group_90_MR647488EN847
Som_Gr90M235EN847
Group_90849
90_06_M235EN849
90_07_M235EN857
Group_110_MR647488EN867
Som_GR110_M235EN867
Group_110869
110_01_M235EN869
AIR CONDITIONER870
OPERATING PRINCIPLE870
DESCRIPTION OF THE WORKING871
FLUID CIRCUIT872
DESCRIPTION OF THE COMPONENTS873
110_03_M235EN875
AIR-CONDITIONING COMPONENTS OVERVIEW876
POSITION OF AIR CONDITIONING COMPONENTS879
POSITION OF AIR CONDITIONING CONNECTORS880
POSITION OF AIR CONDITIONING CONNECTORS ON DIAGRAM 881
110_04_M235EN883
INSTRUCTIONS FOR ASSEMBLING THE AIR CONDITIONER884
FEATURES OF COOLANT R134a885
PRECAUTIONS FOR HANDLING R134a885
FILLING COOLANT IN THE AIR CONDITIONING SYSTEM886
FILLING METHOD886
CHECKING THE WORKING887
AIR CONDITIONER CONTROLS887
ADJUSTING THE AIR CONDITIONING PRESSURES890
110_07_M235EN893
ASSEMBLING THE AIR CONDITIONING894
GENERAL INFORMATION894
PREPARATION AND SAFETY INSTRUCTIONS 894
ASSEMBLING THE AIR CONDITIONING IN THE CAB895
ASSEMBLING THE AIR CONDITIONING DRIVE UNIT896
ASSEMBLING THE AIR CONDITIONING HYDRAULIC SYSTEM898
INSPECTIONS AND CHECKS902
S.M 11/24
