Manitou TJ 80P T4 S1, TJ 85 T4 S1 Repair Manual 647779EN

Description

• Model List:
  • TJ 80P T4 S1
  • TJ 85 T4 S1

• 1. N (13/11/2019) TJ 80P T4 S1 TJ 85 T4 S1 Repair Manual
• 2. HOW TO USE THIS REPAIR MANUAL
• 3. GLOSSARY
• 4. SUMMARY
• 5. GR00 GENERAL CHARACTERISTICS AND SAFETY
• 5.1. GENERAL CHARACTERISTICS AND SAFETY
• 5.1.1. PREAMBLE
• 5.1.2. MAINTENANCE POSITION
• 5.1.3. RULES FOR MAINTENANCE
• 5.2. GENERAL CHARACTERISTICS AND SPECIFICATIONS
• 5.2.1. Characteristics TJ 80P T4 S1 TJ 85 T4 S1
• 5.3. GENERAL COMPONENTS LOCATION
• 5.3.1. LOCATION OF NAME AND IDENTIFICATION PLATE
• 5.4. GENERAL CONTROL AND ADJUSTMENT
• 5.4.1. STANDARD TIGHTENING TORQUES
• 5.4.2. METRIC IMPERIAL UNIT CONVERSION
• 6. GR10 ENGINE
• 6.1. ENGINE COMPONENTS LOCATION
• 6.1.1. Engine components
• 6.2. ENGINE REMOVAL
• 6.2.1. REMOVE THE ENGINE
• 6.2.2. REFIT
• 7. GR20 TRANSMISSION
• 7.1. TRANSMISSION CONTROL AND ADJUSTMENT
• 7.1.1. DESCRIPTION
• 7.1.2. HYDROSTATIC PRESSURE
• 7.2. TRANSMISSION REMOVAL
• 7.2.1. HYDROSTATIC PUMP REMOVAL
• 7.2.2. HYDROSTATIC PUMP REMOVAL
• 7.2.3. HYDROSTATIC MOTOR REMOVAL
• 7.2.4. PARKER F12 motor
• 7.2.5. HYDROSTATIC MOTOR REFIT
• 8. GR30 AXLE
• 8.1. AXLE CONTROL AND ADJUSTMENT
• 8.1.1. PLACING IN FREEWHEEL MODE FOR WINCHING
• 8.1.2. Restoring brake function
• 8.1.3. TIGHTENING TORQUE
• 8.2. AXLE REMOVAL
• 8.2.1. FRONT AXLE REMOVAL
• 8.2.2. REAR AXLE REMOVAL
• 8.2.3. REAR AXLE REFIT
• 9. GR55 JIB ACCESS PLATFORM
• 9.1. JIB ACCESS PLATFORM CHARACTERISTICS ANDSPECIFICATIONS
• 9.1.1. BOOM
• 9.2. JIB ACCESS PLATFORM SCHEMATIC DIAGRAMS
• 9.2.1. BOOM KINEMATICS
• 9.3. JIB ACCESS PLATFORM COMPONENTS LOCATION
• 9.3.1. BOOM COMPONENTS
• 9.4. JIB ACCESS PLATFORM CONTROL AND ADJUSTMENT
• 9.4.1. PREPARATION AND SAFETY INSTRUCTIONS
• 9.4.2. IMPORTANT INFORMATION
• 9.4.3. JIB ACCESS PLATFORM CABLE INSPECTION
• 9.4.4. STEPS NECESSARY FOR REMOVING THE TELESCOPE
• 9.4.5. STEPS NECESSARY FOR REMOVING TELESCOPE COMPONENTS
• 9.4.6. STEPS NECESSARY FOR REFITTING TELESCOPE COMPONENTS
• 9.4.7. STEPS NECESSARY FOR REFITTING THE TELESCOPE
• 9.5. JIB ACCESS PLATFORM REMOVAL
• 9.5.1. JIB ACCESS PLATFORM DISASSEMBLY
• 9.6. JIB ACCESS PLATFORM REASSEMBLY
• 9.6.1. TOOLS FOR REASSEMBLY
• 9.6.2. JIB PIVOT PIECE REASSEMBLY
• 9.6.3. CYLINDER REFIT
• 9.6.4. JIB REASSEMBLY
• 9.6.5. BASKET OVERLOAD REFIT
