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Manitou MLA-T 533 145 V PLUS D ST5 S1 Lift Truck Repair Manual 647872EN – PDF DOWNLOAD
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Description
Manitou MLA-T 533 145 V PLUS D ST5 S1 Lift Truck Repair Manual 647872EN – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Manitou MLA-T 533 145 V PLUS D ST5 S1 Lift Truck Repair Manual 647872EN – PDF DOWNLOAD
INTRODUCTION:
This chapter deals with the general instructions and safety notice during inspection and maintenance
work.
Other instructions and warnings are indicated in each chapter concerned.
In order to reduce accident risks, make sure to:
– Follow the instructions in the truck operating and maintenance manual.
⇒ This manual should be found in all trucks.
– Please follow all safety instructions.
– Use the appropriate tools for any work to be performed.
– Use original Manitou spare parts.
Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily
harm and even death.
An efficient, dependable and profitable combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.
TABLE OF CONTENTS:
Manitou MLA-T 533 145 V PLUS D ST5 S1 Lift Truck Repair Manual 647872EN – PDF DOWNLOAD
GENERAL CHARACTERISTICS AND SAFETY
ENGINE
TRANSMISSION
AXLE
BRAKE
ENGINE
TRANSMISSION
AXLE
BRAKE
BOOM
HYDRAULIC
ELECTRICITY
DRIVER’S CAB
FRAME – BODY
OPTIONS – ATTACHMENTS
HYDRAULIC
ELECTRICITY
DRIVER’S CAB
FRAME – BODY
OPTIONS – ATTACHMENTS
GROUP_00_MR647872EN
1Sommaire général – General table of content 3
00 1 GENERAL INSTRUCTIONS AND SAFETY NOTICE 8
00 1 1 INTRODUCTION 8
00 1 2 SERVICING POSITION 8
00 1 3 EXPLANATION OF SYMBOLS 9
00 1 4 SERVICING RULES 10
00 2 GENERAL CHARACTERISTICS AND SPECITICATION 13
00 2 1 CHARACTERISTICS 13
00 2 2 LUBRIFICANTS AND FUEL 13
RECOMMENDED LUBRICANT 14
PACKAGING 15
00 1 1 Dimensions 16
00 3 GENERAL LOCATION 17
00 3 1 NAME AND IDENTIFICATION PLATE 17
00 4 GENERAL CONTROL AND ADJUSTMENT 19
00 4 1 STANDARD TIGHTENING TORQUES 19
00 4 2 METRIC – IMPERIAL UNIT CONVERSION 20
00 4 3 FILTER ELEMENTS AND BELTS 21
GROUP_10_MR647872EN 23
10 23
10 1 ENGINE CHARACTERISTICS AND SPECIFICATION 25
10 1 1 CHARACTERISTICS 25
10 1 2 INJECTION CYCLE 26
Effects of fuel pre-injection 26
Effects of fuel post-injection 26
10 1 3 HIGH PRESSURE PUMP 27
10 2 ENGINE SCHEMATIC DIAGRAM 28
10 2 1 AIR INTAKE CIRCUIT AND EGR (EXHAUST GAS RECIRCULATION) 28
10 2 2 EXHAUST GAS AFTERTREATMENT SYSTEM (DOC/DPF+SCR) 29
10 2 3 ENGINE REDUCTION LEVELS 30
10 2 4 SCR-SYSTEM (EU) 31
10 2 5 DPF-SYSTEM (EU) 35
10 2 6 SCR-SYSTEM (EPA) 37
10 2 7 DPF-SYSTEM (EPA) 41
10 2 8 Lubricating oil diagram 42
10 2 9 COOLING CIRCUIT 43
10 2 10 FUEL CIRCUIT 44
10 2 11 DEF (Diesel Exhaust Fluid) circuit 45
10 3 ENGINE COMPONENTS LOCATION 46
10 3 1 10 3 1 ENGINE ELEMENTS 46
10 3 2 air COOLING CIRCUIT 47
10 3 3 Water COOLING CIRCUIT 47
