Mustang All Wheel Loader ML360 ML460 Service Manual (918294)

®

ML360 ML460 All-Wheel-Steer Loaders

SERVICE MANUAL PART #918294 Revision A - 12/08

®

Mustang Manufacturing Company, Inc.

Table of contents

Table of contents

Table of contents Operation 1 Important information about this manual ................................................................. 1-1 Abbreviations/symbols ....................................................................................... 1-2 Brief description ....................................................................................................... 1-2 Hydrostatic drive ................................................................................................ 1-2 Work hydraulics and four-wheel steering .......................................................... 1-2 Cooling system .................................................................................................. 1-2 Machine overview .................................................................................................... 1-3 Serial plates and component numbers .................................................................... 1-4 Serial number .................................................................................................... 1-4 Cab number ....................................................................................................... 1-4 Engine number .................................................................................................. 1-4 Hydraulic pump number .................................................................................... 1-5 Hydraulic motor number .................................................................................... 1-5 Rear axle number .............................................................................................. 1-5 Front axle number ............................................................................................. 1-5 Safety decals ........................................................................................................... 1-6 Fire extinguisher (option) ......................................................................................... 1-8 Cab overview ........................................................................................................... 1-9 Instrument panel, multi-functional lever and switch panel: overview ..................... 1-10 Indicators and warning lights: overview ................................................................ 1-11 Oil and fuel pre-heater (option) .............................................................................. 1-12 Jump-starting the engine ....................................................................................... 1-13 Backup warning system (option) ............................................................................ 1-14 Manual throttle (option) .......................................................................................... 1-14 Low-speed control (option) .................................................................................... 1-15 Towing the machine ............................................................................................... 1-16 Safety instructions for towing ........................................................................... 1-16 Towing preparation .......................................................................................... 1-16 After towing ...................................................................................................... 1-17 Specifications 2 Frame ...................................................................................................................... 2-0 Types and Models: overview ................................................................................... 2-0 Engine ...................................................................................................................... 2-0 Power train ............................................................................................................... 2-1 Variable-displacement pump ............................................................................. 2-1 Boost pump ....................................................................................................... 2-1 Variable-displacement motor ............................................................................. 2-1 Axles ........................................................................................................................ 2-2 Front axle ........................................................................................................... 2-2 Rear axle ........................................................................................................... 2-2 Brakes ...................................................................................................................... 2-2 Steering system ....................................................................................................... 2-3 Work hydraulics ....................................................................................................... 2-3 Pilot control .............................................................................................................. 2-3 Loader unit with bucket — model ML360 ................................................................ 2-4 Loader unit with bucket — model ML460 ................................................................ 2-4 Loader unit with pallet forks — model ML360 .......................................................... 2-5 Loader unit with pallet forks — model ML460 .......................................................... 2-5 Alternator, starter, battery ........................................................................................ 2-5 Fuse box .................................................................................................................. 2-6 Main fuse box — model ML360 ............................................................................... 2-7 Main fuse box — model ML460 ............................................................................... 2-7 Overview of switching relays ................................................................................... 2-8 Printed in U.S.A

I-1

918294/AP1208

Table of contents Tires for wheel loader — model ML360 ................................................................... 2-9 Tires for wheel loader — model ML460 ................................................................... 2-9 Weights .................................................................................................................... 2-9 Noise levels .............................................................................................................. 2-9 Vibration ................................................................................................................. 2-10 Hardware torques .................................................................................................. 2-10 General torques ............................................................................................... 2-10 Specific torques .............................................................................................. 2-10 Dimensions — model ML360 ................................................................................. 2-11 Dimensions — model ML460 ................................................................................. 2-12 Maintenance 3 Introduction .............................................................................................................. 3-0 Important information on maintenance and service work .................................. 3-0 Fluids and lubricants ............................................................................................... 3-1 Index to component maintenance ............................................................................ 3-2 Explanation of symbols on maintenance label ......................................................... 3-3 Maintenance label .................................................................................................... 3-4 Maintenance schedule ............................................................................................. 3-5 Maintenance of the fuel system ............................................................................... 3-8 Specific safety instructions ................................................................................ 3-8 Refueling ............................................................................................................ 3-8 Stationary fuel pumps ........................................................................................ 3-8 Diesel fuel specification ..................................................................................... 3-8 Replacing the fuel filter ............................................................................................ 3-9 Cleaning the fuel pump screen filter ...................................................................... 3-10 Bleeding the fuel system ........................................................................................ 3-10 Checking/adding engine oil .................................................................................... 3-11 Changing engine oil ............................................................................................... 3-12 Changing the engine oil filter cartridge .................................................................. 3-13 Engine and hydraulics cooling system ................................................................... 3-14 Specific safety instructions .............................................................................. 3-14 Cleaning the oil cooler ........................................................................................... 3-14 Hydraulic system .................................................................................................... 3-15 Specific safety instructions .............................................................................. 3-15 Checking hydraulic pressure lines ......................................................................... 3-16 Specific safety instructions .............................................................................. 3-16 Monitoring the hydraulic oil return filter .................................................................. 3-17 Important information for the use of biodegradable oil .................................... 3-17 Hydraulic oil return filter ......................................................................................... 3-18 Changing the filter insert .................................................................................. 3-18 Checking the hydraulic oil level .............................................................................. 3-19 Adding hydraulic oil ................................................................................................ 3-19 Changing the hydraulic oil ...................................................................................... 3-20 Rear axle transfer gearbox oil levels ...................................................................... 3-21 Front and rear axle differential oil levels ................................................................ 3-22 Front and rear axle planetary drive oil levels ......................................................... 3-23 Air filter maintenance ............................................................................................. 3-24 Check: air filter contamination ......................................................................... 3-24 Replacing the air filter cartridge ............................................................................. 3-25 V-belt ...................................................................................................................... 3-26 Checking V-belt tension ................................................................................... 3-26 Tensioning the V-belt ....................................................................................... 3-26 Lubrication points ................................................................................................... 3-27 Lubricating the rear axle oscillation-type bearing ............................................ 3-27 Lubricating the front and rear axle planetary drive bearings ............................ 3-27 Lubricating the loader unit ...................................................................................... 3-28 918294/AP1208

I-2

Printed in U.S.A

Table of contents Attachment maintenance ....................................................................................... 3-28 Brake system ......................................................................................................... 3-29 Specific safety instructions .............................................................................. 3-29 Checking/adding brake fluid ............................................................................ 3-29 Repair work on the brake system .................................................................... 3-29 Tire care ................................................................................................................. 3-30 Daily tire check ................................................................................................ 3-30 Weekly check .................................................................................................. 3-30 Changing wheels ................................................................................................... 3-31 Heating .................................................................................................................. 3-32 Cleaning the dust filter of the heating system .................................................. 3-32 Electric system ....................................................................................................... 3-33 Safety instructions ........................................................................................... 3-33 Service and maintenance work at regular intervals ......................................... 3-34 Cables, bulbs and fuses .................................................................................. 3-34 Alternator ......................................................................................................... 3-34 Battery maintenance .............................................................................................. 3-35 General maintenance work .................................................................................... 3-36 Cleaning .......................................................................................................... 3-36 When using washing solvents ......................................................................... 3-36 When using compressed air ............................................................................ 3-36 When using a high-pressure or steam jet cleaner ........................................... 3-36 When using volatile and flammable anti-corrosion agents and sprays ............ 3-36 Cleaning inside the cab ......................................................................................... 3-37 Cleaning the seat belt ............................................................................................ 3-37 Machine exterior .................................................................................................... 3-37 Engine compartment .............................................................................................. 3-38 Bolted connections, hinges .................................................................................... 3-38 Engine 4 F4M 2011/BF4M 2011 engine: overview ................................................................. 4-0 Engine oil cooling ..................................................................................................... 4-1 Fuel system ............................................................................................................. 4-2 Checking and adjusting valve clearance ................................................................. 4-3 Replacing the fuel injection pump ............................................................................ 4-4 Setting the charge-air pressure — model ML460 .................................................... 4-9 Charge-pressure dependent full-load stop — model ML460 ................................. 4-10 Turning off minus compensation ............................................................................ 4-10 Minus compensation — function ..................................................................... 4-10 Switching off minus compensation — model ML360 ............................................. 4-11 Heating connection ................................................................................................ 4-11 Removing/mounting the cylinder head .................................................................. 4-12 Sealing the bleeder valve ...................................................................................... 4-16 Intake/exhaust manifold ................................................................................... 4-16 Engine trouble ....................................................................................................... 4-17 Power train 5 Variable-displacement pump test ports — model ML360 ........................................ 5-0 Variable-displacement pump — model ML360 ........................................................ 5-1 Variable-displacement pump test ports, 12 mph (20 kph) — model ML460 ............ 5-2 Variable-displacement pump, 12 mph (20 kph) — model ML460 ............................ 5-3 Variable-displacement motor, 12 mph (20 kph) — all models ................................. 5-4 ................................................................................................................................. 5-4 Variable-displacement pump test po ....................................................................... 5-4 Inching valve overview ............................................................................................. 5-5 Inching valve circuit, 12 mph (20 kph) ..................................................................... 5-6 Drive circuit, 12 mph (20 kph) — model ML360 ...................................................... 5-7 Drive, 12 mph (20 kph): wiring diagram ................................................................... 5-8 Printed in U.S.A

I-3

918294/AP1208

Table of contents Towing and transporting the machine ...................................................................... 5-9 Transporting ....................................................................................................... 5-9 Towing ............................................................................................................... 5-9 Test report — model ML360 .................................................................................. 5-10 Test report — model ML460 .................................................................................. 5-11 Power train adjustment .......................................................................................... 5-12 Tools required .................................................................................................. 5-12 Adjusting boost pressure ....................................................................................... 5-12 Adjusting starting speed ......................................................................................... 5-12 Setting high pressure/drive pressure ..................................................................... 5-13 Setting the secondary valves for forward/reverse driving ...................................... 5-14 Setting the pump hydraulic resistance (characteristic curve) ................................. 5-14 Setting engine droop .............................................................................................. 5-15 Setting control initiation on the hydraulic motor ..................................................... 5-15 Setting the wheel speed ......................................................................................... 5-16 Tools required .................................................................................................. 5-16 Axles 6 Axle overview ........................................................................................................... 6-0 Sealing service (joint housing/axle carrier) .............................................................. 6-1 Bevel gear shaft seals ............................................................................................ 6-12 Differential cage/differential lock screw connections ............................................. 6-13 Overview of differential lock and differential cage .................................................. 6-14 Removing the differential cage with the differential lock ........................................ 6-15 Removing the differential lock ................................................................................ 6-16 Assembling the differential lock ............................................................................. 6-17 Removing the gearbox ........................................................................................... 6-18 Input shaft version 1 sealing: overview .................................................................. 6-24 Assembling the gearbox ........................................................................................ 6-25 Brakes 7 Brake circuit ............................................................................................................. 7-0 Brake diagram .......................................................................................................... 7-1 Handbrake circuit ..................................................................................................... 7-2 Inching valve circuit, 12 mph (20 kph) ..................................................................... 7-3 Service brake ........................................................................................................... 7-4 Brake caliper maintenance ................................................................................ 7-4 Steering 8 Steering circuit for model ML360 ............................................................................. 8-0 Steering diagram for model ML360 .......................................................................... 8-1 Steering circuit for model ML460 ............................................................................. 8-2 Steering diagram for model ML460 .......................................................................... 8-3 Steering system adjustment ..................................................................................... 8-4 Function ............................................................................................................. 8-4 Checking a steering cylinder .............................................................................. 8-4 Checking the check block .................................................................................. 8-4 Hydraulic ports on servostat .................................................................................... 8-5 Pressure relief valve: adjustment ............................................................................. 8-5 Steering cylinder: seals ............................................................................................ 8-6 Overview of steering cylinder adjustment ................................................................ 8-7 Necessary tools ................................................................................................. 8-7 How to adjust the steering cylinders ........................................................................ 8-8 Checking the track setting ........................................................................................ 8-9 Correcting the track setting ...................................................................................... 8-9 Setting the steering limit ......................................................................................... 8-10 Checking steering synchronization ........................................................................ 8-11 Checking the bypass ....................................................................................... 8-11 Bleeding the steering cylinders ........................................................................ 8-12 918294/AP1208

