Manitou Work Platforms ATJ 46 T4 S2 Service Manual 647951 – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Manitou Work Platforms ATJ 46 T4 S2 Service Manual 647951 – PDF DOWNLOAD
GENERAL AND SAFETY CHARACTERISTICS:
00.1. FOREWORD:
This chapter deals with the general instructions and safety notice during servicing checks and work. The
other instructions and warning texts are indicated in the chapters concerned.
In order to reduce the risk of accidents, please:
• Follow the instructions in the operator’s manual and
the truck servicing instructions.
• > This manual should be found in all trucks.
• Please follow the safety instructions.
• Use the appropriate tools for all work to be carried
out.
• Use original Manitou spare parts.
If these instructions are not followed there is a risk of
accidents occurring, the severity of which could go as
far as causing death.
A person who follows the safety instructions and a wellserviced
machine make a safe, effective and profitable
combination.
TABLE OF CONTENTS:
Manitou Work Platforms ATJ 46 T4 S2 Service Manual 647951 – PDF DOWNLOAD
00 GENERAL AND SAFETY CHARACTERISTICS 10
00 1 FOREWORD 10
00 2 WORK DURING THE WARRANTY PERIOD 10
00 3 LIST OF SUPPLIER DOCUMENTATION 10
00 4 SAFETY 11
00 4 1 Maintenance rules 11
00 5 MACHINE SERVICE OPERATIONS 14
00 5 1 Maintenance position 14
00 5 2 Preparation and safety instructions 14
00 6 CHARACTERISTICS AND SPECIFICATIONS 14
00 6 1 Technical Data Sheet (ATJ 46 T4 S2) 14
00 6 2 Machine Dimensions (ATJ 46 T4 S2) 19
00 6 3 Lubricants and Fuel 21
00 7 REFERENCE INFORMATION 22
00 7 1 Explanation of symbols 22
00 7 2 List of abbreviations 22
00 7 3 Standard tightening torques 24
00 7 4 Metric – imperial unit conversion 26
10 ENGINE 28
10 1 CHARACTERISTICS AND SPECIFICATIONS 28
10 1 1 Supplier Documentation 28
10 1 2 Specifications of the D1105-E4B engine 28
10 2 LOCATION 29
10 2 1 Location of engine components 29
10 2 2 Location of Diesel Fuel Circuit Components 30
10 3 CONTROL AND ADJUSTMENT 31
10 3 1 Engine Tightening Torques 31
10 3 2 Engine Speed Block Adjustment 31
10 3 3 Adjust the alternator belt tension 32
4 647951EN-USM3(A-12/2020)
TABLE OF CONTENTS
10 4 REMOVAL 32
10 4 1 Placing the strut 32
10 4 2 Removing the engine access covers 33
10 4 3 Removing the cooling system 33
10 4 4 Removing the muffler 35
10 4 5 Removing the harnesses 35
10 4 6 Removing the air intake circuit 36
10 4 7 Removing the diesel circuit 36
10 4 8 Removing the hoses from the hydrostatic and auxiliary pumps 37
10 4 9 Removing the engine speed block 37
10 4 10 Remove the engine 38
10 5 REFIT 38
10 5 1 Refitting the engine 38
10 6 TROUBLESHOOTING 39
10 6 1 Troubleshooting 39
10 6 2 Kubota Engine Fault Codes D1105–E4B 41
20 TRANSMISSION 42
20 1 CHARACTERISTICS AND SPECIFICATIONS 42
20 1 1 Supplier Documentation 42
20 2 LOCATION 42
20 2 1 Transmission Components Location 43
20 3 CONTROL AND ADJUSTMENT 45
20 3 1 Transmission tightening torques 45
20 3 2 Location of pressure connectors (Rexroth A10VG pump) 46
20 3 3 Location of adjustment points (Rexroth A10VG pump) 47
20 3 4 Calibration of the LP Booster Valve 47
20 3 5 Neutral point adjustment – servo-control piston 48
20 3 6 Calibration – HP Valves 48
20 3 7 Calibration – Zero flow valve DR 49
20 4 REMOVAL 50
20 4 1 Removing the Hydrostatic Pump 50
20 4 2 Removing the Hydrostatic Motor 51
TABLE OF CONTENTS
647951EN-USM3(A-12/2020) 5
20 5 REFIT 52
20 5 1 Refitting the hydrostatic pump 52
20 5 2 Refitting the Hydrostatic Motor 52
30 AXLE 53
30 1 CHARACTERISTICS AND SPECIFICATIONS 53
30 1 1 Supplier Documentation 53
30 2 CONTROL AND ADJUSTMENT 53
