Manitou Gehl MT 420 H 57K ST5 S1 MT 420 H TSS 57K ST5 S1 (RS4-14) Repair Manual – PDF DOWNLOAD
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Manitou Gehl MT 420 H 57K ST5 S1 MT 420 H TSS 57K ST5 S1 (RS4-14) Repair Manual – PDF DOWNLOAD
Language : English
Pages :204
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Manitou Gehl MT 420 H 57K ST5 S1 MT 420 H TSS 57K ST5 S1 (RS4-14) Repair Manual – PDF DOWNLOAD
Page de garde / Front page 1
Sommaire général – General table of content 3
00 9
GENERAL, CHARACTERISTICS AND SAFETY 10
001GENERAL INSTRUCTIONS AND SAFETY NOTICE 10
0011INTRODUCTION 10
0012SERVICING POSITION 10
0013EXPLANATION OF SYMBOLS 11
0014SERVICING RULES 12
002GENERAL CHARACTERISTICS AND SPECIFICATIONS 15
0021CHARACTERISTICS 15
0022LUBRICANTS AND FUEL 15
0023DIMENSIONS 16
MT 420 H 57K ST5 S1 (RS4-14) (Standard carriage) 16
MT 420 H TSS 57K ST5 S1 (Skid-steer carriage) 17
003GENERAL LOCATION 18
0031LOCATION OF NAME AND IDENTIFICATION PLATE 18
004GENERAL CONTROL AND ADJUSTMENT 19
0041STANDARD TIGHTENING TORQUES 19
0042METRIC – IMPERIAL UNIT CONVERSION 20
10 21
ENGINE 23
101ENGINE CHARACTERISTICS AND SPECIFICATION 23
1011GENERAL CHARACTERISTICS 23
Engine V2607-CR-E5-B 23
1012REGENERATION CHARACTERISTICS 24
1013DECONTAMINATION PROMPT LEVELS (DEGRADED OPERATING MODES) 24
102ENGINE CIRCUITS FLOW DIAGRAM 25
1021FUEL CIRCUIT: OVERVIEW OF THE FUEL SYSTEM 25
1022COOLING SYSTEM: LOWER BYPASS SYSTEM 25
1023EXHAUST CIRCUIT: AFTER-TREATMENT DEVICES 26
103Engine components location 27
1031engine components 27
104Engine controls and adjustments 28
1041Fan control 28
LOCATION 28
PURPOSE: 28
DESCRIPTION OF HYDRAULIC VENTILATION BLOCK: 29
Engine hydraulic diagram: 29
THE THREE MODES OF OPERATION: 30
ADJUSTMENT: 31
Fan control system architecture diagram: 32
1042ENGINE SILENT BLOCK TIGHTENING TORQUES 33
1043COOLING SYSTEM TIGHTENING TORQUES 33
105Engine removal – refitting 34
PREPARATION AND SAFETY INSTRUCTIONS 34
1051Side casing and engine cover removal 34
1052Remove engine rear casing and mudguard 35
1053Alternator belt removal/refit 35
1054Alternator removal 35
1055STARTER removal 36
1056Air filter assembly removal 36
1057Cooler removal 37
Ventilation grille removal 37
RADIATOR removal 38
Ventilation control block removal 38
Cooler support bracket removal 39
1058Exhaust pipe removal 39
1059Fuel tank removal 41
10510Engine removal 42
10511Engine refit 46
10512Water pump removal 46
106Engine troubleshooting 46
107Specific engine tooling 46
1071Special engine tooling 46
1072Electronic tension meter 46
20 47
TRANSMISSION 49
201Transmission schematic diagrams 49
2011DRIVE TRAIN 49
2012Key to diagrams 50
2013FORWARD GEAR Diagram 51
2014REVERSE GEAR Diagram 52
2015HYDROSTATIC TRANSMISSION PRESSURE TEST PORT LOCATION 53
2016TOWING PROCEDURE 54
2017TRANSMISSION TIGHTENING TORQUES 55
202Transmission removal – refit 56
