Manitou Telehandler TMT 25 S K ST5 S1 TMT 27 S K ST5 S1 TMT 27 P K ST5 S1 TMT 25 I K ST5 S1 TMT 25 S 4W K ST5 S1 Service Manual 647915EN-USM14 – PDF DOWNLOAD
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Manitou Telehandler TMT 25 S K ST5 S1 TMT 27 S K ST5 S1 TMT 27 P K ST5 S1 TMT 25 I K ST5 S1 TMT 25 S 4W K ST5 S1 Service Manual 647915EN-USM14 – PDF DOWNLOAD
GENERAL AND SAFETY CHARACTERISTICS:
00.1. FOREWORD:
This chapter deals with the general instructions and safety notice during servicing checks and work. The
other instructions and warning texts are indicated in the chapters concerned.
In order to reduce the risk of accidents, please:
• Follow the instructions in the operator’s manual and
the truck servicing instructions.
• > This manual should be found in all trucks.
• Please follow the safety instructions.
• Use the appropriate tools for all work to be carried
out.
• Use original Manitou spare parts.
If these instructions are not followed there is a risk of accidents occurring, the severity of which could go as far as causing death. A person who follows the safety instructions and a wellserviced machine make a safe, effective and profitable combination.
TABLE OF CONTENTS:
Manitou Telehandler TMT 25 S K ST5 S1 TMT 27 S K ST5 S1 TMT 27 P K ST5 S1 TMT 25 I K ST5 S1 TMT 25 S 4W K ST5 S1 Service Manual 647915EN-USM14 – PDF DOWNLOAD
GENERAL INSTRUCTIONS AND SAFETY NOTICE
GROUP 00 GENERAL AND SAFETY CHARACTERISTICS 251
ENGINE
GROUP 10 ENGINE 284
TRANSMISSION
GROUP 20 TRANSMISSION 296
AXLE ASSEMBLY – AXLE
GROUP 30 AXLE 336
BRAKE
GROUP 40 BRAKE 347
TELESCOPIC BOOM
GROUP 50 LIFT STRUCTURE 350
HYDRAULIC
GROUP 70 HYDRAULICS 370
ELECTRICITY
GROUP 80 ELECTRICITY 396
OPTIONS – ACCESSORIES
GROUPE 120 DIAGNOSTIC TOOLS AND SOFTWARE 486
00 GENERAL AND SAFETY CHARACTERISTICS 10
00 1 FOREWORD 10
00 2 LIST OF ABBREVIATIONS 10
00 3 WORK DURING THE WARRANTY PERIOD 12
00 4 MAINTENANCE RULES 12
00 5 EXPLANATION OF SYMBOLS 16
00 6 MAINTENANCE POSITION 16
00 7 LIST OF SUPPLIER DOCUMENTATION 17
00 8 CHARACTERISTICS AND SPECIFICATIONS 17
00 8 1 Weights and forces 17
00 8 2 Dimensions TMT 25 S K ST5 S1 18
00 8 3 Dimensions TMT 27 S K ST5 S1 20
00 8 4 Dimensions TMT 27 P K ST5 S1 22
00 8 5 Dimensions TMT 25 I K ST5 S1 24
00 8 6 Dimensions TMT 25 S 4W K ST5 S1 26
00 8 7 Lubricants and fuels 27
00 8 8 Lubricants and fuels 28
00 9 LOCATION 30
00 9 1 Name and identification plates 30
00 10 CONTROL AND ADJUSTMENT 31
00 10 1 Standard tightening torques 31
00 10 2 Metric – imperial unit conversion 32
10 ENGINE 34
10 1 CHARACTERISTICS AND SPECIFICATIONS 34
10 1 1 Engine specifications D1803-CR-TE5 34
10 2 LOCATION 35
10 2 1 Location of engine components — TMT ST5 35
10 3 REMOVAL 36
10 3 1 Preparation and safety instructions 36
10 3 2 Remove the engine — TMT ST5 36
10 3 3 Remove the cooling radiator 43
4 647915EN-USM14(B-06/2021)
TABLE OF CONTENTS
10 4 REFIT 45
10 4 1 Refit the components (TMT ST5 S1) (TMT HT & XT) 45
20 TRANSMISSION 46
