Manitou AETJL 120 Operating instructions

MANITOU BF
Head oce: 430, Rue de l’Aubinière
44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: [phone]
www.manitou.com
REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
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La présente brochure n’est fournie qu’à titre consultatif, toute reproduction, copie, représentation, captation, cession, distribution, ou
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les indications, l’organisation même du document qui sont rapportés dans la présente documentation, sont la propriété intellectuelle
de MANITOU BF. Toute infraction à ce qui précède est susceptible d’entraîner des condamnations civiles et pénales. Les logos ainsi que
l’identité visuelle de l’entreprise sont la propriété de MANITOU BF et ne peuvent être utilisés sans autorisation exprès et formelle. Tous
droits réservés.
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. Anyviolation 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.
Die vorliegende Broschüre dient allein zur Beratung. Nachdruck, Fotokopieren, Vervielfältigung, Darstellung, Erfassung,
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antedicho puede acarrear condenas civiles y penales. Los logotipos y la identidad visual de la empresa son propiedad de MANITOU
BF y no pueden utilizarse sin su autorización expresa y formaL. Reservados todos los derechos.
Il presente manuale è fornito esclusivamente a titolo di consultazione; è vietata qualsiasi riproduzione, copia, rappresentazione,
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dell’azienda sono di proprietà di MANITOU BF e non possono essere utilizzati senza previa autorizzazione espressa e formale. Tutti i
diritti sono riservati.

COMPLET REPAIR MANUAL 120 AETJL 150 AETJC - AETJ 43150 AETJC 3D - AETJ 43
3D 150 AETJL170 AETJL - AETJ 49 1
GENERAL INSTRUCTIONS AND SAFETY NOTICE
GROUP 00 GENERAL CHARACTERISTICS AND SAFETY 3-1
AXLE ASSEMBLY - AXLE
GROUP 30 AXLE 4-1
FRONT ARMS
GROUP 55 JIB - BASKET 5-1
HYDRAULIC
GROUP 70 HYDRAULIC 6-1
ELECTRICITY
GROUP 80 ELECTRICITY 7-1

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120 AETJL
150 AETJC  AETJ 43
150 AETJC 3D  AETJ 43 3D
150 AETJL
170 AETJL  AETJ 49
REPAIR MANUAL

07/01/2005
12/01/2005
01/01/2008
04/01/2008
03/08/2017
Addition of platforms: 120 AETJL, 150 AETJ COMPACT
Change of machine names:
150 AETJ became 150 AETJL, 170 AETJ became AETJL
Updated: GENERAL CHARACTERISTICS AND SAFETY
Updated:
REAR AXLE - OPERATION IN FREEWHEEL MODE
TELESCOPE PADS - REMOVAL
HYDRAULIC
ELECTRICITY
Updated:
Addition of machines 150 AETJC 3D, AETJ 43, AETJ 43 3D, AETJ 49
GENERAL CHARACTERISTICS AND SAFETY
HYDRAULIC
ELECTRICITY
DATE OF ISSUE OBSERVATION
- 1st ISSUE
MANITOU BF S.A Limited liability company with a Board of Directors.
Head oce: 430, Rue de l’Aubinière - 44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: [phone]
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. Anyviolation 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.
2
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JIB  BASKET
GENERAL CHARACTERISTICS AND SAFETY
ENGINE
TRANSMISSION
AXLE
BRAKE
HYDRAULIC
ELECTRICITY
DRIVER’S CAB
FRAME  BODY
OPTIONS  ATTACHMENTS
0020304070808590110 55 10