I-4

Printed in U.S.A

Table of contents Setting steering synchronization ............................................................................ 8-13 Final check/test run ......................................................................................... 8-13 Hydraulic system 9 Test report for model ML360 ................................................................................... 9-0 Test report for model ML460 ................................................................................... 9-1 Work hydraulics oil supply ....................................................................................... 9-2 Control valve ports ................................................................................................... 9-3 Priority valve ports ................................................................................................... 9-3 Priority valve diagram .............................................................................................. 9-4 Load stabilizer ports ................................................................................................. 9-4 Load stabilizer circuit ............................................................................................... 9-5 Load stabilizer diagram ............................................................................................ 9-5 Lift cylinder: seals .................................................................................................... 9-6 Tilt cylinder: seals .................................................................................................... 9-7 Control cylinder (quick-hitch frame): seals ............................................................... 9-8 Work hydraulics diagram ....................................................................................... 9-10 Electrical system 10 Ohm’s Law ............................................................................................................. 10-0 Measuring equipment and methods ...................................................................... 10-0 Terminal description .............................................................................................. 10-2 Cable color coding ................................................................................................. 10-6 Other color codes ............................................................................................ 10-8 Relays .................................................................................................................... 10-8 Use, mode of function ...................................................................................... 10-8 Terminal description on relay ......................................................................... 10-8 Starter, battery, alternator ..................................................................................... 10-9 Fuse box ................................................................................................................ 10-9 Main fuse box with relays for model ML360 ........................................................ 10-10 Main fuse box with relays for model ML460 ........................................................ 10-10 Switching relays ................................................................................................... 10-11 Description of blocking diodes ............................................................................. 10-12 Blocking diodes V8, V9 .................................................................................. 10-12 Blocking diode V10 ........................................................................................ 10-12 Blocking diode V11 ........................................................................................ 10-12 Blocking diodes V16, V17 .............................................................................. 10-12 Blocking diodes V20, V21 .............................................................................. 10-12 Overview of switch assignment ........................................................................... 10-13 Installing a rotating beacon .................................................................................. 10-14 Installing the backup warning system .................................................................. 10-14 Installing two front work lights .............................................................................. 10-15 Installing two front work lights and one rear work light ........................................ 10-15 Electric diagram (sheet 1) for model ML360 ........................................................ 10-17 Electric diagram (sheet 2) for model ML360 ........................................................ 10-18 Legend: electric diagram for model ML460 ......................................................... 10-19 Electric diagram (sheet 1) for model ML460 ........................................................ 10-20 Electric diagram (sheet 2) for model ML460 ........................................................ 10-21

Printed in U.S.A

I-5

918294/AP1208

Table of contents

918294/AP1208

I-6

Printed in U.S.A

Operation

1

Operation

1.1

Important information about this manual Your decision to purchase Mustang equipment was a good one. We are sure that your decision was carefully considered and that you are looking forward to many years of reliable performance from this machine.

Mustang Manufacturing has invested much time and effort in developing its lines of equipment. The equipment you have purchased is built with a great deal of pride, and designed to provide long life, efficient operation, durability, and dependability.

Modern machinery has become more sophisticated and, with that in mind, Mustang Manufacturing asks that you read and COMPLETELY understand the contents of this manual and become familiar with your new machine, BEFORE attempting to service it.

This manual was developed specifically for the machine you have purchased. The information within is for your assistance in preparing, adjusting, maintaining, and servicing your machine. More importantly, this manual provides a service plan for safe and proper use of your machine. Refer to the Table of Contents for an outline (by chapters) of this manual.

Use the Index, located at the back of this manual, for specific chapter and topic/page number references.

If this machine is re-sold, Mustang Manufacturing recommends that this manual be given to the new owner.

If this machine was purchased “used,” or if the owner’s address has changed, please provide your Mustang dealer or Mustang Manufacturing Company with the owner’s name and current address, along with the machine model and serial number. This will allow the registered owner’s information to be updated, so that the owner can be notified directly in case of an important product issue, such as a safety update program.

“Right” and “left” are determined from the position of sitting in the operator’s seat, facing forward.

Mustang Manufacturing reserves the right to make changes or improvements in the design or construction of any part without incurring the obligation to install such changes on any unit previously delivered.

Throughout this manual, information is provided that is introduced by the word “NOTE” or “IMPORTANT.” Be sure to read carefully and comply with the message or directive given.

Following this information will improve your maintenance efficiency, help you to avoid costly breakdowns or unnecessary damage, and extend your machine’s life.

Operational safety and readiness of the machine depend partially on maintenance and service of the machine. This is why regular maintenance and service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by a qualified technician with appropriate training. Insist on using Mustang original service parts when carrying out maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value.

Our wide dealership network stands ready to provide any assistance required, including genuine Mustang service parts. All parts should be obtained from or ordered through your Mustang dealer. Give complete information about the part as well as the model number and serial number of your machine. Record numbers, in the spaces provided, as a handy record for quick reference.

Purchased from: ___________________________________ Date of Purchase: __________________________________ Model No.: _______________________________________ Serial No.: ________________________________________

Printed in U.S.A.

1-1

918294/AP1208

Operation

Abbreviations/symbols

• This symbol stands for a list.

• Subdivision within lists or an activity. Follow the steps in the recommended sequence.

☞ This symbol requires you to perform the activity described. ➥ This symbol marks the passages in the text describing the effects or results of an activity.

n. s. = not shown.

“Option” = optional equipment. Stated whenever controls or other components of the machine are installed as an option.

This symbol shows the driving direction for better orientation in figures and graphics.

1.2

Brief description Get informed on and follow the legal regulations of your country.

The machine is a versatile and powerful helper for moving earth, gravel, and debris on construction sites and elsewhere. A wide range of attachments allows for numerous applications: fork lift, snow plow, spreader, sweeper, etc.

The main features are: • ROPS/FOPS tested closed cab • Oil-cooled Deutz four-cylinder in-line engine, exhaust emissions according to EC standard 97/68 EC • Sturdy steel sheet frame; rubber-mounted engine • Automotive drive, infinitely variable hydrostatic axial-piston gearbox; maximum speed 12 mph (20 kph).

• Hydraulic four-wheel power steering with emergency steering features • Front and rear planetary steering axles, rear axle with oscillation • Service brake (mechanical and hydrostatic), mechanical disk-type handbrake

Hydrostatic drive

The diesel engine drives a hydraulic pump (variable-displacement pump), which sends oil to a hydraulic motor flanged on the gearbox. The force of the hydraulic motor is transmitted to the rear axle through the transfer gearbox. At the same time, the front axle is driven by the drive shaft, ensuring permanent four-wheel drive.

Work hydraulics and four-wheel steering

The diesel engine also drives a gear pump for work hydraulics and hydrostatic four-wheel steering. The oil flow of the gear pump depends on the diesel engine speed.

When the machine is in operation, the entire diesel engine output can be transmitted to the gear pump for work hydraulics and steering. Flow is diverted from the drive wheels when the service brake is used, making engine output fully available for work hydraulics by pressing the accelerator pedal and the brake pedal at the same time.

Cooling system

A combined engine/hydraulic oil cooler (for the diesel engine and the hydraulic oil) is located at the rear of the machine.

The indicator lights on the instrument panel of the machine provide engine and hydraulic oil temperature monitoring.

918294/AP1208

1-2

Printed in U.S.A.

Operation 1.3

Machine overview 3

4

5

3

6 7

1 2

15

14

8 20 9 10 11

19

18

17

16

12

13 14

15

1

Tilt cylinder

12 Door handle

2

Service access (fuses, relays, recirculated air filter)

13 Headlight with turn indicator

3

Rearview mirror

14 Position lights (white)

4

Handle

15 Position lights (red)

5

Rear work light

16 Cab access

6

Eye hook (for cab removal)

17 Wheel chock

7

Brake, rear and turn indicator lights

18 Loader unit

8

Door arrester

19 Front eye hook for tying down the machine

9

Towing apparatus

20 Lift cylinder

10 Reflectors 11 Fig. 1:

Rear eye hook for tying down the machine

Machine overview

Printed in U.S.A.

1-3

918294/AP1208

Operation 1.4

Serial plates and component numbers

Serial number The serial number is stamped on the cab support A (on the right as seen in driving direct, behind the cab door lining). It is also located on the serial plate.

A

The serial plate is located on the machine frame on the right, next to the loader unit bulkhead (on the right above the front axle).

Made in Germany

00 435 12 21

Example:

Fhzg-Typ Model ModŁle Typ / Ausf.

Version Version Fg.-Nr. Serial no.

No. de sØrie Baujahr Model year AnnØe fabr.

Zul. Achslast vorn Front GAWR [ kg ] PNBE AV Zul. Achslast hinten Rear GAWR [ kg ] PNBE AR Zul. Ges. Gew. GWR [ kg ] PTAC Leistung Output [ kW ] Performance 30300b0010.e

Fig. 2:

Model

ML360

ML460

Machine:

346

347

Version:

346 00

347 04

Serial no.:

346 01 0001

347 01 0023

Model year:

2008

2008

Front gross axle weight rating: 7,937 lbs. (3600 kg)

9,921 lbs. (4500 kg)

Rear gross axle weight rating: 8,818 lbs. (4000 kg)

9,921 lbs. (4500 kg)

Gross weight rating:

12,125 lbs. (5500 kg)

15,432 lbs. (7000 kg)

Output:

60 hp (44 kW)

78 hp (58 kW)

Serial plate

Cab number The cab number decal (arrow) is located in the cab at the top right frame member.

Fig. 3:

Cab number decal location

Engine number The engine number serial plate (arrow) is located on the cylinder-head cover (engine).

Example:

Fig. 4:

Deutz DZ011 L04 W

Diesel engine number

918294/AP1208

1-4

Printed in U.S.A.

Operation Hydraulic pump number The hydraulic pump serial plate (arrow) is located on the hydraulic pump housing (next to where the pump is attached to the diesel engine).

Fig. 5:

Hydraulic pump serial plate

Hydraulic motor number The hydrauilc motor serial plate (arrow) is located above the cardan shaft on the right of the hydraulic motor.

Fig. 6:

Hydraulic motor serial plate

Rear axle number The rear axle serial plate (arrow) is located on the upper side of the differential housing at the rear.

Fig. 7:

Rear axle and gearbox serial plate

Front axle number The front axle serial plate (arrow) is located on the inside of the axle tube, on the right side.

Fig. 8:

Front axle serial plate

Printed in U.S.A.

1-5

918294/AP1208

Operation 1.5

Safety decals The following section explains signs and symbols that may not be easily understood.

Warning!

Safety decals must be replaced if they become unreadable.

Meaning

Warning!

Do not use the eye hooks on the cab to crane-lift the machine.

Location Fig. 9:

Eye hook decal

Cab roof (4x).

Meaning Points for tying down the machine.

The eye hooks are used for tying down the machine during loading and transport.

Location On the left and right of the machine frame above the front axle attachment, and at the rear underneath the engine.

Fig. 10: Machine tie down point decal

Meaning Sound levels produced by the machine.

LWA = sound power level.

For additional information, see Section "Noise levels" on page 2-9.

XX

Location Rear window.

Fig. 11: Sound levels decal

Meaning General indication of danger.

This decal warns persons standing or working near the machine of existing hazards within the area of increased danger around the machine.

Location Gefahr2.ai

Front left and right of machine frame and at rear of machine.

Fig. 12: Danger decal

Meaning DO NOT open engine cover before engine is at a standstill.

