Manitou MAN GO 12 Operating instructions

647534EN- 20/01/2017
MAN GO 12
MAN GO 33
REPAIR MANUAL
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16/10/2015
22/06/2017 Addition of MAN GO 33 (US)
PUBLICATION DATE COMMENT
1st EDITION
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.
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JIB  ACCESS PLATFORM
GENERAL
MOTORIZATION
TRANSMISSION
AXLE
BRAKE
HYDRAULICS
ELECTRICITY
DRIVER'S CAB
FRAME  BODY
OPTIONS  ATTACHMENTS
0020304070808590110 55 10
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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).
GLOSSARY
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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.
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TABLE OF CONTENTS
00
GENERAL
00.1 GENERAL INSTRUCTIONS AND SAFETY NOTICE ..............................................8
00.1.1 PREAMBLE .................................................................................8
00.1.2 MAINTENANCE POSITION ..................................................................8
00.1.3 EXPLANATION OF SYMBOLS ................................................................9
00.1.4 RULES FOR MAINTENANCE ................................................................10
00.2 GENERAL CONTROLS AND ADJUSTMENTS ................................................. 13
00.2.1 STANDARD TIGHTENING TORQUES ........................................................13
00.2.2 METRIC  IMPERIAL UNIT CONVERSION ....................................................14
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00
GENERAL
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GENERAL
00.1 GENERAL INSTRUCTIONS AND SAFETY NOTICE
00.1.1 PREAMBLE
00.1.2 MAINTENANCE 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
GENERAL
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00.2.2 METRIC  IMPERIAL UNIT CONVERSION
RULES
-The tolerance has the same unit as the value and is not a percentage :
Example : 120 ± 12  , not
120 ± 10 %.
-The unit is separated from the value by a space and placed after the tolerance :
Example: 120  ou 120 ± 12  except for angle degrees : 40° ou 40 ± 3°.
-The conversion of some marks is not possible :
Example: thread of a screw : M12x1.75.
-Use decimals to convert precise values :
Example: 190 mm = 7.48 in.
-Write lengths in feet-inches format:
Example: 20 m = 65 ft 7.4 in or in a table 20 (m) = 65-7.4 (ft-in).
CONVERSION COEFFICIENTS:
Metric Unit (S.I) Coefficient Imperial Unit US
°C (Celsius degree) x 1.8 + 32 = °F (Fahrenheit degree)
cm
3(centimeter cube) x 0.06102 = cu.in. (cubic inches)
cv (cheval vapeur) x 0.9859 = hp (horsepower)
bar (bar) x 14.51 = psi (pound-force/square inch)
g (gram) x 0.0353 = oz av (ounce avoirdupois) (oz : lat. onza)
kg (kilogram) x 2.2046 = lb (pound) (lat . libra)
km/h (kilometer per hour) x 0.6214 = mph (miles per hour)
kW (kilowatt) x 1.34048 = hp (horsepower)
 (liter) x 0.2642 = gal US (US gallon)
 (liter) x 1.0567 = qt US (quart US gallon)
m (meter) x 3.2808 = ft (foot)
m (meter) x 39.37 = in (inch)
m (milliliter) x 0.0338 =  oz (uid ounce) ( : uid, oz : lat. onza)
mm (millimeter) x 0.03937 = in (inch)
µm (micrometer) x 0.03937 = mil (thousands of an inch)
N (Newton) x 0.2248 = lbf (pound-force) (lb : lat. libra, f : force)
N.m (Newton meter) x 0.7376 = ft-lb (pound-force-foot) (ft : foot, lb : lat. libra)
rad/s (radian/second) x 9.5493 = rpm (revolution per minute)
t (metric ton) x 2204.62 = lb (pound) (lat. libra)
tr/min (tour per minute) x 1 = rpm (revolution per minute)
Other unit conversions Coefficient
ft (foot) x 12 = in (inch)
lb (pound) (lat . libra) x 16 = oz av (ounce avoirdupois)
m (meter) x 1000 = mm (millimeter)