INTERACTIVE REPAIR MANUAL
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GLOSSARY
AOC
Ammonia Oxidation Catalysts: elimination by oxidation of the excess ammonia
(NH3) from exhaust gases having undergone selective catalytic reduction
(SCR) of nitrogen oxides (NOx), by injection of ammonia.
APC
After Power Contact: post-ignition current.
BMEP Bloc Manipulateur ÉlectroProportionnel : Controls the hydraulic movements
of: lowering, lifting, tilting and digging by electronic sensors.
CAN
Controller Area Network: control communication network for communication
between systems (J1939, Open, etc.).
CO
Carbon Monoxide: colourless, odourless and highly toxic gas.
CVT
Continuous Variable Transmission.
DEF Diesel Exhaust Fluid: aqueous solution consisting of 32,5% urea and 67,5%
demineralised water, used to transform 85% of pollutants (NOx) into water
vapour (H2O) and harmless nitrogen (N2).
DOC Diesel Oxide Catalyst: part of the exhaust gas lter or a post-treatment device
used to reduce polluting emissions (HC and CO).
DSB
Double switch Board: smart switch board connected to a LIN network via a
wiring harness.
DPF (=FAP) Diesel Particulate Filter (= Filtre À Particule) : device designed to remove diesel
particulate matter or soot from the exhaust gas of a diesel engine.
DTC
Data Trouble Code: standard fault codes
ECU Electronic Control Unit or Engine Control Unit: machine or engine control
computer.
FMI
Failure Mode Identier: fault code & description:
0 – The data is valid but the data is above the normal operational range.
1 – The data is valid but the data is below the normal operational range.
2 – The data is erratic, intermittent, or incorrect.
3 – The voltage is above normal or the voltage is shorted high.
4 – The voltage is below normal or the voltage is shorted low.
5 – The current is below normal or the circuit is open.
6 – The current is above normal or the circuit is grounded.
7 – The mechanical system is not responding properly.
8 – There is an abnormal frequency, an abnormal pulse width, or an abnormal
time period.
9 – There has been an abnormal update.
10 – There is an abnormal rate of change.
11 – The failure mode is not identiable.
12 – The device or the component is damaged.
13 – The device requires calibration.
15 – The signal from the device is high (least severe).

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FMI
16 – The signal from the device is high (moderate severity) .
17 – The signal from the device is low (least severe) .
18 – The signal from the device is low (moderate severity) .
19 – There is an error in the data from the device.
20 – There is an error in the data from the device (high).
21 – There is an error in the data from the device (low).
31 – The device has failed and the engine has shutdown.
HC
Hydrocarbon: organic compound consisting exclusively of carbon (C) and
hydrogen (H) atoms.
HS
High Side: power side power supply.
HVAC
Heating, Fan and Air-Conditioning: in-cab heating, ventilation and air-
conditioning block.
IHM
Interface Homme Machine : Human-Machine Interface, dashboard screens.
JSM
Joystick Switch & Move: joystick serving to perform all telescope movements,
as well as to control machine forward and reverse movements with one hand.
LIN
Local Interconnect Network.
LLMI
Limit Load Moment Indicator: strain gauge ensuring machine stability.
LS
Low Side: ground side power supply.
LSU
Load Sensing Ultra: hydraulic load detection.
NC (=NF)
Normally Closed (= Normalement Fermé) : normally closed contact.
NO
Normally Open: normally open contact.
NOx
Nitrogen Oxide: regulated air pollutants.
PAD
Plug And Diag: machine diagnostic touchscreen tablet.
PS / PS+
Power Shift: semi-automatic gear box.
Power Shift +: automatic gear box from 3rd gear and higher.
PWM
PulseWidth Modulation: Modulation of the pulse
width of a xed-frequency digital electronic signal
synthesising intermediate analog signals over a
certain duration.
SAHR
Spring Applied Hydraulically Released: method of blocking the parking brake
(negative brake).
SCR
Selective Catalytic Reduction: reduction of nitrogen oxides (NOx) emitted by
internal combustion engines.
SPU
Safety Power Unit: machine controller.
USB
Universal Serial Bus.

TABLE OF CONTENTS
00
GENERAL CHARACTERISTICS AND SAFETY
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 SPECIFICATIONS ........................................ 13
00.2.1 CHARACTERISTICS.........................................................................13
00.2.2 LUBRICANTS AND FUEL....................................................................13
00.2.3 DIMENSIONS ..............................................................................14
DIMENSIONS 120AETJL ......................................................................................14
DIMENSIONS 150AETJC  AETJ 43  AETJC 43 3D..............................................................16
DIMENSIONS 150AETJL ......................................................................................18
DIMENSIONS 170AETJL  49 AETJC ...........................................................................20
00.2.4 LOCATION OF NAME AND IDENTIFICATION PLATE .........................................22
ACCESS PLATFORM MANUFACTURER’S PLATE ...............................................................22
LOCATION OF MANUFACTURER'S PLATE .................................................................
120 AETJ .....................................................................................................22
00.3 GENERAL CONTROL AND ADJUSTMENT ................................................... 23
00.3.1 STANDARD TIGHTENING TORQUES ........................................................23
00.3.2 METRIC  IMPERIAL UNIT CONVERSION ....................................................24

