Manitou Work Platforms ATJ 46P RC T4 S2 Service Manual 647820EN-USM3 – PDF DOWNLOAD
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Manitou Work Platforms ATJ 46P RC T4 S2 Service Manual 647820EN-USM3 – PDF DOWNLOAD
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 46P RC T4 S2 Service Manual 647820EN-USM3 – PDF DOWNLOAD
Legal disclaimer 3
Foreword 10
Intervention during the warranty period 10
Supplier Documentation List 10
Safety 11
Servicing Rules 11
Machine Service Operations 14
Servicing position 14
Preparation and safety instructions MEWP 14
Characteristics and specifications 14
Technical Datasheet (ATJ 46P RC T4 S2) 14
Load Specifications 15
Speeds and Movements 15
Diesel Engine 16
Transmission 16
Braking 17
Hydraulic System 17
Electrical Circuit 17
Backup pump 17
Dimensions 18
Noise and Vibration 18
Machine Dimensions (ATJ 46P RC T4 S2) 18
Dimensions 19
Dimensions and amplitude of movement 19
Amplitude of movements 20
Amplitude of movement diagram 20
Lubricants and Fuel 21
Lubricants and fuel 21
Reference Information 21
Explanation of symbols 21
List of Abbreviations 22
Standard tightening torques 24
Metric – imperial unit conversion 26
Characteristics and specifications 27
Supplier Documentation 27
General characteristics – Kubota D1105-E4B 27
Location 28
Location of engine components – Kubota D1105-E4B 28
Location of engine components 28
Fuel Circuit Component Location 29
Location of Diesel Fuel Circuit Components 29
Control and adjustment 30
Engine Tightening Torques 30
Engine mount and Engine flywheel coupling tightening torques 30
Adjusting the Proportional Engine Speed Block 30
alternator belt tension adjustment 31
Alternator belt tension adjustment 31
Removal 31
Setting up the crutch 31
Distance between counterweight and upper hinge 31
Placing the strut 31
Engine Access Covers Removal 31
Battery cover and engine access grille 32
Left-hand turntable cover 32
Cooling System Removal 32
Water radiator filler cap 32
Low radiator bleed button 32
Hoses on radiator 33
Radiator filler cover 33
Oil radiator connector and radiator grille 33
Oil radiator connector and fastening screws 33
Removing the Silencer 34
Muffler fastening screws 34
Harnesses Removal 34
Alternator harnesses 34
Starter harnesses 34
Preheat harness and temperature sensor 34
Engine stop solenoid valve 34
Hydrostatic pump control 35
Removal of Air Intake Circuit 35
Air intake circuit 35
Removal of Fuel Circuit 35
Diesel inlet hoses 35
Diesel hoses 35
Hoses Removal for Hydrostatic and Auxiliary Pump 35
Hydrostatic and auxiliary pumps and filter 36
Proportional Engine Speed Block Removing 36
Location of the engine speed block 36
Removal of cable and spring hoses 36
Connecting rod removal 36
Removal of connecting rods 37
Engine Removal 37
Engine removal 37
Refit 37
Installing Engine Components 37
Hydraulic oil tank check 38
Troubleshooting 38
Engine Troubleshooting Details 38
Engine Diagnostic Codes (Refer to Section 120) 40
Characteristics and specifications 41
Supplier Documentation 41
Location 41
Transmission Components Location 43
Location of transmission components 43
Control and adjustment 45
Transmission Tightening Torques 45
Transmission tightening torques 45
Location of Pressure Ports (A10VG Rexroth Pump) 46
Location of pressure connectors 46
Location of Adjustment Points (A10VG Rexroth Pump) 47
Location of adjustment points 47
Calibration of LP Booster Valve 47
Calibration of the LP booster valve 48
Pressure relief valve removal 48
Adjustment of the Neutral Point Servo Control Piston 48
Neutral point adjustment 48
Calibration of HP Valves 48
Calibration of Zero Flow Valve DR 49
DR valve 50
Removal 50
Removing the Hydrostatic Pump 50
Low basket position 50
Removing the Hydrostatic Motor 51
Location of hydrostatic motor cover plate 51