µm (micrometer) x 0.001 = mm (millimeter)
t (metric ton) x 1000 = kg (kilogram)
° (angle degree) x 0.01745 = rad (radian)
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TABLE OF CONTENTS
MOTORIZATION
10.1 ENGINE CHARACTERISTICS AND SPECIFICATIONS.......................................... 16
10.2 ENGINE REMOVAL  REFITTING ............................................................ 17
10.2.1 PREPARATION AND SAFETY INSTRUCTIONS ...............................................17
10.2.2 RADIATOR REMOVAL ......................................................................17
10.2.3 THROTTLE VALVE REMOVAL  REFIT ........................................................18
ACCELERATOR VALVE REFITTING.............................................................................18
10.2.4 ENGINE SILENT BLOCK REFIT...............................................................19
10.2.5 ENGINE REMOVAL .........................................................................19
10.2.6 ENGINE REFIT..............................................................................20
10.2.7 ENGINE CHANGE ..........................................................................20
10
LINKS TO REPAIR MANUALS:
MANUAL REFERENCE
NUMBER DESIGNATION
647553 KUBOTA ENGINE D1105E2B
647639 KUBOTA ENGINE D1105E4B
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MOTORIZATION
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10.2 ENGINE REMOVAL - REFITTING
10.2.1 PREPARATION AND SAFETY INSTRUCTIONS
Place the basket 45° towards the left.
Take o the front casing (1, 010 - 2).
PRECAUTION
1Battery cut-o: the alternator is still connected, it is therefore
necessary to disconnect the battery.
Disconnect the battery's negative terminal, then the positive
terminal.
10.2.2 RADIATOR REMOVAL
Remove the engine cover (1, 010 - 3).
Remove the protective plate from the underside of the frame (2,
010 - 3).
Place a container under the machine, remove the radiator drain
plug and ller plug.
Remove the grill (1, 010 - 4).
Remove the upper crossbar (3 screws) (2, 010 - 4).
10 - 1
10 - 2
1
10 - 3 1
2
10 - 4
2
1
2
2
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MOTORIZATION
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Disconnect the upper and lower water hoses (1, 010 - 5).
Disconnect the upper and lower hydraulic hoses (2, 010 - 5), t the
plugs.
Remove the hydraulic radiator (3, 010 - 5), if necessary.
Cut the Serex collar of the air intake pipe.
Lift the cooling system radiator straight up to clear the anti vibration
rings and tilt it to extract it (4, 010 - 5).
10.2.3 THROTTLE VALVE REMOVAL  REFIT
Remove the plate on the left-hand side of the frame (4 screws).
Disconnect electrovalve EW102 (1, 010 - 6).
Remove the throttle cable retaining pin (1, 010 - 7).
Disconnect the 2 hoses (2, 010 - 7).
Undo the 2 bolts (3, 010 - 7).
Unhook the spring (4, 010 - 7).
ACCELERATOR VALVE REFITTING
Ret in the reverse order without tightening the 2 bolts (3, 010 - 7).
Tension the spring (4, 010 - 7) by means of the screw (5, 010 - 7), and
the adjuster (1, 010 - 8).
Turn the adjustment screw (5, 010 - 7) to tension the throttle cable
without detaching the throttle end stop (6, 010 - 7).
Tighten the 2 bolts (3, 010 - 7).
Perform the engine speed calibration procedure from the base
control panel (680.4.3 ENGINE SPEED CALIBRATION, 577).
If the valve support bracket has been removed, adjust the throttle
cable tension via the holes of the fastener (1, 010 - 8).
10 - 5
2
1
3
4
2
10 - 6
1
10 - 7
6
1
2
5
3
4
10 - 8
1
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MOTORIZATION
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10.2.4 ENGINE SILENT BLOCK REFIT
2Engine silent block screws: 44 N.m (389.43 lb-in) ±10 % (1, 010 - 9).
