Manitou MT 835 EASY 75D ST3B S1 to MT 1335 HA EASY 75D ST3B S1 Repair Manual 647578EN

Description

• Model List:
  • MT 835 EASY 75D ST3B S1
  • MT 1135 EASY 75D ST3B S1
  • MT 1135 HA EASY 75D ST3B S1
  • MT 1335 EASY 75D ST3B S1
  • MT 1335 H EASY 75D ST3B S1
  • MT 1335 HA EASY 75D ST3B S1

• 1. Front page
• 2. General table of content
• 3. GENERAL CHARACTERISTICS AND SAFETY
• 3.1. GENERAL INSTRUCTIONS AND SAFETY NOTICE
• 3.1.1. PREAMBLE
• 3.1.2. MAINTENANCE POSITION
• 3.1.3. RULES FOR MAINTENANCE
• 3.2. GENERAL CHARACTERISTICS AND SPECIFICATIONS
• 3.2.1. MT 835 EASY 75D
• 3.2.2. MT 1135 HA EASY 75D
• 3.2.3. MT 1335 H HA EASY 75D
• 3.3. GENERAL LOCATION
• 3.3.1. LOCATION OF NAME AND IDENTIFICATION PLATE
• 3.4. GENERAL CONTROL AND ADJUSTMENT
• 3.4.1. STANDARD TIGHTENING TORQUES
• 4. ENGINE
• 4.1. ENGINE GENERAL CHARACTERISTICS ANDSPECIFICATIONS
• 4.1.1. CHARACTERISTICS
• 4.1.2. POLLUTION MANAGEMENT
• 4.1.3. INJECTION CYCLE
• 4.1.4. BOSCH CP4.1 HIGH PRESSURE PUMP
• 4.2. ENGINE CIRCUITS FLOW DIAGRAM
• 4.2.1. AIR INTAKE CIRCUIT AND EGR (Exhaust Gas Recirculation)
• 4.2.2. LUBRICATION CIRCUIT
• 4.2.3. COOLING SYSTEM
• 4.2.4. FUEL CIRCUIT
• 4.3. ENGINE COMPONENTS LOCATION
• 4.3.1. ENGINE ELEMENTS
• 4.3.2. WATER COOLING SYSTEM
• 4.3.3. AIR INTAKE CIRCUIT
• 4.3.4. HYDRAULIC VENTILATION SYSTEM
• 4.3.5. DIESEL FUEL CIRCUIT
• 4.3.6. FUEL INJECTION CIRCUIT
• 4.3.7. EGR (Exhaust Gas Recirculation) CIRCUIT
• 4.4. ENGINE CONTROL AND ADJUSTMENT
• 4.4.1. ENGINE TIGHTENING TORQUES
• 4.4.2. VENTILATION MANAGEMENT
• 4.5. ENGINE REMOVAL
• 4.5.1. PREPARATION AND SAFETY INSTRUCTIONS
• 4.5.2. STARTER REMOVAL
• 4.5.3. DRIVE BELT REMOVAL
• 4.5.4. ALTERNATOR REMOVAL
• 4.5.5. FAN ENGINE REMOVAL
• 4.5.6. ENGINE ECU REMOVAL
• 4.5.7. CATALYTIC CONVERTER REMOVAL
• 4.5.8. COOLER REMOVAL
• 4.5.9. ENGINE REMOVAL
• 4.6. ENGINE TROUBLESHOOTING
• 4.6.1. FAULT TABLE
• 4.6.2. IGNITION SWITCHING TEST
• 4.6.3. STARTUP CONDITIONS
• 4.6.4. LACK OF POWER
• 4.6.5. INJECTION CODE
• 4.6.6. FAN CHECK POINTS
• 4.6.7. ENGINE ERROR CODES
• 4.7. SPECIFIC ENGINE TOOLING
• 4.7.1. ELECTRONIC TENSION METER
• 4.7.2. ADDITIONAL ENGINE TOOLS
• 5. TRANSMISSION
• 5.1. TRANSMISSION SCHEMATIC DIAGRAMS
• 5.1.1. MECHANICAL TRANSMISSION (STANDARD)
• 5.1.2. HYDROSTATIC TRANSMISSION
• 5.2. TRANSMISSION CONTROL AND ADJUSTMENT
• 5.2.1. MECHANICAL TRANSMISSION
• 5.2.2. PRESSURE TEST PORTS
• 5.2.3. TRANSMISSION ASSEMBLY TIGHTENING TORQUES
• 5.2.4. BLOCKING 4TH GEAR
• 5.2.5. HYDROSTATIC TRANSMISSION
• 5.2.6. LOCATION OF PORTS
• 5.2.7. TRANSMISSION ASSEMBLY TIGHTENING TORQUES
• 5.2.8. PRESSURE TEST PORTS
• 5.2.9. PUMP / ENGINE CONTROL AND ADJUSTMENT
