Manitou TMT-X 25 S K E3 S2, TMT-X 25 S 4W K E3 S2 Repair Manual 647917EN

Description

• Model List:
  • TMT-X 25 S K E3 S2
  • TMT-X 25 S 4W K E3 S2

• 1. N(29/01/2021)TMTX 25 S K E3 S2TMTX 25 S 4W K E3 S2REPAIR MANUAL
• 2. HOW TO USE THIS REPAIR MANUAL
• 3. GLOSSARY
• 4. SUMMARY
• 5. GR00GENERAL, CHARACTERISTICS AND SAFETY
• 5.1. GENERAL INSTRUCTIONS AND SAFETY NOTICE
• 5.1.1. INTRODUCTION
• 5.1.2. SERVICING POSITION
• 5.1.3. SERVICING RULES
• 5.2. GENERAL CHARACTERISTICS AND SPECIFICATIONS
• 5.2.1. Machine TMTX 25 S K E3 S2
• 5.2.1.1. SPECIFICATIONS TMTX 25 S K E3 S2
• 5.2.1.2. DIMENSIONS TMTX 25 S K E3 S2
• 5.2.1.3. LOAD CHARTS TMTX 25 S K E3 S2
• 5.2.2. Machine TMTX 25 S 4W K E3 S2
• 5.2.2.1. SPECIFICATIONS TMTX 25 S 4W K E3 S2
• 5.2.2.2. DIMENSIONS TMTX 25 S 4W K E3 S2
• 5.2.2.3. LOAD CHARTS TMTX 25 S 4W K E3 S2
• 5.3. GENERAL LOCATION
• 5.3.1. LOCATION OF NAME AND IDENTIFICATION PLATE
• 5.4. GENERAL CONTROL AND ADJUSTMENT
• 5.4.1. STANDARD TIGHTENING TORQUES
• 5.4.2. METRIC IMPERIAL UNIT CONVERSION
• 6. GR10ENGINE
• 6.1. ENGINE COMPONENTS LOCATION
• 6.1.1. ENGINE
• 6.1.2. COOLING SYSTEM
• 6.2. ENGINE CONTROL AND ADJUSTMENT
• 6.2.1. SILENTBLOCS REMOVAL AND REPLACEMENT
• 6.3. ENGINE ASSEMBLY REMOVAL
• 6.3.1. PREPARATION AND SAFETY INSTRUCTIONS
• 6.3.2. ELECTRICAL HOUSING B
• 6.3.3. COOLING SYSTEM C
• 6.3.4. EXHAUST PIPE D
• 6.3.5. AIR FILTER E
• 6.3.6. ENGINE SURROUNDINGS
• 6.3.7. ENGINE F
• 6.3.8. COUPLING G
• 6.4. REFIT ENGINE ASSEMBLY
• 6.4.1. PREPARATION AND SAFETY INSTRUCTIONS
• 6.4.2. COUPLING G
• 6.4.3. ENGINE F
• 6.4.4. ENGINE SURROUNDINGS
• 6.4.5. AIR FILTER E
• 6.4.6. EXHAUST PIPE D
• 6.4.7. COOLING SYSTEM C
• 6.4.8. ELECTRICAL HOUSING B
• 7. GR20TRANSMISSION
• 7.1. TRANSMISSION COMPONENTS LOCATION
• 7.2. TRANSMISSION SCHEMATIC DIAGRAMS
• 7.2.1. HYDROSTATIC TRANSMISSION FORWARD GEAR SCHEMATIC DIAGRAM
• 7.2.2. HYDROSTATIC TRANSMISSION REVERSE GEAR SCHEMATIC DIAGRAM
• 7.3. TRANSMISSION CONTROL AND ADJUSTMENT
• 7.3.1. HYDROSTATIC TRANSMISSION PRESSURE CONNECTOR LOCATION
• 7.3.2. PRESSURE CONNECTOR VALUES
• 7.3.3. TRANSMISSION CONTROL AND ADJUSTMENT
• 7.3.4. TOWING THE MACHINE
• 7.3.5. A4VGDA HYDROSTATIC TRANSMISSION SETTING DATA
• 7.4. TRANSMISSION REMOVAL
• 7.4.1. STEERING BLOCK REMOVAL
• 7.4.2. TH7 VALVE REMOVAL
• 7.4.3. FRONT WHEEL MOTOR REMOVAL
• 7.4.4. REAR WHEEL MOTOR REMOVAL
• 7.4.5. REAR STEERING CYLINDER REMOVAL
• 7.4.6. FRONT STEERING CYLINDER REMOVAL 4 Way
• 7.4.7. STEERING MODE SELECTION BLOCK BSD REMOVAL 4 Way
• 7.4.8. INV HP SHUTTLE UNIT REMOVAL 4 Way