10.2.5 ENGINE REMOVAL
Carry out the operation (610.2.2 Radiator removal, 517).
Close the diesel valve (left-hand side of the machine).
Remove the side casing on the left of the frame.
Remove the exhaust.
Unscrew the hydrostatic pump left and right fastening screws, hold
the pump in place (620.4.1 Hydrostatic pump removal - retting,
5 26).
Remove the throttle cable retaining pin (1, 010 - 11).
Mark the position of the throttle electrovalve support bracket
relative to the upper elongated holes (1, 010 - 8), unscrew the
2bolts (2, 010 - 11).
Shift the throttle electrovalve support bracket towards the outside.
Disconnect the braided ground wire (3, 010 - 11).
Remove the air intake hose (1, 010 - 12).
Locate and disconnect the 4 diesel hoses (2, 010 - 12), plug them.
Disconnect the preheat harness (3, 010 - 12) (AC101).
Disconnect the water temperature sensor (4, 010 - 12) (DS101).
Disconnect the engine stop electrovalve (5, 010 - 12) (EV102).
10 - 9
1111
10 - 10
10 - 11
2 2
1
3
10 - 12
12
5
2
2
2
3
4
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MOTORIZATION
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Cut the tie (1, 010 - 13).
Disconnect the alternator controller (2, 010 - 13) (AC102).
Disconnect the alternator power output cable (3, 010 - 13).
PRECAUTION
1Battery cut-o: Cable connected to battery positive terminal,
disconnect the battery before handling.
Disconnect the oil pressure sensor (4, 010 - 13) (DS100).
Disconnect the starter excitation (5, 010 - 13) (AC100).
Disconnect the starter power supply cable (6, 010 - 13).
Undo the upper screw of the 4 left-hand and right-hand silent
blocks (1, 010 - 14).
Pass a sling through the engine lifting rings and lift it out carefully
10.2.6 ENGINE REFIT
Proceed in reverse order to removal.
Adjust the position of the throttle valve (6ACCELERATOR VALVE
REFITTING, 518).
Ret the 2 ties near to the alternator and on the radiator air intake
hose.
2Silent block center screw: 27 N.m (238.97 lb-in) ±10%.
2Exhaust support screw: 22 N.m (194.72 lb-in) ± 10%.
10.2.7 ENGINE CHANGE
2Engine support bracket screws: 47 N.m (415.99 lb-in) ±10%
(1, 010 - 15)
2Engine ywheel casing screws: 24 N.m (212.42 lb-in)±10% (1,
010 - 16).
2Engine ywheel casing screws: 47 N.m (415.99 lb-in)±10% (2,
010 - 16).
2Coupling screws: 20 N.m (177.01 lb-in)±10% (3, 010 - 16).
