2014 Manitou AXLE ASSEMBLY TYPE 212 Repair Manual 547983EN – PDF DOWNLOAD

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2014 Manitou AXLE ASSEMBLY TYPE 212 Repair Manual 547983EN – PDF DOWNLOAD

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2014 Manitou AXLE ASSEMBLY TYPE 212 Repair Manual 547983EN – PDF DOWNLOAD

Language : English
Pages : 1302
Downloadable : Yes
File Type : PDF
Size: 71.1 MB

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DESCRIPTION:

2014 Manitou AXLE ASSEMBLY TYPE 212 Repair Manual 547983EN – PDF DOWNLOAD

INTRODUCTION:

The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on efficient repair work, should there be a break-down or malfunction. The instructions contained in this manual have been based on a complete overhaul of the unit. However, it is up to the mechanic to decide whether or not it is necessary to assemble only individual components, when partial repair work is needed. The manual provides a quick and sure guide which, with the use of photographs and diagrams illustrating the various phases of the operations, allows accurate work to be performed.All the information needed for correct disassembly, checks and assembly of each individual component is set out below. In order to remove the differential unit from the vehicle, the manuals provided by the vehicle manufacturer should be consulted. In describing the following operations it is presumed that the unit has already been removed from the vehicle.

TABLE OF CONTENTS:

