Manitou 220 TJ, 220 TJ-, 220 TJ-X 2RD ST3A S1, 220 TJ-XP 4RD ST3A S1 Repair Manual 647648EN
$30
- Type Of Manual: Repair Manual
- Manual ID: 647648EN
- Format: PDF
- Size: 36.2MB
- Number of Pages: 224
Description
-
Model List:
- 220 TJ
- 220 TJ-
- 220 TJ-X 2RD ST3A S1
- 220 TJ-XP 4RD ST3A S1
- 1. N (16/07/2021)220 TJ220 TJ220 TJX 2RD ST3A S1220 TJXP 4RD ST3A S1REPAIR MANUAL
- 2. Sommaire général General table of content
- 4. GENERAL, CHARACTERISTICS AND SAFETY
- 4.1. GENERAL INSTRUCTIONS AND SAFETY NOTICE
- 4.1.1. FOREWORD
- 4.1.2. SERVICING POSITION
- 4.1.3. EXPLANATION OF SYMBOLS
- 4.1.4. SERVICING RULES
- 4.2. GENERAL CHARACTERISTICS AND SPECIFICATIONS
- 4.2.1. SPECIFICATIONS
- 4.2.2. LUBRICANTS AND FUEL
- 4.2.3. DIMENSIONS AND DIAGRAMS
- 4.2.3.1. Dimensions (220 TJ, 220 TJX 2RD ST3A S1)
- 4.2.3.2. Diagram (220 TJ, 220 TJXP 2RD ST3A S1)
- 4.2.3.3. DIMENSIONS (220 TJ, 220 TJXP 4RD ST3A S1)
- 4.2.3.4. DIAGRAM (220 TJ, 220 TJXP 4RD ST3A S1)
- 4.3. GENERAL LOCATION
- 4.3.1. LOCATION OF NAME AND IDENTIFICATION PLATE
- 4.4. GENERAL CONTROL AND ADJUSTMENT
- 4.4.1. STANDARD TIGHTENING TORQUES
- 4.4.2. METRIC IMPERIAL UNIT CONVERSION
- 6. ENGINE
- 6.1. ENGINE CHARACTERISTICS AND SPECIFICATION
- 6.1.1. V1505E3B engine
- 6.2. Engine components location
- 6.2.1. Engine components
- 6.3. Engine controls and adjustments
- 6.3.1. ENGINE SILENT BLOCK TIGHTENING TORQUES
- 6.4. Engine removal refitting
- 6.4.1. Preparation and safety instructions
- 6.4.2. Throttle valve block Removal Refit
- 6.4.2.1. Throttle valve block Refit.
- 6.4.3. Engine removal
- 6.4.4. Engine refit
- 6.5. Specific engine tooling
- 6.5.1. Special engine tooling
- 6.5.2. Electronic tension meter
- 8. TRANSMISSION
- 8.1. Transmission characteristics and specifications
- 8.1.1. PRESSURE CONNECTORS
- 8.1.2. ADJUSTMENT POINTS
- 8.1.3. Transmission locations
- 8.2. Transmission controls and adjustments
- 8.2.1. HYDROSTATIC PRESSURE
- 8.2.1.1. PREPARATION
- 8.2.2. CALIBRATION LP BOOSTER VALVE
- 8.2.3. NEUTRAL POINT ADJUSTMENT SERVOCONTROL PISTON
- 8.2.4. CALIBRATION ZERO FLOW VALVE DR
- 8.2.5. CALIBRATION HP VALVES
- 8.3. TRANSMISSION REMOVAL REFIT
- 8.3.1. HYDROSTATIC PUMP REMOVAL
- 8.3.2. HYDROSTATIC PUMP REFIT
- 8.3.3. HYDROSTATIC MOTOR REMOVAL
- 8.3.4. HYDROSTATIC MOTOR REFIT
- 8.4. Specific transmission tooling
- 8.4.1. Basic manometer box
- 8.4.2. Digital manometer box
- 10. AXLE
- 10.1. AXLE CONTROL AND ADJUSTMENT
- 10.1.1. TIGHTENING TORQUE
- 10.1.2. PLACING IN FREEWHEEL MODE
- 10.1.3. FRONT AXLE REMOVAL
- 10.1.4. FRONT AXLE REFIT
- 10.1.5. REAR AXLE REMOVAL
- 10.1.6. REAR AXLE REFIT
- 12. JIB Basket
