Gehl AL550 Mustang AL508 Manitou MLA 5-60 Articulated Loader Service Manual 50940658 – PDF DOWNLOAD

Gehl AL550 Mustang AL508 Manitou MLA 5-60 Articulated Loader Service Manual 50940658 – PDF DOWNLOAD

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Gehl AL550 Mustang AL508 Manitou MLA 5-60 Articulated Loader Service Manual 50940658 – PDF DOWNLOAD

Language : English
Pages : 310
Downloadable : Yes
File Type : PDF
Size: 35 MB

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DESCRIPTION:

Gehl AL550 Mustang AL508 Manitou MLA 5-60 Articulated Loader Service Manual 50940658 – PDF DOWNLOAD

General:
Manual Purpose/Foreword:

• This manual provides information about the safe service procedures for the machine. Major points of safety are detailed in the Safety section of this manual. This manual also includes troubleshooting and specification information about the machine.
• Follow the instructions in this manual concerning accident prevention regulations, safety and occupational regulations, and machine and traffic regulations. Manitou Americas is not liable for damage resulting from the failure to follow these regulations.
• The machine is designed only for digging, picking up, raising, transporting and unloading materials. Approved attachment use is also allowed. Using the machine in any other way is considered contrary to the intended use. Compliance with, and strict adherence to, the conditions of operation, service and repair as specified in this manual and by the manufacturer, also constitute essential elements of the intended use.
• The machine was designed and built according to the best available technology and approved safety regulations in the countries where it is sold. However, it is impossible to completely safeguard against abusive, improper use. Always consider potential safety risks and hazards during operation, maintenance and service.
• Accident prevention regulations, all road traffic regulations, and all other generally recognized safety and occupational medicine regulations must be observed at all times. The machine must be maintained in proper operating condition. Any damaged or malfunctioning parts must be repaired or replaced immediately.

TABLE OF CONTENTS:

Gehl AL550 Mustang AL508 Manitou MLA 5-60 Articulated Loader Service Manual 50940658 – PDF DOWNLOAD

