647123EN (09/06/2016)
160 ATJ EURO 3
180 ATJ 2 EURO 3
REPAIR MANUAL
2 647123EN
DATE OF ISSUE OBSERVATION
19 / 09 / 2012
19 / 03 / 2013
02 / 05 / 2013
19 / 11 / 2013
23 / 12 / 2015
31 / 05 / 2016
09 / 06 / 2016
1st PUBLICATION DATE
UPDATE ADDITION OF THE 180 ATJ 2 EURO 3
UPDATE ref. CP-NI 547>647, addition ref MR DANA axle som30, modication of
hydraulic diagram 70-02, addition of machine selection 80-04, modication speed
settings 80-04
UPDATE 1004 ENGINE VALUES, 2004 HYDRAULIC VALUES, 2006 HYDROSTATIC
ENGINE REMOVAL, 7002 HYDRAULIC DIAGRAM, 7004 HYDRAULIC VALUES, 80
01 LOCATION AND BUNDLES, 8002 ELECTRIC DIAGRAM, 8004 NEW UPC
UPDATE : Update electric localisation et electric diagrams
UPDATE : separation of V2 and V3 electrical diagrams
UPDATE : ELECTRICAL CONTROL AND ADJUSTMENT (ASSIST)
MANITOU BF S.A Limited liability company with a Board of Directors.
Head oce: 430, Rue de l’Aubinière - 44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: +33 (0)2 40 09 10 11
www.manitou.com
This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other,
in part or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document
organization that are found in this document, are the intellectual property of MANITOU BF. Anyviolation of the aforementioned
may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU-BF
and may not be used without express and formal authorization. All rights are reserved.
M
(29/09/2011) 00-M173EN
(29/09/2011)00-M173EN
HOW TO USE THIS REPAIR MANUAL ?
647123EN
3
1
GENERAL, CHARACTERISTICS AND SAFETY
ENGINE
TRANSMISSION
AXLE
BRAKE
BOOM
HYDRAULIC
ELECTRIC
DRIVER’S CAB
FRAME - BODY
OPTIONS - ATTACHMENTS
00102030405070808590110
2
GENERAL, CHARACTERISTICS AND SAFETY
- GENERAL INSTRUCTIONS AND SAFETY NOTICE
00
3
GENERAL INSTRUCTIONS AND SAFETY NOTICE
PREAMBLE........................................................................2
MAINTENANCE POSITION .........................................................3
RULES FOR MAINTENANCE ........................................................4
pages
00
4
General instructions and safety
notice4
00
00
RULES FOR MAINTENANCE
Do not carry out any work on the machine unless you have followed
a suitable training course and have the knowledge required for it.
Make sure you have taken into consideration all the indicator plates
on the machine and in the instruction manual.
Be careful not to burn yourself when touching hot liquids or parts
when operations have to be done before the machine has had
time to cool down.
Before carrying out any operation on an electrically powered
1
component, activate the battery cut-o.
If the telehandler does not have a battery isolation device, disconnect
2
the battery connecters then re-assemble them.
Before carrying out any welding operations, think about
ECU
disconnecting computers.
A machine operating in a contaminated environment should be
specifically equipped. Moreover, local safety notices deal with
maintenance and repair work on such machines.
R
547982 : See the repair manual N° 547982.
70 - HYDRAULIC : See the group N° 70 called «Hydraulic».
GENERAL
ENGINE SPECIFICATION
TRANSMISSION
AXLE
BRAKE
00102030405570808590110
JIB - ACCESS PLATFORM
HYDRAULICS
ELECTRICITY
DRIVER'S CAB
FRAME - BODY
OPTIONS - ATTACHMENTS
GENERAL
GENERAL INSTRUCTIONS AND SAFETY
NOTICE
GENERAL CONTROL AND ADJUSTMENT
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
00
pages
GENERAL INSTRUCTIONS..........................................................2
SPARE PARTS .....................................................................3
TECHNICAL DOCUMENTATION.....................................................4
REPAIR PROCEDURES..............................................................5
HYDRAULICS......................................................................6
SYMBOLS .........................................................................7
SERVICING AND REPAIR EQUIPMENT...............................................8
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2
00
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
GENERAL INSTRUCTIONS
This chapter sets out the safety instructions to be followed when carrying out repairs on an access
platform.
