manitou r522-4tc

[irnwrkr]

new member here. nice informative site. i do all my maintenance on my manitou telehandler. are there any other owners out there.? I have some questions. mostly they have to do with redoing the seals on the cylinders. i just did the main boom lift, what a bear that was. but the shorter cylinder at the base of the boom needs redoing. it looks like it helps the main lifting boom , but it is located just a short distance from the boom hinge pin it looks like it would not be able to offer much support in lifting.
maybe it is a method of keeping the forks level as the boom goes up, interacting with the fork cylinder? or a safety mechanism?
anyway i do not want to take it out of the hydraulic circuit till i understand its function. also the method to remove it?
anyone familiar with its function?

 

[ACEngineering]

new member here. nice informative site. i do all my maintenance on my manitou telehandler. are there any other owners out there.? I have some questions. mostly they have to do with redoing the seals on the cylinders. i just did the main boom lift, what a bear that was. but the shorter cylinder at the base of the boom needs redoing. it looks like it helps the main lifting boom , but it is located just a short distance from the boom hinge pin it looks like it would not be able to offer much support in lifting.
maybe it is a method of keeping the forks level as the boom goes up, interacting with the fork cylinder? or a safety mechanism?
anyway i do not want to take it out of the hydraulic circuit till i understand its function. also the method to remove it?
anyone familiar with its function?

No idea what model that is never heard of it!
But yes it will be a self leveling ram for the pallet forks etc. Sometimes called a compensating ram.

As you lift and lower the oil in it gets pushed out and in to the tilt ram to keep it level.

 

[Sparkplug]

Is the machine around the mid 80's? - -think its an American model called a Reach Chief - basically a MT420 or MT422 or MT425 probably followed by FC - so maybe Ford Four Cylinder Engine around 86HP with Ford 4 speed Torque Converter.

 

[irnwrkr]

Yes,a 1980 'a machine. A four speed mechanical trany with a torque converter driving the clutch pack. It has the torque converter driving the clutch pack with a small pedal above the brake to divert clutch pack pressure when you need to gas it to drive the hydraulic pump for the boom. That little electric solenoid is bolted to the side of trany. The oil passage on that piece of plumbing is very very small and tends to get blocked leaving the oil bypassing the clutch pAcks. It only takes a few hours to remove and clean
Back to the compensating ram, since there is no handle in the cab to flush out the air after rebuild I guess the fork lever will flush both rams?

 

[Sparkplug]

Just pull main bucket lever tip and crowd back to its stops to allow it to fill the compensating ram and also tip the bucket fully down to the stops - now @ace knows it is a MT422FC he may be able to offer a more technical solution - the same Engine Transmission was used in the bigger Sanderson and Manitou RTFLT from the same era - known as a Manitou MB26PC or its 4 wd equivalent

 

[irnwrkr]

I will order up the seal kit. That cylinder probably runs 300 lbs. I will get my game plan down for field removal,and take it to shop.
More fun and games
Thanks for the help
One thing more,has anyone ever tried to build a low cost oil filter cart?

 

[Farmer87]

Yes,a 1980 'a machine. A four speed mechanical trany with a torque converter driving the clutch pack. It has the torque converter driving the clutch pack with a small pedal above the brake to divert clutch pack pressure when you need to gas it to drive the hydraulic pump for the boom. That little electric solenoid is bolted to the side of trany. The oil passage on that piece of plumbing is very very small and tends to get blocked leaving the oil bypassing the clutch pAcks. It only takes a few hours to remove and clean
Back to the compensating ram, since there is no handle in the cab to flush out the air after rebuild I guess the fork lever will flush both rams?

I have a R522-4TC and am having trouble with the drive. I loaded it on a trailer when I bought it and hauled it 2 hrs home and backed it off and drove it to the shed. Stopped to open the door to the shed and when I got back on the machine it would not move forward or reverse. Boom works fine and solenoid on the side of the transmission for flow is working fine but still no movement. Thinking that maybe something is plugged somewhere but just seems odd that it happened so fast. Did seem a little sluggish when I unloaded it though

 

[Sparkplug]

Can't remember that far back but it may have had the micro switch on the handbrake to cut out the transmission drive when on - if it has one it may be seized or faulty and maybe all connected with the little foot pedal you mention - they were never the fastest transmission and often felt lazy unless you gave it plenty of Gas in the correct gear for the conditions.

 

[Farmer87]

Can't remember that far back but it may have had the micro switch on the handbrake to cut out the transmission drive when on - if it has one it may be seized or faulty and maybe all connected with the little foot pedal you mention - they were never the fastest transmission and often felt lazy unless you gave it plenty of Gas in the correct gear for the conditions.

Yes it does have the micro switch on the pedal that is located just above the brake pedal. I tested the switch and it is good and is sending power to the solenoid on the side of the transmission. I did remove the solenoid and valve this past weekend and it looks like someone had tried to bypass it by cutting the end of the plunger off. Not sure why they would do this though. While I had that out I did start the machine and tried to move it back and forth to see if oil would come out of that port and only got a drip every few seconds. Oil is full in transmission so not sure how those ports are routed. Guessing it has an internal pump for supplying the pressure need to engage the clutch pack