• 5.2.10. A4VGDA / A6VMDA HYDROSTATIC TRANSMISSION SETTINGS SHEET
• 5.3. TRANSMISSION REMOVAL
• 5.3.1. PREPARATION AND SAFETY INSTRUCTIONS
• 5.3.2. GEARBOX REMOVAL
• 5.3.3. HYDROSTATIC TRANSMISSION REMOVAL
• 5.4. TRANSMISSION TROUBLESHOOTING
• 5.4.1. HYDROSTATIC SYSTEM TROUBLESHOOTING
• 5.5. SPECIFIC TRANSMISSION TOOLING
• 5.5.1. BASIC MANOMETER SET
• 5.5.2. DIGITAL MANOMETER SET
• 5.5.3. HYDROMATIK KIT (2nd Replacement A 4 VG DA pump/A 6 VM DA engine)
• 5.5.4. TH7 VALVE HOSE AND CONNECTOR
• 5.5.5. MM MACHINED SOCKET
• 6. AXLE
• 6.1. AXLE CONTROL AND ADJUSTMENT
• 6.1.1. AXLE TIGHTENING TORQUE
• 7. BRAKE
• 7.1. BRAKE CHARACTERISTICS AND SPECIFICATIONS
• 7.1.1. SERVICE BRAKE (MECHANICAL AND HYDROSTATIC)
• 7.1.2. PARKING BRAKE (MECHANICAL TRANSMISSION)
• 7.1.3. PARKING BRAKE (HYDROSTATIC TRANSMISSION)
• 7.2. BRAKE CONTROL AND ADJUSTMENT
• 7.2.1. SERVICE BRAKE
• 7.2.2. FREEWHEEL AND TOWING
• 7.2.3. PARKING BRAKE
• 7.3. BRAKE REMOVAL
• 7.3.1. PREPARATION AND SAFETY INSTRUCTIONS
• 7.3.2. MASTER CYLINDER REMOVAL
• 7.3.3. PARKING BRAKE
• 7.4. SPECIFIC BRAKE TOOLING
• 7.4.1. HYDRAULIC BRAKE BLEED VALVE
• 7.4.2. PARKING BRAKE BLEEDER HARNESS
• 8. BOOM
• 8.1. BOOM CHARACTERISTICS AND SPECIFICATIONS
• 8.1.1. DUPLEX (MT 8 METERS)
• 8.1.2. TRIPLEX (MT 11 and 13 METERS)
• 8.2. BOOM COMPONENTS LOCATION
• 8.2.1. LOCATION OF THE DUPLEX BOOM MAIN COMPONENTS
• 8.2.2. LOCATION OF TRIPLEX BOOM MAIN COMPONENTS
• 8.3. BOOM CONTROL AND ADJUSTMENT
• 8.3.1. TELESCOPE ADJUSTMENT, EXTENSION AND RETRACTION PROCEDURE
• 8.3.2. MT 835…
• 8.3.3. MT 1135/1335…
• 8.4. BOOM REMOVAL
• 8.4.1. DUPLEX BOOM
• 8.4.2. TRIPLEX BOOM
• 8.5. BOOM REFIT
• 8.5.1. DUPLEX BOOM
• 8.5.2. TRIPLEX BOOM
• 8.6. SPECIFIC BOOM TOOLING
• 8.6.1. FLARE NUT WRENCH
• 8.6.2. MAGNETIC LIFTER
• 9. HYDRAULIC
• 9.1. HYDRAULIC CHARACTERISTICS ANDSPECIFICATIONS
• 9.1.1. Accumulator block
• 9.1.2. PVG 100 DISTRIBUTOR (ELEMENT)
• 9.1.3. PVG100 DISTRIBUTOR (EE INLET ELEMENT)
• 9.1.4. PVG100 DISTRIBUTOR (ES OUTPUT ELEMENT)
• 9.1.5. PVG100 DISTRIBUTOR (ET TELESCOPE ELEMENT)
• 9.1.6. PVG32 DISTRIBUTOR (EA ATTACHMENT ELEMENT)
• 9.1.7. SD 8/7 Distributor
• 9.1.8. SDM 140/4 distributor
• 9.1.9. Powerassisted brake master cylinder
• 9.1.10. LAGU 250/125 STEERING PUMP
• 9.1.11. Hydraulic pump with load detection priority valve
• 9.1.12. position steering selector
• 9.1.13. CONTROL HEAD
• 9.1.14. CONTROL HEAD
• 9.1.15. LEVELING VALVE
• 9.1.16. Discharge valve
• 9.1.17. Discharge valve ACCESS
• 9.1.18. Discharge valve Mechanical
• 9.1.19. Flow control valve
• 9.1.20. DOUBLE TELESCOPE COUNTERBALANCE VALVE
• 9.1.21. STABILIZER COUNTERBALANCE VALVE
• 9.2. HYDRAULIC SCHEMATIC DIAGRAMS