- 12.1. JIB BASKET CHARACTERISTICS AND SPECIFICATIONS
- 12.2. JIB ACCESS PLATFORM SCHEMATIC DIAGRAMS
- 12.2.1. BOOM KINEMATICS
- 12.3. Jib Basket locations
- 12.4. Jib basket controls and adjustments
- 12.4.1. PREPARATION AND SAFETY INSTRUCTIONS
- 12.4.2. JIB ACCESS PLATFORM CABLE INSPECTION
- 12.4.2.1. CHECKING REEVING CABLE TENSION
- 12.4.2.2. CHECKING TELESCOPE SHIMS
- 12.5. Jib basket removal refit
- 12.5.1. PREPARATION AND SAFETY INSTRUCTIONS
- 12.5.2. JIB BASKET ASSEMBLY REMOVAL
- 12.5.3. JIB BASKET ASSEMBLY REFIT
- 12.5.4. TELESCOPE REMOVAL
- 12.5.5. TELESCOPE REASSEMBLY
- 12.5.6. TELESCOPE COMPONENT REMOVAL
- 12.5.7. TELESCOPE COMPONENT REFIT
- 14. HYDRAULICS
- 14.1. Hydraulic characteristics and specifications
- 14.1.1. Hydraulic component sheets
- 14.1.1.1. DANFOSS DISTRIBUTOR CONTROL COMPONENT
- 14.1.1.2. PVG 32 ELEMENT WITH PRESSURE BALANCE
- 14.1.1.3. ENTRY PLATE PVG 32
- 14.1.1.4. PVG 32 VALVE BANK
- 14.2. Hydraulic schematic diagrams
- 14.2.2. Diagram
- 14.3. Hydraulic locations
- 14.4. Hydraulic controls and adjustments
- 14.4.1. Pressure adjustment
- 14.4.1.1. Menu search
- 14.4.2. PROPORTIONAL DISTRIBUTOR CALIBRATION
- 14.4.3. LS AUXILIARY PUMP VALVE CALIBRATION
- 14.4.3.1. PREPARATION
- 14.4.3.2. Check and adjust LS auxiliary pump DR (pressure relief) and FR (flow control) valves
- 14.4.4. TURNTABLE FUNCTION BLOCK CALIBRATION
- 14.4.5. JIB FUNCTION BLOCK CALIBRATION
- 14.4.6. Bleeding the structure lifting cylinder
- 14.5. Hydraulics removal refit
- 14.5.1. PROPORTIONAL VALVE BANK REMOVAL REFIT
- 14.5.2. TURNTABLE FUNCTION BLOCK REFIT
- 14.5.3. TURNTABLE FUNCTION BLOCK REMOVAL
- 14.5.4. TURNTABLE FUNCTION BLOCK REFIT
- 14.5.5. DECOMPRESSION OF HOSES
- 14.5.6. HOSE REMOVAL PROCEDURE
- 14.5.7. STRUCTURE LIFTING CYLINDER REMOVAL
- 14.5.8. JIB LIFTING CYLINDER REMOVAL 220TJ
- 14.5.9. JIB LIFTING CYLINDER REFIT 220TJ
- 14.5.10. JIB LIFTING CYLINDER REMOVAL 220TJ
- 14.5.11. JIB LIFTING CYLINDER REFIT 220TJ
- 14.5.12. BASKET ROTATION CYLINDER REMOVAL
- 14.5.13. BASKET ROTATION CYLINDER REFIT
- 14.5.14. Valve block and valve removal
- 14.6. Specific transmission tooling
- 14.6.1. Basic manometer box
- 14.6.2. Digital manometer box
- 16. ELECTRICITY
- 16.1. Electricity characteristics and specifications
- 16.1.1. Fuse and relay box
- 16.1.1.1. Power fuse box (BFP)
- 16.1.1.2. Fuse and relay box (BF)
- 16.1.2. Turntable fuses
- 16.1.2.1. Base control panel fuses
- 16.2. WIRING DIAGRAMS
- 16.2.1. POSITIONS BY DIAGRAM
- 16.2.2. Diagram 1 Power Supplies Emergency Stop BACKUP PUMP Engine Functions
- 16.2.3. Diagram 2 Can bus network
- 16.2.4. Diagram 3 SIGNALING Generator TRACKUNIT