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GENERAL CHARACTERISTICS AND SAFETY
00.1 GENERAL INSTRUCTIONS AND SAFETY NOTICE
00.1.1 INTRODUCTION
00.1.2 SERVICING POSITION
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 ecient, dependable and protable combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.
Before any intervention
:
1 - Place the machine on a at surface and chock the wheels.
2 - Turn o the engine and remove the ignition key.
3 - Let the machine cool down.
4 - Take all the pressure out of the circuits concerned.

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00.1.3 EXPLANATION OF SYMBOLS
The symbols shown below are used to warn of potential hazards as well as to provide useful information
concerning a procedure.
SYMBOLE OBSERVATION
DANGER Indicates an imminent hazardous situation which, if not avoided
will result in death or serious injury.
WARNING Indicates a potentially hazardous situation which, if not avoided,
may result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided,
may result in minor injury or damage to property. It is also used to
warn users of unsafe practices.
TIP Indicates a tip to facilitate the performance of a procedure.
PROTECT THE ENVIRONMENT Indicates a message to draw attention to important information
regarding environmental protection.
SPECIFIC TOOLING Indicates special tools for performing a task.
4"SEE": Indicates a cross-reference to a manual.
5“SEE”: Indicates a cross-reference to a page.
0“SEE”: Indicates a cross-reference to a picture.
3"WEIGHT": Indicates the weight of an item.
(E.g.: it helps to anticipate an action linked to a person's health orthe
choice of lifting equipment)
2"TIGHTENING TORQUE": Indicates the value of tightening torque
to be applied.
1"OPTION": Indicates the presence of an option.
The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions
givenin the manual are not exhaustive.
At any time, as an operator, you must consider, within reason, the possible risk to yourself, to others
ortothe lift truck itself when you repair, service or drive it.
Manitou cannot be held responsible for the use of any lifting devices, tools or operating methods other
than those specied.

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00.1.4 SERVICING RULES
Do not carry out any work on the machine unless you have
followed a suitable training course and have the knowledge
required for it.
4
Make sure you have taken into consideration all the indicator
plates on the machine and in the instruction manual.
PRÉCAUTION
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.
AVERTISSEMENT
Before carrying out any operation on an electrically powered component,
activate the battery cut-o.
PRÉCAUTION
Press the battery switch at least 30 seconds after disconnecting the electrical
contact with the ignition key.
AVERTISSEMENT
If the telehandler does not have a battery isolating switch, disconnect the
battery terminals then gather them.
PRÉCAUTION
Before carrying out any welding operations, think of disconnecting computers.
PRÉCAUTION
A machine operating in a contaminated environment should be specically
equipped. Moreover, local safety notices deal with maintenance and repair
work on such machines.
ECU
2
1

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AVERTISSEMENT
Never step on a part of the machine that has not been designed for it.
AVERTISSEMENT
Never wear clothes, jewelry or objects that could get caught during work and
cause accidents.
Always wear protection glasses, gloves, safety shoes as well as any other
protection required for the work to be carried out.
DANGER
When carrying out maintenance
operations near a mobile object,
make sure it is securitized.
PROTÉGER L’ENVIRONNEMENT
When changing, or draining oils or fuel, or any other operation with liquids,
solids, gases that are harmful to the environment, make sure the necessary
precautions are taken to avoid contaminating the environment.