• 7.5. SPECIFIC TRANSMISSION TOOLING
• 7.5.1. BASIC KIT
• 7.5.2. DIGITAL MANOMETER BOX
• 8. GR30PIVOT
• 8.1. PIVOT CHARACTERISTICS AND SPECIFICATIONS
• 8.1.1. PIVOT CHARACTERISTICS
• 8.2. PIVOT COMPONENTS LOCATION
• 8.2.1. REAR PIVOT COMPONENTS LOCATION
• 8.2.2. FRONT PIVOT COMPONENTS LOCATION
• 8.3. PIVOT REMOVAL
• 8.3.1. REAR pivot removal
• 8.3.2. FRONT PIVOT REMOVAL
• 8.4. PIVOT REFITTING
• 8.4.1. PIVOT REPLACEMENT
• 8.4.2. REFITTING THE HYDRAULIC MOTOR
• 9. GR40BRAKE
• 9.1. BRAKE COMPONENTS LOCATIONS
• 9.1.1. INCHING PEDAL Series 2 LOCATION
• 9.2. BRAKE CONTROL AND ADJUSTMENT
• 9.2.1. INCHING PEDAL ADJUSTMENT
• 9.2.2. VALVE TH7 HYDRAULIC TIGHTENING TORQUES
• 9.2.3. STEERING BLOCK HYDRAULIC (Orbitrol) TIGHTENING TORQUE
• 9.3. BRAKE REMOVAL
• 9.3.1. REMOVE the valve TH7
• 10. GR50BOOM
• 10.1. BOOM CHARACTERISTICS AND SPECIFICATIONS
• 10.1.1. DUPLEX BOOM
• 10.2. BOOM COMPONENTS LOCATION
• 10.2.2. DIAGRAM
• 10.3. BOOM CONTROL AND ADJUSTMENT
• 10.3.1. PREPARATION AND SAFETY INSTRUCTIONS
• 10.3.2. TILTING CYLINDER REMOVAL
• 10.3.3. REFITTING TILTING CYLINDER
• 10.3.4. CARRIAGE REMOVAL
• 10.3.5. CARRIAGE REASSEMBLY
• 10.3.6. BOOM EXTENSION CYLINDER REMOVAL
• 10.3.7. REFITTING THE BOOM EXTENSION CYLINDER
• 10.3.8. TELESCOPE REMOVAL
• 10.3.9. TELESCOPE REASSEMBLY
• 10.3.10. SIDE SHIFT CYLINDER REMOVAL
• 10.3.11. SIDE SHIFT CYLINDER REASSEMBLY
• 10.4. BOOM SECTIONS AND DIAGRAMS
• 10.4.1. BOOM CROSS SECTIONS/SLIDE PAD ADJUSTMENTS
• 10.5. BOOM REMOVAL
• 10.5.1. PREPARATION AND SAFETY INSTRUCTIONS
• 10.5.2. BOOM REMOVAL
• 10.6. BOOM REFIT
• 10.6.1. BOOM REFIT
• 11. GR70HYDRAULICS
• 11.1. HYDRAULIC SCHEMATIC DIAGRAMS
• 11.1.1. TMTX 25 S K E3 S2
• 11.1.2. TMTX 25 S 4W K E3 S2
• 11.2. HYDRAULIC COMPONENTS LOCATION
• 11.3. Hydraulic circuits key
• 11.3.1. Diagrams
• 11.3.1.1. MAIN HYDRAULIC CIRCUIT / STEERING / TELESCOPE / TILTING / LIFTING / COMPENSATING
• 11.3.1.2. BRAKING HYDRAULIC CIRCUIT / OIL COOLING
• 11.3.1.3. HYDRAULIC SELF LOADING KIT CIRCUIT / HYDRAULIC LINE
• 11.3.1.4. BOOM COMPENSATION HYDRAULIC CIRCUIT BOOM SUPPLY
• 11.4. HYDRAULIC CONTROL AND ADJUSTMENT
• 11.4.1. Distributor connector tightening torques
• 11.4.2. Distributor component tightening torques
• 11.4.3. Hydrostatic pump tightening torques
• 11.4.4. Hydrostatic pump tightening torques
• 11.4.5. Tightening torques of the 4WAY stabilizer valve
• 11.4.6. Folding arms electrovalve tightening torques
• 11.4.7. BLEEDING THE FRONT STEERING CYLINDERS (TMT 25S 4W)
• 11.5. HYDRAULIC COMPONENT REMOVAL
• 11.5.1. REMOVE FOLDABLE ARM ELECTROVALVE
