Teardown of the planetary reduction 1:6 and steering case opens the procedures in this 248-page Manitou Type 211 repair manual PDF (OEM ID 647041EN), a factory reference for the Type 211 axle assembly. Exploded views precede each disassembly and assembly sequence, covering the steering cylinder, service and negative brakes, the 1:4,23 planetary reduction, the 603 reduction gear, bevel pinion builds and old, intermediate and last versions of the normal, preloaded, 100% locking and 45% limited slip differentials. Torque tables cover coarse pitch, fine pitch and wheel nuts. Use Loctite 638 where the fit clearance runs 0.1 to 0.25 mm, and switch to 648 when radial clearance is below 0.1 mm. The job you bring might be a brake piston gap check, a fail safe brake reset or a ring and pinion adjustment. Bookmarks jump straight to each procedure, starting with the 1:6 planetary reduction.
What's Inside This Manitou 211, TYPE 211 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 7-18 | Maintenance, Repair Work, Disassembly, Assembly, Classification, Spare Parts, Definition of Viewpoints, Data Plate, Conversion Tables, Torque Specifications (Coarse Pitch, Fine Pitch, Wheel Nut Tightening Torques), Trestles, Supporting Benches, Tools, Torque Wrenches, Protective Gear, Solvents, Specifications, Safety Precautions |
| Planetary Reduction 1:6 and the Steering Case | 19-48 | Exploded View, Disassembly, Assembly, Special Tools, Steering Cylinder |
| Brake: Service Brake, Negative Brake, 100% Locked | 49-74 | Exploded View, Brake Working Conditions (Sahr Brake Applied, Sahr Brake Released, Service Brake Applied, Differential Lock Applied), Disassembly, Assembly, Brake: Negative Brake 4 Cup Springs Version |
| Normal Preloaded Differential Unit (Old Version) | 75-96 | Exploded View, Disassembly, Assembly, Normal Preloaded Differential Unit (Intermediate Version), Normal Preloaded Differential Unit (Last Version) |
| Flanged Reduction Gear 603 Type: Integral 603 Input Gear | 97-122 | Exploded View, Disassembly, Assembly, Special Tools, Assembly (Normal Flange Version, Revolution Counter Version), Bevel Pinion: Normal Flange and Nut Revolution Counter Version |
| Ring and Pinion Adjusting: Step for Preloaded Differential | 123-132 | Exploded View, Install and Adjust, Disassembly, Assembly, Swinging Support |
| Planetary Reduction: 1:4,23 | 133-136 | Exploded View, Disassembly, Assembly |
| Brake: Incoming Disc Brake | 137-160 | Exploded View, Disassembly, Assembly, Braking Pads, Service and Mechanical Parking Brake, Parking Brake and Differential Hydraulic Lock 100% |
| Differential with Block to Spheres 100% (Old Version) | 161-192 | Exploded View, Disassembly, Assembly, Differential with Block to Spheres 100% (Last Version), Normal Differential (Old Version), Normal Differential (Last Version) |
| Limited Slip Differential Unit 45% (Old Version) | 193-228 | Exploded View, Disassembly, Assembly, Ring Gear, Planetary Gear, Satellite Gears, Cross Bolts, Friction Discs, Thrust Block, Limited Slip Differential Unit 45% (Last Version), Preloaded Limited Slip Differential Unit 45% Unit (Old Version), Preloaded Limited Slip Differential Unit 45% (Intermediate Version), Preloaded Limited Slip Differential Unit 45% (Last Version) |
| Bevel Pinion: Flanged to Reduction Gear 603 | 229-238 | Exploded View, Disassembly, Assembly, Special Tools |
| Ring and Pinion Adjusting: Version Pinion Cover and Single Arm | 239-248 | Exploded View, Install and Adjust, Ring and Pinion Adjusting: Version Pinion Integral and Double Arm |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Loctite 638 clearance | 0.1 to 0.25 mm | p. 15 |
| Loctite 648 radial clearance | below 0.1 mm | p. 15 |
| Loctite 510 clearance | up to 0.2 mm | p. 15 |
| Loctite 275 diametrical clearance | maximum 0.25 mm | p. 15 |
| Continuous rolling torque on the hub | 7 - 20 N·m | p. 31 |
| Crown wheel and pinion clearance | 0,13-0,20 mm | p. 125 |
| Torque for nut (9) on pinion | 260 - 300 N·m | p. 141 |
| Differential Oil Change Interval | 1000/1200 hours | p. 13 |
| Planetary Reduction Oil Change Interval | 1000/1200 hours | p. 13 |
| Planetary Reduction w/brakes Oil Change Interval | 500/600 hours | p. 13 |
| Negative Brake Adjustment Interval | 1000 hours | p. 14 |
| Service Brake Adjustment Interval | 500 hours | p. 14 |
Manitou 211, TYPE 211 Common Problems This Manual Covers
Manitou 211 axle planetary reduction 1:6 wheel hub bearings showing play or rough rotation
Remove the planetary carrier cover, crown flange and hub starting on page 20, tapping bearing thrust blocks out alternately. On reassembly, face the jointed side of the bearing inner ring toward the pin bottom, torque nuts (32) to 90 then 100 N·m per page 30, and verify hub rolling torque of 7 to 20 N·m on page 31.