DO NOT touch any moving or turning parts.

Location On the engine cover of the machine.

Fig. 13: Prohibitory decal

918294/AP1208

1-6

Printed in U.S.A.

Operation Load diagram for pallet forks and tire pressure table Indicates the maximum authorized load on the fork arms. The maximum load varies according to the distance from the load center.

Tire pressure table List of authorized types of tires with prescribed tire inflation pressures.

For additional information, see Tires for wheel loader — model AWS36 and “Tires for wheel loader — model AWS46” on page 2-9.

Location Inside the cab on left window.

Warning!

The load diagram is valid only for applications with certified pallet forks.

• Observe the specific load diagrams for other attachments.

Fig. 14: Load diagram label

Brake fluid label Use only LHM brake fluids. ➥ Section "Brake system" on page 3-29.

➥ Section "Fluids and lubricants" on page 3-1.

Location On the brake fluid tank.

Fig. 15: Brake fluid label

A

B

C

Label: control lever (joystick) operation label A = driving direction: (F) forward/(R) reverse and (N) neutral position B = control lever (joystick) unlocked/locked

D

C = control lever (3rd control circuit for attachments) unlocked/locked E

D = loader unit operation: raise, lower, dump in/out E = 3rd control circuit operation: pick up/set down attachment F = loader unit operation: raise, lower with float position, dump in/out Location On the lower right on the side window.

F

Fig. 16: Control lever operation (overview) label

Printed in U.S.A.

1-7

918294/AP1208

Operation Label: avoiding danger Label for avoiding danger of serious/fatal injuries.

Danger!

Read and understand the Operator’s Manual before using the machine.

Location Inside the cab on the right pillar.

Fig. 17: Avoiding danger label

Fasten seat belt Always fasten the seat belt before using the machine — risk of injury.

Buckle up before moving or working with the machine.

Location Inside the cab on the right pillar.

Fig. 18: Seat belt label

1.6

Fire extinguisher (option) The fire extinguisher is not included as standard equipment (option).

Location On the rear wall to the left of the seat.

Fig. 19: Fire extinguisher

918294/AP1208

1-8

Printed in U.S.A.

Operation 4

33

1

2

Operation

Cab overview

3

Pos.

4

1 2

Description Roof console Sun visor Interior light

Cab 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

5 6 32 7 31 8 30 9 29

I 0

10 28

11

10

12

27

13

26 25

14

24

15

23

16

22

17

21

Cab overview

18

19

Wiper motor (front) Air vent — leg room Accelerator pedal Instrument panel Lock — side window Control lever (joystick) Control lever — 3rd control circuit Window Retainer — left-hand side cab door/right-hand side window Switch panel — speed range Lever — horizontal seat adjustment Parking brake lever Switch panel Fuse box Instrument panel Prepared installation for radio (option) Wiper motor (rear) Bracket — left-hand side/right-hand side window Storage pocket for operation manual Lever — backrest adjustment — seat Seat Storage compartment Fixture — first-aid kit Seat belt Lever — weight adjustment Steering wheel Multi-functional lever Outer door handle Service brake pedal (hydrostatic)/inching Tank — washer system Brake fluid tank Front window defroster vents

19 20

Printed in U.S.A

1-9

918294/AP1208

Operation 37

38

39

40

41

Instrument panel, multi-functional lever and switch panel: overview Pos.

36

42

35

Instrument panel 34 35 36 37 38 39 40 41 42 43 44 45

43

1

71

34 49

44 46

47

50

48

45

70 46 47 48

I 0

49 50 51 52 53 54 55 56 57 58 59 60 61

52

53

59 60

62

61

62 63 64 65 66 67 68 69 70 71

15 54 63

64

65

66

67

55 56 57

68 918294/AP1208

Warning lighit (yellow) – hose burst valve (option) Warning lighit (green) – right/left turn indicator for rear implements Warning lighit (green) – right/left turn indicator Warning lighit (red) – hydraulic oil filter Warning lighit (red) – hydraulic oil temperature Warning lighit (red) – alternator charge function Warning lighit (red) – parking brake Warning lighit (red) – engine oil pressure Temperature indicator – engine coolant Warning lighit (blue) – high beam Fuel level indicator Hourmeter

Multi-functional lever 51

58

Description

Horn button Rotary switch – front/rear washer system Rotary switch – front wiper

Switches and control lever (side console) Differential lock warning light (model ML460) Control lever with lock – loader unit Control lever with lock – 3rd control circuit Switch – speed range selection Not assigned Preheating start switch (engine start) Hazard warning switch Socket/cigarette lighter Rotary switch – heating (warm/cold) Warning lighit (green) – forwards driving direction Switch – driving direction selection Warning lighit (green) – reverse driving direction Switch – neutral speed range Differential lock switch (model ML460) Lights switch Not assigned Not assigned Heater fan switch switch – rear working light (option) Switch – working light Switch – rotating beacon (option) Differential lock indicator Warning lighit (red) – coolant level

69 1-10

Printed in U.S.A

1.7

Indicators and warning lights: overview

34

34 Indicator (yellow) — hose burst valve (option) Indicates that the hose burst valve is switched on. This avoids lowering or dumping out the loader unit without any resistance.

35

35 Indicator (green) — right/left turn indicator on rear attachments Flashes repeatedly: • When the turn indicators are used.

• If there is an electrical connection to a rear implement.

36

36 Indicator (green) — right/left turn indicator Flashes repeatedly when the turn indicators are used.

37 Indicator (red) — hydraulic oil filter

37

Indicates that the pressure in the hydraulic return line to the tank is too high. In this case:

☞ Have the hydraulic oil filter checked and, if necessary, replaced by an authorized dealer.

38 Indicator (red) — hydraulic oil temperature

38

Comes on if the hydraulic oil temperature exceeds 203°F (95°C).

Risk of hydraulic damage as soon as temperature indicator 38 comes on.

☞ Relieve work and driving hydraulics. To do this: • Stop the machine.

• Move control lever 51 to neutral. (➠See Section "Instrument panel, multi-functional lever and drive lever: overview" on page 1-10.)

• Select neutral by using tip switch 62. (➠See Section "Instrument panel, multi-functional lever and drive lever: overview" on page 1-10.)

• Run the engine at increased speeds until temperature indicator 38 goes out.

39

39 Indicator (red) — alternator charge function Comes on after the ignition is switched on and goes out after the engine runs.

Comes on while the engine is running if: • The V-belt or charging circuit for the alternator is faulty. (➠ See Section "Checking V-belt tension" on page 3-26).

• The battery is discharged (➠ See Section "Battery maintenance" on page 3-35).

40

P

Printed in U.S.A.

40 Indicator (red) — parking brake Comes on when parking brake lever 13 is applied.

1-11

918294/AP1208

41 Indicator (red) — engine oil pressure

41

Comes on if the engine oil pressure is too low. If the oil pressure is too low:

☞ Stop the machine. ☞ Turn off the engine immediately and check the oil level (➠ see Section "Checking/ adding engine oil" on page 3-11).

Comes on after the ignition is turned on and goes out after the engine is running.

42 Temperature indicator — engine coolant

42

Comes on if the engine temperature is too high.

43 Indicator (blue) — high beam

43

Comes on if high beam is turned on or during headlight flashing.

44 Indicator — Fuel Level

44

Indicates current level of fuel in the fuel tank.

71 Indicator (Green) — differential lock

71

1.8

Indicates that the differential lock is switched on.

Oil and fuel pre-heater (option) This equipment is for cold starting at temperatures below 23°F (–5°C).

Oil pre-heater (option)

A

B

The engine and hydraulic oil is heated by means of heating elements (750 W) in the engine oil pan and in the hydraulic oil tank. Employing the gravity principle, warm oil rises and is replaced by cold oil. The oil can only be thoroughly warmed up to service temperature if the oil pre-heater is connected over a long enough period of time — preferably overnight.

☞ Connect the oil pre-heater as follows: • Park the machine near a 110 V socket.

Fig. 20: Oil pre-heater

• Connect extension cord.

• Insert the plug into the 110 V socket.

☞ Before starting the engine: • Remove the plug from the 110 V socket.

• Unplug extension cord.

• Close the engine cover.

Fuel pre-heater (option) The fuel pre-heater prevents paraffin crystals from forming, which clog the fuel filter at low temperatures.

A temperature switch automatically switches on a heating element in the fuel line between the tank and the fuel pre-filter when ignition is switched on at temperatures below 50°F (10°C).

918294/AP1208

1-12

Printed in U.S.A.

1.9

Jump-starting the engine Safety instructions

Danger!

Never jump-start the engine if the discharged battery is frozen, because there is a risk of explosion. Replace the battery. The machines must not touch when jump-starting, because when both machines are connected by jump leads, there is a risk of sparking.

• The external power source must deliver 12 volts. Supply voltages higher than 12 V will damage the electrical systems of both machines.

• Only use authorized jumper cables that are in good condition.

Important!

The jumper cable connected to the positive (+) terminal of the starting battery must never touch electrically conductive machine parts, because there is a risk of short circuit.

• Route the jumper cables so that they cannot catch on rotating components in the engine.

Procedure

☞ Start the engine of the jump-starting machine. ☞ Connect one end of the red positive (+) jumper cable to the positive (+) terminal of the

dead battery, then connect the other end to the positive (+) terminal of the starting battery.

Dead battery

12 V

☞ Connect one end of the black negative (–) jumper cable to the negative (–) terminal of the starting battery.

☞ Clip the other end of the black negative (–) jumper cable onto the engine block.

Danger!

DO NOT connect the other end of the jump lead to the negative terminal of the dead battery, because gas emerging from the battery may ignite if sparks are formed.

12 V Starting battery

☞ Start the engine of the machine with the dead battery.

After the engine has started:

☞ While the engine is running, disconnect both jumper cables in exactly the reverse order Fig. 21: Starting aid with jumper cables 34001b710_05.eps

Printed in U.S.A.

(first the negative (–) terminal, then the positive (+) terminal to avoid sparking near the battery.

1-13

918294/AP1208

1.10 Backup warning system (option) The backup warning system consists of backup alarm A, a switch and wiring. The backup alarm generates an acoustic signal when the machine is shifted into reverse. The acoustic level is about 103 dB(A) at a distance of 3 ft (1 m) and at a frequency of 2800 Hz.

A

Warning!

When backing up with the machine –

Accident risk! ☞ Make sure nobody is within the work area of the machine. ☞ Do not rely exclusively on the backup alarm to alert others.

Fig. 22: Backup warning system

1.11 Manual throttle (option) The optional manual throttle is located on the right of the side console.

B

Danger!

A

Do not use the manual throttle lever C when driving on public roads –

Accident risk! ☞ Use the manual throttle C during work operation only. ☞ Before driving on public roads:

C

• Move the manual throttle lever C to the idle speed position A.

Fig. 23: Manual throttle (option)

• Control engine speed only with the accelerator pedal.

Function Engine speed control for work operation.

Position

Engine revs

A

Idle = minimum speed

B

Full throttle = maximum speed

Important!

This feature is especially useful for operating hydraulic attachments powered by the 3rd control circuit. Drive speed is then controlled with the brake/inching pedal or with the low-speed control (option).

918294/AP1208

1-14

Printed in U.S.A.

1.12 Low-speed control (option) The optional control lever is located on the right side of the console.

Function Drive speed can be set more precisely, independent from engine speed, using control lever D. This feature corresponds to inching with the brake/inching pedal.

Maximum drive speed depends on the speed range selected.

A

B

D

☞ Select the driving direction. ☞ Select a speed range. ☞ Set constant engine speed with the accelerator pedal or the manual throttle (option). ☞ Select the required drive speed. ➥ Move control lever D toward A. ☞ Stop the machine. ➥ Move control lever D to limit B. Position

Fig. 24: Low-speed control (option)

Printed in U.S.A.