Maintenance or repairs other than those detailed in part: 3 - MAINTENANCE OF THE OPERATOR’S MANUAL
for the platform, are to be carried out by qualied personnel (consult your dealer) and under optimum
safety conditions to maintain the health of the operator and of others, as well as to avoid damage to
the platform.
Insofar that the platform manufacturer does not directly control maintenance or repair operations,
theoperator and the manager in charge of the establishment shall be responsible for the safety of
these processes.
BEWARE OF LEAKS - Diesel fuel or hydraulic uid escaping under high pressure may pierce the
skin and cause serious injury. In the event of injury due to a pressurised liquid jet, immediately
b
consult a doctor.
FRONT and rear are indicated in the gures for ease of understanding.
For information:
PLATFORM TYPE FRONT REAR
ARTICULATED Counterweight Basket
SCISSOR Steering axle Steps
VERTICAL MAST Counterweight Basket
TRUCK-MOUNTED PLATFORM Driver's cab Basket
TELESCOPIC Basket extension Steps
As our policy is one of constant improvement of our products, our range of access platforms may undergo
certain modications, without obligation for us to advise our customers.
(02/05/2013)00-00-M193EN
SPARE PARTS
Our platforms must be serviced using original MANITOU parts.
BY ALLOWING THE USE OF NON ORIGINAL MANITOU PARTS, YOU RISK:
- Legally, to be held responsible in the event of an accident.
- Technically, to cause operating malfunctions or shorten the life of the lift truck.
The use of counterfeit parts or components not approved by the manufacturer, will cause you to loose
the benet of the contractual guarantee. BY USING ORIGINAL MANITOU PARTS FOR MAINTENANCE
OPERATIONS:
YOU BENEFIT FROM OUR KNOW-HOW.
Through its network, MANITOU provides the user with:
GENERAL INSTRUCTIONS AND SAFETY NOTICE
3
00
00
- Know-how and competence.
- The guarantee of high-quality work.
- Original replacement parts.
- Help with preventive maintenance.
- Ecient diagnostic help.
- Improvements due to feedback.
- Operator training.
Only the MANITOU network has detailed knowledge of the design of the access platform and therefore
the best technical ability to provide maintenance.
FOR COMMERCIALLY-AVAILABLE COMPONENTS (CYLINDERS, ELECTRIC PUMP, SPEED CONTROLLER,
CHARGER, ENGINE, ETC.) AND DURING THE PLATFORM GUARANTEE PERIOD:
- Component removal ALLOWED
- Component removal FORMALLY FORBIDDEN AT THE RISK OF INVALIDATING THE GUARANTEE
Original replacement parts are distributed exclusively by MANITOU and its dealer network.
The dealer network list is available on the MANITOU web site: www.manitou.com.
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4
00
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
TECHNICAL DOCUMENTATION
READ and UNDERSTAND the contents of the OPERATOR’S MANUAL regarding the platform (this manual
must be stored in the black storage compartment located in the platform basket). COMPLY in particular
with the contents of Chapter 1 - OPERATING AND SAFETY INSTRUCTIONS as well as the sections marked
with a DANGER symbol.
READ and UNDERSTAND the operating and/or safety instructions given by the STICKERS applied to the
platform.
Before starting a procedure given in this REPAIR MANUAL, fully READ it and understand what you have
read.
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REPAIR PROCEDURES
GENERAL:
POSITION the platform within a horizontal working area that is clean, cleared of any objects and mark
it out. If all of these conditions cannot be met (platform on site, in a cold store, etc.), chock the wheels,
mark the platform and familiarise yourself with the hazards associated with the environment.
SWITCH OFF THE PLATFORM by means of the battery cut-o before starting a procedure (unless otherwise
specied).
The procedure indicates when the weight of a component or an assembly of components exceeds 20kg,
requiring the use of HANDLING EQUIPMENT for removal, insofar as their characteristics (indicated on
the manufacturer's plates or the tare plates) are suitable for the operation to be performed.
For cleaning, use non-ammable solvents approved for that purpose.