• 9.6.6. BASKET REASSEMBLY
• 10. GR70 HYDRAULICS
• 10.1. HYDRAULIC CHARACTERISTICS ANDSPECIFICATIONS
• 10.1.1. DANFOSS VALVE BANK CONTROL COMPONENT
• 10.1.2. PVG 32 ELEMENT WITH PRESSURE BALANCE
• 10.1.3. ENTRY PLATE PVG 32
• 10.1.4. PVG 32 VALVE BANK
• 10.1.5. TURNTABLE HYDRAULIC BLOCK
• 10.1.6. JIB FUNCTION BLOCK (TJ 80P T4 S1)
• 10.1.7. JIB FUNCTION BLOCK (TJ 85 T4 S1
• 10.1.8. BASKET ROTATION CYLINDER
• 10.1.9. BRAKE AND STEERING BLOCK
• 10.1.10. GENERATOR BLOCK (OPTION)
• 10.2. HYDRAULIC SCHEMATIC DIAGRAMS
• 10.2.1. KEY TO COMPONENTS/HYDRAULIC COMPONENTS
• 10.2.2. KEY TO RELIEF VALVES / REDUCING VALVES / SLIDE VALVES
• 10.2.3. KEY TO ELECTROVALVES
• 10.2.4. ELECTROVALVE ACTUATION TABLE
• 10.2.5. HYDRAULIC DIAGRAM
• 10.3. HYDRAULIC COMPONENTS LOCATION
• 10.3.1. FRAME COMPONENTS LOCATION
• 10.3.2. TURNTABLE COMPONENTS LOCATION
• 10.3.3. BOOM COMPONENTS LOCATION
• 10.3.4. LOCATION OF COMPONENTS ON PVG32 VALVE BANK
• 10.3.5. LOCATION OF COMPONENTS ON HYDROSTATIC PUMP A4VG56
• 10.3.6. TURNTABLE BLOCK COMPONENTS LOCATION
• 10.3.7. JIB BLOCK COMPONENTS LOCATION TJ 80P T4 S1
• 10.3.8. JIB BLOCK COMPONENTS LOCATION TJ 85 T4 S1
• 10.3.9. BRAKE BLOCK COMPONENTS LOCATION
• 10.4. HYDRAULIC CONTROL AND ADJUSTMENT
• 10.4.1. MENU SEARCH
• 10.4.2. PRESSURE ADJUSTMENTS PROPORTIONAL VALVE BANK CALIBRATION
• 10.4.3. TURNTABLE FUNCTION BLOCK CALIBRATION
• 10.4.4. JIB FUNCTION BLOCK CALIBRATION TJ 80P T4 S1
• 10.4.5. JIB FUNCTION BLOCK CALIBRATION TJ 85 T4 S1
• 10.4.6. BASKET COMPENSATING / TILTING CIRCUIT TJ 85 T4 S1
• 10.4.7. BLEEDING THE LIFTING AND BASKET COMPENSATING / TILTING CYLINDERS TJ 85 T4 S1
• 10.5. HYDRAULIC COMPONENTS REMOVAL
• 10.5.1. PROPORTIONAL VALVE BANK REMOVAL
• 10.5.2. TURNTABLE BLOCK REMOVAL
• 10.5.3. DECOMPRESSION OF HOSES
• 10.5.4. HOSE REMOVAL PROCEDURE
• 10.5.5. STRUCTURE LIFTING CYLINDER REMOVAL
• 10.5.6. JIB TILTING CYLINDER REMOVAL
• 10.5.7. JIB LIFTING CYLINDER REMOVAL TJ80P T4 S1
• 10.5.8. JIB LIFTING CYLINDER REMOVAL TJ85 T4 S1
• 10.5.9. JIB TELESCOPE CYLINDER REMOVAL TJ85 T4 S1
• 10.5.10. BASKET COMPENSATING CYLINDER REMOVAL TJ85 T4 S1
• 10.5.11. BASKET ROTATION CYLINDER REMOVAL TJ80P T4 S1
• 10.5.12. BASKET ROTATION CYLINDER REMOVAL TJ85 T4 S1
• 10.5.13. 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. Electrical characteristics and specifications