Drive speed

A

Maximum drive speed

B

Machine at a standstill

1-15

918294/AP1208

1.13 Towing the machine Safety instructions for towing If the engine and/or the hydraulic drive stop functioning, the machine can be towed under the following conditions: • Tow the machine with a tow bar only. The brake and steering systems hydraulic assists are not activated if the engine and/or the hydraulic systems are not functioning.

• Make sure nobody is dangerously close to the tow bar.

• The machine may only be towed using suitable tow equipment (towing bar) in connection with suitable towing apparatus, such as a tow coupling, hooks, and eyes.

• Tow the machine slowly and cautiously.

Danger!

Be careful when towing the machine –

Accident risk! ☞ The towing vehicle must have enough tractive power to pull the machine and be fitted with a safe brake system.

☞ Only tow with a tow bar. ➥ See Section "Weights" on page 2-9, Section "Dimensions — model

AWS36" on page 2-11 and Section "Dimensions — model AWS46" on page 2-12 for the machine’s dimensions and weights.

☞ Eye hooks for towing the machine. See Section "Machine overview" on page 1-3.

☞ If possible, run the engine at idling speed when towing the machine. ➥ Turning the steering wheel requires greater effort if the diesel engine and/or the hydraulic system are not functioning.

☞ Tow the machine from the area only after you have opened the HP pressure relief valves on the variable-displacement pump.

➥ Tow the machine only at walking speed and only over short distances.

Towing preparation C

Disabling the variable-displacement drive pump

B

Important!

A

The hydrostatic power train can be damaged when towing the machine.

☞ Tow the machine only after opening the HP pressure relief valves. ☞ Tow the machine only at walking speed and only over short distances. .

A

B C

Fig. 25: Hydraulic pump

☞ Stop the engine. ☞ Turn off the ignition and remove the ignition key.

Variable-displacement 12 mph (20 kph) drive pump ☞ Switch over the HP pressure relief valves A on the variable-displacement pump. To do this: • Loosen locknuts B on both HP valves A. • Tighten screws C on both HP valves A until they are flush with locknuts B. • Secure screws C on both HP valves A by tightening locknuts B.

918294/AP1208

1-16

Printed in U.S.A.

After towing C

Enabling the variable-displacement 12 mph (20 kph) drive pump ☞ Switch over the HP pressure relief valves A on the variable-displacement pump. To do this:

B

A

• Loosen locknuts B on both HP valves A. • Loosen screws C on both HP valves A as far as they will go and secure them with locknuts B. A

B C

Fig. 27: Hydraulic pump

Printed in U.S.A.

1-17

918294/AP1208

918294/AP1208

1-18

Printed in U.S.A.

Specifications

2

Specifications

2.1

Frame Sturdy steel sheet frame, rubber-mounted engine

2.2

Types and Models: overview Type 346-02 347-02

2.3

Model ML360 ML460

Engine Wheel loader model

ML360

Engine

Deutz diesel engine

Model

F4M 2011

Design

BF4M 2011 In-line

No. of cylinders

4

Displacement

189.7 in.³ (3109 cm³)

Bore and stroke

3.7 in. x 4.4 in. (94 x 112 mm)

Compression ratio

1:19

Output (as per ISO 9249) Max. torque Specific minimum fuel consumption Fuel injection system Firing order

1:17.5

59 hp/44 kW 76 hp/56 kW at 2400 rpm at 2300 rpm 143.8 lb.-ft. (195 Nm) at 199.1 lb.-ft. (270 Nm) at 1700 rpm 1600 rpm 7.8 oz/kWh 7.4 oz/kWh (222 g/kWh) (210 g/kWh) Direct fuel injection 1-3-4-2

Starting aid

Glow plug

Max. inclined position (engine no longer supplied with oil) Oil pressure

Max. lateral left/right inclination: 30 and 57% Max. uphill/downhill inclination: 30 and 57% Observe the tilting limit of the machine!

45.5–65.2 psi (3.0–4.5 bar) at 2300 rpm

Valve tip clearance (engine at cold temperature)

Printed in U.S.A.

ML460

2-0

Intake valve 0.01 in. (0.3 mm) Exhaust valve 0.02 in. (0.5 mm)

918294/AP1208

Specifications 2.4

Power train

Variable-displacement pump Wheel loader model Design

ML360 ML460 Automotive, infinitely-variable hydrostatic axial-piston gearbox

Displacement 20 kph

0–2.7 in.³/rev (0–45 cm³/rev)

0–3.4 in.³/rev (0–56 cm³/rev)

Max. operating pressure

4931 psi (340 bar)

6962 (480 bar)

1250–1300 rpm at 725 psi (50 bar)

1150–1250 rpm at 725 psi (50 bar)

2250±150 rpm at 3626 psi (250 bar)

2150+150 rpm at 3626 psi (250 bar)

Starting revs Droop Boost pump Design

Internal gear pump

Displacement 20 kph

0.70 in.³/rev (11.6 cm³/rev)

Charging/boost pressure

435 psi (30 bar) at 1500 rpm Speed-sensitive, hydraulic displacement adjustment with pressure cutoff

Control Driving direction

Electro-hydraulic control

Inching

Inching valve

Variable-displacement motor Wheel loader model Design Capacity 20 kph

1.25–4.92 in.³/rev (20.6–80.7 cm³/rev)

Tractive effort

918294/AP1208

1.79–6.52 in.³/rev (29.4–107 cm³/rev)

1st speed range: 0–3.7 mph (0–6 kph), forward and reverse 2nd speed range: 0–12.5 mph (0–20 kph), forward and reverse 9217 lbf (41.0 kN1)/ 7756 lbf (34.5 kN) 10,341 lbf (46.0 kN)2

Drive speed 20 kph

1 2

ML360 ML460 Automotive, infinitely-variable hydrostatic axial-piston gearbox

With 16/70-20 tires With 405/70-24 tires

2-1

Printed in U.S.A.

Specifications 2.5

Axles

Front axle Wheel loader model Design Differential lock

ML360 ML460 Planetary steering and drive axle, rigid connection with frame Self-locking differential 45%

King-pin inclination

0°

Camber

0°

Steering angle

40°

Toe-in

0 in./0 mm 55.1 in. (1400 mm)1

Tread width 1 2

100% differential

60.2 in. (1530 mm)2

With 12.5-20 tires With 405/70-24 tires

Rear axle Wheel loader model Design

ML360

Oscillating planetary steering and drive axle

Differential lock

Self-locking differential 45% 0°

Camber

0°

Total oscillation angle

+/- 11°

Steering angle

40° 0 in./0 mm 55.1 in. (1400 mm)1

Tread width

2.6

No

King-pin inclination

Toe-in 1 2

ML460

60.2 in. (1530 mm)2

With 12.5-20 tires With 405/70-24 tires

Brakes Service brake Design

Foot-operated hydraulic disc brake

Location

Front axle input

Effect

On both axles via cardan shaft

Brake fluid

Section "Fluids and lubricants" on page 3-1

Handbrake

Printed in U.S.A.

Design

Manual mechanical disc brake

Location

Front axle input

2-2

918294/AP1208

Specifications 2.7

Steering system Wheel loader model Design

ML360 ML460 Hydrostatic 4-wheel steering with emergency steering feature

Steering mode

4-wheel steering

Assemblies

Hydraulic pump, steering unit with priority valve, steering cylinders with automatic synchronization in left and right final positions

Max. pressure of hydraulic lines Hydraulic pump (gear pump)

2538–2611 psi (175–180 bar) Displacement 1.95 in.³/rev (32 cm³/rev)

Maximum steering angle

2.8

±40°

Work hydraulics Wheel loader model

ML360

ML460

Hydraulic pump

Gear pump 1.95 in.³/rev (32 cm³/rev) 19.5 gpm (74 L/min) at 2300 rpm

Displacement Control valve

2.31 in.³/rev (38 cm³/rev) 21.1 gpm (84 L/min) at 2300 rpm

3 sections (control circuits)

Max. service pressure

3046 psi (210 bar)

3626 psi (250 bar)

Secondary protection tilt cylinder Rod side Base side

3481 psi (240 bar) 1740 psi (100 bar)

4061 psi (280 bar) 1740 psi (120 bar)

Secondary protection Lift cylinder Rod side Base side

Anti-cavitation valve 3481 psi (240 bar)

Anti-cavitation valve 4061 psi (280 bar)

Filter

2.9

Displacement 2.31 in.³/rev (38 cm³/rev)

Suction return filter

Pilot control Pilot control unit Four-way lever — control of lift and tilt cylinders, • with mechanical lock against unintentional actuation Control lever (joystick)

• with electric control (switch) for driving direction and neutral position • with electric control (tip switch) for differential lock

➥ Only for model ML460 3rd control circuit control lever

918294/AP1208

2-3

Operation of quick-hitch facility or implements with hydraulic functions • with mechanical lock against unintentional actuation Printed in U.S.A.

Specifications 2.10 Loader unit with bucket — model ML360 **Loader unit with bucket — model

Bucket 1 2

1 2

Bucket capacity

30 ft³ (0.85 m³) according to ISO 14397

Tipping load

7054 lbs. (3200 kg)

Payload

3527 lbs. (1600 kg)

Dump height

8 ft. 2 in. (2500 mm)

Pin height

10 ft. 8 in. (3250 mm)

Dump reach

2 ft.. 4 in. (700 mm)

Scraping depth

2.4 in. (60 mm)

Bucket roll back / dump angle

50°

Breakout force (lift cyl)

8992 lbf (40 kN)

Breakout force (tilt cyl)

7868 lbf (35 kN)

Model ML360 with 12.5-20 tires With standard bucket

2.11 Loader unit with bucket — model ML460 Bucket1 2

1 2

Printed in U.S.A.

Bucket capacity

41 ft³ (1.15 m³) according to ISO 14397

Tipping load

9127 lbs. (4100 kg)

Payload

4564 lbs. (2070 kg)

Dump height

8 ft. 11 in. (2670 mm)

Pin height

11 ft. 4 in. (3450 mm)

Dump reach

2 ft. 2 in. (660 mm)

Scraping depth

1.5 in. (40 mm)

Bucket roll back / dump angle

50° / 45°

Breakout force (lift cyl)

10,971 lbf (48 kN)

Breakout force (tilt cyl)

9667 lbf (43 kN)

Model ML460 with 405/70-24 tires With standard bucket

2-4

918294/AP1208

Specifications 2.12 Loader unit with pallet forks — model ML360 24 in. (610 mm) load distance

1

Payload1

2590 lbs. (1175 kg)

Lift height1

118in. (3000 mm)

Model ML360 with 12.5-20 tires

2.13 Loader unit with pallet forks — model ML460 20 in. (500 mm) load distance

1

Payload1

3790 lbs (1719 kg)

Lift height1

129 in. (3280 mm)

Model ML460 with 405/70-24 tires

2.14 Alternator, starter, battery Electrical system

918294/AP1208

Alternator

12 V, 95 A

Starter

12 V, 4.0 hp (3.0 kW)

Battery

12 V, 88 Ah

2-5

Printed in U.S.A.

Specifications 2.15 Fuse box

F7

F6

F5 F4

F3 F2

F16 F15 F14 F13 F12 F11 F10 F9 Fig. 29: Fuse box

Printed in U.S.A.

F1

F8

No.

