PDF Repair Manual Manitou 80 VJR 100 VJR Evolution - 2 MB
This repair manual covers the Manitou 80 VJR Evolution, 100 VJR Evolution, and 100 VJR AUS vertical mast platforms.
It contains detailed instructions for service, troubleshooting, and major repairs.
With this manual, technicians can confidently work on the hydraulic, electrical, and mechanical systems.
Keep your aerial work platforms safe and fully functional with this comprehensive guide.
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--- Page 1 ---
547398EN (12/03/2015) VJR EVOLUTION
VJR AUS
Repair manual
80 VJR EVOLUTION
100 VJR EVOLUTION
100 VJR AUS
--- Page 3 ---
GENERAL INSTRUCTIONS AND SAFETY NOTICE 3
00
00
MAINTENANCE POSITION
2 4
1 3
Before any intervention:
1 - Place the machine on a flat surface and chock the wheels.
2 - Turn off the engine and remove the ignition key.
3 - Let the machine cool down.
4 - Take all the pressure out of the circuits concerned.
(12/03/2015) 00-00-M161EN
--- Page 4 ---
JIB - ACCESS PLATFORM REMOVAL
Pages
A - TELESCOPING CYLINDER SLIDE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2
B - PROCEDURE FOR SETTING THE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 5
C - GREASING THE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 7
D - LATERAL OFFSET OF THE TELESCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 8
55
E - CONTROLLING THE SETTING OF THE TELESCOPE . . . . . . . . . . . . . . . . . . . . P 9
(12/03/2015) 55-06-M161EN
--- Page 5 ---
JIB - ACCESS PLATFORM REMOVAL 11
TELESCOPE
TELESKOP
TELESCOPIO
5 BA 575 JIB TELESCOPE 100 VJR EVOLUTION
BRACCIO TELESCOPICO
5 5
6 6 5
6
1 2 3 4
7
7
7
7
7 5 5 5
5 6 6 6
55
6
10
10
7
7 7 9
9 8
P. A . O . i l l u s
8
15 / 10 / 08
(12/03/2015) 55-06-M161EN
--- Page 6 ---
HYDRAULIC COMPONENTS LOCATION 3
PUMP - DISTRIBUTOR CIRCUIT
UIT
IRC
BC
E - JI
OP
LESC
: TE
SEE
12
1
70
A
2 1
T1
11
(11/03/2015) 70-03-M161EN
--- Page 8 ---
HYDRAULIC COMPONENTS REMOVAL 3
70
(11/03/2015) 70-06-M161EN
--- Page 9 ---
ELECTRICITY
ELECTRICAL SCHEMATIC DIAGRAMS
ELECTRICAL COMPONENTS LOCATION
ELECTRICAL CONTROL AND ADJUSTMENT
ELECTRICAL COMPONENTS REMOVAL
ELECTRICAL COMPONENTS REFIT
ELECTRICAL TROUBLESHOOTING
80
--- Page 10 ---
ELECTRICAL COMPONENTS LOCATION 5
JIB EV HARNESS
CNF CNC
3 6 4 1
2 5 5 2
1 4 6 3
CNE CNB CNA
2 1
10 9 8 7 6 14 13 12 11 10 9 8 10 9 8 7 6
CND
EV12 PENDULAR ARM LOWERING
5 4 3 2 1 7 6 5 4 3 2 1 5 4 3 2 1
1 2
PIN Wire Signal
To basket
1 Red Sensor supply
control plate
2 NΒ°2 Pendular arm EV - Lowering
PENDULAR ARM
ELECTRO-VALVE
A B E F BUNDLE
685824-B
To 10-way
connector E
bundle
685825-B
10 9 8 7 6
E 5 4 3 2 1
EV11 PENDULAR ARM RAISING
PIN Wire Signal
2 NΒ°1 +24V
5 Green/Yellow EV pendular arm - Raising NΒ°1 Green/Yellow
10 NΒ°2 EV pendular arm - Lowering
NΒ°2
1 2
PIN Wire Signal
1 Red Sensor supply
2 Green/Yellow EV pendular arm - Raising
OVERLOAD END OF TRAVEL - OVERLOAD SENSORS HARNESS
OVERLOAD
CNF CNC SENSOR
3 6 4 1 685823-A
2 5 5 2
1 4 6 3
Ref. XX
CNE CNB CNA
2 1
10 9 8 7 6 14 13 12 11 10 9 8 10 9 8 7 6
CND
80
5 4 3 2 1 7 6 5 4 3 2 1 5 4 3 2 1
To basket
control plate
A B E F
2 1 2 1
To 14-way
connector B
PIN Wire PIN Wire
bundle
1 Black/White 1 Black/White
685825-B
2 Black 2 Black
14 13 12 11 10 9 8
B 7 6 5 4 3 2 1 2
1
PIN Wire Signal PIN Wire Signal
11 NΒ°4 Overload 1 - HBT2 NΒ°4 1 NΒ°1 Supply to sensors 1 2 1 2
2 NΒ°2 Overload 2 - HBT3
PIN Wire Signal PIN Wire Signal
1 Red Supply to sensors 1 Red Supply to sensors
