Mustang Compact Track Loader 1750RT 2100RT 2500RT Service Manual (50940165) – PDF DOWNLOAD

Mustang Compact Track Loader 1750RT 2100RT 2500RT Service Manual (50940165) – PDF DOWNLOAD

DESCRIPTION:

Mustang Compact Track Loader 1750RT 2100RT 2500RT Service Manual (50940165) – PDF DOWNLOAD

1750RT
1750RT NXT2/3
2100RT
2100RT NXT2/3
2500RT
2500RT NXT3

Safety Alert Symbol

This symbol identifies potential safety hazards, which, if not properly avoided, could result in injury. When you see this symbol in this manual or on the machine, you are reminded to BE ALERT! Your personal safety is involved

Introduction

Contents and Use of this Manual

• This manual provides information about the safe and proper operation, maintenance and service procedures for the machine. Major points of safe operation, maintenance and service are detailed in the Safety chapter of this manual. This manual also includes general troubleshooting and specification information about the machine.
• Follow the instructions in the Safety, Operation and Maintenance chapters concerning accident prevention regulations, safety and occupational regulations, and machine and traffic regulations. Manitou Americas is not liable for damage resulting from the failure to follow these regulations.
• CAUTION Improper operation, inspection, maintenance and service of the machine can cause injury or death. Become familiar with the machine before operating it. It is the owner’s or employer’s responsibility to fully instruct each operator in the proper and safe operation and maintenance of the machine.
• It is the owner’s or employer’s responsibility to fully instruct each operator in the proper and safe operation and maintenance of the machine. A storage container is provided behind the operator’s seat for storing the Operator’s Manual. After using the manual, return it to the storage container. This manual is considered a permanent part of the machine and should be with the machine at all times.
• If the machine is resold, include this operator’s manual as part of the sale. Replace this manual promptly if it becomes damaged, lost or stolen. Some illustrations in this manual may show doors, guards and shields open or removed for illustrative purposes only. BE SURE all doors, guards and shields are in their proper operating positions BEFORE starting the engine to operate the machine.
• Because of ongoing product improvements, information included in this manual may not exactly match the machine. Manitou Americas reserves the right to modify and improve products at any time without notice or obligation.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Mustang Compact Track Loader 1750RT 2100RT 2500RT Service Manual (50940165) – PDF DOWNLOAD

Introduction11
Safety Symbol 11
Contents and Use of this Manual 11
Safety Symbol and Signal Words12
Safety Alert Symbol 12
Signal Words 12
Machine Orientation 12
Proper Machine Use12
Service and Registration 13
Machine Model and Serial Numbers 13
Component Serial Numbers 13
ROPS/FOPS Certification Label14
Component Identification15
Fields of Application 16
Using Attachments 16
Vibration Information 17
Vibration Measurement and Actions17
Vibration Levels 18
Fire Extinguisher 18
Manufacturer Information 18
Indicator and Operation Symbols19
Safety21
Safety Symbol and Signal Words21
Safety Alert Symbol 21
Signal Words 21