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DANGER
When lifting or shoring a component of the machine, make sure the equipment
used is suitable for at least the load for which it is subjected by the component
and that it meets the national standards for lifting devices.
When using a jack, make sure it is used on a at, uniform surface, is sturdy
enough to support the load, that its lifting capacity is sucient and that it is
correctly placed and positioned under the machine.
PRÉCAUTION
Make sure no object or tool which could cause an accident is left in the machine.
AVERTISSEMENT
Never control any leaks using a hand.
PRÉCAUTION
Never adjust a component to over the maximum capacity indicated by the
manufacturer.
max.
min.
MIN
MAX

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00.2 GENERAL CHARACTERISTICS AND SPECIFICATIONS
00.2.1 CHARACTERISTICS
Designation 120 AETJL 150 AETJC 150 AETJC 3D 150 AETJL 170 AETJL AETJ 43 AETJ 43 3D AETJ 49
Unladen weight of carriage 5050 kg
(11,133 lbs)
6700 kg
(14,771 lbs)
6760 kg
(14,904 lbs)
5910 kg
(13,030 lbs)
6910 kg
(15,234 lbs)
7100 kg
(15,653 lbs)
7160 kg
(15,785 lbs)
7105 kg
(15,684 lbs)
Unladen pneumatic
load
FRONT 1185 kg
(2,613 lbs)
1465 kg
(3,230 lbs)
1465 kg
(3,230 lbs)
1240 kg
(2,734 lbs)
1534 kg
(3,389 lbs) - - 1555 kg (3,428 lbs)
REAR 1340 kg
(2,954 lbs)
1885 kg
(4,156 lbs)
1885 kg
(4,156 lbs)
1715 kg
(3,781 lbs)
1921 kg
(4,325 lbs)
- - 1992.5 kg
(4,393 lbs)
Nominal capacity
(2 people)
200 kg
(441 lbs)
200 kg
(441 lbs)
200 kg
(441 lbs)
230 kg
(507 lbs)
200 kg
(441 lbs)
227 kg
(500 lbs)
227 kg
(500 lbs)
227 kg
(500 lbs)
00.2.2 LUBRICANTS AND FUEL
Designation Type Quantity
Hydraulic tank MANITOU ISO VG 46 Hydraulic oil 18 
(4.76 US gallons)
Wheel motor (each)
Turret rotation motor SHELL SPIRAX A90 oil
0.8 
(0.21 US gallons)
1.5 
(0.40 US gallons)
General greasing SHELL RETINAX HD grease -
Greasing of turret crown of
bearing track Grease SHELL ALVANIA EP LF 2 -
Lubrication of turret crown
gear teeth SHELL MALLEUS GL 205 oil -

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D
E
B
C
F
H
G
I
A1A1
C1
A
00.2.3 DIMENSIONS
DIMENSIONS 120AETJL
mm ft-in
A 5520 18-1.3
A1 3930 12-10.7
B 2000 6-6.7
C 1995 6-6.5
C1 2210 7-3.0
D 1500 4-11.1
E 153 0-6.0
F 2640 8-8.0
G 1870 6-1.6
H 3960 12-11.9
I 4520 14-9.9

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mm ft-in mm ft-in
G1 2350 7-8.5 H1 9950 32-7.7
G2 3105 10-2.2 H2 8795 28-10.3
G3 6370 20-10.8 H3 4775 15-8.0
G4 5640 18-6.0 H4 545 1-9.5
G1
G2
H2 H1
G3
H3
G4
H4
12
11
10
9
8
7
6
5
4
3
2
1
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D
E
F
H
G
I
B
C1
A1
C
A
DIMENSIONS 150AETJC - AETJ 43 - AETJC 43 3D
mm ft-in
A 6050 19-10.2
A1 4400 14-5.2
B 2000 6-6.7
C 1965 6-5.4
C1 2080 6-9.9
D 1500 4-11.1
E 143 0-5.6
F 2640 8-7.9
G 1870 6-1.6
H 3960 12-11.9
I 4820 15-9.7

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mm ft-in mm ft-in
G1 2665 8-8.9 H1 12985 42-7.2
G2 3425 11-2.8 H2 11835 38-9.9
G3 7105 23-3.7 H3 7165 23-6.1
G4 6300 20-8.0 H4 235 0-9.2
G1
G2
H2 H1
G3
H3
G4
H4
897
12
11
10
9
8
7
6
5
4
3
2
1
456789
16
15
14
13
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