GENERAL INSTRUCTIONS AND SAFETY NOTICE
5
00
00
When removing or retting a component, scrupulously follow the procedure step by step. Alwayscomplete
the current stage before commencing the next.
If resistance is felt when removing a component: STOP. Check that the nuts, screws and cables have
been removed and that there is no interference with adjoining components.
The most important factor in the preservation of the working life of the platform is to ensure that its
vital components are kept very clean.
When it is not specied, retting operations consist in performing the removal operations in reverse order.
MECHANICAL COMPONENTS:
Use screws having identical characteristics to the original screws and of an appropriate length.
Insofar that the procedures do not specify the values of the tightening torques to be applied to threaded
fasteners, the appropriate standard values must be used to suit the characteristics of these fasteners.
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6
00
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
HYDRAULICS
Certain hydraulic lines ARE UNDER VERY HIGH PRESSURE, even when the platform is not operating.
Inorder to avoid any accidents:
- Follow the hydraulic line decompression procedure before servicing or repairing one of their components.
Certain cylinders are tted with valves that are used to secure the platform the moment the movements
are stopped, by maintaining hydraulic pressure in the chambers of the cylinder. As a result, a chambers of
a cylinder that has been removed might be under VERY HIGH PRESSURE (in excess of 100 bar, inparticular
in the case of the tilt compensation circuit). You should:
- Perform the operations for decompressing the cylinder to be removed.
- Eliminate any pressure from the chambers of a cylinder before it is removed.
Prior to working on a hydraulic component, clean the area immediately around it, provide containers
or rags to recover any uid leakage during removal. Also provide caps and covers to plug openings and
prevent the contamination of the circuit.
Covers, hatches, seals and lters are provided to ensure the purity of the hydraulic uid and prevent
contamination of the circuit. These parts therefore require to be periodically:
- Checked for damage.
- Kept clean.
A cloudy uid indicates a high moisture content, which will lead to oxidation / corrosion of the circuit's
metal components: drain and clean the whole of the circuit, then rell with fresh hydraulic uid.
Should the circuit prove to be contaminated with foreign matter (metal, rubber, etc.), drain and clean
the whole of the circuit then ll with fresh hydraulic uid.
It is not recommended to mix hydraulic uids of dierent types or makes insofar that they cannot be
guaranteed to be of similar composition or viscosity.
Refer to Chapter 3 - MAINTENANCE of the OPERATOR’S MANUAL to select the appropriate oil for the use
of the platform.
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SYMBOLS
GENERAL:
GENERAL HAZARD The associated text must be READ and UNDERSTOOD
ELECTRICAL HAZARD The associated text must be READ and UNDERSTOOD
HIGH TEMPERATURE HAZARD The associated text must be READ and UNDERSTOOD
GENERAL INSTRUCTIONS AND SAFETY NOTICE
before continuing to the next stage of the procedure.
before continuing to the next stage of the procedure.
before continuing to the next stage of the procedure.
7
00
00
HYDRAULIC PRESSURE HAZARD The associated text must be READ and UNDERSTOOD
before continuing to the next stage of the procedure.
MINIMUM WEIGHT Indicated in removal procedures, this sign enables
the selection of the appropriate handling equipment.
647400EN Refer to Operator’s Manual no. 647400EN.
647400 Refer to spare parts catalogue no. 647400.
80-08-M.193EN Refer to Chapter no. 80-08-M.193EN of the current repair manual.
§ B - 1 Refer to paragraph B - 1 of the current chapter.
(A1-1) (Figure A1 - Item 1)
Indicates attachment points or bearing surfaces (for lift truck forks) to be used
during removal operations.
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8
00
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
SERVICING AND REPAIR EQUIPMENT
- Tool box.
- MANITOU hydraulic kit: Part no. to be selected from catalogue 647400.
- Male and female plug adapters for plugging hydraulic hoses and couplers.
- Calibrator: Part no. according to platform type, see the relevant chapter.
- Multimeter.