10 - 13 2
3
1
4
5
6
10 - 14
1
1
10 - 15
1 1 1
1111
1
10 - 16
1
1
1
1
3
1
1
1
2
2
3
3
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TABLE OF CONTENTS
TRANSMISSION
20.1 TRANSMISSION CHARACTERISTICS AND SPECIFICATIONS .................................. 22
20.1.1 PERMITTED MOVEMENTS..................................................................22
20.2 TRANSMISSION LOCATIONS............................................................... 22
20.2.1 TRANSMISSION OVERVIEW ................................................................22
20.2.2 TRANSMISSION CIRCUIT ...................................................................23
20.2.3 BRAKING AND DRAINAGE CIRCUIT.........................................................24
20.3 TRANSMISSION CONTROLS AND ADJUSTMENTS ........................................... 25
20.3.1 CONNECTION OF WHEEL MOTOR HOSES ..................................................25
20.3.2 TRANSMISSION BLOCK TIGHTENING TORQUE..............................................25
20.4 TRANSMISSION REMOVAL  REFITTING .................................................... 26
20.4.1 HYDROSTATIC PUMP REMOVAL  REFITTING ...............................................26
HYDROSTATIC PUMP REFIT ..................................................................................26
20.4.2 FRONT WHEEL MOTOR REMOVAL  REFIT ..................................................26
FRONT WHEEL ENGINE REFIT ................................................................................27
20.4.3 REAR WHEEL MOTOR REMOVAL  REFIT....................................................27
REAR WHEEL ENGINE REFIT ..................................................................................27
20.4.4 STEERING CYLINDER REMOVAL  REFIT.....................................................27
STEERING CYLINDER REFIT...................................................................................28
20
LINKS TO REPAIR MANUALS:
MANUAL REFERENCE
NUMBER DESIGNATION
647053 MS/MSE HYDRAULIC ENGINE
647557 PM10 HYDRAULIC PUMP
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TRANSMISSION
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TRANSMISSION
20.1 TRANSMISSION CHARACTERISTICS AND SPECIFICATIONS
20.1.1 PERMITTED MOVEMENTS
WORKING mode TRANSPORTmode
BASE BASKET BASE BASKET
Normal Tilt Overload Normal Tilt Overload Normal Tilt Overload Normal Tilt Overload
Travelling √ √ √
Steering
√
√
√
20.2 TRANSMISSION LOCATIONS
20.2.1 TRANSMISSION OVERVIEW
Accelerator valve
Brake unit
Steering
cylinder
Frame
function
block
Hydrostatic
pump
Front left-hand wheel motor
Rear left-hand wheel motor
Rear right-hand wheel motor
Front right-hand wheel motor
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TRANSMISSION
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20.2.2 TRANSMISSION CIRCUIT
AV.G.
(F.L.)
AR.G.
(R.L.)
AR.D.
(R.R.)
AV.D.
(F.R.)
A - A
Dessus (Bottom)
A - A
EW100
EW101
EV103A
EV100
EV103B
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TRANSMISSION
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20.2.3 BRAKING AND DRAINAGE CIRCUIT
AV.G.
(F.L.)
AR.G.
(R.L.)
AR.D.
(R.R.)
AV.D.
(F.R.)
B - B
B - B
Dessous (Under)
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TRANSMISSION
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20.3 TRANSMISSION CONTROLS AND ADJUSTMENTS
20.3.1 CONNECTION OF WHEEL MOTOR HOSES
Brake hose (1, 020 - 17).
Drain hose (2, 020 - 17).
Travel hoses (3 , 020 - 17).
20.3.2 TRANSMISSION BLOCK TIGHTENING TORQUE
20 - 17 1
3
2
3
EV100
EV103B
EV103A
5 N.m (3.68 ft-lb)
1 in
50 N.m
(36.88 ft-lb)
8 mm
40 N.m (29.5 ft-lb)
5 mm
10 N.m (7.37 ft-lb)
5 mm
10 N.m
(7.37 ft-lb)
5 mm
10 N.m (7.37 ft-lb)
5 mm
10 N.m
(7.37 ft-lb)
5 N.m
(3.68 ft-lb)
5 N.m
(3.68 ft-lb)
3 mm
5 N.m
(3.68 ft-lb)
3 mm
5 N.m (3.68 ft-lb)
3 mm
5 N.m (3.68 ft-lb)
3 mm
5 N.m
(3.68 ft-lb)
3 mm
5 N.m (3.68 ft-lb)
32 mm
75 N.m (55.32 ft-lb)
32 mm
75 N.m
(55.32 ft-lb)
32 mm
75 N.m (55.32 ft-lb)
3 mm
5 N.m (3.68 ft-lb)
8 mm
40 N.m (29.5 ft-lb)
8 mm
40 N.m (29.5 ft-lb)
8 mm
40 N.m (29.5 ft-lb)
7/8 in
35 N.m
(25.8 ft-lb)
7/8 in
35 N.m
(25.8 ft-lb)
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TRANSMISSION
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20.4 TRANSMISSION REMOVAL - REFITTING
20.4.1 HYDROSTATIC PUMP REMOVAL  REFITTING
Carry out the operation (670.5.1 Hydraulic pump removal - ret,
5 45).