Mandatory Safety Shutdown Procedure22
Before Starting 22
During Operation 23
Applications with Load-Handling Devices 26
Parking the Machine27
Electrical Energy 27
Maintenance and Service Safety Practices27
Battery Hazards29
Fire Hazards30
Additional Safety Equipment 30
Crystalline Silica Exposure31
Transporting the Machine31
Lifting the Machine with a Crane 31
Loading and Transporting the Machine31
Safety Decals 32
New Decal Application32
ANSI-Style Safety Decals33
ISO-Style Safety Decals35
Specifications 37
Fluids/Lubricants Types and Capacities37
Dimensions38
Payloads/Capacities40
Weights 41
Track Drive 41
Coolant Compound Table 41
Engine 42
Table of Contents
50940165/C0718 2 Printed in USA
Hydraulic System 43
General 43
Drive Hydraulics 44
Pumps 44
Cylinders 45
Forces and Cycle Times 45
Electrical System 46
Sound Power/Pressure Levels 46
Vibration Levels 46
Features 47
Standard Features 47
Optional Features 47
Common Materials and Densities 48
Controls 49
Multi-Function Display 50
Switches/Indicators 51
Multi-Function Display Screens 52
Screen Access 52
Status, Maintenance and Error Code Screens 52
Configuration Screens 54
Audible Alerts 57
Control Joysticks 57
Joystick Tilt Function ISO/D-H Control Patterns 57
Activating D-H Control Pattern Option 57
Deactivating D-H Control Pattern Option 58
Left Joystick Functions 58
Right Joystick Functions 59
Joystick Buttons/Switch Functions 59
Joystick Control Sensitivity 60
Configuring Control Sensitivity 60
Straight Tracking Adjust 61
Parking Brake/Work Hydraulics Lock-out 63
Cab Heat and Air Conditioning (Option) 63
Operator’s Seat 64
Seat Forward and Back Horizontal Adjustment 64
Seat Height Vertical Height/Weight Suspension Adjustment 64
Air Suspension 64
Mechanical Suspension 64
Seat Belt 64
Fastening/Unfastening the Seat Belt 65
Armrest/Joystick Console Adjustment 65
Throttle Controls 66
Travel Controls 66
Travel Speed Range Selection 66
Travel Speed Limit (Option) 67
Activating Travel Speed Limit Option 67
Deactivating Travel Speed Limit Option 68
Travel Speed Limit Option Operation 68
Lift Arm Float Button 69
Hydraglide™ Button (Option) 69
Work Lights 70
Work Lights 70
Battery Disconnect Switch (Option) 70
Windshield Wipers/Washer 71
Wiper/Washer Control 71
Washer Fluid Reservoir 71
Printed in USA 3 50940165/C0718
Operation73
Operational Checks73
Pre-Start Checks 73
Checks During Operation 74
Parking Checks 74
Before Operation 75
Cab Entry and Exit75
Opening/Closing the Cab Door (Option)75
Cab Door Removal76
Seat and Armrest/Joystick Console Adjustment76
Seat Belt 77
Parking Brake 77
Disengage Parking Brake 78
Starting the Engine78
Cold-Starting79
After Starting79
Warm Up 80
Run-In Period 80
Stopping the Engine 80
Engine Stalling 81
Diesel Particulate Filter (DPF) Regeneration Procedures81
Reset Regeneration82
Stationary Regeneration82
Forcing Stationary Regeneration 83
Regeneration Inhibit 85
Cancelling Regeneration Inhibit 86
DPF Service 87
After Operation 88
Jump-Starting 88
Travel Drive Operation 90
ISO Pattern Travel Drive Controls91
D-H Pattern Travel Drive Controls (Option) 91
Straight Tracking Adjust 92
Rubber Track Use Cautions and Tips 92
Travel Drive Error Condition Operation (Limp Mode) 94
Alternate Transport Mode Activation94
Alternate Transport Mode Cancel 95
Backup Alarm 95
Lift Arm Operation 96
Attachment Transport Position 96