Hydrostatic motor hoses 51
Refit 52
Installing the Hydrostatic Pump 52
Installing the Hydrostatic Motor 52
Characteristics and specifications 53
Supplier Documentation 53
Control and adjustment 53
Freewheel Operation 53
Pressure relief valve screws and nuts 53
Screws and nuts 53
Seals 54
Coil location 54
Removal 54
Removing the Front Axle 54
Oscillation part process 55
Mounting flanges 55
Front chassis slinging 55
Location of hoses 55
Axle / Chassis attachment 56
Removing the Rear Axle 56
Cover plate location 56
Translation motor location 56
Removing the universal joint 56
Location of rear chassis slinging 57
Location of steering cylinder hoses 57
Location of brake and differential hoses 57
Refit 57
Refitting the Front and Rear Axles 57
Section Not Applicable 63
Removal 64
Removing the Telescope Cylinder Slide Pads 64
Removing the Arm 3 Pads 64
Arm 3 slide pads 64
Removing the Moving Tube Pads 64
basket 65
Boom head slide pads 65
Boom foot slide pads 65
Removing the Basket 65
Removing the Jib 67
Characteristics and specifications 69
Supplier Documentation 69
Flow diagrams and schematic diagrams 69
Hydraulic Schematic Diagram 71
Key to components 71
Settings 72
Key to Solenoid valves 72
SV Activation Table E = Energized 73
Hydraulic diagram (160 ATJP RC ST5 S1 — ATJ 46P RC T4 S2 — 160 ATJP ST5 S1) 74
Location 75
Location of Hydraulic Components in the Chassis 77
Location of hydraulic components in chassis 77
Location of Hydraulic Components in the Turntable 79
Location of hydraulic components in the turntable 79
Location of Hydraulic Components in the arms 81
Location of hydraulic components in the arms 81
Control and adjustment 83
Prerequisites for Taring Proportional Distributor 83
Location of the proportional distributor and the base turntable function block 83
Proportional Distributor Calibration (PVG32-4T) 83
Pressure connector (M) on the inlet plate 83
Calibration of the arm 1&2 lifting cylinder’s pressure relief valves (L2)(L3) 84
Calibration of the telescopic boom cylinder’s pressure relief valves (L4)(L5) 84
Calibration of the arm 3 lifting cylinder’s pressure relief valves (L6)(L7) 84
Distributor Block Calibration 85
cylinder lifting valve plug 85
cylinder lowering valve plug 85
Compensating/tilting cylinder hose decompression 85
Removal of hoses 86
arm lifting and basket tilting 86
Arm lowering 86
Tilting cylinder extension valve 86
basket crowd 87
Arm lifting 87
Tilting cylinder retraction valve 87
Compensating – Tilting Circuit 87
Hose decompression movements for the compensation and tilt cylinders 88
Short circuit of the compensating cylinder 88
Short circuit of the compensating cylinder 88
Installation of the control system with 2 pressure gauges on outlets A1 and B1 of the tilting cylinder 88
Tilting and crowding movement 88
Removal 89
Removing the elements of Proportional Distributor 89
Location of proportional distributor 89
control blocks and proportional distributor fastening screws 89
Removing the Distributor block 89
Location of distributor block 89
Distributor block retaining screws 90
Removing Distributor Block Valve 90
Prerequisites for Cylinder Removal 91
Location of cylinders 92
Location of the compensating cylinder 92
Location of arm 1/2 and arm 3 cylinders 92
Hose Decompression 92
location of proportional distributor and lever 92
Location of cylinder controls 93
Location of valves on distributor block 93
Compensating/tilting circuit 93
Removing the Cylinders 93
Basket rotation cylinder location 94
Basket rotation removal 94
Cylinder removal 94
Removing Valve Blocks and Valves 95
Risk of sprayed oil between the valve block and the cylinder 95
Removal of the cylinder’s valve block 95
Refit 95
Refitting Distributor Block Valve 95
Refitting cylinders 97
Step 1 97
Step 2 97
Step 3 97