10 3 4 DIESEL FUEL CIRCUIT 48
10 3 5 FUEL INJECTION CIRCUIT 49
10 3 6 EGR (Exhaust Gas Recirculation) CIRCUIT 50
10 3 7 DEF (DIESEL EXHAUST FLUID) SYSTEM 51
10 3 8 SILENT BLOCK TIGHTENING TORQUES 52
10 3 9 DEF (DIESEL EXHAUST FLUID) SYSTEM TIGHTENING TORQUES 53
PREPARATION AND SAFETY INSTRUCTIONS 54
10 4 CHECKING AND ADJUSTING THE ENGINE 54
10 4 1 ENGINE COMPONENTS 54
A – REMOVING ALTERNATOR BELT 55
B – REMOVING THE ALTERNATOR 58
C – REMOVING THE STARTER MOTOR 59
D – removal A/C COMPRESSOR (OPTION) 60
e – removal A/C BELT (OPTION) 61
10 5 REMOVING THE ENGINE 62
GENERAL INFORMATION 62
PREPARATION AND SAFETY INSTRUCTIONS 62
SPECIFIC TOOLING 62
10 5 1 REMOVING THE ENGINE 63
10 6 REMOVING DEF (Diesel Exhaust Fluid) circuit 71
GENERAL INFORMATION 71
PREPARATION AND SAFETY INSTRUCTIONS 71
SPECIFIC TOOLING 71
10 6 1 Air filter assembly removal 72
10 6 2 DEF tank removal 73
10 6 3 DOC EXHAUST PIPE REMOVAL 73
10 6 4 SCR EXHAUST PIPE REMOVAL 75
10 6 5 MIXING PIPE REMOVAL 75
10 6 6 DEF INJECTION SYSTEM REMOVAL 76
10 7 REMOVING the radiator 77
GENERAL INFORMATION 77
PREPARATION AND SAFETY INSTRUCTIONS 77
SPECIFIC TOOLING 77
10 7 1 REMOVING THE radiator 78
10 8 Engine troubleshooting 81
10 9 Specific engine tooling 81
10 9 1 Special engine tooling 81
10 9 2 Electronic tension meter 81
GROUP_20_MR647872EN 83
20 83
20 1 TRANSMISSION LAYOUTS 85
20 1 1 HYDROSTATIC TRANSMISSION LAYOUT – FORWARD MOVEMENT 85
20 1 2 HYDROSTATIC TRANSMISSION LAYOUT – REVERSING MOVEMENT 86
20 2 POSITION OF THE TRANSMISSION COMPONENTS 87
20 2 1 HYDROSTATIC TRANSMISSION CIRCUIT 87
20 3 TRANSMISSION ASSEMBLY TIGHTENING TORQUES 89
20 4 PRESSURE TAKE-OFF POINTS 91
20 4 1 A4Vxg 90 DA SERIES 32 PUMP 91
20 4 2 A10VO DA SERIES 53 PUMP 92
20 4 3 A6VM 60 EP1 AND A6VM 115 EP1 DA SERIES 71 MOTOR 92
20 5 PRESSURE TEST PORTS 93
20 5 1 LOCATION 93
20 5 2 VALUES 93
20 6 PUMP / MOTOR CONTROL AND ADJUSTMENT 94
20 6 1 TRANSMISSION ADJUSTMENT POINTS 94
A4Vxg 90 DA SERIES 32 PUMP 94
A6VM 60 EP1 AND A6VM 115 EP1 DA SERIES 71 MOTOR 95
20 6 2 PRE START-UP OR POST MAINTENANCE CHECKS 96
20 6 3 PUMP MECHANICAL “0” ADJUSTMENT 97
20 6 4 CHECKING PRESSURE CUT-OFF (DR) 98
20 6 5 A6VM MOTOR CONTROL ADJUSTMENT 99
A CHECKING MIN DISPLACEMENT (MAX SPEED) 99
B CHECKING MAXIMUM DISPLACEMENT (MAXIMUM TRACTION FORCE) 100
20 6 6 TROUBLE-SHOOTING 101
PUMP/MOTOR 101
VEHICLE 102
20 6 7 MANITOU – HYDROSTATIC TRANSMISSION REGULATION CHART 103
20 6 8 TRANSMISSION DIAGNOSTIC 105
20 7 REMOVING THE HYDROSTATIC TRANSMISSION 117
GENERAL INFORMATION 117
PREPARATION AND SAFETY INSTRUCTIONS 117
20 7 1 REMOVING THE HYDROSTATIC TRANSMISSION 118
REMOVING THE UNIVERSAL SHAFTS 118
REMOVING THE HYDRAULIC MOTORS 120
REMOVING THE GEAR 123
20 8 SPECIAL TOOLS FOR THE TRANSMISSION 125
20 8 1 STANDARD BOX 125
20 8 2 DIGITAL GAUGE KIT 127
GROUP_30_MR647872EN 129
20 129
30 1 REMOVING THE AXLE 131