Manual Section: Planetary Reduction 1:6 and the Steering Case p. 20Bevel pinion sealing ring leaking oil around the input flange and pinion nut
Mark the nut (1) and pinion tang, then heat the check nut to 80°C if the Loctite resists, holding the pinion with tool T1 per page 108. Replace the sealing ring (3) every time, coat its outer surface with Arexons rubber cement, oil the lips, and apply Loctite 270 to the pinion tang before tightening the nut (page 116).
Manual Section: Bevel Pinion: Normal Flange and Nut Revolution Counter Version p. 108SAHR negative brake piston module failing to fully release the brake discs
Verify SAHR release pressure against 15 to 30 bar on page 51. Before opening the brakes with the axle on the machine, follow every safety instruction in the OEM vehicle manual (page 54). To strip it, pressurize union P1 with an external pump, fit block screws, and pull the piston module per pages 55 and 56. Replace o-ring (31) and fit o-rings from the pressure facing side (page 61).
Manual Section: Brake: Service Brake, Negative Brake, 100% Locked p. 55Differential hydraulic lock piston not engaging when the 100% differential lock is selected
Test differential lock pressure against 15 to 25 bar on page 53. If pressure holds, follow the OEM vehicle manual safety instructions before working on brakes with the axle installed (page 54), then remove the hydraulic block piston (12) by applying pressure to the second hole per page 57. Check anti-extrusion ring and o-ring positions on page 58 and inspect hydraulic block discs (20)(24) on page 77.
Manual Section: Brake: Service Brake, Negative Brake, 100% Locked p. 57Steering cylinder leaking hydraulic oil past the piston seal and cylinder head seals
Drain the oil from both cylinder chambers before stripping it, and note the piston seal ring direction toward the head (page 41). Replace every seal, anti-extrusion ring and scraper ring (page 42). Fit the piston with magnetic ring, anti-extrusion ring and piston seal, grease seals and cylinder, do not roll seal (9), and tap the piston in 100 mm (page 43).
Manual Section: Steering Cylinder p. 41Crown wheel and pinion set on the preloaded differential whining or noisy after reassembly
Check nominal dimension 'I' marked on the pinion and apply the 'Y' variation to get the actual center distance (page 111). Install the differential, torque the arm screws to 128 N·m, then measure crown wheel and pinion clearance against 0.13 to 0.20 mm per page 125. Avoid bending the cap or damaging the o-ring sealing surface (page 124).
Manual Section: Ring and Pinion Adjusting: Step for Preloaded Differential p. 125Frequently Asked Questions
What are the replacement specifications for the pinion seal on the Manitou 211, TYPE 211 axle assembly?
The manual states that sealing rings must be replaced every time a component is overhauled or repaired. During assembly, the sealing rings must be lubricated on the sealing edge. For the bevel pinion, the sealing ring (3) must be replaced each time the unit is disassembled. p. 108
What's the ring gear capscrew torque spec for the Manitou 211, TYPE 211 normal preloaded differential?
When installing the ring gear on the normal preloaded differential unit, the capscrews must be tightened to a torque setting of 78-86 N·m using a criss-cross method. p. 82
What is the required oil type for the differential and planetary reduction?
The recommended lubricant for both the differential and planetary reduction is SAE85W90 (API GL4 - MIL L-2105). If the planetary reduction includes brakes, it requires specific additives for oil-bath brakes. p. 13
What is the torque setting for the steering cylinder securing screws on the Manitou 211, TYPE 211 axle assembly?
The securing screws (19) for the steering cylinder (16) must be tightened to a torque setting of 90-100 N·m using a criss-cross method. p. 45
What is the procedure for emergency release of the negative brake?
To release the negative brake in an emergency, disconnect the hydraulic pipe from port P1, loosen the two screws (30) on the axle cover, and remove the spacer (32). Tighten both screws (30) by hand until they contact the internal pusher plate, then tighten alternatively by 1/4 turn until fully tightened. p. 54
How is this Manitou 211 Repair Manual delivered?
This is a 248-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Am I free to print this Manitou 211 Repair Manual?
Yes. Many mechanics print the section they need for their own shop and bring it to the bench.
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