PREPARATION AND SAFETY INSTRUCTIONS 56
2021HYDROSTATIC PUMP REMOVAL 56
2022HYDROSTATIC MOTOR REMOVAL 59
203Specific transmission tooling 61
2031BASIC MANOMETER BOX 61
2032DIGITAL MANOMETER BOX 62
30 63
AXLE 64
301Axle control and adjustment 64
3011Tightening torques 64
40 65
BRAKE 67
401BRAKE CHARACTERISTICS AND SPECIFICATIONS 67
4011SERVICE BRAKE / PARKING BRAKE 67
402Brake controls and adjustment 68
4021BRAKE AND INCHING PEDAL ADJUSTMENT 68
Adjusting procedure: 68
BRAKE AND INCHING PHASES: REST, BRAKING AND ASSOCIATED VALUES FOR TRANSMISSION ECU: 68
4022BLEEDING PROCEDURE 69
LOCATION: 69
Bleed the brake calliper: 69
Bleed the brake master cylinder: 70
403Specific brake tooling 72
4031BRAKE FLUID BLEEDER 72
50 73
BOOM 75
501Boom removal – refit 75
PREPARATION AND SAFETY INSTRUCTIONS 75
5011Telescopic Cylinder Removal 75
5012Telescope removal 77
5013Telescope reassembly 79
5014Complete boom removal 81
70 85
HYDRAULICS 87
701Hydraulic characteristics and specifications 87
7011Hydraulic component sheets 87
DISTRIBUTOR 5000 (INLET ELEMENTS) 87
DISTRIBUTOR 5000 (TILTING ELEMENT) 89
DISTRIBUTOR 5000 (ATTACHMENT ELEMENT) 91
DISTRIBUTOR 5000 (TELESCOPING ELEMENT) 93
DISTRIBUTOR 5000 (LIFTING ELEMENT) 95
CONTROL ACCUMULATOR BLOCK 97
STEERING PUMP/STEERING UNIT OSPC 160 LS 98
3-POSITION STEERING SELECTOR100
FAN CONTROL UNIT + (FAN REVERSE OPTION)101
COUNTERBALANCE VALVE VBSN102
COMPENSATION INSULATION VALVE VIC103
702Hydraulic schematic diagrams104
7021Key104
7022 Diagram105
703Hydraulic component locations106
7031Key106
704Hydraulics removal – refit107
PREPARATION AND SAFETY INSTRUCTIONS107
7041Hydraulic pump removal107
7042Main hydraulic tank removal 107
7043Suction strainer removal109
7044Accumulator block removal110
7045Control unit and distributor assembly removal110
7046Lifting cylinder removal111
7047Compensating cylinder removal113
7048Tilting cylinder removal114
80115
ELECTRICITY118
801Electricity characteristics and specifications118
8011Location of relays and fuses118
8012Electrical network architecture119
8013ECU INPUTS/OUTPUTS120
X13 – DASHBOARD MODULE (BAUSER) – A1120
X291 / X295 / X298 / X299 – TRANSMISSION ECU – A2121
X55 – Main ECU SPU 40-26 (A3) 122
X56 – Main ECU SPU 40-26 (A3) 123
X57 – Main ECU SPU 40-26 (A3) 124
X174 – ENGINE ECU – ECM – A13125
X175- ENGINE ECU – ECM – A13126
8014TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS127
X1 / X2 – STARTER IGNITION SWITCH (S2)127
X6 – Rotating beacon light (E15)127
X11 / 12 – windscreen wiper commutator switch (S28)128
X14 – lighting commutator switch (S26)128
X22-1 / X22-2 – brake fluid level switch (S11)129
X38 – REVERSING BUZZER (B1)129
X39 – HORN (B2)130
X62 – TRANSMISSION SPEED SENSOR (B13)130
x63 – fuel gauge (B34)131
X65 / X66 – WHEEL ALIGNMENT SENSOR (B12 / B24)132
X67 / X68 – JSM (A4)133
X77A / X77B – BMEP (A14)134
X134 – BOOM RETRACTED SWITCH (S34)135