Remove the left-hand side frame casing (1, 020 - 18).
Disconnect the electrovalve (1, 020 - 19) (EW100)
Disconnect the hose (2, 020 - 19).
Unscrew the left hand pump fastening screw (3 , 020 - 19).
Open the right-hand side frame casing.
Disconnect the electrovalve (1, 020 - 20) (EW101).
Disconnect the 4 hoses (2, 020 - 20).
Unscrew the left hand pump fastening screw (3 , 020 - 20).
Remove the hydrostatic pump (320 kg (44.09 lbs)).
HYDROSTATIC PUMP REFIT
2Fastening screw: 44 N.m (389.43 lb-in)±10% + thread lock
No.243.
Perform speed calibration (680.4.5 Speed calibration, 5 79) after
each electrovalve or pump replacement.
20.4.2 FRONT WHEEL MOTOR REMOVAL  REFIT
WARNING
Reminder: Load on one wheel (396 kg (211 lbs)): from 1200 kg (2645 lbs)
(transport) to 2700 kg (5952 lbs) (max working).
Change the Norlock washers following each removal.
Place the front axle on 2 axle stands (1, 020 - 21).
Remove the wheel.
Place an oil container under the wheel engine.
20 - 18
1
20 - 19
3
1
2
20 - 20
1
22
3
22
20 - 21
1
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TRANSMISSION
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Identify the 4 hoses (1, 020 - 22) and disconnect them.
Remove the rear wheel engine (2, 020 - 22).
FRONT WHEEL ENGINE REFIT
Check the cleanliness of the engine bearing, the passage of the
hoses and seat the engine rmly on its bearing.
2Wheel motor fastening nuts: 111 N.m (982.43 lb-in) ±10%.
2Wheel screws: 250 N.m (2212.69 lb-in) ±10%.
WARNING
Change the Norlock washers following each removal.
20.4.3 REAR WHEEL MOTOR REMOVAL  REFIT
WARNING
Reminder: Load on one wheel (396 kg (211 lbs)): from 1000 kg (2204 lbs)
(transport) to 2700 kg (5952 lbs) (max working).
Change the Norlock washers following each removal.
Place the rear axle on 2 axle stands (1, 020 - 23).
Remove the wheel.
Place an oil container under the wheel engine.
Identify the 4 hoses (1, 020 - 24) and disconnect them.
Remove the rear wheel engine (2, 020 - 24).
REAR WHEEL ENGINE REFIT
Check the cleanliness of the engine bearing, the passage of the
hoses and seat the engine rmly on its bearing.
2Wheel motor fastening nuts: 111 Nm (982.43 lb-in) ±10%.
2Wheel screws: 250 N.m (2212.69 lb-in) ±10%.
WARNING
Change the Norlock washers following each removal.
20.4.4 STEERING CYLINDER REMOVAL  REFIT
Place the axle on two axle stands (1, 020 - 25), place a container
beneath it.
Remove the front cover (2, 020 - 25)
20 - 22
1
2
Move to 85 N.m (752.31 lb-in) (Dacromet black screw)
when DT is applied.
Old screw 111 N.m (982.43 lb-in) (yellow + washer).
Consult After-Sales Service or Product Quality to
speak of screw change when retting.
20 - 23
1
20 - 24
1
2
Move to 85 N.m (752.31 lb-in) (Dacromet black screw)
when DT is applied.
Old screw 111 N.m (982.43 lb-in) (yellow + washer).
Consult After-Sales Service or Product Quality to
speak of screw change when retting.
20 - 25 2
1
1
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