2014 Manitou AXLE ASSEMBLY TYPE 212 Repair Manual 547983EN – PDF DOWNLOAD

547983EN……………………………………………. 1
INTRODUCTION…………………………………….. 7
SPECIFICATIONS…………………………………… 9
DEFINITION OF VIEWPOINTS………………………. 9
DATA PLATE…………………………………… 9
CONVERSION TABLES…………………………….. 10
TORQUE SPECIFICATIONS…………………………. 11
COARSE PITCH……………………………… 11
FINE PITCH……………………………….. 11
WHEEL NUT TIGHTENING TORQUES……………….. 12
MAINTENANCE………………………………….. 13
MAINTENANCE POINTS………………………… 13
MAINTENANCE INTERVALS……………………… 14
ADJUSTMENT AND CHECKS……………………… 14
LUBRICANT & SEALANT SPECIFICATIONS………….. 15
SAFETY PRECAUTIONS……………………………….. 17
CHECKING WEAR AND REPLACING THE BRAKING DISCS……….. 19
EXPLODED VIEW………………………………… 19
DISASSEMBLY………………………………….. 20
ASSEMBLY…………………………………….. 22
SPECIAL TOOLS………………………………… 24
T1………………………………………. 24
T2………………………………………. 24
COMPLETE STEERING CASE……………………………. 25
EXPLODED VIEW………………………………… 25
DISASSEMBLY………………………………….. 26
ASSEMBLY…………………………………….. 27
DOUBLE U-JOINT…………………………………… 29
EXPLODED VIEW………………………………… 29
DISASSEMBLY………………………………….. 30
ASSEMBLY…………………………………….. 31
SPECIAL TOOLS………………………………… 33
T1………………………………………. 33
T2………………………………………. 33
PLANETARY REDUCTION GEAR………………………….. 35
EXPLODED VIEW………………………………… 35
DISASSEMBLY………………………………….. 36
ASSEMBLY…………………………………….. 40
SPECIAL TOOLS………………………………… 44
T1………………………………………. 44
T2………………………………………. 44
T3………………………………………. 45
T4………………………………………. 46
T5………………………………………. 46
STEERING CYLINDER………………………………… 47
EXPLODED VIEW………………………………… 47
OPTICAL SENSOR AND MAGNETIC SENSOR……………… 48
DISASSEMBLY………………………………….. 49
ASSEMBLY…………………………………….. 52
SPECIAL TOOLS………………………………… 58
T1………………………………………. 58
T2………………………………………. 59
DIFFERENTIAL UNIT………………………………… 61
EXPLODED VIEW………………………………… 61
DISASSEMBLY………………………………….. 62
ASSEMBLY…………………………………….. 64
SPECIAL TOOLS………………………………… 66
T1………………………………………. 66
T2………………………………………. 66
BEVEL PINION…………………………………….. 67
EXPLODED VIEW………………………………… 67
DISASSEMBLY………………………………….. 68
ASSEMBLY…………………………………….. 71
SPECIAL TOOLS………………………………… 77
T1………………………………………. 77
T2………………………………………. 78
T3………………………………………. 78
T4………………………………………. 79
T5………………………………………. 79
T6………………………………………. 80
T7………………………………………. 81
T8………………………………………. 82
T9………………………………………. 82
MANUAL EMERGENCY RELASE…………………………… 83
EXPLODED VIEW………………………………… 83
RELEASE……………………………………… 84
ADJUST………………………………………. 85
MECHANICAL PARKING BRAKE………………………….. 87
EXPLODED VIEW………………………………… 87
DISASSEMBLY………………………………….. 88
ASSEMBLY…………………………………….. 90
EXTERNAL HYDRAULIC NEGATIVE BRAKE………………….. 93
EXPLODED VIEW………………………………… 93
DISASSEMBLY………………………………….. 94
ASSEMBLY…………………………………….. 95
EXTERNAL HYDRAULIC NEGATIVE BRAKE WITH QUICK RELEASE…. 97
EXPLODED VIEW………………………………… 97
DISASSEMBLY………………………………….. 98
ASSEMBLY…………………………………….. 100
INCOMING DRUM BRAKE………………………………. 103
EXPLODED VIEW………………………………… 103
DISASSEMBLY………………………………….. 104
ASSEMBLY…………………………………….. 106
SPECIAL TOOLS………………………………… 108
T1………………………………………. 108
T2………………………………………. 109
4″ INCOMING BRAKE (2 AND 3 FUNCTION VERSIONS)……….. 111
EXPLODED VIEW………………………………… 111
DISASSEMBLY………………………………….. 112
ASSEMBLY…………………………………….. 116
SPECIAL TOOLS………………………………… 122
T1………………………………………. 122
T2………………………………………. 122
T3………………………………………. 123
NORMAL DIFFERENTIAL UNIT………………………….. 125
EXPLODED VIEW………………………………… 125
DISASSEMBLY………………………………….. 126
ASSEMBLY…………………………………….. 128
SPECIAL TOOLS………………………………… 131
T1………………………………………. 131
T2………………………………………. 131
T3………………………………………. 132
T4………………………………………. 132
LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%)………… 133
EXPLODED VIEW………………………………… 133
DISASSEMBLY………………………………….. 134
ASSEMBLY…………………………………….. 137
SPECIAL TOOLS………………………………… 140
T1………………………………………. 140
T2………………………………………. 140
T3………………………………………. 141
T4………………………………………. 141
HYDRAULIC DIFFERENTIAL LOCK……………………….. 143
EXPLODED VIEW………………………………… 143
DISASSEMBLY………………………………….. 144
ASSEMBLY…………………………………….. 147
SPECIAL TOOLS………………………………… 149
T1………………………………………. 149
T2………………………………………. 149
HYDRAULIC NEGATIVE BRAKE………………………….. 151
EXPLODED VIEW………………………………… 151
DISASSEMBLY………………………………….. 152
ASSEMBLY…………………………………….. 155
INCORPORATED REDUCTION GEAR AND PINION 602………….. 161
EXPLODED VIEW………………………………… 161
DISASSEMBLY………………………………….. 162
ASSEMBLY…………………………………….. 166
SPECIAL TOOLS………………………………… 169
T1………………………………………. 169
T2………………………………………. 170
T3………………………………………. 171
T4………………………………………. 172
T5………………………………………. 173
T6………………………………………. 174
GROUP 0 ……………………………………………. 175
LIFT TRUCK CHARACTERISTICS ……………………….. 177
LIFT TRUCK CHARACTERISTICS ……………………….. 207
GROUP 10 …………………………………………… 277
REMOVAL OF THE I.C ENGINE ………………………… 279
DISASSEMBLY OF THE I.C. ENGINE ……………………. 291
GROUP 12 …………………………………………… 599
FUEL SENDER ASSEMBLY …………………………….. 601
GROUP 15 …………………………………………… 605
FAN BELT ADJUSTMENT ……………………………… 607
GROUP 20 …………………………………………… 611
REMOVAL OF THE TRANSMISSION ……………………… 613
REMOVAL OF THE TRANSMISSION ………………………. 629
GEAR BOX DISASSEMBLY …………………………….. 637
GEAR BOX DISASSEMBLY …………………………….. 691
BEVEL GEAR DISASSEMBLY …………………………… 767
GROUP 30 …………………………………………… 791
REMOVAL OF THE FRONT AND REAR AXLE ASSEMBLY ………… 793
DISASSEMBLY OF THE AXLE ASSEMBLY 212 ………………. 807
GROUP 40 …………………………………………… 973
DISASSEMBLY OF THE PARKING BRAKE ………………….. 975
BLEEDING THE BRAKE CIRCUIT ……………………….. 979
BLEEDING THE TRAILER BRAKE CIRCUIT (OPTION) ………… 983
HYDRAULIC BRAKING CIRCUIT ………………………… 987
OPERATION OF THE BRAKE SYSTEM …………………….. 999
GROUP 70 ……………………………………………1019
REMOVAL OF THE VALVE BANK …………………………1021
DISTRIBUTOR DISASSEMBLY …………………………..1029
DISTRIBUTOR DISASSEMBLY …………………………..1035
DISMANTLING THE MAIN HYDRAULIC PUMP ………………..1049
DISMANTLING THE MAIN HYDRAULIC PUMP ………………..1065
CYLINDER DISASSEMBLY ……………………………..1077
TAKING OF PRESSURE ……………………………….1097
Sans titre……………………………………….1105
HYDRAULIC DIAGRAM ………………………………..1119
HYDRAULIC DIAGRAM ……………………………….1147
GROUP 80 ……………………………………………1159
ELECTRIC DIAGRAM …………………………………1161
ELECTRIC DIAGRAM ………………………………..1197
PLATE ELECTRIC DIAGRAM ……………………………1217
OPERATING AND SETTING OF THE SAFETY SYSTEM ………….1225

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