Joystick Control Patterns96
ISO Pattern Lift Arm Operation Controls96
D-H Pattern Lift Arm Operation Controls (Option)97
Self-Leveling98
Self-Leveling Cancel (Option)98
Lift Arm Float 99
Hydraglide™ Ride Control System (Option)100
Hydraulics Control Lock 101
Lift Arm Support 102
Engage Lift Arm Support 102
Model 1750RT (Serial Numbers 131001 and Up) Model 2100RT (Serial Numbers 241001 and
Up) Model 2500RT (All Serial Numbers)102
Model 1750RT (Serial Numbers 131001 and before) Model 2100RT (Serial Numbers 241001
and before)103
Release Lift Arm Support 104
Model 1750RT (Serial Numbers 30871 and Up) Model 2100RT (Serial Numbers 40421 and Up)
Model 2500RT (All Serial Numbers) 104
50940165/C0718 4 Printed in USA
Model 1750RT (Serial Numbers 30870 and before) / Model 2100RT (Serial Numbers 40420
and before) 104
Connecting/Disconnecting Attachments 105
Connecting Attachments 105
Disconnecting Attachments 106
Powering Attachments with Hydraulic Function 107
Connecting Hydraulic Attachments to the Auxiliary Hydraulic Circuits 107
Disconnecting Hydraulic Attachments from the Auxiliary Hydraulics Circuit 108
Auxiliary Hydraulics Operation 108
Standard-Flow Auxiliary Hydraulics Control 108
High-Flow Auxiliary Hydraulics Control (Option) 109
Optional 14-Pin Connector 109
Switch / Pin Assignments 109
Lifting the Machine using a Crane 110
Crane Lifting Preparation 110
Loading and Transporting the Machine on a Transport Vehicle 111
Loading and Securing the Machine 112
Storage Box 113
Maintenance 115
Maintenance Schedule 116
Checks, Cleaning and Inspection 116
Leakage Check 117
Lubrication and Filter Changes 117
Functional Check 117
Maintenance Interval 118
Engine Maintenance 119
Engine Access 119
Closing Engine Covers 119
Engine Oil 120
Checking Engine Oil Level 120
Changing Engine Oil and Filter 121
Engine Air Filters 123
Changing Air Filter Elements 123
Engine Cooling System 124
Checking Coolant Level 124
Cleaning Radiator Fins 125
Draining/Refilling Cooling System 125
Belt Maintenance 126
Checking and Adjusting Belt Tension 126
Air Conditioning Belt 127
DPF Service 127
Fuel System Maintenance 127
Adding Fuel 128
Water Separator Inspection/Maintenance 128
Changing Fuel Filter 130
Hydraulic System Maintenance 131
Checking Hydraulic Oil Level 131
Changing Hydraulic Oil and Filter 132
Hydraulic Hose Maintenance 134
Travel Motor Maintenance 135
Travel Motor Gearbox Oil 135
Track Maintenance 135
Track Replacement 136
General Lubrication 139
Tilting ROPS/FOPS 140
Raising ROPS/FOPS 140
Printed in USA 5 50940165/C0718
Lower ROPS/FOPS142
Electrical System143
Battery 143
Using a Booster Battery (Jump-Starting)144
Fuses and Relays145
Engine Compartment Fuses/Relays
(Model 2500RT)145
Engine Compartment Fuses/Relays 147
Engine Compartment Fuses/Relays 149
Fuses Under ROPS/FOPS150
Control Modules 151
Multi-function Control Module 151
Lift Arm and Standard Auxiliary Flow Control Module151
Engine Control Module (ECU)151
Main/Drive Control Module151
Long-Term Storage 152
Before Storage 152
After Storage 152
Air Conditioning Maintenance 153
Air Conditioning Filters 153
Cab Air Filter 153
Outside Air Intake Filter153
Windshield Washer Reservoir 154
Final Shutdown / Decommissioning 155
Before Disposal 155
Machine Disposal 155
Maintenance Log156
Lift Arm and ROPS/FOPS 159
Lift Arm Alignment Stops159
Tilt Stop Adjustment 159
Lift Arm Removal162