Rated current

Protected circuit

F1

7.5

High beam (left)

F2

7.5

High beam (right)

F3

5

Left parking and rear lights, front socket

F4

5

Switch assignment: 4th control circuit S11, front/rear working light, front implements (option), rotating beacon (option) Switch lights: lights, heating S5, load stabilizer S8, 3rd control circuit Right parking and rear lights, front socket (option)

F5

7.5

High-current relay — pre-heating and starting, high-current relay, interior light, relays — minus compensation, pre-heating indicator hazard warning indicator

F6

25

Cigarette lighter, rotating beacon (option), front/rear working light

F7

25

High beam indicator

F8

7.5

Low-beam (left)

F9

7.5

Low-beam (right)

F10

5

Switching relays — front implement (option), instrument panel, cutoff solenoid

F11

15

Washer pump, rear wiper, relays — wiper, front wiper, horn

F12

5

1st/2nd speed solenoid valve

F13

7.5

Relays — forward/reverse, solenoid valve – forward/reverse, backup warning system

F14

20

Front implement (option), heating fan

F15

7.5

Relays — turn indicator, brake lights

F16

5

Radio (option)

2-6

918294/AP1208

Specifications 2.16 Main fuse box — model ML360 The main fuse box with the power relays and the pre-heating time control unit is located in the engine compartment on the left, underneath the battery.

F18 F17

K5 K7

F19

K29 Fig. 30: Main fuse box model ML360

Fuse no.

Rated current (A)

Protected circuit

F17

80 A

Main fuse

F18

40 A

Pre-heating/start fuse (starter)

F19

10 A

Minus compensation

Relay no.

Protected circuit

K5

Pre-heating: power relay

K7

Start: starter relay

K29

Minus compensation

2.17 Main fuse box — model ML460 K6

F20

F17

F18

The main fuse box with the power relays and the pre-heating time control unit is located in the engine compartment on the left, underneath the battery.

Fuse no.

Rated current (A)

Protected circuit

K5

F17

80 A

Main fuse

K7

F18

40 A

Pre-heating/start fuse (starter)

F19

10 A

Minus compensation

F20

50 A

Pre-heating (2nd glow plug, intake-air pre-heating)

Relay no.

Protected circuit

K5

Pre-heating: power relay

K6

Pre-heating time control unit

K7

Start: starter relay

K29

Minus compensation

F19

Fig. 31: Main fuse box model ML460

918294/AP1208

K29

2-7

Printed in U.S.A.

Specifications 2.18 Overview of switching relays The switching relays are located underneath the switch panel (board) on the right in the side console. Access is via the maintenance flap on the right on the outside of the cab.

K10

Switching relay no.

K3 K4 K16

Protected circuit

K1

High-current relay

K3

Reverse driving switching relay

K4

Forward driving switching relay

K10

Switching relay — turn indicator

K16

Switching relay — front socket (option)

K23

Wiper switching relay

K23

K1

Fig. 32: Relays

Printed in U.S.A.

2-8

918294/AP1208

Specifications 2.19 Tires for wheel loader — model ML360 Tire pressure1 Tire size

Front

12.5-20 MPT 04 10 PR 1

Rear

36 psi 2.5 bar

Wheel rims Wheel rim

Wheel offset

11 x 20

0 in. (0 mm)

20 psi 2.0 bar

Increase front tire pressure by 7.25 psi (0.5 bar) during pallet forks operation.

2.20 Tires for wheel loader — model ML460 Tire pressure1

tire size 405/70-24 MPT01 152 B 1

Wheel rims

Front

Rear

Wheel rim

Wheel offset

36 psi 2.5 bar

20 psi 2.0 bar

13 x 24

0 in. (0 mm)

Increase front tire pressure by 7.25 psi (0.5 bar) during pallet forks operation.

2.21 Weights Wheel loader model

ML360

ML460

Operating weight1

9,921 lbs. (4500 kg)

13,007 lbs. (5900 kg)

Gross weight rating

13,228 lbs. (6000 kg)

15,432 lbs. 7000 kg

8,818 lbs. (4000 kg)

9,921 lbs. (4500 kg)

Front axle weight rating Rear axle weight rating Max. authorized load for towing facility 1

None

With standard bucket, operator and full fuel tank

2.22 Noise levels Sound power level Measured value Until 12/2005 From 01/2006

102 dB (A) 99.8 dB (A)

Guaranteed value Until 12/2005 From 01/2006

104 dB (A) 101 dB (A)

Noise level in the cab

78 dB (A)

Important!

Measurement of sound power level according to EC Directive 2000/14/EC. Noise level at the driver’s ear measured according to EC Directives 84/532/EEC, 89/514/EEC and 95/27/EEC. Measurements carried out on asphalted surface.

918294/AP1208

2-9

Printed in U.S.A.

Specifications 2.23 Vibration Vibration Effective acceleration value for the upper extremities of the body

m < 2.5 ----2

Effective acceleration value for the body

m < 0.5 ----2

s

s

2.24 Hardware torques General torques Capscrew dimensions

Torques in lb.-ft. (Nm)1 Grade 7 (8.8)

Grade 8 (10.9)

Grade 10 (12.9)

2 (3) 4 (5.5) 7 (10) 17 (23) 34 (46) 58 (79) 92 (125) 144 (195) 207 (280) 291 (395) 398 (540) 502 (680) 738 (1000) 996 (1350)

3 (4) 6 (8) 10 (14) 25 (34) 49 (67) 85 (115) 136 (185) 214 (290) 295 (400) 413 (560) 561 (760) 715 (970) 1069 (1450) 1438 (1950)

4 (5) 7 (10) 12 (16) 30 (40) 58 (79) 100 (135) 162 (220) 251 (340) 347 (470) 487 (660) 656 (890) 848 (1150) 1254 (1700) 1696 (2300)

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 1

These values are valid for capscrews with untreated, non-lubricated surfaces

Specific torques

Printed in U.S.A.

Description

Torque

Wheel nut

288 ±7 lb.-ft. (390 ±10 Nm)

Track-rod end (steering cylinder)

207 ±7 lb.-ft. (280 ±10 Nm)

Piston rod (steering cylinder/track rod)

192 ±7 lb.-ft. (260 ±10 Nm)

2-10

918294/AP1208

Specifications 2.25 Dimensions — model ML360

8 (200)

107 (2710)

99 (2510)

98.5 (2500)

128 (3250)

122 (3100)

26 (660)

12 (300) 70 (1770)

75.5 (1920)

53 (1350)

198.5 (5040)

55 (1400) 73 (1850)

Fig. 33: Machine dimensions — model ML360

Dimensions

1 2 3 4

918294/AP1208

Overall length1

198.5 in. (5040 mm)

Overall height 2

99 in. (2510 mm)

Overall height with rotating beacon 2

107 in. (2710 mm)

Overall width without bucket3

68 in. (1720 mm)

Overall width1

73 in. (1850 mm)

Ground clearance in transport position of loader unit

8 in. (200 mm)

Ground clearance2 below rear axle gearbox

12 in. (300 mm)

Pin height

128 in. (3250 mm)

Load-over height

122 in. (3100 mm)

Dump height

98.5 in. (2500 mm)

Dump reach

26 in. (660 mm)

Pallet height

118 in. (2990 mm)

Track width, front/rear

55 in. (1400 mm)

Wheelbase (front/rear axle)

75.5 in. (1920 mm)

Turning radius4

100 in. (2550 mm)

With standard bucket With 12.5-20 tires With outside mirrors folded in Measured at outer edge of wheel

2-11

Printed in U.S.A.

Specifications 2.26 Dimensions — model ML460

8 (200)

112.5 (2850)

104.5 (2650) 108.3 (2750)

127.5 (3235)

105 (2670)

136 (3450)

26 (660)

13 (325) 85.4 (2170)

84.5 (2150)

58 (1480)

228.5 (5800)

59 (1490) (60 (1530)) 84.5 (2150)

Fig. 34: Machine dimensions — model ML460

Dimensions

1 2 3 4 5 6

Printed in U.S.A.

Overall length1

228.5 in. (5800 mm)

Overall height 2, 3

104.5 in. (2650 mm)

Overall height with protective screen2, 3

108.3 in. (2750 mm)

Overall height with rotating beacon2, 3

112.5 in. (2850 mm)

Overall width1, 4

84.5 in. (2150 mm)

Ground clearance in transport position of loader unit

8 in. (200 mm)

Ground clearance2, 3below rear axle gearbox

13 in. (325 mm)

Pin height2, 3

136 in. (3450 mm)

Load-over height 2, 3

127.5 in. (3235 mm)

Dump height2, 3

105 in. (2670 mm)

Dump reach1

26 in. (660 mm)

Pallet height2, 3

129 in. (3280 mm)

Track width, front/rear 5

59 in. (1490 mm)

Wheelbase (front/rear axle)

84.5 in. (2150 mm)

Turning radius 6

112 in. (2850 mm)

With standard bucket With 16/70-20 tires + 50 mm with tires 405/70-24 With outside mirrors folded in With tires 405/70-24 ==> 60 in. (1530 mm) Measured at outer edge of wheel

2-12

918294/AP1208

Specifications

918294/AP1208

2-13

Printed in U.S.A.

Maintenance

3

Maintenance

3.1

Introduction Operational readiness and the service life of the machine are heavily dependent on maintenance.

It is in the best interest of the machine owner to perform the prescribed maintenance as described in this manual.

Before carrying out service and maintenance work, always read, understand and follow the instructions given in: • Chapter 2 “Safety Instructions” of the operator’s manual.

• The operator’s manuals of the attachments.

Important information on maintenance and service work

The maintenance plans indicate when the maintenance work mentioned below must be performed.

Section "Maintenance schedule" on page 3-5.

Printed in U.S.A.

3-0

918294/AP1208

Maintenance 3.2

Fluids and lubricants

Component/application

Engine/machine fluid

SAE grade specification SAE 10W; EO103 SAE 20W20; EO203

Diesel engine

Engine oil2 with filter

SAE 30; EO303 HD-C 10W40; EO1040B3 HD-C 15W40; EO1540B3

Gearbox Front/rear axle differential

Gearbox oil4

Planetary drives — left and right

Engine oil2 Hydraulic oil tank

Biodegradable oil

Capacities1

11.2 qt.

(10.5 L)

Year-round 0.86 qt. (0.8 L)

85 W 90 API GL5 or SAE 90 LS (hypoid gear oil)

Year-round

SAE 5W30

Up to –13°F (–25°C)

4.24 qt. (4.0 L) 0.96 qt.

(0.9 L) each

SAE 5W40; EO 0540B3 SAE 10W40; EO 0540B3 SAE 15W40; EO 1540B

Hydraulic oil5

Season/ temperature Below 23°F (–5°C) 14–50°F (–10–+10°C) 41–86°F (5–30°C)

3

Up to 5°F (–15°C) Up to 14°F (–10°C)

About 132 gals.

(50 L)

HVLPD 46 (HYD05303) AVILUB Syntofluid 46

Year-round

PANOLIN HLP Synth 46

Grease nipples

Multipurpose grease

Lithium-saponified brand-name grease MPG-A3

Year-round

As required

Battery terminals

Acid-proof grease

SP-B3

Year-round

As required

Aggressive media (option)

Anti-corrosion protection

Anticorit BW 3666

Year-round

As required

Mounting of pins, shafts etc.

Special grease

Optimoly paste “TA”7 White paste

Year-round

As required

Fuel tank

Diesel fuel8

Brake system Washer system 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Grade no. 2-D

Over 39°F (4°C)

Grade no. 1-D

Below 39°F (4°C)

Brake fluid9

Agip LHM Super/Shell LHM

Year-round

Cleaning agent

Water + antifreeze10

Year-round

About 159 gals.

(60 L)

About 1.6 qt.

(1.5 L)

The capacities indicated are approximate values; the oil level check alone is relevant for the correct oil level MIL-L-2104C; API CD/CE/CH4; CCMC-D4 Abbreviation for lubricants (Hauptverband der Deutschen Bauindustrie e. V. – German construction engineering association) MIL-L-2105B; API-GL5 DIN 51 521 T3 TI 8030-015/K 19/MIL-C-16 173 C-Grade 4 250 gr tube DIN 51 601, min 45 cetane Standard: B 71 2710 Refer to the antifreeze compound table—see manufacturer’s instructions on the packaging

918294/AP1208

3-1

Printed in U.S.A.

Maintenance 3.3

Index to component maintenance Section "Engine" on page 4-0.

Section "Power train" on page 5-0.