X139 – Inching brake pedal angle sensor (B9)135
X199 – Warm Up ELECTROVALVE (oil heater) (Y23)136
X295 – FORWARD AND REVERSE ELECTROVALVE (y3 / Y4)136
X325 – Air-conditioning thermostat sensor supplied with the thermostat (Y17)137
X385 – VENTILATION CONTROL ELECTROVALVE (Y19)137
X386 – VENTILATION REVERSAL ELECTROVALVE (OPTIONAL) (Y20)138
802WIRING DIAGRAMS139
8021ELECTRICAL DIAGRAM CODIFICATION EXAMPLE 139
8022CABLE IDENTIFICATION ON A WIRING HARNESS 140
8023POSITIONS BY DIAGRAM141
8024ELECTRICAL DIAGRAMS BY FUNCTION144
Diagram 1 – STARTING144
Diagram 2 – Networks (CAN & lin)146
Diagram 3 – Transmission148
Diagram 4 – Hydraulic movements150
Diagram 5 – Sensors152
Diagram 6 – Ventilation and wipers154
Diagram 7 – Options156
Diagram 8 – Lights and signals 158
Diagram 9 – KUBOTA ENGINE sensors160
803Electricity locations161
8031Key161
8032Main Harness 3D163
8033MAIN Harness 2D164
8034Engine 3D harness165
8035Engine 2D harness166
80368 electrovalve hydraulic block 2D harness167
DASHBOARD CALIBRATION MENU168
CALIBRATION MODE: ACTIVATION168
CALIBRATION SELECTION168
LIFT TRUCK SERIAL NUMBER DISPLAY168
RESETTING THE PARTIAL HOUR METER168
INCHING BRAKE PEDAL CALIBRATION169
TELESCOPING SPEED CALIBRATION169
ATTACHMENT FLOW RATE CALIBRATION170
FORCED OPERATION171
MAINTENANCE HOUR METER RESET171
SELECTION OF SPEED UNIT KM/H OR MPH 171
8037Removal – Refit of JSM on BMEP172
804Electrical troubleshooting173
8041Reading of error codes173
DASHBOARD ERROR CODES173
PAD ERROR CODES173
8042DTC DASHBOARD MODULE ECU (BAUSER) – (X13 ECU-A1)174
8043DTC Main ECU (X55 – X56 – X57 – SPU 40-26-A3)174
8044DTC Transmission ECU (X291 / X295 / X298 / X299 – ECU A2)177
8045ENGINE ECU DTC (X174 / X175 – ECM A13)178
805Specific electric tooling179
8051Diagnostic tools179
Version 1179
Version 2181
Engine adaptation kit182
8052Breakout boxes183
85185
DRIVER’S CAB186
851DRIVER’S CAB CONTROL AND ADJUSTMENT186
8511TIGHTENING TORQUES186
CAB SILENT BLOCK186
PREPARATION AND SAFETY INSTRUCTIONS186
852Driver’s cab removal – refit187
8521Removing the cabin187
8522Refitting the cab191
110193
OPTIONS – ATTACHMENTS194
110 AIR CONDITIONING OPTION194
1101Air conditioning characteristics and specifications194
11011Description of air-conditioning operation194
11012Principle of air-conditioning operation195
11013Description of air-conditioning components196
1102Air conditioning controls and adjustments197
11021Safety measures for handling air-conditioning R134a197
11022ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT197
11023Air-conditioning R134a REFRIGERANT FLUID CHARACTERISTICS199
11024Refrigerant fluid load for the air conditioning circuit199
11025Air-conditioning CHARGING METHOD199
11026Air-conditioning OPERATIONAL CHECK200
1103Air-conditioning troubleshooting203
11031Air-conditioning FAULT DIAGNOSTICS203
FAULTY AIR-CONDITIONING203
FAULTY VENTILATION204
FAULTY HEATING204
S.M 11/24