GENERAL INFORMATION 131
PREPARATION AND SAFETY INSTRUCTIONS 131
30 1 1 REMOVING THE FRONT AXLE 132
30 1 2 REMOVING THE rear AXLE 134
GROUP_40_MR647872EN 137
40 1 POSITION OF THE BRAKES COMPONENTS 139
40 1 1 THE BRAKES COMPONENTS 139
40 2 FEATURES AND TECHNICAL SPECIFICATIONS OF THE BRAKES 140
40 2 1 PARKING BRAKE 140
40 3 BRAKES system layout 141
40 4 brake hydraulic circuit 142
40 5 REMOVING THE brake pump 143
GENERAL INFORMATION 143
PREPARATION AND SAFETY INSTRUCTIONS 143
40 5 1 removing BRAKE PUMP 144
40 5 2 Inching pedal and steering sensor calibration procedure 145
GROUP_50_MR647872EN 147
50 147
50 1 BOOM CHARACTERISTICS AND SPECIFICATIONS 149
50 1 1 BOOM WITH ONE EXTENSION 149
50 2 BOOM COMPONENTS LOCATION 151
50 2 1 POSITION OF COMPONENTS OF BOOM 152
50 3 BOOM CONTROL AND ADJUSTMENT 153
PREPARATION AND SAFETY INSTRUCTIONS 153
50 3 1 ADJUSTING THE SLIDING BLOCKS OF THE BOOM 153
50 3 2 REPLACING THE REAR SLIDING BLOCKS 153
50 3 3 REPLACING THE FRONT SLIDING BLOCKS 154
50 3 4 TELESCOPE EXTENSION AND RETRACTION ADJUSTMENT PROCEDURE 156
TELESCOPE EXTENSION SPEED ADJUSTMENT (TRIPLEX BOOM) 156
TELESCOPE RETRACTION SPEED ADJUSTMENT (DUPLEX AND TRIPLEX BOOM) 156
INNER TELESCOPE RETRACTION DE-SYNCHRONIZATION (TRIPLEX BOOM) 156
ADJUSTING THE SLIDING BLOCKS 157
50 4 boom removal 159
50 4 1 REMOVING THE ENTIRE TELESCOPIC BOOM 159
GENERAL INFORMATION 159
PREPARATION AND SAFETY INSTRUCTIONS 159
50 4 2 REMOVING THE TELESCOPIC BOOM FROM THE VEHICLE 160
50 4 3 REMOVING THE COMPONENTS FROM THE BOOM 162
REMOVING THE BOOM HYDRAULIC SYSTEM AND EXTENSION CYLINDER 162
REMOVING THE QUICK COUPLING 163
REMOVING THE SLEWING CYLINDER 164
GROUP_70_MR647872EN 165
70 165
70 1 HYDRAULIC SCHEMATIC DIAGRAM 167
70 1 1 HYDRAULIC SCHEMATIC DIAGRAM 167
LEGEND 167
HYDRAULIC DIAGRAM 168
70 2 HYDRAULIC COMPONENTS LOCATION 169
70 2 1 HYDRAULIC COMPONENTS LOCATION 169
LEGEND 169
DIAGRAM 170
70 3 HYDRAULIC CONTOL AND ADJUSTMENT 171
70 3 1 PRESSURE TEST PORTS 171
70 3 2 HYDRAULIC CIRCUITS 172
70 3 3 MAXIMUM PRESSURE LISTED ON PUMP AND DISTRIBUTOR 173
70 4 HYDRAULIC COMPONENTS REMOVAL 174
GENERAL INFORMATION 174
PREPARATION AND SAFETY INSTRUCTIONS 174
70 4 1 removing the lifting cylinders 175
REMOVING THE compensation CYLINDER 175
REMOVING THE lifting CYLINDER 176
70 4 2 REMOVING THE DIRECTIONAL CONTROL VALVE 177
70 4 3 REMOVING THE steering cylinders 179
70 4 4 REMOVING THE pumps 181
REMOVING THE SERVICE PUMP 181
REMOVING THE hydraulic PUMP 181
GROUP_80_MR647872EN 183
80 1 ELECTRICAL CHARACTERISTICS 187
80 1 1 LOCATION OF RELAYS AND FUSES 187
FUSES AND RELAYS IN CAB 187
FUSES AND RELAYS IN CAB DESCRIPTION 188
FUSES AND RELAYS UNDER THE ENGINE BONNET 189
FUSES AND RELAYS UNDER THE ENGINE BONNET DESCRIPTION 189
80 1 2 MENU ARCHITECTURE – DASHBOARD DISPLAY 190
WARNING AND INDICATOR LAMPS ON DISPLAY 190