Table of Contents……………………………………………………………………………………… 3
000 – General…………………………………………………………………………………………. 9
Manual Purpose/Foreword…………………………………………………………………………….. 9
Machine Orientation…………………………………………………………………………….. 9
Manufacturer Information……………………………………………………………………………. 9
Proper Machine Use…………………………………………………………………………………. 9
Product Support……………………………………………………………………………………. 10
Machine Model and Serial Numbers…………………………………………………………………. 10
Component Serial Numbers………………………………………………………………………… 10
Additional Service Documentation…………………………………………………………………….. 11
Characteristics and Specifications…………………………………………………………………… 12
Component Identification………………………………………………………………………… 12
Fluids/Lubricants Types and Capacities……………………………………………………………. 13
Payloads/Capacities…………………………………………………………………………….. 14
Dimensions…………………………………………………………………………………….. 16
Weights……………………………………………………………………………………….. 17
Coolant Compound Table………………………………………………………………………….. 17
Direct and/or Indirect Visibility……………………………………………………………………. 18
Wheels/Tires…………………………………………………………………………………… 19
Electrical…………………………………………………………………………………….. 19
Hydraulic System……………………………………………………………………………….. 19
Drive Hydraulics……………………………………………………………………………. 19
Work Hydraulics…………………………………………………………………………….. 19
Sound Power/Pressure Levels……………………………………………………………………… 19
Vibration Levels……………………………………………………………………………….. 20
Reference Information………………………………………………………………………………. 20
List of Abbreviations…………………………………………………………………………… 20
Standard Tightening Torques……………………………………………………………………… 21
Indicator and Operation Symbols……………………………………………………………………… 23
Safety……………………………………………………………………………………………….. 25
Safety Symbol and Signal Words………………………………………………………………………. 25
Signal Words…………………………………………………………………………………… 25
Mandatory Safety Shutdown Procedure………………………………………………………………….. 26
Before Starting……………………………………………………………………………………. 26
During Operation…………………………………………………………………………………… 28
Provision for Stability/Avoiding Rollover and Tipover Accidents…………………………………………. 30
Articulated Loader Stability………………………………………………………………………… 32
Effect of Uneven or Unstable Ground on Stability…………………………………………………… 32
Effect of Machine Travel on Stability…………………………………………………………….. 33
Effect of Load Movement on Stability……………………………………………………………… 33
Applications with Load-Handling Devices………………………………………………………………. 33
Parking the Machine………………………………………………………………………………… 33
Electrical Energy………………………………………………………………………………….. 34
Maintenance and Service Safety Practices……………………………………………………………… 34
Battery Hazards……………………………………………………………………………………. 36
Fire Hazards………………………………………………………………………………………. 36
Additional Safety Equipment…………………………………………………………………………. 37
Crystalline Silica Exposure…………………………………………………………………………. 37
Transporting the Machine……………………………………………………………………………. 37
Raising the Machine with a Crane…………………………………………………………………….. 37
Loading and Transporting the Machine…………………………………………………………………. 38
Safety Decals……………………………………………………………………………………… 38
New Decal Application…………………………………………………………………………… 38
Safety Decal Locations……………………………………………………………………………… 39
ANSI-Style and Common Safety Decal Locations………………………………………………………….. 40
ISO-Style Safety Decal Locations…………………………………………………………………….. 44
002 – Machine Service Operation…………………………………………………………………………. 47
Additional Information……………………………………………………………………………… 47
Mandatory Safety Shutdown Procedure………………………………………………………………….. 47
Preparation and Safety Instruction…………………………………………………………………… 47
Lift Structure Support……………………………………………………………………………… 47
Supporting the Lift Structure……………………………………………………………………. 47
Disengage Lift Structure Support…………………………………………………………………. 48
Hydraulics Transport Lock-Out Operation………………………………………………………………. 49
Auxiliary Circuit Pressure Relief……………………………………………………………………. 49
Raising the Machine using a Crane……………………………………………………………………. 50
Crane Lifting Preparation……………………………………………………………………….. 50
Towing……………………………………………………………………………………………. 51
Precautions……………………………………………………………………………………. 51
Towing Preparation……………………………………………………………………………… 51
Towing Procedure……………………………………………………………………………….. 52
After Towing…………………………………………………………………………………… 53
Loading and Transporting the Machine on a Transport Vehicle…………………………………………….. 53
