Manitou AXLE TYPE 211 Repair Manual 647041 – PDF DOWNLOAD
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Manitou AXLE TYPE 211 Repair Manual 647041 – 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.
IMPORTANT:
- In order to facilitate work and protect both working surfaces and operators, it is advisable to use proper equipment
such as: trestles or supporting benches, plastic or copper hammers, appropriate levers, pullers and specific spanners or wrenches. - Before going on to disassemble the parts and drain the oil, it is best to thoroughly clean the unit, removing any encrusted or accumulated grease.
TABLE OF CONTENTS:
Manitou AXLE TYPE 211 Repair Manual 647041 – PDF DOWNLOAD
CONTENTS 5
INTRODUCTION 11
VERSION TRACKING 12
MANUAL APPLICABILITY AND SUPPORTED MODELS 12
SPECIFICATIONS 13
DEFINITION OF VIEWPOINTS 13
DATA PLATE 13
CONVERSION TABLES 14
TORQUE SPECIFICATIONS 15
COARSE PITCH 15
FINE PITCH 15
WHEEL NUT TIGHTENING TORQUES 16
MAINTENANCE 17
MAINTENANCE POINTS 17
MANDATORY PROCEDURE 19
OIL DRAINING 19
CENTRAL HOUSING 19
PLANETARY GEAR REDUCTION 19
END-STOP PLIER SETTING 20
RETAINING SNAP RING FOR BORES 20
RETAINING SNAP RING FOR SHAFTS 20
INPUT SEAL GREASING 21
Handling instruction greasing 1 21
Handling instruction greasing 2 21
MAINTENANCE INTERVALS 22
LUBRICANT & SEALANT SPECIFICATIONS 23
SAFETY PRECAUTIONS 25
PLANETARY REDUCTION 1:6 AND THE STEERING CASE 27
EXPLODED VIEW 27
DISASSEMBLY 28
ASSEMBLY 34
SPECIAL TOOLS 41
T1 41
T2 42
T3 43
T4 44
T5 45
STEERING CYLINDER 47
EXPLODED VIEW 47
DISASSEMBLY 48
ASSEMBLY 51
SPECIAL TOOLS 58
T1 58
BRAKE: SERVICE BRAKE, NEGATIVE BRAKE, 45% LOCKED AND 100% LOCKED 59
EXPLODED VIEW 59
BRAKE WORKING CONDITIONS 60
SAHR BRAKE A PPLIED 60
SAHR BRAKE RELEASED 61
SERVICE BRAKE APPLIED 62
DIFFERENTIAL LOCK APPLIED 63
EMERGENCY RELEASE INSTRUCTIONS 64
RESET OF FAILS SAFE BRAKE FUNCTION 64
DISASSEMBLY 65
ASSEMBLY 72
BRAKE PISTON GAP CHECK 81
SPECIAL TOOLS 82
T1 82
BRAKE: NEGATIVE BRAKE 4 CUP SPRINGS VERSION 83
EXPLODED VIEW 83
DISASSEMBLY 84
ASSEMBLY 85
NORMAL PRELOADED DIFFERENTIAL UNIT (OLD VERSION) 87
EXPLODED VIEW 87
DISASSEMBLY 88
ASSEMBLY 92
NORMAL PRELOADED DIFFERENTIAL UNIT (INTERMEDIATE VERSION) 97
EXPLODED VIEW 97
DISASSEMBLY 98
ASSEMBLY 103
NORMAL PRELOADED DIFFERENTIAL UNIT (LAST VERSION) 107
EXPLODED VIEW 107
DISASSEMBLY 108
ASSEMBLY 111
FLANGED REDUCTION GEAR 603 TYPE: INTEGRAL 603 INPUT GEAR 115
EXPLODED VIEW 115
DISASSEMBLY 116
ASSEMBLY 120
SPECIAL TOOLS 123
T1 123
T2 124
BEVEL PINION: NORMAL FLANGE AND NUT REVOLUTION COUNTER VERSION 125
EXPLODED VIEW 125
DISASSEMBLY 126
ASSEMBLY 129
NORMAL FLANGE VERSION 131
REVOLUTION COUNTER VERSION 134
SPECIAL TOOLS 136
T1 136
T2 137
T3 138
T4 139
T5 140
RING AND PINION ADJUSTING: STEP FOR PRELOADED DIFFERENTIAL 141
EXPLODED VIEW 141
INSTALL AND ADJUST 142
SWINGING SUPPORT 145