30 2 1 Freewheeling mode 53
30 3 REMOVAL 54
30 3 1 Removing the Front Axle 54
30 3 2 Removing the Rear Axle 56
30 4 REFIT 57
30 4 1 Refitting Front Axle and Rear Axle 57
40 BRAKE 63
50 LIFTING STRUCTURE 64
50 1 REMOVAL 64
50 1 1 Removing the telescoping cylinder slide pads 64
50 1 2 Remove the pads from arm 3 64
50 1 3 Removing the pads from the moving tube cylinder 64
50 1 4 Remove the basket 65
50 1 5 Removing the jib 67
70 HYDRAULICS 69
70 1 CHARACTERISTICS AND SPECIFICATIONS 69
70 1 1 Supplier Documentation 69
70 2 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 69
70 2 1 Hydraulic diagram (ATJ 46 T4 S2 — 160 ATJ 4RD ST5 S2 – 160 ATJ RC 4RD ST5 S2 — 180 ATJ
4RD ST5 S2 – 180 ATJ RC 4RD ST5 S2) 71
6 647951EN-USM3(A-12/2020)
TABLE OF CONTENTS
70 3 LOCATION 75
70 3 1 Location of hydraulic components in chassis 77
70 3 2 Location of hydraulic components in the turntable 79
70 3 3 Location of hydraulic components in the arms 81
70 4 CONTROL AND ADJUSTMENT 83
70 4 1 Prerequisite for proportional valve group calibration 83
70 4 2 Proportional valve group calibration 83
70 4 3 Distributor Block calibration 85
70 4 4 Compensating and tilting circuit 87
70 5 REMOVAL 89
70 5 1 Remove the elements of the proportional valve group 89
70 5 2 Removing the distributor block 89
70 5 3 Removing a valve from the Distributor block 90
70 5 4 Preparing for cylinder removal 91
70 5 5 Decompressing the hoses 92
70 5 6 Removing the cylinders 93
70 5 7 Removing valve blocks and valves 94
70 6 REFIT 95
70 6 1 Refitting a valve on the Distributor block 95
70 6 2 Reinstall the cylinders 97
70 7 SPECIFIC TOOLING 98
70 7 1 Digital manometer box 98
70 7 2 Basic manometer box 99
80 ELECTRICITY 100
80 1 CHARACTERISTICS AND SPECIFICATIONS 100
80 1 1 Fuses and relays 100
80 2 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 102
80 2 1 Examples of coding on the wiring diagrams 102
80 2 2 Cable marking on an electrical wiring harness 103
80 2 3 Electrical diagrams (ATJ 46 T4 S2 — 160 ATJ 4RD ST5 S2 – 160 ATJ RC 4RD ST5 S2 — 180 ATJ
4RD ST5 S2 – 180 ATJ RC 4RD ST5 S2) 105
TABLE OF CONTENTS
647951EN-USM3(A-12/2020) 7
80 3 LOCATION 121
80 3 1 Location of electrical control components 123
80 3 2 Location of electrical power components 125
80 3 3 Option electrical components location 127
80 3 4 Location of Harnesses 129
80 3 5 Locations of controls, base control panel indicator lamps 141
80 3 6 Location of controls, indicators of the basket control panel and wiring 147
80 4 CONTROL AND ADJUSTMENT 157
80 4 1 Program Operation 157
80 4 2 Program Parameters 160
80 4 3 Joystick Calibration 174
80 4 4 Joystick Testing 175
80 4 5 Telescope Retracted Sensor Adjustment 175
80 4 6 Arm Down Sensor Adjustment 176
80 4 7 Tilt Calibration 176
80 4 8 Overload Sensor Adjustment 177
80 4 9 Maximum Movement Speed Calibration 178
80 4 10 Generator Setting (optional) 179
80 4 11 Stop&Go option management 180
80 5 REMOVAL 181
80 5 1 Remove the board UC234 from the base control panel 181
80 5 2 Remove board UD22 from the base control panel 182
80 6 TROUBLESHOOTING 184
80 6 1 Fault Codification 184
80 6 2 Warning and Fault code list 186
80 7 SPECIFIC TOOLING 188
80 7 1 Breakout boxes 188
85 OPERATOR STATION 189
90 CHASSIS 190
90 1 CONTROL AND ADJUSTMENT 190
90 1 1 Check slewing ring gear play 190
8 647951EN-USM3(A-12/2020)
TABLE OF CONTENTS
110 ADDITIONAL EQUIPMENT 192
120 DIAGNOSTIC TOOLS AND SOFTWARE 193
120 1 KUBOTA ENGINE FAULT CODES D1105–E4B 193
120 2 KUBOTA ENGINE FAULT CODES AFTER TREATMENT D1105–E4B 198
120 3 REPROGRAMMING CASE (MEWP) 199
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V