Section "Axles" on page 6-0.

Section "Brakes" on page 7-0.

Section "Steering" on page 8-0.

Section "Hydraulic system" on page 9-0.

Section "Electrical system" on page 10-0.

Printed in U.S.A.

3-2

918294/AP1208

Maintenance 3.4

Explanation of symbols on maintenance label Symbol

Explanation Before starting maintenance work, read the safety instructions in the Operator’s Manual.

Before starting maintenance work, read the “Maintenance” section in the Operator’s Manual.

Check that the light system functions correctly.

Check tires for damage, pressure, and tread depth.

Complete a functional check and synchronize the steering system.

Complete a functional check of the brake system.

Check hydraulic oil level. Add oil if necessary.

Check engine oil level. Add oil if necessary.

Compress the dust valve.

Check radiator for engine coolant and hydraulic oil for contamination. Clean if necessary.

Check condition and initial tension of V-belt. Tighten or replace if necessary.

Leakage check: Check for tightness, leakage and chafing of pipes, flexible lines and screw connections. Correct if necessary.

Leakage check: Check the fuel/water separator. Drain water if necessary.

Lubrication service: Lubricate the assemblies.

918294/AP1208

3-3

Printed in U.S.A.

Maintenance 3.5

Maintenance label

100 010 40 14

Location: inside the cab, on the rear window

10 h

Daily Daily

50 h

Weekly

Täglich Tous les jours

I=>347 02 0001 (AWS46)

Printed in U.S.A.

I=>346 02 0001 (AWS36)

3-4

918294/AP1208

“B” every 500 s/h2 2nd Inspection

“C” every 1500 s/h once a year

at 100 s/h

Oil and filter changes (

“A” every 50 s/h once a week

For service and maintenance work on the attachment, also refer to the operation and maintenance manual of the attachment manufacturer.

Maintenance work (once a day)

Work description

Maintenance plan/service hours (s/h) 1st Inspection1

Maintenance schedule

Delivery inspection

918294/AP1208

3.6

● ● ● ●

● ● ● ● ● ● ● ● ●

):

Carry out the following oil and filter changes (check oil levels after test run):

3-5

• • • • • • • • •

● ● ●

Engine oil Engine oil filter Fuel filter, fuel prefilter Air filter insert 3,4: replace safety cartridge every 3rd time the air filter insert is replaced Gearbox oil in front and rear axle differentials and in rear axle gearbox Gearbox oil in front and rear axle planetary drives (left and right) Hydraulic oil5 Hydraulic oil filter insert Breather filter – hydraulic oil tank 4

Inspection work (

● ● ●

):

Check the following material. Refill if necessary:

Printed in U.S.A.

• • • • • • • • • • • • • • • • •

Engine oil Hydraulic oil Gearbox oil in front and rear axle differentials and in rear axle gearbox Gearbox oil in front and rear axle planetary drives (left and right) Brake fluid6 Check radiator for engine and hydraulic oil for contamination. Clean if necessary7 When using biodegradable oil: drain the condensation water in the hydraulic oil tank 5 Clean dust valve on air filter housing 3 V-belt: check condition and pre-tension. Retighten or replace if necessary8 Check the fuel/water separator. Drain water if necessary Clean filter insert on fuel pump. Replace if necessary Check valve tip clearance (engine timing). Set if necessary Battery: check charge condition Heating: clean dust filter. Replace every 1500 s/h if necessary9 Check and set service brake and handbrake pads. Replace if necessary Tire check (damage, air pressure, tread depth) Engine coolant (also check antifreeze in autumn/winter and temps below 40°F (4°C)

● ● ● ● ●

● ●

● ●

●

● ●

● ● ● ● ●

● ●

● ●

● ● ● ●

● ● ● ●

● ●

●

●

● ● ●

● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ● ● ● ●

Maintenance plan/service hours (s/h) “B” every 500 s/h2 2nd Inspection

“C” every 1500 s/h once a year

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

at 100 s/h

“A” every 50 s/h once a week

For service and maintenance work on the attachment, also refer to the operation and maintenance manual of the attachment manufacturer.

Maintenance work (once a day)

Work description

1st Inspection1

Maintenance schedule

Delivery inspection

Printed in U.S.A.

3.6

Check screws and nuts or screw connections for tightness on the following assemblies/components. Tighten if necessary: • • • • • • • • •

Engine and engine mounts Steering system Hydraulic system Loader unit (pin locking) Axle mounting, axle suspension Counterweight (attachment) Fastening screws of cardan shafts Fastening screws of cab Wheel nuts

Electric system: check electric and earth connections, chafing on wiring harness, battery terminals 3-6

Lubrication service (

● ●

):

Lubricate the following assemblies/components: • • • •

Hinges, joints and fittings (e.g., door latches) Rear axle oscillating bearing Front and rear axle planetary drive bearings (left and right) Loader unit • Lift frame bearing • Tilt rod bearing • Tilt lever bearing • Lift cylinder bearing • Tilt cylinder bearing • Quick-hitch facility: bearing on lift frame • Hinges, joints, and fittings

918294/AP1208

Functional check (

●

● ● ●

● ● ●

● ● ●

● ● ●

● ● ● ● ● ● ●

● ● ●

● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ●

● ● ●

● ● ●

● ● ●

● ● ●

● ● ●

● ●

):

Check the function of the following assemblies/components. Service if necessary: • Service brake and handbrake • Steering system • Lights and electric system

“B” every 500 s/h2 2nd Inspection

“C” every 1500 s/h once a year

at 100 s/h

Leakage check (

“A” every 50 s/h once a week

For service and maintenance work on the attachment, also refer to the operation and maintenance manual of the attachment manufacturer.

Maintenance work (once a day)

Work description

Maintenance plan/service hours (s/h) 1st Inspection1

Maintenance schedule

Delivery inspection

918294/AP1208

3.6

● ● ● ● ● ● ●

● ● ● ● ● ● ●

):

Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Service if necessary:

3-7

• • • • • • •

Air intake line (air filter – engine) Engine lubrication (engine – filter) Fuel lines10 Cooling system (engine – hydraulic oil) Steering system (hoses and cylinders) Hydraulic system/loader unit (hoses and cylinders) Brake system (hoses and cylinders)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Work to be carried out once after the first 100 service hours. This work must be carried out by an authorized dealer.

Work after the first 500 service hours (2nd Inspection) must be carried out by an authorized dealer.

Replace filter insert as indicated by the indicator on the air filter housing; however, at least every 12 months or 1500 service hours.

When working in an acidic environment, replace the filter every 300 service hours.

When using biodegradable oil: drain the condensation water in the hydraulic oil reservoir every 500 service hours, in any case before the cold season.

Replace every 2 years.

Depending on operation and dust conditions, it may be necessary to clean the radiator more frequently.

Replace the toothed belt every 3000 service hours or after 5 years at the latest (toothed belt must be replaced by authorized staff).

Depending on operation and dust conditions, it may be necessary to replace the dust filter more frequently.

Replace hoses every 6 years.

Lubricate attachments according to manufacturer’s instructions.

Replace fuel lines every 2 years.

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

Printed in U.S.A.

3.7

Maintenance of the fuel system

Specific safety instructions

• When handling fuel, there is a risk of fire.

• Never work on the fuel system around open flames or sparks.

• DO NOT smoke when working on the fuel system or while refueling.

• Before refueling, turn off the engine and remove the ignition key.

• Do not refuel in closed rooms.

• Wipe up fuel spills immediately.

• Keep the machine clean to reduce the risk of fire.

Refueling The filler inlet of the fuel tank is located on the left side of the machine.

Danger!

All work involving fuel carries an increased –

Risk of fire and poisoning ☞ Do not refuel in closed rooms. ☞ Never work on the fuel system in the vicinity of open flames or sparks.

Fig. 35: Fuel filler inlet

Environment!

Collect and dispose of fuel according to environmental laws.

Stationary fuel pumps

General

Important!

Only refuel from stationary fuel pumps. Fuel from barrels or canisters can be contaminated.

Even the smallest particles of dirt can cause: • Increased engine wear • Malfunctions in the fuel system • Reduced effectiveness of the fuel filters

Diesel fuel specification

Use only high-grade fuels.

Cetane number

Grade No. 2-D according to EN 590 No. 1-D according to EN 590

Printed in U.S.A.

3-8

Use For normal outside temperatures

Min. 45

For outside temperatures below 39.2°F (4°C) or for operation above 5000 ft. (1500 m) altitude

918294/AP1208

3.8

Replacing the fuel filter Warning!

B

If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased –

Risk of burns

A

☞ Never change the fuel filter if the engine is hot.

Fig. 36: Fuel filter position

Environment!

Use a container to collect the fuel as it drains and dispose of it according to environmental laws.

☞ Change fuel filter 36/A as follows: • Pinch off fuel feed line 36/B with a suitable tool.

• Thoroughly clean the outside surfaces of fuel filter 36/A. • Loosen and unscrew fuel filter cartridge using a commercially available tool.

• Collect the fuel as it drains.

Fig. 37: Unscrewing the fuel filter

• Clean the sealing surface of the filter carrier.

• Lightly oil the rubber gasket of the new filter cartridge or apply a thin coat of clean diesel fuel to it.

• Screw the cartridge on by hand until the gasket makes contact.

Fig. 38: Cleaning the sealing surface and oiling the gasket

• Tighten the fuel filter cartridge by turning it another half revolution.

• Remove the tool used to pinch off the fuel feed line 36/B. • Make a test run and check for tightness.

• Dispose of the old fuel filter cartridge according to environmental laws.

NOTE: Fig. 39: Tightening the fuel filter

918294/AP1208

The fuel system bleeds itself automatically.

3-9

Printed in U.S.A.

3.9

Cleaning the fuel pump screen filter Warning!

If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased –

Risk of burns ☞ Never clean the screen filter when the engine is hot. ☞ Proceed as follows: • Pinch off fuel feed line 27/B with a suitable tool.

• Loosen and unscrew hex head screw A. B

C

• Remove fuel screen B (cover and screen come out together).

• Clean fuel screen B with fuel; replace if necessary.

• Position sealing rings C.

A

• Replace fuel screen B (cover with screen).

• Tighten hex head screw A. • Remove the tool used to pinch off the fuel feed line 27/B.

Fig. 40: Removing the screen filter

• Make a test run and check for tightness.

3.10 Bleeding the fuel system Important!

The fuel system of the machine is bled automatically.

Printed in U.S.A.

3-10

918294/AP1208

3.11 Checking/adding engine oil Important!

If the engine oil level is too high or too low, or if an oil change is overdue, this may cause engine damage or loss of output.

☞ Use only the specified engine oil

Section "Fluids and lubricants" on page 3-1.

Important!

Check the oil level every 10 service hours or daily.

After stopping a warm engine, wait at least 5 minutes before checking.

☞ Proceed as follows: • Park the machine on level ground.

• Stop the engine.

• Remove the key.

max min

• Apply the parking brake.

• Open the engine cover.

• Pull out oil dipstick A.

A

• Wipe the dipstick with a lint-free cloth.

• Push the dipstick back in as far as possible.

• Withdraw the dipstick and read the oil level.

Fig. 41: Checking the oil level

☞ You must fill the oil tank when the level reaches the MIN mark on the oil dipstick A.

Environment!

Use a container to collect the engine oil as it drains and dispose of it according to environmental laws.

☞ Proceed as follows: • Clean the area around oil filler cap B with a lint-free cloth.

OIL

B

• Open filler cap B. • Raise oil dipstick A slightly to allow any trapped air to escape.

• Add engine oil.

• Wait for all the oil to run into the oil sump.

A

• Check the oil level.

• Add oil if necessary and check the oil level again.

• Close filler cap B.

Fig. 42: Oil dipstick and oil filler cap

• Push oil dipstick A back in as far as possible.

• Completely remove all oil spills from the engine.

918294/AP1208

3-11

Printed in U.S.A.