Long-Term Storage………………………………………………………………………………….. 54
Before Storage…………………………………………………………………………………. 54
After Storage………………………………………………………………………………….. 54
Final Shutdown / Decommissioning…………………………………………………………………….. 54
Before Disposal………………………………………………………………………………… 54
Machine Disposal……………………………………………………………………………….. 55
010 – Engine………………………………………………………………………………………….. 57
Engine Specifications………………………………………………………………………………. 57
Engine Assembly……………………………………………………………………………………. 58
Engine Operation…………………………………………………………………………………… 63
Engine Maintenance…………………………………………………………………………………. 63
Belt Maintenance / Service………………………………………………………………………….. 63
Alternator Belt Removal…………………………………………………………………………. 63
Alternator Belt Installation…………………………………………………………………….. 64
Engine Removal…………………………………………………………………………………….. 65
Engine Installation………………………………………………………………………………… 72
Engine Troubleshooting……………………………………………………………………………… 79
Engine Diagnostic Trouble Codes (DTC)…………………………………………………………….. 80
011 – Engine Cooling System…………………………………………………………………………….. 99
Engine Cooling System General Information…………………………………………………………….. 99
Cooling Package Removal……………………………………………………………………………..103
Cooling Package Installation…………………………………………………………………………106
020 – Drive System / Transmission………………………………………………………………………..109
Drive System General Information……………………………………………………………………..109
Drive Hydraulics………………………………………………………………………………..110
Hydrostatic Travel Motor…………………………………………………………………………….113
Pump and Drive Motor Error Codes……………………………………………………………………..114
Hydrostatic Travel Motor Removal………………………………………………………………….115
Hydrostatic Travel Motor Installation……………………………………………………………..117
Travel Motor Service………………………………………………………………………………..121
Hand/Foot Throttle………………………………………………………………………………….122
Transmission Control Unit (TCU) / Drive Controller……………………………………………………..122
Travel Drive Control Module Error Codes……………………………………………………………122
030 – Axles……………………………………………………………………………………………125
Hydrostatic Drive Motor……………………………………………………………………………..126
040 – Brake……………………………………………………………………………………………127
Brake/Inching Pedal Calibration………………………………………………………………………127
Bleeding the Brake System……………………………………………………………………………129
Brake/Inching Pedal Electrical……………………………………………………………………….130
Parking Brake Adjustment/Service……………………………………………………………………..130
Parking Brake Cable Adjustment……………………………………………………………………130
050 – Lift Structure……………………………………………………………………………………131
Lift Structure Hydraulics……………………………………………………………………………139
Lift Structure Support…………………………………………………………………………..139
070 – Hydraulics……………………………………………………………………………………….141
Hydraulic System General Information………………………………………………………………….141
Open-Type / Hydrostatic Systems…………………………………………………………………..141
Open-Type…………………………………………………………………………………..141
Hydrostatic-Type…………………………………………………………………………….141
General Hydraulic Service Notes………………………………………………………………………142
Hydraulic Hoses/Tubes……………………………………………………………………………142
Seals………………………………………………………………………………………….142
Main Pressure Test and Adjustment…………………………………………………………………….146
High-Flow Auxiliary Hydraulics Pressure Test and Adjustment……………………………………………..147
Control Valve………………………………………………………………………………………149
Main Control Valve Removal……………………………………………………………………….151
Main Control Valve Installation…………………………………………………………………..151
Control Valve Disassembly/Assembly………………………………………………………………..152
Disassembly…………………………………………………………………………………152
Control Valve Assembly……………………………………………………………………….153
Tilt/Lift Cylinder Tests…………………………………………………………………………….153
Tilt Cylinder Drift Test…………………………………………………………………………153
Tilt Cylinder Internal Leakage Test……………………………………………………………….153
Lift Cylinder Drift Test…………………………………………………………………………154
Lift Cylinder Internal Leakage Test……………………………………………………………….155
Hydraulic Cylinder Disassembly/ Assembly………………………………………………………………156
Cylinder Disassembly…………………………………………………………………………….156
Cylinder Assembly……………………………………………………………………………….156
Bleeding Air After Cylinder Installation…………………………………………………………..156
Hydraulic Solenoid Valves and Tests…………………………………………………………………..157
Standard Auxiliary (Front Standard Only) Hydraulics Pressure Release Valve and Test…………………….157
Secondary Auxiliary Hydraulics Diverter Valve and Test………………………………………………159
