Manitou ATJ 60 RC T4 S1 Repair Manual 647778EN

Description

• Model List:
  • ATJ 60 RC T4 S1

• 1. Page de garde 647778201905
• 2. SOMMAIRY
• 3. _GENERAL CHARACTERISTICS AND SAFETY
• 3.1. GENERAL INSTRUCTIONS AND SAFETY NOTICE
• 3.1.1. FOREWORD
• 3.1.2. SERVICING POSITION
• 3.1.3. SERVICING RULES
• 3.2. GENERAL CHARACTERISTICS AND SPECIFICATIONS
• 3.2.1. CHARACTERISTICS AND FLUIDS
• 3.2.2. DIMENSIONS
• 3.3. GENERAL LOCATION
• 3.3.1. LOCATION OF NAME AND IDENTIFICATION PLATE
• 3.4. GENERAL CONTROLS AND ADJUSTMENTS
• 3.4.1. STANDARD TIGHTENING TORQUES
• 3.4.2. METRIC IMPERIAL UNIT CONVERSION
• 4. _ENGINE SPECIFICATION
• 4.1. ENGINE REMOVAL
• 4.1.1. ENGINE REMOVAL
• 4.1.1.1. A Remove the covers
• 4.1.1.2. B Remove the air filter
• 4.1.1.3. C Remove the harnesses
• 4.1.1.4. D Drain the cooling system
• 4.1.1.5. D Drain the oil circuit
• 4.1.1.6. E Disconnect the diesel circuit hoses
• 4.1.1.7. F Remove the hoses from the hydrostatic and auxiliary pumps
• 4.1.1.8. F Take out the engine
• 4.1.2. REFIT
• 5. _TRANSMISSION
• 5.1. TRANSMISSION CONTROLS AND ADJUSTMENTS
• 5.1.1. DESCRIPTION OF HYDROSTATIC PUMP (REXROTH)
• 5.1.1.1. Pressure test ports
• 5.1.1.2. Adjustment points
• 5.1.2. HYDROSTATIC PRESSURE ADJUSTMENT (REXROTH)
• 5.1.2.1. Engine speed unladen
• 5.1.2.2. Calibrate LP booster valve
• 5.1.2.3. Adjust the neutral point Servocontrol piston
• 5.1.2.3.1. A Without manometer
• 5.1.2.3.2. B With manometer
• 5.1.2.4. Calibrate HP Valves
• 5.1.2.5. Calibrate Zero flow valve DR
• 5.2. TRANSMISSION REMOVAL
• 5.2.1. HYDROSTATIC PUMP REMOVAL
• 5.2.1.1. REFIT
• 5.2.2. HYDROSTATIC MOTOR REMOVAL
• 5.2.2.1. REFIT
• 6. _AXLE
• 6.1. AXLE CONTROL AND ADJUSTMENT
• 6.1.1. FREEWHEEL CONFIGURATION FORWINCHING
• 6.1.1.1. RELEASE THE BRAKES AND WINCH THE MACHINE
• 6.1.1.2. RESTORING BRAKE FUNCTION
• 6.2. AXLE REMOVAL
• 6.2.1. FRONT AXLE REMOVAL
• 6.2.1.1. FRONT AXLE REFIT
• 6.2.2. REAR AXLE REMOVAL
• 6.2.2.1. REAR AXLE REFIT
• 7. _ARM BASKET
• 7.1. ARM BASKET REMOVAL
• 7.1.1. REMOVE THE TELESCOPIC BOOM CYLINDER PADS
• 7.1.1.1. REFIT
• 7.1.2. REMOVE THE ARM 3 PADS
• 7.1.2.1. REFIT
• 7.1.3. REMOVE THE PADS FROM THE MOVING TUBE
• 7.1.3.1. REFIT
• 8. _HYDRAULICS
• 8.1. HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
• 8.1.1. PVG32 4T PROPORTIONAL DISTRIBUTOR
• 8.1.2. DISTRIBUTOR BLOCK MA250CDC 016
• 8.1.3. BRAKE AND STEERING DISTRIBUTOR
• 8.1.4. VARIABLE DISPLACEMENT PUMP A10 VG
• 8.1.5. STEERING ROTATION BLOCK
• 8.1.6. GENERATOR UNIT
• 8.2. HYDRAULIC SCHEMATIC DIAGRAMS
• 8.2.1. HYDRAULIC COMPONENTS DIAGRAM KEY