• 9.2.2. HYDRAULIC DIAGRAM
• 9.3. HYDRAULIC COMPONENTS LOCATION
• 9.3.2. COMPONENTS LOCATION
• 9.4. HYDRAULIC CONTROL AND ADJUSTMENT
• 9.4.1. OPERATION OF COMPENSATING ISOLATION VALVES (VIC)
• 9.4.2. ACCUMULATION OF THE FLOW RATES OF THE ACCESS DISCHARGE VALVE
• 9.4.3. PRESSURE TEST PORTS
• 9.4.4. PROCEDURES FOR BLEEDING REAR AXLE LOCKING CYLINDERS
• 9.4.5. TIGHTENING TORQUES
• 9.4.6. COUNTERBALANCE VALVE TEST PROCEDURE (MT 1135/1335 HA)
• 9.5. HYDRAULIC COMPONENTS REMOVAL
• 9.5.1. COMPONENTS LOCATION
• 9.5.2. DISTRIBUTOR REMOVAL
• 9.5.3. HYDRAULIC PUMP REMOVAL
• 9.5.4. ACCUMULATOR UNIT REMOVAL
• 9.5.5. AXLE LOCK CYLINDER REMOVAL
• 9.5.6. STABILIZER CYLINDER REMOVAL (MT 1135/1335 H A)
• 9.5.7. LEVELING CYLINDER REMOVAL (MT 1135/1335 H A)
• 9.6. HYDRAULIC SPECIFIC TOOLING
• 9.6.1. BASIC MANOMETER SET
• 9.6.2. DIGITAL MANOMETER SET
• 10. ELECTRICITY
• 10.1. ELECTRICAL CHARACTERISTICS ANDSPECIFICATIONS
• 10.1.1. FUSES AND RELAYS
• 10.1.2. CONNECTORS
• 10.1.3. OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM
• 10.1.4. ECU INPUTS/OUTPUTS
• 10.1.5. DATA SHEETS FOR ELECTRICAL COMPONENTS
• 10.2. ELECTRICAL SCHEMATIC DIAGRAMS
• 10.2.1. ELECTRICAL DIAGRAM CODIFICATION EXAMPLE
• 10.2.2. CABLE IDENTIFICATION ON A WIRING HARNESS
• 10.2.3. MT 835 1135 1335 H
• 10.2.4. MT 11351335 H A
• 10.3. ELECTRICAL COMPONENTS LOCATION
• 10.3.1. MT 835 1135 1335 H ST3B
• 10.3.2. MT 1135 1335 H A ST3B
• 10.3.3. ENGINE HARNESS
• 10.3.4. ENGINE HARNESS 3D
• 10.3.5. FRAME HARNESS
• 10.4. ELECTRICAL CONTROL AND ADJUSTMENT
• 10.4.1. ADJUSTMENT OF INDUCTIVE SENSOR ON BOOM
• 10.4.2. GAUGE DRIVEN LED DISPLAY
• 10.4.3. WARNING DEVICE / LONGITUDINAL STABILITY LIMITER TEST
• 10.4.4. MENU CLUSTER ARCHITECTURE
• 10.4.5. BOOM ANGLE ANGULAR SENSOR ADJUSTMENT
• 10.5. ELECTRICAL COMPONENTS REFIT
• 10.5.1. STRAIN GAUGE
• 10.6. ELECTRICAL TROUBLESHOOTING
• 10.6.1. INPUT/OUTPUT STATES
• 10.6.2. ERROR CODES (DTC)
• 10.7. ELECTRICAL SPECIFIC TOOLING
• 10.7.1. DIAGNOSTIC TOOLS
• 10.7.2. BREAKOUT BOXES
• 10.7.3. ELECTROVALVE ADAPTER
• 11. DRIVERS CAB
• 11.1. DRIVERS CAB REMOVAL
• 11.1.1. ELECTRIC WINDOW AND ENGINE REMOVAL
• 11.1.2. REMOVE THE LOWER DASHBOARD LINING
• 11.2. DRIVERS CAB REFIT
• 11.2.1. ELECTRIC WINDOW AND ENGINE REFIT
• 12. FRAME BODY
• 12.1. FRAME BODY CONTROL AND ADJUSTMENT
• 12.1.1. STOP ADJUSTMENT FUEL TANK AND OIL TANK
• 13. OPTIONS ATTACHMENTS
• 13.1. AIRCONDITIONING OPTION
• 13.1.1. Air conditioning characteristics and specifications
• 13.1.2. Airconditioning locations
• 13.1.3. Air conditioning controls and adjustments
• 13.1.4. Air conditioning removal refit
• 13.1.5. Air conditioning troubleshooting