Manitou ATJ 46 RNC 2RD T4 S1 to 180 ATJ RC 4RD ST5 S1 Repair Manual 647697EN

Manitou ATJ 46 RNC 2RD T4 S1 to 180 ATJ RC 4RD ST5 S1 Repair Manual 647697EN - Image 2

Manitou ATJ 46 RNC 2RD T4 S1 to 180 ATJ RC 4RD ST5 S1 Repair Manual 647697EN - Image 3

Manitou ATJ 46 RNC 2RD T4 S1 to 180 ATJ RC 4RD ST5 S1 Repair Manual 647697EN - Image 4

Manitou ATJ 46 RNC 2RD T4 S1 to 180 ATJ RC 4RD ST5 S1 Repair Manual 647697EN - Image 5

manitou atj 46 rnc 2rd t4 s1 to 180 atj rc 4rd st5 s1 repair manual 647697en 2

manitou atj 46 rnc 2rd t4 s1 to 180 atj rc 4rd st5 s1 repair manual 647697en 3

Manitou ATJ 46 RNC 2RD T4 S1 to 180 ATJ RC 4RD ST5 S1 Repair Manual 647697EN

Type Of Manual: Repair Manual
Manual ID: 647697EN
Format: PDF
Size: 38.0MB
Number of Pages: 286

Category: Manitou Repair Manual PDF

Description

Model List:
- ATJ 46 RNC 2RD T4 S1
- 160 ATJ RNC 4RD ST5 S1
- 160 ATJ RC 4RD ST5 S1
- 180 ATJ RNC 4RD ST5 S1
- 180 ATJ RC 4RD ST5 S1