• 8.2.2. SETTINGS
• 8.2.3. HYDRAULIC SCHEMATIC DIAGRAM
• 8.2.4. ELECTROVALVE ACTIVATION TABLE
• 8.3. HYDRAULIC LOCATIONS
• 8.3.1. HYDRAULIC COMPONENTS IN THE FRAME
• 8.3.2. HYDRAULIC COMPONENTS IN THE TURRET
• 8.3.3. HYDRAULIC COMPONENTS IN THE ARMS
• 8.4. HYDRAULIC CONTROLS AND ADJUSTMENTS
• 8.4.1. A PROPORTIONAL DISTRIBUTOR CALIBRATION
• 8.4.1.1. Inlet plate relief valve
• 8.4.1.2. arm lifting cylinder block valves
• 8.4.1.3. Telescopic boom cylinder block valves
• 8.4.1.4. arm lifting cylinder block valves
• 8.4.2. B DISTRIBUTOR BLOCK CALIBRATION
• 8.4.2.1. Jib supply circuit valves
• 8.4.2.2. Compensating/tilting supply circuit valves
• 8.4.2.3. Tilting cylinder extension valve adjustment
• 8.4.2.4. Tilting cylinder extension valve adjustment
• 8.4.3. C COMPENSATING/TILTING CIRCUIT
• 8.4.3.1. Resolving problems
• 8.4.3.2. Analysis of results
• 8.5. HYDRAULIC COMPONENT REMOVAL
• 8.5.1. REMOVAL OF PROPORTIONAL DISTRIBUTOR ELEMENTS
• 8.5.1.1. REFIT
• 8.5.2. DISTRIBUTOR BLOCK REMOVAL
• 8.5.2.1. REFIT
• 8.5.3. REMOVING A DISTRIBUTOR BLOCK VALVE
• 8.5.3.1. REFITTING A DISTRIBUTOR BLOCK VALVE
• 8.5.4. CYLINDER REMOVAL
• 8.5.4.1. PREPARING THE PLATFORM
• 8.5.4.2. DECOMPRESSION OF HOSES
• 8.5.4.3. CYLINDER REMOVAL
• 8.5.4.4. CYLINDER REFIT
• 8.5.4.5. REMOVAL OF VALVE BLOCKS AND VALVES
• 8.6. SPECIFIC HYDRAULIC TOOLING
• 8.6.1. BASIC MANOMETER BOX
• 8.6.2. DIGITAL MANOMETER BOX
• 8.6.3. LOOSENING AND POSITIONING TOOLS
• 9. _ELECTRICITY
• 9.1. ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS
• 9.1.1. FUSE AND RELAY BOXES
• 9.1.1.1. Power fuse box (BFP)
• 9.1.1.2. Fuse and relay box (BF)
• 9.1.1.3. Base ECU fuses UC234
• 9.1.2. TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS
• 9.1.2.1. HORN
• 9.1.2.2. ROTATING BEACON LIGHT
• 9.1.2.3. FUEL GAUGE
• 9.1.2.4. SA1 SA2 JOYSTICK
• 9.1.2.5. SA3 JOYSTICK
• 9.1.2.6. S2 IGNITION KEY
• 9.1.2.7. S4 S11 EMERGENCY STOP BUTTON
• 9.1.2.8. S9 S14 OVERLOAD SENSOR
• 9.1.2.9. AXLE DETECTOR
• 9.1.2.10. ARM DOWN SENSOR
• 9.1.2.11. BOOM RETRACTED SENSOR
• 9.1.2.12. EV1 HYDRAULIC SAFETY ELECTROVALVE
• 9.1.2.13. EV2 EV3 OSCILLATION ELECTROVALVE
• 9.1.2.14. EV4 EV17 BRAKE UNIT ELECTROVALVE
• 9.1.2.15. EV5 EV6 STEERING MODE ELECTROVALVE
• 9.1.2.16. EV7 EV8 STEERING ELECTROVALVE
• 9.1.2.17. EV9 EV10 TURRET ROTATION ELECTROVALVE
• 9.1.2.18. EV11 à EV14 BASKET ROTATION/INCLINATION ELECTROVALVE
• 9.1.2.19. EV15 EV16 JIB LIFTING ELECTROVALVE
• 9.1.2.20. EW1 EW2 PUMP ELECTROVALVE
• 9.1.2.21. EW4 GENERATOR ELECTROVALVE
• 9.1.2.22. EW5 to EW8 PROPORTIONAL ELECTROVALVE CONTROL