- 16.2.5. Diagram 4 Sensor inputs
- 16.2.6. Diagram 5 Travel
- 16.2.7. Diagram 6 PROPORTIONAL MOVEMENTS
- 16.2.8. Diagram 7 AUXILIARY PROPORTIONAL MOVEMENTS
- 16.2.9. Diagram 8 Overload Hydraulic safety
- 16.3. Electricity locations
- 16.3.1. Harness parts list
- 16.3.2. Harness assembly
- 16.3.3. AMP1 harness
- 16.3.4. AMP2 harness
- 16.3.5. AMP3 harness
- 16.3.6. Basket harness
- 16.3.7. Chassis Harness
- 16.3.8. Basket UPC102 ECU harness
- 16.3.9. Arm structure/telescope sensor harness
- 16.3.10. Jib function harness
- 16.3.11. Jib hinge harness
- 16.3.12. Base and basket control panels
- 16.3.12.1. Control panel parts list
- 16.3.12.2. Base and basket control panel controls and indicator lamps
- 16.3.12.3. Base control panel wiring
- 16.3.12.4. Basket control panel wiring sheet 1
- 16.3.12.5. Basket control panel wiring sheet 2
- 16.3.12.6. BASKET CONTROL PANEL WIRING sheet 3
- 16.4. ELECTRICAL CONTROL AND ADJUSTMENT
- 16.4.1. CONTROLS USED ON THE BASE CONTROL PANEL
- 16.4.2. IMPORTANT GENERAL COMMENTS
- 16.4.3. PROGRAMME OPERATION
- 16.4.3.1. Startup page
- 16.4.3.2. Preheat pages
- 16.4.3.3. Work pages
- 16.4.3.4. Screen tab
- 16.4.3.5. CODIFICATION tab
- 16.4.3.6. DIAGNOSTIC tab
- 16.4.3.7. Secret Code tab
- 16.4.3.8. CONFIGURATION tab
- 16.4.3.9. Maintenance CONFIGURATION tab
- 16.4.3.10. CALIBRATION tab
- 16.4.3.11. Engine speed calibration
- 16.4.3.12. Immobilizer Option
- 16.4.3.13. USB Transfer Option
- 16.4.4. PROGRAM PARAMETERS
- 16.5. SENSOR ADJUSTMENT
- 16.5.1. Overload sensor adjustment
- 16.5.2. FAULT CODIFICATION
- 16.5.2.1. TYPE DE COMPONENT OR SYSTEM OR MAINTENANCE OR I/O
- 16.5.2.2. LOCATIONIDENTIFICATION OF COMPONENTS OR FAULT CODE No.
- 16.5.2.3. TYPE OF FAULT
- 16.5.3. FAULT CODE LIST
- 16.6. Specific electric tooling
- 16.6.1. Breakout boxes
- 16.6.2. Electrovalve adapter
- 18. CHASSIS BODYWORK
- 18.1. CHECKING AND MEASURING CROWN GEAR PLAY
- 18.2. COUNTERWEIGHT REMOVAL/REFIT
- 18.2.1. PREPARATION AND SAFETY INSTRUCTIONS
- 18.2.2. SIDE COUNTERWEIGHT REMOVAL
- 20. OPTIONS ATTACHMENTS
- 20.1. SafeManSystem secondary PROTECTION SYSTEM FIRST VERSION
- 20.1.1. LOCATION OF COMPONENTS
- 20.1.2. HARNESSES
- 20.1.2.1. RESET PUSHBUTTON HARNESS (BASKET CONTROL PANEL)
- 20.1.2.2. EXTENSION HARNESS (BASE CONTROL PANEL)
- 20.2. SPS secondary PROTECTION SYSTEM SECOND VERSION
- 20.2.1. LOCATION OF COMPONENTS
- 20.2.2. HARNESSES
- 20.2.2.1. RESET PUSHBUTTON HARNESS (BASKET CONTROL PANEL)
- 20.2.2.2. SENSOR HARNESS (BASKET CONTROL PANEL)
- 20.2.2.3. EXTENSION HARNESS (BASE CONTROL PANEL)
- 20.2.3. ADJUSTING THE DETECTION CABLE
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