20 1 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 46
20 1 1 Schematic diagram for hydrostatic transmission – Forward gear 47
20 1 2 Hydrostatic transmission reverse gear schematic diagram – Reverse 51
20 1 3 Schematic diagram for hydrostatic transmission – Forward – 4-WAY 55
20 1 4 Hydrostatic transmission schematic diagram – Reverse— 4 WAY 59
20 2 LOCATION 63
20 2 1 Key to hydrostatic components 63
20 2 2 Key to steering components 64
20 3 CONTROL AND ADJUSTMENT 65
20 3 1 Hydrostatic pump adjustment prerequisites 65
20 3 2 Location of the hydrostatic transmission pump pressure connectors 65
20 3 3 Transmission A4VG40 hydrostatic pump pressure values 65
20 3 4 Adjusting the hydrostatic pump traction force 66
20 3 5 Adjusting the hydrostatic pump for lift truck travel 66
20 3 6 Hydrostatic transmission adjustment sheet — A4VG-DA 69
20 3 7 Tow the lift truck 71
20 3 8 Hydrostatic pump tightening torques 73
20 3 9 Flow divider tightening torques 73
20 3 10 4-Way steering selection block tightening torques 73
20 3 11 Rear wheel motor screw tightening torques 74
20 3 12 Front wheel motor screw tightening torques 74
20 4 REMOVAL 74
20 4 1 Remove the hydrostatic pump 74
20 4 2 Removing the steering block 77
20 4 3 Removing the front wheel motor 78
20 4 4 Remove the front wheel motor – 4-Way 78
20 4 5 Remove the rear wheel motor 79
20 4 6 Remove the rear steering cylinder 80
20 4 7 Removing the 4-Way front steering cylinder 82
20 4 8 Removing the 4-Way steering mode selection unit BSD 83
20 4 9 Removing the 4-Way INV HP shuttle unit 84
TABLE OF CONTENTS
647915EN-USM14(B-06/2021) 5
20 5 SPECIFIC TOOLING 85
20 5 1 Basic manometer box 85
20 5 2 Digital manometer box 85
30 AXLE 86
30 1 CHARACTERISTICS AND SPECIFICATIONS 86
30 1 1 Pivot characteristics 86
30 2 LOCATION 87
30 2 1 Location of rear pivot components 87
30 2 2 Location of front pivot components 88
30 3 REMOVAL 89
30 3 1 Removing the rear pivot 89
30 3 2 Removing the front pivot — 4 Way 91
30 4 REFIT 92
30 4 1 Refitting the rear pivot 92
40 BRAKE 97
40 1 LOCATION 97
40 1 1 Location of the service brake pedal and transmission cut-off components (inching) 97
40 2 CONTROL AND ADJUSTMENT 98
40 2 1 Adjusting the service brake pedal and transmission cut-off (inching) 98
40 2 2 Valve TH7 (hydraulic) tightening torque 98
40 2 3 Hydraulic tightening torques of the steering bloc (orbitrol) 99
40 3 REMOVAL 99
40 3 1 Remove valve TH7 99
50 LIFT STRUCTURE 100
50 1 CHARACTERISTICS AND SPECIFICATIONS 100
50 1 1 Duplex boom composition 100
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TABLE OF CONTENTS
50 2 LOCATION 100
50 2 1 Boom location 100
50 3 CONTROL AND ADJUSTMENT 101
50 3 1 Preparation and safety instructions 101
50 3 2 Remove the tilting cylinder 101
50 3 3 Refit the tilting cylinder 102
50 3 4 Removing the forks carriage 103
50 3 5 Refit the forks carriage 104
50 3 6 Remove the telescopic boom cylinder 105
50 3 7 Refit the telescopic boom cylinder 106
50 3 8 Remove the telescope 107
50 3 9 Refit the telescope 109