2 NΒ°4 Overload 1 - HBT2 2 NΒ°2 Overload 2 - HBT3
OVERLOAD
LIMIT SWITCH BUNDLE
685821-B
Ref. XX
OVERLOAD LS
(10/03/2015) 80-03-M161EN
--- Page 11 ---
ELECTRICAL CONTROL AND ADJUSTMENT
Pages
BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ββ REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ββ DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ββ CHARGE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ββ INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTRONIC CONTROL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ββ REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ββ DESCRIPTION AND CABLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VARIABLE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ββ CABLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ββ DIAGNOSTIC AND ADJUSTMENT TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SAFETY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
80
ββ SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ββ TILT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ββ TELESCOPE LOW POSITION SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ββ JIB LOW POSITION SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ββ OVERLOAD SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ββ STEERING SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MANIPULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ββ ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ββ TEST WITH A VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
(10/03/2015) 80-04-M161EN
--- Page 12 ---
ELECTRICAL CONTROL AND ADJUSTMENT 11
E1 OVERLOAD SENSORS
ADJUSTMENT
2
Setting the overload spring:
1 - Place 200 kg in the basket (evenly distributed)
- Tighten the prestressing screw of the spring (E2-1), leaving
the βscrew + lock nutβ pair free in rotation (E3-1 and E3-2).
PS: The clearance between the nut and the connecting rod
should be as small as possible (E3-1 and E3-2).
NB: Prior to any operation, tighten the two adjustment screws
so as to be certain not to come into contact with the sensor.
E2
Adjusting the overload sensors (E1-1)
Adjustment screw - Place 220 kg in the basket (evenly distributed).
- Loosen screw reference E2-3 until a discontinuous beep is
3 heard
-> The sensor E1-1 is adjusted.
Spring
+ overload
Checking the adjustment:
spacer - With the 220 kg still in the basket, take out 10 to 20 kg and
1
check that the alarm stops sounding.
- Return the weight to the basket and check that the alarm
Pre-tensioning screw
is triggered as required.
- If necessary, repeat the adjustment of the sensor.
The smallest
E3 Adjusting the overload sensor (E1-2):
possible play - The beep is still discontinuous with 220 kg in the basket
between the nut (evenly distributed).
and the oxyacetylene
cut-out with 200kg - Loosen screw reference E2-3 until a continuous beep is heard
in the basket -> The sensor E1-2 is adjusted.
80
Checking the adjustment:
1 - With the 220 kg still in the basket, take out 10 to 20 kg and
check that the alarm stops sounding.
- Return the weight to the basket and check that the alarm
2 is triggered as required.
- If necessary, repeat the adjustment of the sensor.
The overload is adjusted. Confirm the adjustment with
yellow paint!
(10/03/2015) 80-04-M161EN
--- Page 13 ---
ELECTRICAL COMPONENTS REFIT
Pages
WHEEL REDUCING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
80
(10/03/2015) 80-07-M161EN