1. N (31/08/2018) ATJ 46 RNC 2RD T4 S1 160 ATJ RNC 4RD ST5 S1 160 ATJ RC 4RD ST5 S1 180 ATJ RNC 4RD ST5 S1 180 ATJ RC 4RD ST5 S1 REPAIR MANUAL
2. HOW TO USE THIS REPAIR MANUAL
3. GLOSSARY
4. SUMMARY
5. GR00 GENERAL, CHARACTERISTICS AND SAFETY
5.1. GENERAL INSTRUCTIONS AND SAFETY NOTICE
5.1.1. GENERAL INSTRUCTIONS
5.1.2. SPARE PARTS
5.1.3. TECHNICAL DOCUMENTATION
5.1.4. REPAIR PROCEDURES
5.1.5. HYDRAULICS
5.1.6. SYMBOLS
5.1.7. SERVICING AND REPAIR EQUIPMENT
5.2. GENERAL CHARACTERISTICS AND SPECIFICATIONS
5.2.1. CHARACTERISTICS AND FLUIDS ATJ 46 /160 180 ATJ
5.2.2. DIMENSIONS AND DIAGRAM ATJ 46…
5.2.3. DIMENSIONS AND DIAGRAM 160 ATJ…
5.2.4. DIMENSIONS AND DIAGRAM 180 ATJ…
5.3. GENERAL CONTROL AND ADJUSTMENT
5.3.1. STANDARD TIGHTENING TORQUES
5.3.2. METRIC IMPERIAL UNIT CONVERSION
6. GR10 ENGINE
6.1. ENGINE CHARACTERISTICS AND SPECIFICATIONS
6.1.1. Engine characteristics and specifications
6.2. ENGINE COMPONENTS LOCATION
6.2.1. ENGINE
6.3. ENGINE CONTROL AND ADJUSTMENT
6.3.1. ENGINE REMOVAL REFITTING
6.3.2. PROPORTIONAL ENGINE SPEED BLOCK REMOVAL
6.3.3. PROPORTIONAL ENGINE SPEED BLOCK ADJUSTMENT
6.4. ENGINE REMOVAL
6.4.1. REMOVAL
6.4.1.1. Dismantling the radiator assembly
6.4.1.2. Removal of harnesses
6.4.1.3. Removal of air intake circuit
6.4.1.4. Removal of diesel fuel circuit
6.4.1.5. Removal of hoses from the hydrostatic and auxiliary pump
6.4.1.6. Removal of proportional engine speed block
6.4.1.7. Handling the engine
6.4.2. REFITTING
7. GR20 TRANSMISSION
7.1. TRANSMISSION CONTROL AND ADJUSTMENT
7.2. DESCRIPTION OF HYDROSTATIC PUMP (REXROTH)
7.2.1. Pressure test ports
7.2.2. Adjustment points
7.3. HYDROSTATIC PRESSURE ADJUSTMENT(REXROTH)
7.3.1. Engine speed unladen
7.3.2. Calibration LP booster valve
7.3.3. Neutral point adjustment servocontrol piston
7.3.4. Calibration HP Valves
7.3.5. Calibration Zero flow valve DR
7.4. TRANSMISSION REMOVAL
7.4.1. HYDROSTATIC PUMP REMOVAL
7.4.1.1. REFITTING
7.4.2. HYDROSTATIC MOTOR REMOVAL
7.4.2.1. REFITTING
8. GR30 AXLE
8.1. AXLE CONTROL AND ADJUSTMENT
8.1.1. PLACING IN FREEWHEEL MODE
8.1.1.1. Restoring brake function
8.2. AXLE REMOVAL
8.2.1. FRONT AXLE REMOVAL
8.2.1.1. FRONT AXLE REFIT
8.2.2. REAR AXLE REMOVAL
8.2.2.1. REAR AXLE REFIT
9. GR55 JIB ACCESS PLATFORM
9.1. JIB ACCESS PLATFORM REMOVAL
9.1.1. TELESCOPE CYLINDER SLIDE PAD REMOVAL
9.1.2. ARM 3 PAD REMOVAL
9.1.3. MOVING TUBE PAD REMOVAL
10. GR70 HYDRAULICS
10.1. HYDRAULIC CHARACTERISTICS ANDSPECIFICATIONS
10.1.1. PVG32 4T PROPORTIONAL DISTRIBUTOR
10.1.2. DISTRIBUTOR BLOCK MA250CDC 016
10.1.3. BRAKE BLOCK AND DIFFERENTIAL LOCK DISTRIBUTOR (ATJ 46)
10.1.4. BRAKE BLOCK AND STEERING DISTRIBUTOR (160 180 ATJ)
10.1.5. VALVE BLOCK
10.1.6. VARIABLE DISPLACEMENT PUMP A10VG
10.1.7. STEERING ROTATION BLOCK (Option)
10.1.8. Generator block (Option)
10.2. HYDRAULIC SCHEMATIC DIAGRAMS
10.2.1. HYDRAULIC COMPONENTS DIAGRAM KEY
10.2.2. SETTINGS
10.2.3. HYDRAULIC SCHEMATIC DIAGRAM
10.2.4. ELECTROVALVE ACTIVATION TABLE
10.3. HYDRAULIC COMPONENTS LOCATION
10.3.1. HYDRAULIC COMPONENTS IN THE FRAME
10.3.2. HYDRAULIC COMPONENTS IN THE TURRET
10.3.3. HYDRAULIC COMPONENTS IN THE ARMS
10.4. HYDRAULIC CONTROL AND ADJUSTMENT
10.4.1. PROPORTIONAL DISTRIBUTOR IDENTIFICATION
10.4.2. PROPORTIONAL DISTRIBUTOR CALIBRATION
10.4.2.1. INLET PLATE RELIEF VALVE
10.4.2.2. ARM 1/2 LIFTING CYLINDER RELIEF VALVES
10.4.2.3. TELESCOPE CYLINDER RELIEF VALVES
10.4.2.4. ARM 3 LIFTING CYLINDER RELIEF VALVES
10.4.3. DISTRIBUTOR BLOCK CALIBRATION
10.4.3.1. JIB SUPPLY CIRCUIT RELIEF VALVES