50 3 10 Remove the side shift cylinder 109
50 3 11 Boom cross sections / slide pad adjustments 111
50 4 REMOVAL 113
50 4 1 Preparation and safety instructions 113
50 4 2 Removing the boom 113
50 5 REFIT 116
50 5 1 Preparation and safety instructions 116
50 5 2 Refitting the boom 116
70 HYDRAULICS 120
70 1 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 120
70 1 1 Hydraulic schematic diagram (TMT 25I ST5 S1) 121
70 1 2 Hydraulic schematic diagram (TMT 25S 27P 27S ST5 S1)(TMT HT & XT T4) 125
70 1 3 Hydraulic schematic diagram — 4 WAY 129
70 2 LOCATION 133
70 2 1 Location of main hydraulic system – steering – telescoping – tilting – lifting – compensation 133
70 2 2 Location of hydraulic brake system – oil cooling 135
70 2 3 Location of the “self loading kit” hydraulic circuit – hydraulic track 136
70 2 4 Location of the folding door hydraulic circuit 137
70 3 CONTROL AND ADJUSTMENT 138
70 3 1 Purge front steering cylinder – 4 Way 138
70 3 2 Distributor union tightening torques 141
TABLE OF CONTENTS
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70 3 3 Valve bank component tightening torques 142
70 3 4 Hydrostatic pump tightening torques 142
70 3 5 Hydraulic pump tightening torques 143
70 3 6 Stabilizer valve tightening torques – 4 Way 143
70 3 7 Folding arms electrovalve tightening torques (option) 143
70 4 REMOVAL 143
70 4 1 Remove the electrovalve from the folding arms (option) 143
70 5 SPECIFIC TOOLING 144
70 5 1 Basic manometer box 144
70 5 2 Digital manometer box 144
80 ELECTRICITY 146
80 1 CHARACTERISTICS AND SPECIFICATIONS 146
80 1 1 E18/S6 electronic module 146
80 1 2 Fuses and relays 147
80 1 3 Connectors 151
80 2 FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS 158
80 2 1 Cable marking on an electrical wiring harness 158
80 2 2 Electrical diagram by function 161
80 3 LOCATION 193
80 3 1 2D location of harnesses 195
80 3 2 3D location of harnesses — (except 4 Way) 203
80 3 3 2D location of the harness — 4 Way 207
80 3 4 3D location of harnesses — 4 Way 209
80 4 CONTROL AND ADJUSTMENT 213
80 4 1 Adjusting the rear pivot sensors 213
80 4 2 Adjusting the telescoping cut-off 213
80 4 3 Adjust the boom angular sensor 215
80 4 4 Checking movement cut-off 216
80 4 5 Check A: Checking movement cut-off 216
80 4 6 Check B: Overload check 217
80 4 7 Testing Overload calibration 218
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80 5 TROUBLESHOOTING 219
80 5 1 Navigate the driver’s cab screen menus 219
80 5 2 Fault and alert screen pages 229
80 5 3 Troubleshooting on the E18/S6 – 4 Way module 233
85 DIAGNOSTIC TOOLS AND SOFTWARE 236
85 1 TMT MALFUNCTION CODES 236
85 2 KUBOTA ENGINE DIAGNOSTICS TOOL – DIAGMASTER 237
85 3 CODES ERREUR (KUBOTA D1803 / V2403) TIER4 & STAGE 5 238
85 4 CODES ERREUR APRÈS TRAITEMENT (KUBOTA D1803 / V2403) TIER4 &
STAGE 5 243
85 5 A DIAGNOSTIC AND “POCKET” ADJUSTMENT TOOL FOR THE ELECTRONIC
MODULE E18/S6 245
TABLE OF CONTENTS
647915EN
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