CONTROL PANEL 191
80 1 7 ELECTRICAL AND ELECTRONIC SYSTEM OVERVIEW 205
CAN-OPEN 205
CAN-DEUTZ 206
CAN-J1939 207
80 1 8 ECU Inputs/Outputs 208
80 1 9 Technical sheets for electrical components 215
80 1 10 STRAIN GAuGE AND ANGLE SENSOR CALIBRATION 228
80 1 11 CONNECTORS, FUSES AND RELAYS 231
CHASSIS HARNESS 234
ENGINE HARNESS 249
CABIN HARNESS 266
cabin ROOF harness 301
driver place harness 307
rear lights harness 313
heating and A/C harness 314
A/c fan harness 316
boom lights harness 316
second boom head exit harness 317
second boom head exit + block accessories harness 317
beacon harness 317
export kit key anti-tipping harness 317
italy kit key anti-tipping harness 318
12V BOOM HEAD CONNECTOR 318
BOOM HEAD KIT HARNESS 319
eco stop KIT HARNESS 320
trailer kit harness 321
GREASE kit harness 321
80 2 WIRING DIAGRAMS 323
80 2 1 IDENTIFICATION MARKINGS REGARDING THE WIRING DIAGRAMS 323
80 2 2 Identification of connectors and conductors of the electric wiring 324
80 2 3 WIRING DIAGRAMS 325
POSITION OF CONNECTORS BY DIAGRAM 325
DIAGRAM 1 – STARTER 334
DIAGRAM 2 – CAN BUS J1939 AND DIAGNOSTIc 336
DIAGRAM 3 – CAN BUS OPEN AND DIAGNOSTIc 338
DIAGRAM 4 – TRASMISSION 340
DIAGRAM 5 – HYDRAULIC MOVEMENTS 342
DIAGRAM 6 – SENSORS 344
DIAGRAM 7 – HEATHER – A/C – FANS 346
DIAGRAM 8 – HEATHER – A/C 348
DIAGRAM 9 – LIGHTS 350
DIAGRAM 10 – CABIN 352
DIAGRAM 11 1 – OPTIONALS 354
DIAGRAM 11 2 – OPTIONALS 356
80 3 POSITION OF THE ELECTRICAL COMPONENTS 358
80 3 1 POSITION OF CONNECTORS ON THE VEHICLE 358
80 3 2 Chassis / REAR LAMPS 3D WIRING 367
80 3 3 ENGINE 3D WIRING 368
80 3 4 CABIN 1 1 3D WIRING 369
80 3 5 CABIN 1 2 3D WIRING 370
80 3 6 CABin heacing / armrest 3D WIRING 371
80 3 7 cabin roof 3D WIRING 372
80 3 8 optionals 1 1 3D WIRING 373
80 3 9 optionals 1 2 3D WIRING 374
80 3 10 cabin 2D WIRING 375
80 3 11 chassis 2D wiring 376
80 3 12 ENGINE 2D WIRING 377
80 3 13 ROOF / beacon lamp / rear lamps / cabin heating 2D WIRING 378
80 3 15 cabin ARMREST / BOOM / ARB 2D WIRING 379
80 3 14 OPTIONALs 1 1 2D WIRING 380
80 3 16 OPTIONALs 1 2 2D WIRING 381
80 4 Electrical removal – refit 383
80 4 1 BATTERY REMOVal 383
80 4 2 eNGINE ECU REMOVAL 383
80 4 3 TRANSMISSION ECU REMOVAL “RC12-10/30 “ 384
80 4 4 ecu mc2m 385
80 4 5 Dashboard display screen removal 386
80 4 6 REMOVAL – REFIT OF JSM ON BMEP 386
80 4 7 STRAIN GAUGE 387
80 5 ELECTRICAL TROUBLESHOOTING 389
80 5 1 WARNING MESSAGES 389
80 5 2 ALARM MESSAGES 390
80 5 3 ENGINE TROUBLE CODE LIST ECU EMR4 391
80 6 SPECIAL TOOLS FOR THE ELECTRICAL SYSTEM 409
80 6 1 DIAGNOSTIC CASE 409
80 6 2 CONNECTION TO TRUCK 410
GROUP_85_MR647872EN 411
85 411
85 1 DRIVER’S CAB REMOVAL 413
GENERAL INFORMATION 413
PREPARATION AND SAFETY INSTRUCTIONS 413
SPECIFIC TOOLING 413
85 1 1 REMOVING THE CAB 414
GROUP_90_MR647872EN 417
90 417
90 1 pivot articulation rEmoval 419
SPECIFIC TOOLING 419
