Manitou TJ 65 2RD T4 S1, TJ 65P 4RD T4 S1 Repair Manual 647783EN

Description

• Model List:
  • TJ 65 2RD T4 S1
  • TJ 65P 4RD T4 S1

• 1. Page de garde / Front page
• 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. CHARACTERISTICS
• 4.2.2. LUBRICANTS AND FUEL
• 4.2.3. DIMENSIONS AND DIAGRAMS
• 4.2.3.1. Dimensions (TJ 65 2RD T4 S1)
• 4.2.3.2. Diagram (TJ 65 2RD T4 S1)
• 4.2.3.3. DIMENSIONS (TJ 65 4RD T4 S1)
• 4.2.3.4. DIAGRAM (TJ 65 4RD T4 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. ENGINES
• 6.1. ENGINE CHARACTERISTICS AND SPECIFICATION
• 6.1.1. Engine D1803 CR TIE4B
• 6.2. Engine components location
• 6.2.1. Engine components
• 6.3. Engine controls and adjustments
• 6.3.1. Engine silent block TIGHTENING TORQUES and adjustment
• 6.4. Engine removal refitting
• 6.4.1. Preparation and safety instructions
• 6.4.2. Removing the engine / hydrostatic pump assembly
• 6.4.2.1. Removing the engine cover
• 6.4.2.2. Draining the cooling circuit
• 6.4.2.3. Air intake removal
• 6.4.2.4. Disconnecting the diesel circuit hoses
• 6.4.2.5. Disconnecting the harnesses.
• 6.4.2.6. Removing the hoses from the hydrostatic and auxiliary pumps
• 6.4.2.7. Removing the engine/hydrostatic pump assembly
• 6.4.3. Refitting the engine/hydrostatic pump assembly
• 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 DR ZERO FLOW VALVE
• 8.2.5. CALIBRATION HP VALVES
• 8.3. TRANSMISSION REMOVAL REFIT
• 8.3.1. Removing the HYDROSTATIC PUMP
• 8.3.2. Refitting the HYDROSTATIC PUMP
• 8.3.3. Removing the HYDROSTATIC MOTOR
• 8.3.4. REFITTING THE HYDROSTATIC MOTOR
• 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. FREEWHEEL FOR WINCHING
• 10.1.3. REMOVING THE FRONT AXLE
• 10.1.4. REFITTING THE FRONT AXLE
• 10.1.5. REMOVING THE REAR AXLE
• 10.1.6. REFITTING THE REAR AXLE
• 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 boxes
• 16.1.1.1. Power fuse box (BFP)
• 16.1.1.2. Engine fuse/relay box UR02 (BF)
• 16.1.1.3. Base control panel fuse/relay box UC234 (BFPB)
• 16.2. WIRING DIAGRAMS
• 16.2.1. POSITIONS BY DIAGRAM
• 16.2.2. ELECTRICAL DIAGRAMS BY FUNCTION
• 16.2.2.1. Power supplies Emergency stop BACKUP PUMP Engine functions
• 16.2.2.2. ENGINE FUNCTIONS POWER SUPPLIES VERSION WITHOUT BATTERY CUTOFF
• 16.2.2.3. ENGINE FUNCTIONS POWER SUPPLIES VERSION WITH BATTERY CUTOFF
• 16.2.2.4. CAN BUS NETWORK
• 16.2.2.5. Signals/Generator/Easy Manager
• 16.2.2.6. SENSOR INPUTS
• 16.2.2.7. TRAVEL
• 16.2.2.8. AUXILIARY PROPORTIONAL MOVEMENTS
• 16.2.2.9. AUXILIARY PROPORTIONAL MOVEMENTS
• 16.2.2.10. OVERLOAD HYDRAULIC SAFETY
• 16.3. Electricity locations
• 16.3.1. Wiring harnesses key
• 16.3.2. Harness assembly
• 16.3.3. Harness AMP1
• 16.3.4. Harness AMP3
• 16.3.5. Basket harness
• 16.3.6. Frame Harness
• 16.3.7. AMP UPC102 Harness
• 16.3.8. Arm structure/telescope sensor harness
• 16.3.9. Jib function harness
• 16.3.10. Jib hinge harness
• 16.3.11. Jib hinge/basket control panel harness
• 16.4. Engine Harness
• 16.4.1. Engine harness key
• 16.4.1.1. Engine harness (part 1)
• 16.4.2. Base and basket control panels
• 16.4.2.1. Base and basket control panels key
• 16.4.2.2. Base and basket control panel controls and indicator lamps
• 16.4.2.3. Base control panel wiring
• 16.4.2.4. Basket control panel wiring sheet 1
• 16.4.2.5. Basket control panel wiring sheet 2
• 16.4.2.6. BASKET CONTROL PANEL WIRING sheet 3
• 16.5. ELECTRICAL CONTROL AND ADJUSTMENT
• 16.5.1. CONTROLS USED ON THE BASE CONTROL PANEL
• 16.5.2. IMPORTANT GENERAL COMMENTS
• 16.5.3. PROGRAMME OPERATION
• 16.5.3.1. Startup page
• 16.5.3.2. Preheat pages
• 16.5.3.3. Work pages
• 16.5.3.4. Screen tab
• 16.5.3.5. CODIFICATION tab
• 16.5.3.6. DIAGNOSTIC tab
• 16.5.3.7. Secret Code tab
• 16.5.3.8. CALIBRATION tab
• 16.5.3.9. ENGINE tab
• 16.5.3.10. Immobiliser Option
• 16.5.3.11. USB Transfer Option
• 16.5.4. PROGRAM PARAMETERS
• 16.6. SENSOR ADJUSTMENT
• 16.6.1. Overload sensor adjustment
• 16.6.2. FAULT CODIFICATION
• 16.6.2.1. TYPE DE COMPONENT OR SYSTEM OR MAINTENANCE OR I/O
• 16.6.2.2. LOCATIONIDENTIFICATION OF COMPONENTS OR FAULT CODE No.
• 16.6.2.3. TYPE OF FAULT
• 16.6.3. MACHINE FAULT CODE LIST
• 16.6.4. ENGINE FAULT CODE LIST
• 16.7. Specific electric tooling
• 16.7.1. Breakout boxes
• 16.7.2. Electrovalve adapter
• 18. FRAME BODYWORK
• 18.1. COUNTERWEIGHT REMOVAL/REFIT
• 18.1.1. PREPARATION AND SAFETY INSTRUCTIONS
• 18.1.2. SIDE COUNTERWEIGHT REMOVAL
• 20. OPTIONS ATTACHMENTS
• 20.1. SMS (Safe MAN System)
• 20.1.1. SMS (Safe Man System) ELECTRICAL COMPONENTS
• 20.1.2. Flashing light extension harness