Lift Arm Installation165
ROPS/FOPS Service 167
ROPS/FOPS Removal 167
ROPS/FOPS Installation 173
Model 2500RT Engine Removal/Installation 181
Engine Removal – Model 2500RT 181
Engine Installation – Model 2500RT 194
Models 1750RT/2100RT Tier 4 Engine Removal/Installation 207
Tier 4 Engine Removal
Model 1750RT (S/N 131001 and Up)
Model 2100RT (S/N 241001 and Up) 207
Tier 4 Engine Installation
Model 1750RT (S/N 131001 and Up)
Model 2100RT (S/N 241001 and Up) 220
1750RT/2100RT interim Tier 4 Engine Removal/Installation 233
Interim Tier 4 Engine Removal
Model 1750RT (S/N 131000 and Before)
Model 2100RT (S/N 241000 and Before) 233
Interim Tier 4 Engine Installation
Model 1750RT (S/N 131000 and Before)
Model 2100RT (S/N 241000 and Before) 247
50940165/C0718 6 Printed in USA
Hydraulic Equipment 263
General Hydraulic Service Notes 263
Hydraulic Hoses/Piping 263
Seals 263
Hydraulic Oil Analysis 264
Hydraulic Control Valve 264
Main Control Valve Removal 265
Main Control Valve Installation 265
High-Flow Hydraulics 266
Hydraulic Pilot Valve 266
Self-Level Valve 267
Float/Hydraglide™ Valve 267
Travel Drive Motors 268
Drive Motor Idle Speed 268
Drive Motor High Speed Adjustment 268
Model 1750RT (Serial Numbers 30871 and Up), Model 2100RT (Serial Numbers 40421 and
Up), Model 2500RT (All Serial Numbers) 268
Model 1750RT (Serial Numbers 30870 and before), Model 2100RT (Serial Numbers 40420
and before) 268
Travel Motor Gearbox Oil 269
Hydrostatic Drive Pump 269
Hydrostatic Pump Swash Plates 269
Swash Plate Sensors 269
Forward and Reverse Solenoids 270
Hydrostatic Pump Removal 270
Hydrostatic Pump Installation 273
Hydrostatic Pump Drive Coupling Removal and Installation 276
Installation 277
Hydrostatic Pump Input Shaft Seal Replacement 278
Input Shaft Seal Removal 278
Input Shaft Seal Installation 279
Hydraulic Gear Pump 280
Hydraulic Cylinder Disassembly/Assembly 280
Cylinder Disassembly 281
Cylinder Assembly 282
Bleeding Air After Cylinder Installation 283
Hydraulic System Tests 285
Hydraulic Pump 285
Hydrostatic Pump (Later Machines) 285
Hydrostatic Pump (Early Machines) 286
Hydrostatic Drive System Pressures 287
Hydrostatic Charge Pressure Test and Adjustment 287
Main Relief Pressure Test 288
Main Pressure Adjustment 289
Tilt/Lift Cylinder Relief Pressure Tests 290
Inspection 290
Cylinder Rod/Base End Pressure Tests 291
Tilt Cylinder Base End Pressure Test 291
Tilt Cylinder Rod End Pressure Test 292
Lift Cylinder Base End Pressure Test 292
Lift Cylinder Rod End Pressure Test 293
Cylinder Drift Tests 294
Tilt Cylinder Drift Test 294
Lift Cylinder Drift Test 294
Cylinder Internal Leakage Tests 294
Tilt Cylinder Internal Leakage Test 294
Printed in USA 7 50940165/C0718
Lift Cylinder Internal Leakage Test295
Lift/Tilt Relief Pressure Adjustment 296
Electrical/Control Systems297
Electrical Schematics 297
Battery 297
Power Distribution 297
Power Distribution Module Fuse Socket Test297
Main Power Relay 298
Relay Testing298
Machine Test 298
Bench Test298
Electrical Control System 299
Electrical Control System General Information299
CAN System General Information 299
Control Module Locations300
Multi-function Control/Interlock Module (Controller 3)301
Engine Control Module (ECU)302
Main ECU Power Relay 2 302
Lift Arm and Standard Auxiliary Flow Control Module (Maestro Controller 1)303
Control Module (Maestro Controller 2)303