3.12 Changing engine oil

Warning!

Careful when draining hot engine oil –

176°F (+ 80°C)

Risk of burns ☞ Wear protective gloves. ☞ Use suitable tools.

OIL Fig. 43: Optimum engine oil temperature

Environment!

Use a container to collect the engine oil as it drains and dispose of it according to environmental laws.

B

C

☞ Change the engine oil as follows: • Park the machine on level ground.

• Let the engine run until reaching service temperature (oil temperature about 176°F [80°C]).

• Stop the engine.

A

• Place a container of about 3 gal. (12 L) capacity under the opening.

• Remove the cover from the frame.

• Unscrew cap 44/A of oil drain valve 44/B.

Fig. 44: Drain plug at rear end of machine

• Screw hose 45/D into the drain coupling, as shown. Be sure the end of the hose is in the container 45/E.

➥ Oil drain valve 45/B opens and the engine oil drains.

• Completely drain the oil.

• Unscrew drain coupling 45/C. • Screw on cap 44/A of the oil drain valve.

B

• Add engine oil.

• Start the engine and run it at low speed for a few minutes.

C D

• Stop the engine.

• Wait a moment until all the oil has run into the oil sump.

E

• Check the oil level again.

• Add oil if necessary and check again.

• Completely remove all oil spills from the engine.

Fig. 45: Drain coupling with hose

Printed in U.S.A.

3-12

918294/AP1208

3.13 Changing the engine oil filter cartridge Warning!

When changing hot engine oil – A

Danger of burns ☞ Wear protective gloves.

Fig. 46: Engine oil filter position

Environment!

Collect the oil in a suitable container as it drains.

Dispose of used oil and filters according to environmental laws.

☞ Change the engine oil as follows: • Stop the engine.

• Place a suitable container underneath the oil filter to collect the oil.

• Loosen and unscrew oil filter cartridge A.

A

• Make sure the thread adapter is correctly placed in the filter head.

Fig. 47: Unscrewing the engine oil filter

• Clean inside the filter head.

• Apply a thin coat of engine oil to the rubber seal 48/B) on the new oil filter cartridge.

• Tighten the new filter cartridge by hand until the gasket makes contact.

B

Fig. 48: Cleaning the filter head and oiling the gasket

• Manually tighten oil filter cartridge A by hand another half revolution.

A

• Check the engine oil level. Add oil.

• Wipe any oil spills from the engine.

• Run the engine for a short time.

• Stop the engine.

• Check the seal of oil filter cartridge A and manually tighten the cartridge if necessary.

• Check the oil level and add engine oil if necessary.

Fig. 49: Tightening the filter cartridge

Environment!

Dispose of the used oil filter according to environmental laws.

918294/AP1208

3-13

Printed in U.S.A.

3.14 Engine and hydraulics cooling system The combined engine radiator/hydraulic oil cooler is located in the engine compartment, to the right of the engine. It cools the diesel engine coolant and hydraulic oil.

Specific safety instructions

• Dirt on the radiator/cooler fins reduces heat dissipation capacity. To avoid this:

☞ Clean the outside of the radiator/cooler at regular intervals. Refer to the maintenance schedule for cleaning intervals.

☞ In dusty or dirty work conditions, clean more frequently than indicated in the maintenance schedule.

• An insufficient coolant level (engine/hydraulic oil) reduces the heat dissipation capacity as well, and can lead to engine damage; therefore:

☞ Check the oil level at regular intervals. Refer to the maintenance schedule in the appendix for the intervals.

☞ If coolant must be added frequently, check the cooling system for leaks.

3.15 Cleaning the oil cooler Danger!

The cooling system remains hot for some time after the engine is stopped –

Risk of burns ☞ Wait at least 10 minutes after stopping the engine. ☞ Wear protective goggles, gloves, and clothing. ☞ Proceed as follows: • Park the machine on level ground.

• Lower the loader unit.

• Apply the parking brake.

A

• Turn off the engine.

• Let the engine cool.

• Remove the key.

• Open the engine cover.

• Clean the cooling fins by blowing compressed air from end A of the radiator.

Fig. 50: Cleaning the oil cooler

Printed in U.S.A.

3-14

918294/AP1208

3.16 Hydraulic system Specific safety instructions

☞ You must depressurize all lines carrying hydraulic oil before performing any maintenance and repair work. To do this:

• Lower all hydraulically controlled attachments to the ground.

• Actuate all control levers of the hydraulic control valves several times.

• Apply the parking brake to prevent the machine from rolling away before you perform service and maintenance work.

Warning!

Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries. Always consult a doctor immediately, even if the wound appears insignificant, to be sure that serious infections do not set in.

Important!

If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has penetrated the hydraulic system. This may damage the hydraulic pump.

Important!

Insufficient, incorrect, or contaminated hydraulic oil –

Risk of severe damage to the hydraulic system ☞ Always add hydraulic oil using the filling screen. ☞ Only use the same type of authorized oils.

Section "Fluids and lubricants" on page 3-1.

☞ Always add the hydraulic oil before the level gets too low. ☞ If the hydraulic system is filled with biodegradable oil, then use only the

same type of biodegradable oil, following the label on the hydraulic oil tank.

☞ Contact your Mustang dealer if the hydraulic system filter is contaminated with metal chips. Otherwise, damage may result.

Environment!

Collect hydraulic oil, including biodegradable oil, with a container. Dispose of drained oil and used filters in accordance with environmental laws.

Always contact the authorities or establishments in charge of oil disposal before disposing of biodegradable oil.

918294/AP1208

3-15

Printed in U.S.A.

3.17 Checking hydraulic pressure lines Specific safety instructions

Danger!

Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries –

Risk of personal injury ☞ Always consult a doctor immediately, even if the wound seems insignificant, to be sure that serious infections do not set in.

☞ Always follow these instructions: • Only tighten leaking threaded fittings and hose connections after you have relieved pressure in the system.

• Only use paper or wood to check for minor leaks. Never use an unprotected light or open flame.

• Only authorized dealers should replace damaged flexible lines.

• Never weld faulty or leaking pressure lines and threaded connections; always replace damaged parts with new ones.

• Never search for leaks with your bare hands; wear protective gloves.

• An authorized dealer or after-sales staff should immediately repair or replace any leaking or damaged pressure lines.

• Replace hydraulic hoses every six years from the date of manufacture, even if they do not appear to be damaged.

The date of manufacture (month or quarter and year) is indicated on the flexible line.

3 Q/06

Example: The indication “3 Q/08” means manufactured in the 3rd quarter of 2008.

Fig. 51: Date of manufacture

Printed in U.S.A.

3-16

918294/AP1208

3.18 Monitoring the hydraulic oil return filter 38

On the instrument panel, the red indicator 37 monitors pressure and the return filter, and indicator 38 monitors hydraulic oil temperature.

37

The filter element must be replaced by an authorized dealer:

☞ If indicator 37 comes on, ➥ The pressure in the filter is too high. ☞ If indicator 38 comes on, ➥ The hydraulic oil temperature is too high. ☞ At the latest after 1500 service hours (once a year).

In cold weather, indicator 37 may come on after starting the engine. This is caused by increased oil viscosity. In this case: Fig. 52: Pre-heating start switch

☞ Set engine speed so that indicator 37 goes out. ☞ Follow the instructions concerning warmup.

Important information for the use of biodegradable oil

• Only use biodegradable hydraulic fluids that are approved by Gehl. In addition, ask the oil supplier for a written guarantee. This guarantee is applicable to damage occurring on the hydraulic components, which can be proved to be due to the hydraulic fluid.

• Only use the same type of biodegradable oil when adding oil. A decal stating the oil used is located on the hydraulic oil tank (next to the filler inlet).

Important!

• Using two different biodegradable oils at the same time can affect the quality of one of the oils. When changing biodegradable oil, be sure that the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8% (manufacturer indications).

• DO NOT top off with mineral oil—the content of mineral oil should not exceed 2%.

• If hydraulic attachments are mounted or operated, use the same type of biodegradable oil for these attachments to avoid mixtures in the hydraulic system.

• If you are running the machine with biodegradable oil, the same oil and filter replacement intervals used for mineral oil are valid.

Section "Maintenance schedule" on page 3-5.

• Have an authorized dealer drain the condensation water in the hydraulic oil tank after every 500 service hours (or before the cold season if you have not yet used your machine for 500 service hours). The water content must NOT exceed 0.1% by weight.

• All environmental instructions stated in this manual are valid for the use of biodegradable oil.

Important!

A change from mineral to biodegradable oil must be carried out by an authorized dealer only.

918294/AP1208

3-17

Printed in U.S.A.

3.19 Hydraulic oil return filter The red indicator on the instrument panel monitors the filter. Replace the filter insert: • If the indicator comes on when the hydraulic oil is at operating temperature.

• After 1500 service hours (annually).

In cold weather the indicator may come on immediately when the engine is started. This is caused by increased oil viscosity. In this case:

☞ Set engine speed so that the indicator goes out.

Changing the filter insert

Important!

Contamination can cause –

Severe damage to the hydraulic system ☞ Avoid contaminating the hydraulic oil. ☞ Proceed as follows:

A

• Stop the engine.

• Open the engine cover.

• Open breather filter A of the hydraulic oil tank.

• Loosen filter cap F and 54/1 by about two turns and wait for the oil level in the filter housing to drop to the oil level in the hydraulic oil tank.

• Unscrew cap F and 54/1 of the filter and remove it.

F

Fig. 53: Location of hydraulic oil return filter

• Twist and pull out filler pipe 2 with filter insert 3.

1

4

2 2

3

5

• Remove filter insert 3 from filler pipe 2 and dispose of it.

• Check that flat gasket 4 on filter cover 1 and O-ring 5 on the filler pipe are in good condition.

• Replace the gasket and/or O-ring if they are damaged.

• Slide filler pipe 2 onto the new filter insert 3 and insert it into the filter.

308b1100.eps

• Tighten cap 53/F and 1 by hand to 14.75 lb.-ft. (20 Nm).

• Tighten breather filter 53/A by hand.

Fig. 54: Exploded view of hydraulic oil return filter

• Perform a test run of the hydraulic system.

With the engine stopped: • Check the filter for leaks.

Printed in U.S.A.

3-18

918294/AP1208

3.20 Checking the hydraulic oil level ☞ Proceed as follows: • Park the machine on level ground.

• Retract all hydraulic cylinders.

✓ A

• Stop the engine.

• Apply the parking brake.

• Open the engine cover.

• Check the hydraulic oil level in sight glass A.

☞ If the oil level is not visible in the sight glass: ➥ Add hydraulic oil.

Fig. 55: Oil level sight glass on the hydraulic oil tank

Important!

Any excess quantity of hydraulic oil in the tank escapes via the breather as soon as the temperature rises.

If the oil level is no longer visible in the upper half of the sight glass:

☞ Drain the hydraulic oil.

3.21 Adding hydraulic oil Important!

Do not add hydraulic oil unless the engine is stopped. If the engine is running, hydraulic oil will run out of the filler opening on the hydraulic tank.

B

☞ Add oil as follows: • Park the machine on level ground.

• Retract all hydraulic cylinders.

• Stop the engine.

• Apply the parking brake.

• Open the engine cover.

• Clean the area around the filler and breather filter B using a cloth.

• Open breather filter B.

☞ With the filter insert in place: Fig. 56: Hydraulic oil tank

• Add hydraulic oil.

• Check the hydraulic oil level in sight glass 55/A. • Add more oil, if necessary and check again.

• Firmly close breather filter B.

918294/AP1208

3-19

Printed in U.S.A.

3.22 Changing the hydraulic oil Caution!

When draining hot hydraulic oil and removing the filter element –

Risk of burns ☞ Wear protective gloves. ☞ Use an oil drain coupling with a sufficiently long hose. ☞ Change the hydraulic oil as follows: • Park the machine on level ground.

• Lower the loader unit completely.