Step 4 98
Step 5 98
Step 6 98
Specific tooling 98
Digital manometer kit 98
Digital manometer box 98
Basic manometer kit 99
Basic manometer box — overview 99
Characteristics and specifications 100
Fuses and Relays 100
Power circuit fuses 100
Fuse box location 100
Location of fuses in the box 100
Diesel Engine Fuses/Relays and Control System 100
Fuse box location 100
Location of fuses and relays in the box 100
Ground Control Panel Fuses/Relays 100
Location of ground control panel Fuses/Relays box 101
Location of fuses and relays in the box 101
Flow diagrams and schematic diagrams 102
Electrical Diagram Codification 102
Example of an electrical diagram 102
Electrical marking of cables 103
Cable marking on an electrical wiring harness 103
Electrical Schematics 105
key to text in diagrams 105
Location of components in diagrams 105
List of diagrams 111
Diag 1 – Power supplies, backup pump emergency stop 112
Diag 2 – CAN BUS network 113
Diag 3 – Signals – Generator – Easy Manager (Track Unit) 114
Diag 4 – Sensor inputs 115
Diag 5 – Travel 116
Diagram 6 – Proportional movements 117
Diagram 7 – Auxiliary proportional movements 118
Diag 8 – Hydraulic safety overload 119
Location 121
Location of Electrical Control Components 123
Location of electrical control components 123
Location of Electrical Power Components 125
Location of electrical power components 125
Electrical Components Location for Options 127
Option electrical components location 127
Harness Location 129
Harness Assembly Location 129
List of Harnesses 131
Chassis Harness 132
Harness AMP1 133
Harness AMP2 134
Harness AMP3 135
Intermediate harness base to upper arm 136
CAN bus harness upper arm to basket 137
Basket harness 138
Arm sensor extension harness 139
Base control panel & indicators lamps & wiring 141
Base control panel controls and indicator lights 142
Base control panel wiring 143
Basket Control Panel & Indicators Lamps & Wiring 147
Basket control panel controls and indicator lights 148
Basket control panel wiring: Folio1 149
Basket control panel wiring: Folio2 150
Basket control panel wiring: Folio3 151
Control and adjustment 157
Program Operation 157
Menu and Sub-Menu tree structure and access level 157
Program Settings 160
Manipulators Calibration 174
Joysticks Testing 175
Telescope Retracted Sensor Adjustment 175
Arm down Sensor Adjustment 176
Tilt Calibration 176
Overload Sensors Adjustment 177
Speed calibration 178
Generator Adjustment 179
Stop&Go option management 180
Removal 182
Removing the UD22 card from the panel control base 182
Protective cover of the UD22 board 182
Fastening of the first element of board UD22 182
Disconnection of the UD22 board’s ribbon cable 183
Unclipping of the UD22 board’s terminal connector 183
Fasteners of the UD22 board’s display 183
Removing the UC234 card from the base console 183
Cables CC1, CC2, CC3 of the UC234 base housing 184
Connectors in the base housing of the UC234 board 184
Location of screws of the UC234 board 184
Troubleshooting 184
Fault Codification 184
List of Alert and Default Codes 186
Specific tooling 189
Breakout boxes 189
Breakout boxes 189
Section Not Applicable 190
Control and adjustment 191
Checking Turntable rotation bearing 191
Section Not Applicable 193
Engine Diagnostic Codes (Kubota D1105-E4B) 194
Engine Diag Codes after Treatment (Kubota D1105-E4B) 199
Diagnostics Case (MEWP) 200
Reprogramming (FILE * H86) + Parameters Access –> Via RS232 UPC 200
Reprogramming (FILE * H86) + Parameters Access –> Via RS232 UPC 201
Reprogramming (FILE * H86) + Parameters Access –> Via RS232 UPC 201
Reprogramming (FILE * H86) + Parameters Access –> Via RS232 UPC 202
Reprogramming via CAN BUS 202
Reprogramming via CAN BUS 203
Contents of reprogramming case 203
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