Machines equipped with secondary auxiliary (2nd front auxiliary and rear auxiliary) hydraulics only:….159
Front High-Flow Auxiliary Hydraulics Valve and Test…………………………………………………160
Lift/Tilt Lockout Valves and Test…………………………………………………………………162
Multi-Purpose Valve Tests………………………………………………………………………..163
Power-A-Tach/Quick Attachment Lock Solenoids Test……………………………………………….164
Differential Lock Solenoid Test……………………………………………………………….164
Standard Auxiliary Hydraulics Forward/Reverse Solenoid Test………………………………………166
Hydraglide…………………………………………………………………………………………167
Hydraglide™ Ride Control Solenoid Test…………………………………………………………….168
Solenoid Valve Disassembly/ Reassembly………………………………………………………………..169
Steering…………………………………………………………………………………………..170
Steering Priority Test…………………………………………………………………………..171
Hydraulic Gear Pump…………………………………………………………………………………172
Hydraulic Gear Pump Removal………………………………………………………………………172
Hydraulic Gear Pump Installation………………………………………………………………….174
Hydraulic System Troubleshooting……………………………………………………………………..176
Hydrostatic Travel Drive System………………………………………………………………………178
Hydrostatic System Basics………………………………………………………………………..178
Hydrostatic System Overview…………………………………………………………………..178
System Control………………………………………………………………………………179
Over-pressure/Over-heating Conditions………………………………………………………….180
Charge Pressure Test and Adjustment……………………………………………………………….183
High-Pressure (Drive) Test……………………………………………………………………….184
Hydrostatic Pump Pressure Relief Valves……………………………………………………………184
071 – Hydraulic Schematics………………………………………………………………………………187
Hydraulics Schematic – Standard-Flow Auxiliary…………………………………………………………187
Hydraulics Schematic – High-Flow Auxiliary…………………………………………………………….188
Hydraulics Schematic – Standard-Flow Auxiliary with Options……………………………………………..189
Hydraulics Schematic – High-Flow Auxiliary with Options…………………………………………………190
080 – Electrical System…………………………………………………………………………………191
Battery……………………………………………………………………………………………197
Battery Compartment Prop…………………………………………………………………………197
Power Distribution………………………………………………………………………………….198
Power Distribution Module Fuse Socket Test…………………………………………………………198
Fuses and Relays………………………………………………………………………………..199
Cab/Canopy Fuse Box………………………………………………………………………….199
HVAC Fuse Box……………………………………………………………………………….200
Engine Compartment Fuse Box…………………………………………………………………..201
Battery Compartment Fuses…………………………………………………………………….202
Engine Compartment Relays…………………………………………………………………….202
Front Electrical Auxiliary Relays……………………………………………………………..202
Rear Window Defrost Timer Relay/Diode (Machine Equipped with Heat/Air Conditioning)…………………203
Chassis Grounds…………………………………………………………………………………203
Relay Testing…………………………………………………………………………………..203
Machine Test………………………………………………………………………………..203
Bench Test………………………………………………………………………………….204
Control Modules…………………………………………………………………………………….204
J1939 Data Connector………………………………………………………………………………..204
Easy Manager……………………………………………………………………………………….204
Easy Manager Fuse……………………………………………………………………………….205
Easy Manager Relay………………………………………………………………………………205
Throttle Pedal Electrical/CAN………………………………………………………………………..205
Hand Throttle Electrical…………………………………………………………………………….207
Brake/Inching Pedal Electrical……………………………………………………………………….208
Wire Harness Diagrams…………………………………………………………………………………..209
Wire Harness Diagram — Front Chassis…………………………………………………………………209
Wire Harness Diagram — Rear Chassis………………………………………………………………….210
Wire Harness Diagram — Lower ROPS/FOPS (1 of 2)……………………………………………………….211
Wire Harness Diagram — Lower ROPS/FOPS (2 of 2)……………………………………………………….212
Wire Harness Diagram — Upper ROPS/FOPS……………………………………………………………….213
Wire Harness Diagram — Steering Column……………………………………………………………….214
Wire Harness Diagram — HVAC…………………………………………………………………………215
Wire Harness Diagram — Rear Electrical Auxiliary………………………………………………………216
Wire Harness Diagram — Front Electrical Auxiliary……………………………………………………..217
Electrical Schematics…………………………………………………………………………………..218
Electrical Schematic – Rear Chassis…………………………………………………………………..218
Electrical Schematic – Front Chassis………………………………………………………………….219
Electrical Schematic – Power Distribution……………………………………………………………..220