(02/05/2013)00-00-M193EN
GENERAL CONTROL AND ADJUSTMENT
00
pages
STANDARD TIGHTENING TORQUES.................................................2
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2
00
00
GENERAL CONTROL AND ADJUSTMENT
STANDARD TIGHTENING TORQUES
Standard tightening torque to be used when not otherwise indicated in the removal and refitting
operations:
- The following tightening torques are given for hexagon head screws without flanges and
cylinder head hexagon socket screws.
- The torques are given for a friction coecient μ = 0,20 corresponding to dry-tted zinc-plated
fasteners and for torque tools having a ± 20% class C tightening torque accuracy (equivalent
to pneumatic screwdrivers).
NF E25-030-1 Screw / Nut connection:
Tightening torque in N.m (±20%)
Ø x "coarse" pitch Grade 8.8 Grade 10.9 Ø x “ne” pitch Grade 8.8 Grade 10.9
M3 x 0,5 1 1,5 - - -
M4 x 0,7 2,4 3,5 - - -
M5 x 0,8 4,8 7,1 - - -
M6 x 1 8,2 12,1 - - -
M8 x 1,25 20 30 M8 x 1 22 32
M10 x 1,5 40 59
M12 x 1,75 69 102
M14 x 2 111 163 M14 x 1,5 123 181
M16 x 2 175 256 M16 x 1,5 190 279
M18 x 2,5 240 352 M18 x 1,5 279 410
M20 x 2,5 341 501 M20 x 1,5 391 574
M22 x 2,5 470 691 M22 x 1,5 531 780
M24 x 3 588 864 M24 x 2 659 967
M27 x 3 874 1284 M27 x 2 965 1418
M30 x 3,5 1181 1735 M30 x 2 1351 1984
M33 x 3,5 1614 2371 M33 x 2 1821 2674
M36 x 4 2068 3037 - - -
M10 x 1,25 43 63
M10 x 1 46 68
M12 x 1,5 74 108
M12 x 1,25 78 115
For hexagon screws with anges:
Apply a torque of accuracy + 10%.
b
(16/04/2012)00-04-M193EN
ENGINE
- ENGINE COMPONENTS LOCATION
- ENGINE CONTROL AND ADJUSTMENT
- ENGINE REMOVAL
10
- ENGINE CHARACTERISTICS AND
SPECIFICATIONS
- ENGINE IDENTIFICATION
- INSPECTION & MAINTENANCE
- SPECIFIC TOOLING
M
R
(KUBOTA V1505 ENGINE)
647124EN
ENGINE COMPONENTS LOCATION
10
pages
ENGINE ...........................................................................2
(22/02/2013) 10-03-M193EN
2
ENGINE COMPONENTS LOCATION
ENGINE
10
Starter
Air lter
Engine accelerator block
Radiator
Alternator
Exhaust
Starter
Oil lter
Alternator
Fuel lter
Thermostat
Belt
Injection pump
Fuel pump
Accelerator
(22/02/2013)10-03-M193EN
ENGINE CONTROL AND ADJUSTMENT
10
pages
PROPORTIONAL ENGINE SPEED BLOCK REMOVAL ..................................2
PROPORTIONAL ENGINE SPEED BLOCK ADJUSTMENT ..............................4
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2
ENGINE CONTROL AND ADJUSTMENT
10
FRONT
FRONT
A
PROPORTIONAL ENGINE SPEED BLOCK REMOVAL
1
B
2
3
1
From the base console, raise arms 1/2 until the upper hinge
(A-1) is one meter above the counterweight.
Climb onto the frame, remove the lock nut, manually raise the
maintenance support arm (B-2) and place the strut (B-3).
From the base console, lower arms 1-2 until the upper hinge
(B-1) comes into contact with the maintenance support arm,
then release the controls.
Switch o the engine.
FRONT
1
FRONT
C
D
1
Remove the battery cover (C-1).
Remove the engine inspection cover (D-1).
(02/10/2013)10-04-M193EN
ENGINE CONTROL AND ADJUSTMENT
3
E
Locate the proportional engine speed block (E-1) on the right-hand
side of the engine.
3
1
Disconnect the power supply harness from the accelerator (E-2).
10
2
F
3
4
1
2
5
6
Disconnect the two hydraulic hoses (F-1) and (F-2) an mark
them for easy ret.
Place the plugs on the hoses.
Remove the accelerator cable (E-3) by removing its pin.