EXPLODED VIEW 145
DISASSEMBLY 146
ASSEMBLY 148
PLANETARY REDUCTION: 1:4,23 151
EXPLODED VIEW 151
DISASSEMBLY 152
ASSEMBLY 153
BRAKE: INCOMING DISC BRAKE 155
EXPLODED VIEW 155
DISASSEMBLY 156
ASSEMBLY 159
CHECKING WEAR AND REPLACING THE BRAKING PADS 161
SERVICE AND MECHANICAL PARKING BRAKE 163
EXPLODED VIEW 163
DISASSEMBLY 164
ASSEMBLY 170
PARKING BRAKE AND DIFFERENTIAL HYDRAULIC LOCK 100% 175
EXPLODED VIEW 175
DISASSEMBLY 176
ASSEMBLY 179
DIFFERENTIAL WITH BLOCK TO SPHERES 100% (OLD VERSION) 181
EXPLODED VIEW 181
DISASSEMBLY 182
ASSEMBLY 187
DIFFERENTIAL WITH BLOCK TO SPHERES 100% (LAST VERSION) 191
EXPLODED VIEW 191
DISASSEMBLY 192
ASSEMBLY 195
NORMAL DIFFERENTIAL (OLD VERSION) 199
EXPLODED VIEW 199
DISASSEMBLY 200
ASSEMBLY 203
NORMAL DIFFERENTIAL (LAST VERSION) 207
EXPLODED VIEW 207
DISASSEMBLY 208
ASSEMBLY 212
LIMITED SLIP DIFFERENTIAL UNIT 45% (OLD VERSION) 215
EXPLODED VIEW 215
DISASSEMBLY 216
ASSEMBLY 219
LIMITED SLIP DIFFERENTIAL UNIT 45% (LAST VERSION) 223
EXPLODED VIEW 223
DISASSEMBLY 224
ASSEMBLY 226
PRELOADED LIMITED SLIP DIFFERENTIAL UNIT 45% UNIT (OLD VERSION) 229
EXPLODED VIEW 229
DISASSEMBLY 230
ASSEMBLY 234
PRELOADED LIMITED SLIP DIFFERENTIAL UNIT 45% (INTERMEDIATE VERSION) 239
EXPLODED VIEW 239
DISASSEMBLY 240
ASSEMBLY 245
PRELOADED LIMITED SLIP DIFFERENTIAL UNIT 45% (LAST VERSION) 249
EXPLODED VIEW 249
DISASSEMBLY 250
ASSEMBLY 253
BEVEL PINION: FLANGED TO REDUCTION GEAR 603 257
EXPLODED VIEW 257
DISASSEMBLY 258
ASSEMBLY 260
SPECIAL TOOLS 264
T1 264
T2 265
T3 266
RING AND PINION ADJUSTING: VERSION PINION COVER AND SINGLE ARM 267
EXPLODED VIEW 267
INSTALL AND ADJUST 268
RING AND PINION ADJUSTING: VERSION PINION INTEGRAL AND DOUBLE ARM 273
EXPLODED VIEW 273
INSTALL AND ADJUST 274
SEPARATE PINION COVER FOR FLANGED GEARBOX 277
EXPLODED VIEW 277
DISASSEMBLY 278
ASSEMBLY 282
CALCULATING PINION BEARINGS ROLLING TORQUE 282
CALCULATING PINION CENTER DISTANCE 284
SPECIAL TOOLS 287
T1 287
T2 288
T3 289
T4 290
UNITED PINION COVER FOR FLANGED GEARBOX 291
EXPLODED VIEW 291
DISASSEMBLY 292
ASSEMBLY 295
CALCULATING PINION CENTER DISTANCE 295
CALCULATING PINION BEARINGS ROLLING TORQUE 296
SPECIAL TOOLS 300
T1 300
T2 301
T3 302
STEERING KNUCKLE KING PIN PRELOADED BY BELLEVILLE WASHERS 303
EXPLODED VIEW 303
DISASSEMBLY 304
ASSEMBLY 307
Special tools 310
T1 310
SERVICE BRAKE, NEGATIVE BRAKE, 100% DIFFERENTIAL LOCK (NEW VERSION – OPTIONAL) 311
EXPLODED VIEW 311
BRAKING DISCS WEAR CHECK 312
EMERGENCY RELEASE INSTRUCTIONS 313
RESET OF FAILS SAFE BRAKE FUNCTION 313
DISASSEMBLY 314
ASSEMBLY 319
BRAKE PISTON GAP CHECK 329
SPECIAL TOOLS 330
T1 330
T2 330
SERVICE BRAKE, 100% DIFFERENTIAL LOCK (NEW VERSION – OPTIONAL) 331
EXPLODED VIEW 331
BRAKING DISCS WEAR CHECK 332
DISASSEMBLY 333
ASSEMBLY 337
BRAKE PISTON GAP CHECK 344
SPECIAL TOOLS 345
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V