Optional High-Flow Module (Early Machines)303
Multi-Function Display304
CAN System Service/Computer Connection305
J1939 Data Connector305
Electronics Diagnostic Kit 305
CAN/Computer Connection Harnesses305
Service Adapter Harness 305
Deutz Engine CAN/Computer Connection Harness (SerDia) (Model 2500RT)306
Lighting307
Work Light Bulb Replacement 307
Tail Light Bulb Replacement308
Dome Light Bulb Replacement309
Electronics Diagnostic Kit 311
Diagnostic Kit Operation311
Displayed Telemetry Information312
Troubleshooting 313
Engine Troubleshooting 313
Indicator Lamp Troubleshooting314
Seal and Hose Troubleshooting 315
Hydraulic System Troubleshooting316
Hydrostatic Travel Drive System Troubleshooting 318
Hydrostatic Drive Motors Troubleshooting 320
Electrical Troubleshooting 321
Miscellaneous Troubleshooting321
Error Codes322
Controller Communication Error Codes322
Yanmar Engine Diagnostic Trouble Codes (DTC) – Models 1750RT/2100RT 322
Deutz Engine Error Codes – Model 2500RT330
Drive and Valve Error Codes335
50940165/C0718 8 Printed in USA
Schematics 343
Schematic Conventions 343
Model 2500RT (SN 80301 and Up) Schematics 344
2500RT Fuse/Relay Locations Index 344
2500RT Connector / Splice Locations Index 345
Engine/Starting and Charging – Model 2500RT 348
Engine Sensors – Models 2500RT 349
Engine ECU – Models 2500RT 350
Power Distribution/Fuses – Models 2500RT 351
Power Distribution/Relays – Models 2500RT 352
I/O Controller – Models 2500RT 353
Solenoid Controller A – Models 2500RT 354
Solenoid Controller B – Models 2500RT 355
Operator/Drive Controls – Models 2500RT 356
High-Flow/Self-Level/Power-A-Tach® Quick Attach System – Models 2500RT 357
HVAC – Models 2500RT 358
Track Tension/Work Lights – Models 2500RT 359
Wipers/Washer Pump – Models 2500RT 360
EU Road Lighting – Models 2500RT 361
Auxiliary Power/Dome Light/Radio – Models 2500RT 362
Operator CAN Interface – Models 2500RT 363
Grounds – Models 2500RT 364
Model 1750RT with Tier 4 Engines (Serial Numbers 131301 and Up) Model 2100RT with Tier 4
Engines (Serial Numbers 280051 and Up) 365
Models 1750RT and 2100RT with Tier 4 Engines – Fuse/Relay Locations Index 365
1750RT / 2100RT with Tier 4 Engines Connector / Splice Locations Index 366
Engine/Starting and Charging – Models 1750RT / 2100RT with Tier 4 Engines 368
Power Distribution/Fuses – Models 1750RT / 2100RT with Tier 4 Engines 369
Power Distribution/Relays – Models 1750RT / 2100RT with Tier 4 Engines 370
Engine Sensors – Models 1750RT / 2100RT with Tier 4 Engines 371
Engine ECU – Models 1750RT / 2100RT with Tier 4 Engines 372
Engine ECU (Continued) – Models 1750RT / 2100RT with Tier 4 Engines 373
I/O Controller – Models 1750RT / 2100RT with Tier 4 Engines 374
Solenoid Controller A – Models 1750RT / 2100RT with Tier 4 Engines 375
Solenoid Controller B – Models 1750RT / 2100RT with Tier 4 Engines 376
Operator/Drive Controls – Models 1750RT / 2100RT with Tier 4 Engines 377
High-Flow/Self-Level/Power-A-Tach® Quick Attach System – Models 1750RT / 2100RT with Tier 4
Engines 378
HVAC – Models 1750RT / 2100RT with Tier 4 Engines 379
Track Tension/Work Lights – Models 1750RT / 2100RT with Tier 4 Engines 380
Wipers/Washer Pumps – Models 1750RT / 2100RT with Tier 4 Engines 381
EU Road Lighting – Models 1750RT / 2100RT with Tier 4 Engines 382
Auxiliary Power/Dome Light/Radio – Models 1750RT / 2100RT with Tier 4 Engines 383