Electrical Schematic – Grounds……………………………………………………………………….221
Electrical Schematic – Lower ROPS/FOPS………………………………………………………………..222
Electrical Schematic – Upper ROPS/FOPS………………………………………………………………..223
Electrical Schematic – Steering Column………………………………………………………………..224
Electrical Schematic – HVAC………………………………………………………………………….225
Electrical Schematic – CAN Network……………………………………………………………………226
Electrical Schematic – Lights………………………………………………………………………..227
Electrical Schematic – Engine (Deutz TD 2.2 L3)………………………………………………………..228
Electrical Schematic — Electrical Auxiliary Circuits……………………………………………………229
Electrical Schematic — Hydraulics Electrical…………………………………………………………..230
085 – Operation Station…………………………………………………………………………………231
HVAC System………………………………………………………………………………………..231
Air Conditioning Service…………………………………………………………………………236
Air Conditioning System Port Access……………………………………………………………236
Air Conditioning Refrigerant Recovery………………………………………………………….236
Air Conditioning System Charging………………………………………………………………236
Air Conditioning Compressor………………………………………………………………………237
Air Conditioning Belt Maintenance / Service………………………………………………………..238
Air Conditioning Belt Removal…………………………………………………………………238
Air Conditioning Belt Installation…………………………………………………………….238
090 – Chassis………………………………………………………………………………………….239
Chassis General Information………………………………………………………………………….239
Side Panel Removal/Replacement……………………………………………………………………….239
Rear Cover Removal/Replacement……………………………………………………………………….241
Service Cover Removal/Replacement…………………………………………………………………….241
ROPS/FOPS………………………………………………………………………………………….242
ROPS/FOPS Removal……………………………………………………………………………….243
ROPS/FOPS Installation…………………………………………………………………………..249
Engine Cover Removal/Replacement……………………………………………………………………..256
Engine Cover Removal…………………………………………………………………………….256
Engine Cover Replacement…………………………………………………………………………257
Articulation Joint………………………………………………………………………………….258
Electrical Control System……………………………………………………………………………….259
Electrical Control System General Information………………………………………………………….259
CAN System General Information……………………………………………………………………259
Control Modules…………………………………………………………………………………….260
Machine Control Unit (MCU)……………………………………………………………………….260
Transmission Control Unit (TCU)…………………………………………………………………..264
Engine Control Unit (ECU)………………………………………………………………………..264
Display/Indicators/Controls………………………………………………………………………264
Display…………………………………………………………………………………….264
Switches……………………………………………………………………………………264
Joystick……………………………………………………………………………………265
Control Lever (Option)……………………………………………………………………….265
CAN System Service/Computer Connection………………………………………………………………..266
J1939 Data Connector…………………………………………………………………………….266
CAN/Computer Connection Harnesses…………………………………………………………………266
Service Adapter Harness………………………………………………………………………266
MCU/TCU Data Connection Harness……………………………………………………………….266
Display Data Connection Harness……………………………………………………………….267
Deutz Engine CAN/Computer Connection Harness (SerDia)……………………………………………….267
Danfoss Service Tool (Plus+1) Software…………………………………………………………….268
Display Service Software Update/Pass Code Reset…………………………………………………….268
Operation/Controller Area Network (CAN) Functional Organization………………………………………….269
Operation/CAN Function Organization Overview……………………………………………………….269
HydralocTM (Safety Interlock) Electrical Functional Detail…………………………………………..270
Ignition/Starting Electrical Functional Detail……………………………………………………..271
Engine Operation Electrical Functional Detail………………………………………………………273
Lift Structure Electrical Functional Detail………………………………………………………..273
Drive System Electrical Functional Detail………………………………………………………….274
Auxiliary Hydraulics Electrical Functional Detail…………………………………………………..278
Lighting Electrical Functional Detail……………………………………………………………..280
Accessories and Options Electrical Functional Detail……………………………………………………282
CAN/Control System Troubleshooting……………………………………………………………………284
Inputs/Outputs Detail……………………………………………………………………………284
Error Codes…………………………………………………………………………………….300
MCU CAN Error Codes……………………………………………………………………………..300
Index…………………………………………………………………………………………………303
Torque Specifications…………………………………………………………………………………..307