• 11.6. SPECIFIC HYDRAULIC TOOLING
• 11.6.1. BASIC MANOMETER BOX
• 11.6.2. DIGITAL MANOMETER BOX
• 12. GR80ELECTRICITY
• 12.1. ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS
• 12.1.1. TMTX 25 S K E3 S2
• 12.1.1.1. Fuses and relays (engine hood)
• 12.1.1.2. Fuses and relays (cab)
• 12.1.1.3. Electrical connectors
• 12.1.1.4. Splices
• 12.1.2. TMTX 25 S 4W K E3 S2
• 12.1.2.1. Fuses and relays
• 12.1.2.2. Electrical connectors
• 12.1.2.3. Splices
• 12.2. ELECTRICAL SCHEMATIC DIAGRAMS
• 12.2.1. CODES ON THE ELECTRICAL DIAGRAMS
• 12.2.2. WIRING MARKINGS
• 12.2.3. ELECTRICAL DIAGRAMS
• 12.2.3.1. TMTX 25 S K E3 S2 / TMTX 25 S 4W K E3 S2
• 12.2.3.1.1. POSITION OF CONNECTORS BY DIAGRAM
• 12.2.3.1.2. Starting/CAN
• 12.2.3.1.3. Lights signaling
• 12.2.3.1.4. Transmission
• 12.2.3.1.5. Movements safety
• 12.2.3.1.6. Lorry lighting
• 12.2.3.1.7. Self Loading Kit and Hydraulic Attachment Circuit Options
• 12.3. ELECTRICAL COMPONENTS LOCATION
• 12.3.1. TMTX 25 S K E3 S2 A
• 12.3.1.1. Key
• 12.3.1.1.1. connectors
• 12.3.1.1.2. Grounds
• 12.3.1.1.3. splices
• 12.3.1.1.4. HARNESS ASSEMBLY
• 12.3.1.1.5. ENGINE HARNESS
• 12.3.1.1.6. CAB HARNESS
• 12.3.1.1.7. SIGNALING HARNESS
• 12.3.1.1.8. LORRY LIGHTING HARNESSES
• 12.3.1.1.9. SELF LOADING KIT (BF3)AND HYDRAULIC ATTACHMENT CIRCUIT (BF2) OPTIONS
• 12.3.2. TMTX 25 S 4W K E3 S2 B
• 12.3.2.1. Key
• 12.3.2.1.1. CONNECTORS
• 12.3.2.1.2. FUSES
• 12.3.2.1.3. SPLICES
• 12.3.2.1.4. WAY 3D harness
• 12.3.2.1.5. WAY 2D harness
• 12.4. ELECTRICAL CONTROL AND ADJUSTMENT
• 12.4.1. PIVOT SENSORS ADJUSTMENT
• 12.4.1.1. ADJUSTING THE TELESCOPE CUTOFF
• 12.4.2. BOOM SENSORS ADJUSTMENT
• 12.4.3. MOVEMENT CUTOFF CHECK
• 12.4.3.1. Check flow chart
• 12.4.3.2. Check A Movement cutoff check
• 12.4.3.3. Check B Overload check
• 12.4.3.4. Test Overload calibration
• 12.5. ELECTRICAL TROUBLESHOOTING
• 12.5.1. DRIVERS CAB SCREEN
• 12.5.1.1. NAVIGATION IN THE ONSCREEN MENUS
• 12.5.1.1.1. INPUT/OUTPUT DISPLAY PAGES
• 12.5.1.1.2. MACHINE PARAMETER DISPLAY PAGES
• 12.5.1.1.3. GENERAL PARAMETERS
• 12.5.1.1.4. FAULT PAGES
• 12.5.1.2. POCKET
• 12.5.1.2.1. DIAGNOSTIC AND ADJUSTMENT TOOL
• 12.5.1.2.2. INSTALLATION
• 12.5.1.2.3. INTRODUCTION TO MODULE E18/S6
• 12.5.1.2.4. USING THE INPUT/OUTPUT MENUS
• 12.5.1.2.5. THE POCKET READOUT
• 12.5.1.2.6. CORRESPONDENCE OF INPUTS/OUTPUTS
• 12.5.1.2.7. OVERVIEW DIAGRAM FOR USING THE POCKET
• 12.5.1.2.8. TROUBLESHOOTING
• 12.6. ELECTRICAL SPECIFIC TOOLING
• 12.6.1. POCKET
• 12.6.1.1. DIAGNOSTIC AND ADJUSTMENT TOOL