GROUP_110_MR647872EN 421
110 421
110 1 Air conditioning characteristics and specifications 422
110 1 1 Description of operation 422
110 1 2 Operating principle 423
110 1 3 Description of components 424
110 2 Air conditioning location 425
110 2 1 2D AND 3D Location 425
110 2 2 HVAC components 426
110 2 3 Condenser components 427
110 3 Air conditioning controls and adjustments 427
110 3 1 General check points 427
110 3 2 Air-conditioning electrical system check points 428
110 3 3 Safety measures for handling r134a 428
110 3 4 Refrigerant fluid load for the air conditioning circuit 428
110 4 Air conditioning troubleshooting 429
110 5 Specific air conditioning tooling 430
110 5 1 Fitting wedge for elastic drive belt 430
00 1 GENERAL INSTRUCTIONS AND SAFETY NOTICE 8
00 1 1 INTRODUCTION 8
00 1 2 SERVICING POSITION 8
00 1 3 EXPLANATION OF SYMBOLS 9
00 1 4 SERVICING RULES 10
00 2 GENERAL CHARACTERISTICS AND SPECITICATION 13
00 2 1 CHARACTERISTICS 13
00 2 2 LUBRIFICANTS AND FUEL 13
RECOMMENDED LUBRICANT 14
PACKAGING 15
00 1 1 Dimensions 16
00 3 GENERAL LOCATION 17
00 3 1 NAME AND IDENTIFICATION PLATE 17
00 4 GENERAL CONTROL AND ADJUSTMENT 19
00 4 1 STANDARD TIGHTENING TORQUES 19
00 4 2 METRIC – IMPERIAL UNIT CONVERSION 20
00 4 3 FILTER ELEMENTS AND BELTS 21
GROUP_10_MR647872EN 23
10 23
10 1 ENGINE CHARACTERISTICS AND SPECIFICATION 25
10 1 1 CHARACTERISTICS 25
10 1 2 INJECTION CYCLE 26
Effects of fuel pre-injection 26
Effects of fuel post-injection 26
10 1 3 HIGH PRESSURE PUMP 27
10 2 ENGINE SCHEMATIC DIAGRAM 28
10 2 1 AIR INTAKE CIRCUIT AND EGR (EXHAUST GAS RECIRCULATION) 28
10 2 2 EXHAUST GAS AFTERTREATMENT SYSTEM (DOC/DPF+SCR) 29
10 2 3 ENGINE REDUCTION LEVELS 30
10 2 4 SCR-SYSTEM (EU) 31
10 2 5 DPF-SYSTEM (EU) 35
10 2 6 SCR-SYSTEM (EPA) 37
10 2 7 DPF-SYSTEM (EPA) 41
10 2 8 Lubricating oil diagram 42
10 2 9 COOLING CIRCUIT 43
10 2 10 FUEL CIRCUIT 44
10 2 11 DEF (Diesel Exhaust Fluid) circuit 45
10 3 ENGINE COMPONENTS LOCATION 46
10 3 1 10 3 1 ENGINE ELEMENTS 46
10 3 2 air COOLING CIRCUIT 47
10 3 3 Water COOLING CIRCUIT 47
10 3 4 DIESEL FUEL CIRCUIT 48
10 3 5 FUEL INJECTION CIRCUIT 49
10 3 6 EGR (Exhaust Gas Recirculation) CIRCUIT 50
10 3 7 DEF (DIESEL EXHAUST FLUID) SYSTEM 51
10 3 8 SILENT BLOCK TIGHTENING TORQUES 52
10 3 9 DEF (DIESEL EXHAUST FLUID) SYSTEM TIGHTENING TORQUES 53
PREPARATION AND SAFETY INSTRUCTIONS 54
10 4 CHECKING AND ADJUSTING THE ENGINE 54
10 4 1 ENGINE COMPONENTS 54
A – REMOVING ALTERNATOR BELT 55
B – REMOVING THE ALTERNATOR 58
C – REMOVING THE STARTER MOTOR 59
D – removal A/C COMPRESSOR (OPTION) 60
e – removal A/C BELT (OPTION) 61
10 5 REMOVING THE ENGINE 62
GENERAL INFORMATION 62
PREPARATION AND SAFETY INSTRUCTIONS 62
SPECIFIC TOOLING 62
10 5 1 REMOVING THE ENGINE 63
10 6 REMOVING DEF (Diesel Exhaust Fluid) circuit 71
GENERAL INFORMATION 71
PREPARATION AND SAFETY INSTRUCTIONS 71