• 9.2. ELECTRICAL SCHEMATIC DIAGRAMS
• 9.2.1. ELECTRICAL COMPONENTS LOCATION
• 9.2.2. ELECTRICAL DIAGRAMS BY FUNCTION
• 9.2.2.1. DIAGRAM 1 POWER SUPPLIES EMERGENCY STOP BACKUP PUMP ENGINE FUNCTIONS
• 9.2.2.2. DIAGRAM 2 ENGINE POWER SUPPLIES VERSION WITHOUT BATTERY CUTOFF
• 9.2.2.3. DIAGRAM 3 ENGINE FUNCTIONS POWER SUPPLIES VERSION WITH BATTERY CUTOFF
• 9.2.2.4. DIAGRAM 4 CAN BUS NETWORK
• 9.2.2.5. DIAGRAM 5 SIGNALS GENERATOR EASY MANAGER
• 9.2.2.6. DIAGRAM 6 SENSOR INPUTS
• 9.2.2.7. DIAGRAM 7 TRAVEL
• 9.2.2.8. DIAGRAM 8 PROPORTIONAL MOVEMENTS
• 9.2.2.9. DIAGRAM 9 AUXILIARY PROPORTIONAL MOVEMENT
• 9.2.2.10. DIAGRAM 10 OVERLOAD HYDRAULIC SAFETY
• 9.3. ELECTRICAL LOCATIONS
• 9.3.1. ELECTRICAL CONTROL COMPONENTS
• 9.3.2. ELECTRICAL POWER COMPONENTS
• 9.3.3. OPTIONAL ELECTRICAL COMPONENTS
• 9.3.4. GENERAL SYNOPSIS OF ELECTRICAL CONNECTIONS
• 9.3.5. CHASSIS harness ITEM 1
• 9.3.6. Intermediate inductive sensors harness ITEM 2
• 9.3.7. BASKET harness ITEM 3
• 9.3.8. AMP1 harness ITEM 4
• 9.3.9. AMP2 harness ITEM 5
• 9.3.10. AMP3 harness ITEM 6
• 9.3.11. ENGINE harness ITEM 7
• 9.3.12. BASKET harness ITEM 7
• 9.3.13. BASE AND BASKET CONTROL PANELS
• 9.3.13.1. Control panel parts list
• 9.4. ELECTRICITY CONTROLS AND ADJUSTMENTS
• 9.4.1. ELECTRICAL CONTROL AND ADJUSTMENT
• 9.4.1.1. CONTROLS USED ON THE BASE CONTROL PANEL
• 9.4.1.1.1. LEVELLING CALIBRATION
• 9.4.1.1.2. OVERLOAD SENSOR ADJUSTMENT
• 9.4.1.1.3. ARM DOWN SENSOR ADJUSTMENT
• 9.4.1.1.4. TELESCOPE RETRACTED SENSOR ADJUSTMENT
• 9.4.1.2. PROGRAMME OPERATION
• 9.4.1.2.1. Screen Menu
• 9.4.1.2.2. Codification menu
• 9.4.1.2.3. Diagnostics menu
• 9.4.1.2.4. Secret Code Menu
• 9.4.1.2.5. Parameters Menu
• 9.4.1.2.6. Maintenance Menu
• 9.4.1.2.7. Engine Menu
• 9.4.1.2.8. Calibration Menu
• 9.4.2. JOYSTICK TESTING
• 9.4.2.1. TESTING FROM THE BASE CONTROL PANEL
• 9.4.2.2. TEST WITH A VOLTMETER
• 9.4.2.3. JOYSTICK CALIBRATION
• 9.4.3. Card removal refit
• 9.4.3.1. Removal of base control panel card UD22
• 9.4.3.2. Removal of base control panel ECU card UC 234
• 9.5. ELECTRICAL TROUBLESHOOTING
• 9.5.1. FAULT CODIFICATION
• 9.5.1.1. BASIC PRINCIPLE
• 9.5.1.2. CREATION OF A COMPONENT TYPE CODE
• 9.5.1.3. COMPONENT IDENTIFICATION
• 9.5.1.4. CREATION OF A FAULT TYPE CODE
• 9.5.1.5. SYSTEM FAULTS
• 9.5.1.6. MAINTENANCE INFORMATION
• 9.5.1.7. INPUT/OUTPUT CONTROL DISPLAY CODIFICATION
• 9.5.2. WARNING AND FAULT CODE LIST
• 10. _OPTIONS ATTACHMENTS
• 10.1. OPTIONS ATTACHMENTS LOCATIONS
• 10.1.1. SMS (Safe Man System) Electrical Components
• 10.1.1.1. Extension harness