Remove the return spring (F-3).
G
1
2
H
Remove the link rod by undoing the two screws (G-1) and (G-2).
Remove the connecting rods (H-1) and (H-2) with a pin drift.
Remove the proportional engine speed block by undoing the
three fastening screws (F-4), (F-5) and (F-6).
PROPORTIONAL ENGINE SPEED BLOCK REFIT
2
1
Perform the removal operations described above in reverse order
then check the proportional engine speed block adjustment
setting.
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4
ENGINE CONTROL AND ADJUSTMENT
10
I
PROPORTIONAL ENGINE SPEED BLOCK ADJUSTMENT
1
Check the tension of the accelerator cable (I-1). Adjust if necessary
with the adjustment screw located on the proportional engine
speed block.
Turn the block so that the accelerator cable (I-1) is slightly
tensioned by moving the block in the direction of the arrow (J).
Start the access platform and check that the engine speed is
at 1000 ± 50 rpm.
J
If not, turn the proportional engine speed block until the desired
value is reached.
Set the dierent engine speed thresholds in accordance with
the procedure described below.
This procedure is to be performed only on a "hot" machine,
withthe hydraulic uid at a temperature exceeding 40°C.
A tolerance of ± 50 rpm. shall apply to each threshold.
Press the Menu key (K-4), position yourself over the padlock
K
B2
1
2
3
4
5
L
B2
1
using the </> keys (K-1) then press OK (K-3).
Enter the code "****" using the +/- keys (K-2), and confirm
bypressing OK after each number.
Go to the "Calibration" icon (L-1) using the arrow keys.
Select the "Calibration accél. Moteur" (Engine accel. Calibration)
group with the +/- keys (K-2) then conrm.
Check the cable tension by setting the max. engine speed to 3050 rpm.
If threshold 5 cannot be set, check and modify the accelerator
cable tension.
Next set the values of each threshold to obtain the desired
results to within +/- 20 rpm.
Between each threshold, press OK to cut-o acceleration then
press OK again to initialize.
When calibration is completed, leave the "Calibration accél.
Moteur" (Engine accel. Calibration) menu by pressing Exit (K-5).
Enter the "Sauvegarde des paramètres" (Save parameters) menu
to record the values.
(02/10/2013)10-04-M193EN
GENERATOR BLOCK
2
3
P
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values present (as an indication)
ROLE :
– Run the generator
– Cut the pressure according to the electrical
instructions.
1
LEGEND :
1 - NC proportional hydraulic slide valve
2 - HP restrictor
1
1
3
2
200 b
240 b
P
2
2
T
70
2
2
Note :
(18/04/2014) F70-3-0072EN
2
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values present (as an indication)
70
(18/04/2014)F70-3-0072EN
VARIABLE CAPACITY PUMP A10VG
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values present (as an indication)
ROLE :
– Enables the machine to translate
(forward / reverse movement)
1
LEGEND :
1 - Proportional distributor (Forward / reverse
movement)
2 - DR valve
3 - HP valve
4 - Force-feed pressure restrictor
5 - Servo-control piston
1
b
T
1
a
5
1
45cm3
365 b
365 b
26 b
70
S
P
G
Fe
BM
8,4cm3
2
A
2
1
X
3
2
X
3
G
4
AM
S
Note :
(02/05/2013) F70-3-0073EN
B
2
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
Values present (as an indication)
2
70
1
3
4
5
3
(02/05/2013)F70-3-0073EN
ELECTRICAL SPECIFIC TOOLING
pages
KIT BOITIERS ÉCLATEURS ..........................................................2
ADAPTATION SOLÉNOÏDE .........................................................2
80
(13/01/2016) 80-09-M193EN
2
ELECTRICAL SPECIFIC TOOLING
BREAKOUT BOX KIT
Breakout box (DT connectors)
Breakout box (DTM connectors)
Breakout box kit ..........................................................785503
Consisting of:
1. 1 breakout box (DT connectors).................................... 785504
2. 1 breakout box (DTM connectors)..................................785505
80
ELECTROVALVE ADAPTER
Electrovalve adapter ......................................................662196
(13/01/2016)80-09-M193EN
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