SPECIFIC TOOLING 71
10 6 1 Air filter assembly removal 72
10 6 2 DEF tank removal 73
10 6 3 DOC EXHAUST PIPE REMOVAL 73
10 6 4 SCR EXHAUST PIPE REMOVAL 75
10 6 5 MIXING PIPE REMOVAL 75
10 6 6 DEF INJECTION SYSTEM REMOVAL 76
10 7 REMOVING the radiator 77
GENERAL INFORMATION 77
PREPARATION AND SAFETY INSTRUCTIONS 77
SPECIFIC TOOLING 77
10 7 1 REMOVING THE radiator 78
10 8 Engine troubleshooting 81
10 9 Specific engine tooling 81
10 9 1 Special engine tooling 81
10 9 2 Electronic tension meter 81
GROUP_20_MR647872EN 83
20 83
20 1 TRANSMISSION LAYOUTS 85
20 1 1 HYDROSTATIC TRANSMISSION LAYOUT – FORWARD MOVEMENT 85
20 1 2 HYDROSTATIC TRANSMISSION LAYOUT – REVERSING MOVEMENT 86
20 2 POSITION OF THE TRANSMISSION COMPONENTS 87
20 2 1 HYDROSTATIC TRANSMISSION CIRCUIT 87
20 3 TRANSMISSION ASSEMBLY TIGHTENING TORQUES 89
20 4 PRESSURE TAKE-OFF POINTS 91
20 4 1 A4Vxg 90 DA SERIES 32 PUMP 91
20 4 2 A10VO DA SERIES 53 PUMP 92
20 4 3 A6VM 60 EP1 AND A6VM 115 EP1 DA SERIES 71 MOTOR 92
20 5 PRESSURE TEST PORTS 93
20 5 1 LOCATION 93
20 5 2 VALUES 93
20 6 PUMP / MOTOR CONTROL AND ADJUSTMENT 94
20 6 1 TRANSMISSION ADJUSTMENT POINTS 94
A4Vxg 90 DA SERIES 32 PUMP 94
A6VM 60 EP1 AND A6VM 115 EP1 DA SERIES 71 MOTOR 95
20 6 2 PRE START-UP OR POST MAINTENANCE CHECKS 96
20 6 3 PUMP MECHANICAL “0” ADJUSTMENT 97
20 6 4 CHECKING PRESSURE CUT-OFF (DR) 98
20 6 5 A6VM MOTOR CONTROL ADJUSTMENT 99
A CHECKING MIN DISPLACEMENT (MAX SPEED) 99
B CHECKING MAXIMUM DISPLACEMENT (MAXIMUM TRACTION FORCE) 100
20 6 6 TROUBLE-SHOOTING 101
PUMP/MOTOR 101
VEHICLE 102
20 6 7 MANITOU – HYDROSTATIC TRANSMISSION REGULATION CHART 103
20 6 8 TRANSMISSION DIAGNOSTIC 105
20 7 REMOVING THE HYDROSTATIC TRANSMISSION 117
GENERAL INFORMATION 117
PREPARATION AND SAFETY INSTRUCTIONS 117
20 7 1 REMOVING THE HYDROSTATIC TRANSMISSION 118
REMOVING THE UNIVERSAL SHAFTS 118
REMOVING THE HYDRAULIC MOTORS 120
REMOVING THE GEAR 123
20 8 SPECIAL TOOLS FOR THE TRANSMISSION 125
20 8 1 STANDARD BOX 125
20 8 2 DIGITAL GAUGE KIT 127
GROUP_30_MR647872EN 129
20 129
30 1 REMOVING THE AXLE 131
GENERAL INFORMATION 131
PREPARATION AND SAFETY INSTRUCTIONS 131
30 1 1 REMOVING THE FRONT AXLE 132
30 1 2 REMOVING THE rear AXLE 134
GROUP_40_MR647872EN 137
40 1 POSITION OF THE BRAKES COMPONENTS 139
40 1 1 THE BRAKES COMPONENTS 139
40 2 FEATURES AND TECHNICAL SPECIFICATIONS OF THE BRAKES 140
40 2 1 PARKING BRAKE 140
40 3 BRAKES system layout 141
40 4 brake hydraulic circuit 142
40 5 REMOVING THE brake pump 143
GENERAL INFORMATION 143
PREPARATION AND SAFETY INSTRUCTIONS 143
40 5 1 removing BRAKE PUMP 144
40 5 2 Inching pedal and steering sensor calibration procedure 145
GROUP_50_MR647872EN 147
50 147
50 1 BOOM CHARACTERISTICS AND SPECIFICATIONS 149
50 1 1 BOOM WITH ONE EXTENSION 149
50 2 BOOM COMPONENTS LOCATION 151
50 2 1 POSITION OF COMPONENTS OF BOOM 152