10.4.3.2. FUNCTION BLOCK SUPPLY CIRCUIT RELIEF VALVES
10.4.3.3. COMPENSATING / TILTING CYLINDER SUPPLY CIRCUIT VALVES
10.4.3.4. TILTING CYLINDER EXTENSION VALVE ADJUSTMENT
10.4.3.5. TILTING CYLINDER RETRACTION VALVE ADJUSTMENT
10.4.4. COMPENSATING / TILTING CIRCUIT
10.4.4.1. TROUBLESHOOTING
10.4.4.2. ANALYSIS OF RESULTS
10.5. HYDRAULIC COMPONENTS REMOVAL
10.5.1. REMOVAL OF PROPORTIONAL DISTRIBUTOR ELEMENTS
10.5.1.1. REFITTING
10.5.2. DISTRIBUTOR BLOCK REMOVAL
10.5.2.1. REFITTING
10.5.3. CYLINDER REMOVAL
10.5.3.1. PREPARING THE PLATFORM
10.5.3.2. DECOMPRESSION OF HOSES
10.5.3.3. CYLINDER REMOVAL
10.5.3.4. CYLINDER REFIT
10.5.3.5. REMOVAL OF VALVE BLOCKS AND VALVES
10.6. HYDRAULIC SPECIFIC TOOLING
10.6.1. BASIC MANOMETER BOX
10.6.2. DIGITAL MANOMETER BOX
11. GR80 ELECTRICITY
11.1. ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS
11.1.1. FUSE BOX
11.1.1.1. Main fuse box
11.1.1.2. Engine fuse/relay box UR01
11.1.2. BASE CONTROL PANEL
11.1.2.1. ECU box UC234
11.1.2.2. Base ECU fuse
11.2. ELECTRICAL SCHEMATIC DIAGRAMS
11.2.1. Electrical components location
11.2.2. ELECTRICAL DIAGRAMS BY FUNCTION
11.2.2.1. DIAGRAM 1 POWER SUPPLIES WITHOUT BATTERY CUTOFF EMERGENCY STOP BACKUP PUMP ENGINE FUNCTION
11.2.2.2. DIAGRAM 2 POWER SUPPLIES WITH BATTERY CUTOFF EMERGENCY STOP BACKUP PUMP ENGINE FUNCTION
11.2.2.3. DIAGRAM 3 CAN BUS NETWORK
11.2.2.4. DIAGRAM 4 SIGNALS GENERATOR EASY MANAGER
11.2.2.5. DIAGRAM 6 TRAVEL
11.2.2.6. DIAGRAM 7 PROPORTIONAL MOVEMENTS
11.2.2.7. DIAGRAM 8 PROPORTIONAL MOVEMENTS
11.2.2.8. DIAGRAM 9 OVERLOAD HYDRAULIC SAFETY
11.3. ELECTRICAL COMPONENTS LOCATION
11.3.1. ELECTRICAL CONTROL COMPONENTS
11.3.2. ELECTRICAL POWER COMPONENTS
11.3.3. Harness assembly
11.3.4. CHASSIS harness ITEM 1
11.3.5. AMP1 harness ITEM 2
11.3.6. AMP2 harness ITEM 3
11.3.7. AMP3 harness ITEM 4
11.3.8. Harness connecting base to upper arm ITEM 5
11.3.9. Upper CAN bus harness item 6
11.3.10. BASKET harness ITEM 7
11.3.11. Basket extension harness ITEM 8
11.3.12. Base and basket control panels
11.4. ELECTRICAL CONTROL AND ADJUSTMENT
11.4.1. ELECTRICAL CONTROL AND ADJUSTMENT
11.4.1.1. MANIPULATOR TESTING
11.4.1.1.1. TESTING FROM THE BASE CONTROL PANEL
11.4.1.1.2. TEST WITH A VOLTMETER
11.4.1.1.3. MANIPULATOR CALIBRATION
11.4.1.2. Card removal refit
11.4.1.2.1. Removal of base control panel card UD22
11.4.1.2.2. Removal of base control panel ECU card UC 234
11.4.1.3. CONTROLS USED ON THE BASE CONTROL PANEL
11.4.1.4. PROGRAMME OPERATION
11.4.1.4.1. Screen Menu
11.4.1.4.2. Codification menu
11.4.1.4.3. Diagnostics menu
11.4.1.4.4. Secret Code Menu
11.4.1.4.5. Parameters Menu
11.4.1.4.6. Maintenance Menu
11.4.1.4.7. Engine Menu
11.4.1.4.8. Calibration Menu
11.4.1.5. GENERATOR PROGRAM MODIFICATION
11.4.1.6. PROGRAM PARAMETERS
11.4.1.7. Levelling CALIBRATION
11.4.1.8. STRAIN GAUGE ADJUSTMENT
11.4.1.9. ARM DOWN SENSOR ADJUSTMENT
11.4.1.10. TELESCOPE RETRACTED SENSOR ADJUSTMENT
11.5. ELECTRICAL TROUBLESHOOTING
11.5.1. FAULT CODIFICATION
11.5.1.1. BASIC PRINCIPLE
11.5.1.2. CREATION OF A COMPONENT TYPE CODE
11.5.1.3. COMPONENT IDENTIFICATION
11.5.1.4. CREATION OF A FAULT TYPE CODE
11.5.1.5. SYSTEM FAULTS
11.5.1.6. MAINTENANCE INFORMATION
11.5.1.7. INPUT/OUTPUT CONTROL DISPLAY CODIFICATION
11.5.2. WARNING AND FAULT CODE LIST
11.6. ELECTRICAL SPECIFIC TOOLING
11.6.1. BREAKOUT BOX KIT
11.6.2. ELECTROVALVE ADAPTER

Manitou ATJ 46 RNC 2RD T4 S1 to 180 ATJ RC 4RD ST5 S1 Repair Manual 647697EN

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