• 11.1.2. FUSE BOX
• 11.1.3. BASE CONTROL PANEL
• 11.1.4. HORN
• 11.1.5. LED ROTATING BEACON LIGHT
• 11.1.6. Fuel gauge
• 11.1.7. BOOM ANGLE SENSOR
• 11.1.8. EMERGENCY STOP
• 11.1.9. BOOM ANGLE POTENTIOMETER
• 11.1.10. PRESSURE SWITCH
• 11.1.11. ROLLER SENSOR
• 11.1.12. BRAKE BLOCK ELECTROVALVE
• 11.1.13. HYDRAULIC SAFETY ELECTROVALVE
• 11.1.14. STEERING MODE ELECTROVALVE
• 11.1.15. OSCILLATION ELECTROVALVE
• 11.1.16. PUMP ELECTROVALVE
• 11.1.17. GENERATOR ELECTROVALVE
• 11.1.18. PVEH ELECTROVALVE
• 11.1.19. PVEA ELECTROVALVE
• 11.1.20. AXLE DETECTOR
• 11.1.21. INDUCTIVE SENSOR
• 11.1.22. MAGNETIC SENSOR
• 11.1.23. JOYSTICK
• 11.1.24. JOYSTICK
• 11.1.25. DEAD MAN PEDAL
• 11.1.26. IGNITION KEY
• 11.2. ELECTRICAL SCHEMATIC DIAGRAMS
• 11.2.1. Electrical components location TJ 80P T4 S1
• 11.2.2. ELECTRICAL DIAGRAMS BY FUNCTION TJ 80P T4 S1
• 11.2.3. Electrical components location TJ 85 T4 S1
• 11.2.4. ELECTRICAL DIAGRAMS BY FUNCTION TJ 85 T4 S1
• 11.3. ELECTRICAL LOCATIONS
• 11.3.1. ELECTRICAL CONTROL COMPONENTS
• 11.3.2. ELECTRICAL POWER COMPONENTS
• 11.3.3. HARNESS LOCATION
• 11.3.4. HARNESS ASSEMBLY
• 11.3.5. Engine Harness ITEM 1
• 11.3.6. AMP1 harness (UC234) ITEM 2
• 11.3.7. AMP2 harness (UC234) ITEM 3
• 11.3.8. AMP3 harness (UC234) ITEM 4
• 11.3.9. AMP4 harness (UPC102) ITEM 5
• 11.3.10. FRAME harness ITEM 11
• 11.3.11. Intermediate harness from base to upper arm ITEM 6
• 11.3.12. Upper CAN bus harness ITEM 7
• 11.3.13. Basket/jib hinge connection ITEM 8
• 11.3.14. Basket/jib hinge connection (TJ80P) ITEM 9
• 11.3.15. BASKET / CONNECTION BOX 2 CONNECTION HARNESS (TJ85) ITEM 9
• 11.3.16. JIB BLOCK CONNECTION HARNESS (TJ80P) ITEM 10
• 11.3.17. BASE AND BASKET CONTROL PANELS
• 11.4. ELECTRICITY CONTROLS AND ADJUSTMENTS
• 11.4.1. ELECTRICAL CONTROL AND ADJUSTMENT
• 11.5. ELECTRICAL TROUBLESHOOTING
• 11.5.1. FAULT CODIFICATION
• 11.5.2. TYPE DE COMPONENT OR SYSTEM OR MAINTENANCE OR I/O
• 11.5.3. LOCATIONIDENTIFICATION OF COMPONENTS OR FAULT CODE No.
• 11.5.4. TYPE OF FAULT
• 11.5.5. FAULT CODE LIST
• 11.6. SPECIFIC ELECTRIC TOOLING
• 11.6.1. BREAKOUT BOX KIT
• 11.6.2. ELECTROVALVE ADAPTER
• 12. GR110 OPTIONS ATTACHMENTS
• 12.1. OPTIONS ATTACHMENTS LOCATIONS
• 12.1.1. SMS (Safe Man System) ELECTRICAL COMPONENTS
• 12.1.2. SMS (Safe Man System) WIRING HARNESSES