50 3 BOOM CONTROL AND ADJUSTMENT 153
PREPARATION AND SAFETY INSTRUCTIONS 153
50 3 1 ADJUSTING THE SLIDING BLOCKS OF THE BOOM 153
50 3 2 REPLACING THE REAR SLIDING BLOCKS 153
50 3 3 REPLACING THE FRONT SLIDING BLOCKS 154
50 3 4 TELESCOPE EXTENSION AND RETRACTION ADJUSTMENT PROCEDURE 156
TELESCOPE EXTENSION SPEED ADJUSTMENT (TRIPLEX BOOM) 156
TELESCOPE RETRACTION SPEED ADJUSTMENT (DUPLEX AND TRIPLEX BOOM) 156
INNER TELESCOPE RETRACTION DE-SYNCHRONIZATION (TRIPLEX BOOM) 156
ADJUSTING THE SLIDING BLOCKS 157
50 4 boom removal 159
50 4 1 REMOVING THE ENTIRE TELESCOPIC BOOM 159
GENERAL INFORMATION 159
PREPARATION AND SAFETY INSTRUCTIONS 159
50 4 2 REMOVING THE TELESCOPIC BOOM FROM THE VEHICLE 160
50 4 3 REMOVING THE COMPONENTS FROM THE BOOM 162
REMOVING THE BOOM HYDRAULIC SYSTEM AND EXTENSION CYLINDER 162
REMOVING THE QUICK COUPLING 163
REMOVING THE SLEWING CYLINDER 164
GROUP_70_MR647872EN 165
70 165
70 1 HYDRAULIC SCHEMATIC DIAGRAM 167
70 1 1 HYDRAULIC SCHEMATIC DIAGRAM 167
LEGEND 167
HYDRAULIC DIAGRAM 168
70 2 HYDRAULIC COMPONENTS LOCATION 169
70 2 1 HYDRAULIC COMPONENTS LOCATION 169
LEGEND 169
DIAGRAM 170
70 3 HYDRAULIC CONTOL AND ADJUSTMENT 171
70 3 1 PRESSURE TEST PORTS 171
70 3 2 HYDRAULIC CIRCUITS 172
70 3 3 MAXIMUM PRESSURE LISTED ON PUMP AND DISTRIBUTOR 173
70 4 HYDRAULIC COMPONENTS REMOVAL 174
GENERAL INFORMATION 174
PREPARATION AND SAFETY INSTRUCTIONS 174
70 4 1 removing the lifting cylinders 175
REMOVING THE compensation CYLINDER 175
REMOVING THE lifting CYLINDER 176
70 4 2 REMOVING THE DIRECTIONAL CONTROL VALVE 177
70 4 3 REMOVING THE steering cylinders 179
70 4 4 REMOVING THE pumps 181
REMOVING THE SERVICE PUMP 181
REMOVING THE hydraulic PUMP 181
GROUP_80_MR647872EN 183
80 1 ELECTRICAL CHARACTERISTICS 187
80 1 1 LOCATION OF RELAYS AND FUSES 187
FUSES AND RELAYS IN CAB 187
FUSES AND RELAYS IN CAB DESCRIPTION 188
FUSES AND RELAYS UNDER THE ENGINE BONNET 189
FUSES AND RELAYS UNDER THE ENGINE BONNET DESCRIPTION 189
80 1 2 MENU ARCHITECTURE – DASHBOARD DISPLAY 190
WARNING AND INDICATOR LAMPS ON DISPLAY 190
CONTROL PANEL 191
80 1 7 ELECTRICAL AND ELECTRONIC SYSTEM OVERVIEW 205
CAN-OPEN 205
CAN-DEUTZ 206
CAN-J1939 207
80 1 8 ECU Inputs/Outputs 208
80 1 9 Technical sheets for electrical components 215
80 1 10 STRAIN GAuGE AND ANGLE SENSOR CALIBRATION 228
80 1 11 CONNECTORS, FUSES AND RELAYS 231
CHASSIS HARNESS 234
ENGINE HARNESS 249
CABIN HARNESS 266
cabin ROOF harness 301
driver place harness 307
rear lights harness 313
heating and A/C harness 314
A/c fan harness 316
boom lights harness 316
second boom head exit harness 317
second boom head exit + block accessories harness 317
beacon harness 317
export kit key anti-tipping harness 317
italy kit key anti-tipping harness 318
12V BOOM HEAD CONNECTOR 318
BOOM HEAD KIT HARNESS 319
eco stop KIT HARNESS 320
trailer kit harness 321