Operator CAN Interface – Models 1750RT / 2100RT with Tier 4 Engines 384
Grounds – Models 1750RT / 2100RT with Tier 4 Engines 385
Model 1750RT with Tier 4 Engine (Serial Numbers 131001 and Up)
Model 2100RT with Tier 4 Engine (Serial Numbers 241001 and Up) 386
Models 1750RT and 2100RT with Tier 4 Engines – Fuse/Relay Locations Index 386
1750RT / 2100RT with Tier 4 Engines Connector / Splice Locations Index 387
Engine/Starting and Charging – Models 1750RT / 2100RT with Tier 4 Engines 389
Power Distribution/Fuses – Models 1750RT / 2100RT with Tier 4 Engines 390
Power Distribution/Relays – Models 1750RT / 2100RT with Tier 4 Engines 391
Engine Sensors – Models 1750RT / 2100RT with Tier 4 Engines 392
Engine ECU – Models 1750RT / 2100RT with Tier 4 Engines 393
Engine ECU (Continued) – Models 1750RT / 2100RT with Tier 4 Engines 394
I/O Controller – Models 1750RT / 2100RT with Tier 4 Engines 395
Solenoid Controller A – Models 1750RT / 2100RT with Tier 4 Engines 396
Printed in USA 9 50940165/C0718
Solenoid Controller B – Models 1750RT / 2100RT with Tier 4 Engines397
Operator/Drive Controls – Models 1750RT / 2100RT with Tier 4 Engines398
High-Flow/Self-Level/Power-A-Tach® Quick Attach System – Models 1750RT / 2100RT with Tier 4
Engines399
HVAC – Models 1750RT / 2100RT with Tier 4 Engines400
Track Tension/Work Lights – Models 1750RT / 2100RT with Tier 4 Engines 401
Wipers/Washer Pumps – Models 1750RT / 2100RT with Tier 4 Engines 402
EU Road Lighting – Models 1750RT / 2100RT with Tier 4 Engines403
Auxiliary Power/Dome Light/Radio – Models 1750RT / 2100RT with Tier 4 Engines 404
Operator CAN Interface – Models 1750RT / 2100RT with Tier 4 Engines 405
Grounds – Models 1750RT / 2100RT with Tier 4 Engines 406
Model 1750RT with interim Tier 4 Engines (Serial Numbers 31051 – 131000), Model 2100RT with interim
Tier 4 Engines (Serial Numbers 40501 – 241000)407
1750RT (Serial Numbers 30981 – 131000), 2100RT (Serial Numbers 40501 – 241000) Fuse/Relay
Locations Index 407
1750RT (Serial Numbers 30981 – 131000), 2100RT (Serial Numbers 40501 – 241000) Connector /
Splice Locations Index408
Engine/Starting and Charging – Model 1750RT / 2100RT with interim Tier 4 Engines411
Engine Sensors – Model 1750RT / 2100RT with interim Tier 4 Engines 412
Engine ECU – Model 1750RT / 2100RT with interim Tier 4 Engines 413
Power Distribution – Model 1750RT / 2100RT with interim Tier 4 Engines414
Controller 3 – Model 1750RT / 2100RT with interim Tier 4 Engines 415
Controller 2 – Model 1750RT / 2100RT with interim Tier 4 Engines 416
Controller 1 – Model 1750RT / 2100RT with interim Tier 4 Engines 417
Operator/Drive Controls – Model 1750RT / 2100RT with interim Tier 4 Engines418
High-Flow/Self-Level/Power-A-Tach® Quick Attach System – Model 1750RT / 2100RT with interim
Tier 4 Engines 419
HVAC – Model 1750RT / 2100RT with interim Tier 4 Engines420
Track Tension/Lighting Control – Model 1750RT / 2100RT with interim Tier 4 Engines421
Wipers/Washer Pumps – Model 1750RT / 2100RT with interim Tier 4 Engines 422
Work Lights – Model 1750RT / 2100RT with interim Tier 4 Engines423
EU Road Lighting – Model 1750RT / 2100RT with interim Tier 4 Engines424
Operator Display/CAN Interface – Model 1750RT / 2100RT with interim Tier 4 Engines 425
Grounds – Model 1750RT / 2100RT with interim Tier 4 Engines 426
Hydraulic Schematic427
Index 429
Torque Specifications435
SAE Torque Values