GREASE kit harness 321
80 2 WIRING DIAGRAMS 323
80 2 1 IDENTIFICATION MARKINGS REGARDING THE WIRING DIAGRAMS 323
80 2 2 Identification of connectors and conductors of the electric wiring 324
80 2 3 WIRING DIAGRAMS 325
POSITION OF CONNECTORS BY DIAGRAM 325
DIAGRAM 1 – STARTER 334
DIAGRAM 2 – CAN BUS J1939 AND DIAGNOSTIc 336
DIAGRAM 3 – CAN BUS OPEN AND DIAGNOSTIc 338
DIAGRAM 4 – TRASMISSION 340
DIAGRAM 5 – HYDRAULIC MOVEMENTS 342
DIAGRAM 6 – SENSORS 344
DIAGRAM 7 – HEATHER – A/C – FANS 346
DIAGRAM 8 – HEATHER – A/C 348
DIAGRAM 9 – LIGHTS 350
DIAGRAM 10 – CABIN 352
DIAGRAM 11 1 – OPTIONALS 354
DIAGRAM 11 2 – OPTIONALS 356
80 3 POSITION OF THE ELECTRICAL COMPONENTS 358
80 3 1 POSITION OF CONNECTORS ON THE VEHICLE 358
80 3 2 Chassis / REAR LAMPS 3D WIRING 367
80 3 3 ENGINE 3D WIRING 368
80 3 4 CABIN 1 1 3D WIRING 369
80 3 5 CABIN 1 2 3D WIRING 370
80 3 6 CABin heacing / armrest 3D WIRING 371
80 3 7 cabin roof 3D WIRING 372
80 3 8 optionals 1 1 3D WIRING 373
80 3 9 optionals 1 2 3D WIRING 374
80 3 10 cabin 2D WIRING 375
80 3 11 chassis 2D wiring 376
80 3 12 ENGINE 2D WIRING 377
80 3 13 ROOF / beacon lamp / rear lamps / cabin heating 2D WIRING 378
80 3 15 cabin ARMREST / BOOM / ARB 2D WIRING 379
80 3 14 OPTIONALs 1 1 2D WIRING 380
80 3 16 OPTIONALs 1 2 2D WIRING 381
80 4 Electrical removal – refit 383
80 4 1 BATTERY REMOVal 383
80 4 2 eNGINE ECU REMOVAL 383
80 4 3 TRANSMISSION ECU REMOVAL “RC12-10/30 “ 384
80 4 4 ecu mc2m 385
80 4 5 Dashboard display screen removal 386
80 4 6 REMOVAL – REFIT OF JSM ON BMEP 386
80 4 7 STRAIN GAUGE 387
80 5 ELECTRICAL TROUBLESHOOTING 389
80 5 1 WARNING MESSAGES 389
80 5 2 ALARM MESSAGES 390
80 5 3 ENGINE TROUBLE CODE LIST ECU EMR4 391
80 6 SPECIAL TOOLS FOR THE ELECTRICAL SYSTEM 409
80 6 1 DIAGNOSTIC CASE 409
80 6 2 CONNECTION TO TRUCK 410
GROUP_85_MR647872EN 411
85 411
85 1 DRIVER’S CAB REMOVAL 413
GENERAL INFORMATION 413
PREPARATION AND SAFETY INSTRUCTIONS 413
SPECIFIC TOOLING 413
85 1 1 REMOVING THE CAB 414
GROUP_90_MR647872EN 417
90 417
90 1 pivot articulation rEmoval 419
SPECIFIC TOOLING 419
GROUP_110_MR647872EN 421
110 421
110 1 Air conditioning characteristics and specifications 422
110 1 1 Description of operation 422
110 1 2 Operating principle 423
110 1 3 Description of components 424
110 2 Air conditioning location 425
110 2 1 2D AND 3D Location 425
110 2 2 HVAC components 426
110 2 3 Condenser components 427
110 3 Air conditioning controls and adjustments 427
110 3 1 General check points 427
110 3 2 Air-conditioning electrical system check points 428
110 3 3 Safety measures for handling r134a 428
110 3 4 Refrigerant fluid load for the air conditioning circuit 428
110 4 Air conditioning troubleshooting 429
110 5 Specific air conditioning tooling 430
110 5 1 Fitting wedge for elastic drive belt 430
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