• Tilt in the bucket completely.

• Stop the engine and block the tires to prevent the machine from rolling.

• Open the engine cover.

• Remove cap 56/B from the hydraulic oil tank.

D E

Under the rear end of the machine: • Place a suitable container with a minimum capacity of 58.5 qts. (55 L) to collect the oil as it drains.

• Remove oil drain valve cap C.

C

• Screw oil drain coupling D onto the oil drain valve with a sufficiently long hose. Make sure the end of the hose is in the collection container.

• Open oil drain valve E. • Rinse the hydraulic oil tank with a small amount of hydraulic oil.

Fig. 57: Oil drain valve with cap

• Remove oil drain coupling D from oil drain valve E. • Replace cap C of the oil drain valve.

• Replace the hydraulic oil return filter.

Section "Hydraulic oil return filter" on page 3-18.

• Inspect the hydraulic oil fill screen and replace if missing or damaged.

Important!

Always use a hydraulic oil fill screen. Contaminated hydraulic oil can cause severe damage to the hydraulic system.

• Add fresh hydraulic oil up to the middle of the sight glass 55/A. • Replace cap 56/B on the hydraulic oil tank.

• Start the engine.

With the engine running at low speed: • Fully extend the lift and tilt cylinders on the loader unit.

• Turn the steering wheel to the left and right several times, from lock to lock.

• Retract all the hydraulic cylinders.

• Stop the engine.

• Check the hydraulic oil level again and add oil if necessary.

Printed in U.S.A.

3-20

918294/AP1208

3.23 Rear axle transfer gearbox oil levels Important!

Only use new sealing rings for oil filler and drain plugs. Drain oil only after running the machine up to operating temperature.

Checking the oil level

☞ Proceed as follows:

A

• Park the machine on level ground, with the gearbox at operating temperature.

• Clean and remove plug A from the transfer gearbox.

If the oil level is below the opening, or if the oil level cannot be seen: • Add oil.

If the oil level is correct: • Replace and tighten plug A with a new sealing ring.

Changing the oil

Fig. 58: Transfer gearbox oil level

Caution!

Draining hot gearbox oil is hazardous –

Risk of burns ☞ Wear protective gloves. ☞ Use a suitable tool to unscrew the oil drain plug. ☞ Proceed as follows: • Park the machine on level ground, with the gearbox at operating temperature.

A

• Place a sufficiently large container under the transfer gearbox to collect the oil.

• Clean and remove plug A from the transfer gearbox.

• Remove screw B from the transfer gearbox.

• Completely drain the gearbox oil.

• Replace and tighten plug B with a new sealing ring.

• Add oil until it runs out of filler opening A.

B Fig. 59: Transfer gearbox oil level

If the oil level in the gearbox remains constant: • Replace and tighten plug A with a new sealing ring.

Start the engine and run up to operating temperature.

• Check the oil level again after about 5 minutes, and add oil if necessary.

918294/AP1208

3-21

Printed in U.S.A.

3.24 Front and rear axle differential oil levels Environment!

Use a suitable container to collect the gearbox oil as it drains and dispose of it according to environmental laws.

Important!

Only use new sealing rings for oil filler and drain plugs. Drain oil only after running the machine up to operating temperature.

Checking the oil level

☞ Proceed as follows: Rear Axle

A

• Park the machine on level ground.

• Clean and remove plugs A. • If the oil level is below the opening or if the oil level cannot be seen: • Add oil.

If the oil level is correct: • Replace and tighten plugs A with new sealing rings.

Adding oil

☞ Proceed as follows:

A

Front Axle

• Park the machine on level ground.

• Clean and remove plug A. • Add oil until it runs out of the filler opening.

• Replace plug A with a new sealing ring.

Changing the oil

☞ Proceed as follows: • Run the machine until it reaches operating temperature and park the machine on level ground.

• Place a container under plug B to collect the oil.

• Clean and remove plug A (axle tube).

• Clean and remove plug B. • Completely drain the oil.

• Replace and tighten plug B with a new sealing ring.

B

• Add fresh oil through opening A (axle tube) until it runs out of the filler opening.

• Replace and tighten plug A (axle tube) with a new sealing ring.

Run the machine until it reaches operating temperature.

• Check the oil level again after about 5 minutes, and add oil if necessary.

Fig. 60: Checking the oil level/draining the oil in the axle

Printed in U.S.A.

3-22

918294/AP1208

3.25 Front and rear axle planetary drive oil levels Checking the oil level and adding oil

Important!

Only use new sealing rings for oil filler and drain plugs. Drain oil only after running the machine up to operating temperature.

A

☞ Proceed as follows: Fig. 61: Oil filler and inspection plug on planetary drive

• Park the machine on level ground and block the tires to prevent the machine from rolling.

• Position plug A at the top as shown in Fig. 61.

• Clean and remove plug A, to release possible overpressure.

• Position opening A in the horizontal position as shown in Fig. 62.

If the oil level is below the opening or if the oil level cannot be seen at all: • Add oil through opening 62/A until it runs out of the filler opening.

• Replace and tighten plug 62/A with a new sealing ring.

A

Fig. 62: Oil filler and inspection plug on planetary drive

Changing the oil

☞ Proceed as follows: • Run the machine up to operating temperature.

• Park the machine on level ground and block the tires to prevent the machine from rolling.

A

• Place a suitable container under drain plug A. • Position plug A at the top as shown in Fig. 63.

• Clean and remove plug A, to release possible overpressure.

Fig. 63: Oil drain plug on planetary drive

• Rotate the planetary drive so opening A is at the bottom.

• Completely drain the oil.

• Position opening A in horizontal position as shown in Fig. 64.

• Add fresh oil through opening A until it runs out of the filler opening.

• Replace and tighten plug A with a new sealing ring.

A

Fig. 64: Oil filler and inspection plug on planetary drive

918294/AP1208

3-23

Printed in U.S.A.

3.26 Air filter maintenance Important!

The filter cartridge will be damaged if it is washed or brushed out.

To avoid premature engine wear:

☞ DO NOT clean the filter cartridge. ☞ Replace the filter cartridge when the indicator comes on. ☞ Never re-use a damaged filter cartridge. ☞ Ensure cleanliness when replacing the filter cartridge.

Check: air filter contamination Maintenance display B on the filter housing monitors the filter cartridge. The dust is removed by squeezing discharge slot E on the dust valve.

☞ Checking the dust valve E: • Stop the engine.

• Remove the ignition key.

• Apply the parking brake.

• Squeeze the discharge slot on the dust valve E. • Remove hardened dust by compressing the upper area of the valve.

E

• Clean the discharge slot if necessary.

☞ Filter cartridge D must be replaced:

A

B

• If the red mark C in maintenance display B is visible.

C

• If 1500 service hours have occurred (or annually).

Section "Replace the filter cartridge when the indicator comes on." on page 3-24.

Important!

For operation in dusty environments, the air filter is fitted with an extra safety cartridge F (standard). Do not clean the safety cartridge. Replace the safety cartridge every third time the air filter is serviced.

D Important!

Filter cartridges degrade prematurely when in use in acidic air for longer periods of time. This risk may be present in acid production facilities, steel and aluminum mills, chemical plants, and other nonferrous-metal plants.

34001b520_02.iso

E

F

Fig. 65: Air filter with safety cartridge

Printed in U.S.A.

☞ In acidic environments replace filter cartridge D and safety cartridge F every 500 service hours.

Section "Replacing the air filter cartridge" on page 3-25.

3-24

918294/AP1208

3.27 Replacing the air filter cartridge ☞ Change the filter cartridge as follows: H

• Stop the engine.

• Apply the parking brake.

G

• Remove the ignition key.

• Open the engine cover.

K

• Fold both bow hooks G to the outside.

• Remove the lower housing section K. • Carefully remove filter cartridge D with a slight twisting motion.

307b0700.ai

Fig. 66: Removing the lower housing section

• Carefully remove safety cartridge 55/F. • Be sure all contamination (such as dust) inside the upper and lower housing sections is removed.

D

H

• Carefully insert a new safety cartridge 65/F into the upper housing section H. • Carefully insert a new filter cartridge D into the upper housing section H. • Clean the dust valve 65/E. • Replace lower housing section K (make sure it is properly seated).

307b0710.ai

• Close both bow hooks G.

Fig. 67: Removing the filter element

• After replacing the filter:

A

B

C

• Reset the red mark C in the inspection window on indicator B. • Press reset button A.

Fig. 68: Air filter with maintenance display

918294/AP1208

3-25

Printed in U.S.A.

3.28 V-belt Danger!

Only check tension or replace the V-belt when the engine is off –

Risk of personal injury ☞ Stop the engine before working on or around the engine.

Important!

Cracked and stretched V-belts cause engine damage.

☞ Replace the V-belt every two years. ☞ Have the V-belt replaced by an authorized dealer.

Checking V-belt tension Check the V-belt once a day or every 10 service hours. Adjust the tension if necessary.

Tighten new V-belts after about 15 minutes of running time.

☞ Check V-belt tension as follows: • Stop the engine.

About 10 mm

1

• Apply the parking brake.

• Remove the ignition key.

• Carefully inspect the V-belt 1 for damage.

☞ If the V-belt is damaged: ➥ Have the V-belt replaced by an authorized dealer. ☞ Press with your thumb to check whether the V-belt can be deflected between the pul-

Fig. 69: Checking V-belt tension

leys by no more than about 0.4 in. (10 mm).

☞ Tighten the V-belt if necessary.

Tensioning the V-belt

☞ Tension the V-belt as follows:

3

• Stop the engine.

• Apply the parking brake.

• Remove the ignition key.

A

• Loosen screws 2 securing alternator 3.

2

• Use a suitable tool to push the alternator in the direction of arrow A until the correct V-belt tension is obtained (Fig. 69).

• Keep the alternator in this position, and at the same time tighten screws 2.

• Check V-belt tension (Fig. 69) again.

Fig. 70: Tensioning the V-belt

Printed in U.S.A.

3-26

918294/AP1208

3.29 Lubrication points Lubricate all lubrication points listed with a lithium-based grease. See Section "Fluids and lubricants" on page 3-1.

Lubricating the rear axle oscillationtype bearing

Important!

The machine has an oscillation-type rear axle. Grease the bearing every 50 service hours or weekly.

☞ Lubricate grease zerk A of the oscillation-type bearing.

A Fig. 71: Grease zerks for oscillation-type bearing

Lubricating the front and rear axle planetary drive bearings

☞ Lubricate grease zerks B (twice) on each planetary drive bearing every 50 service hours or weekly.

B

Fig. 72: Grease zerks on planetary drive bearings

918294/AP1208

3-27

Printed in U.S.A.

3.30 Lubricating the loader unit Lubricate the following lubrication points on the loader unit of the machine:

C

☞ Lubricate grease zerk C on the tilt cylinder bearing on the frame with grease

every 50 service hours (or weekly). Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerk D on the loader unit bearing every 50 service hours (or weekly).

D

Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerk E on the lift cylinder bearing on the frame every 50 service hours (or weekly). Lubricate daily during heavy-duty operation.

E Fig. 73: Lubrication points on frame

☞ Lubricate grease zerk F on the tilt rod bearing every 10 service hours (or daily). LubriF

cate daily during heavy-duty operation.

☞ Lubricate grease zerk G on the tilt cylinder bearing every 50 service hours (or weekly). Lubricate daily during heavy-duty operation.

L

G

☞ Lubricate grease zerk H on the lift cylinder bearing every 50 service hours (or weekly). Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerk I on the tilt lever bearing every 10 service hours (or daily).

Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerks K on the quick-hitch bearing every 10 service hours (or daily).

Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerks L on the tilt lever bearing every 10 service hours (or daily).

Lubricate daily during heavy-duty operation.

K

I

H

Fig. 74: Lubrication points for lift and tilt ram bearings

3.31 Attachment maintenance Important!

Correct maintenance and service improves operation and increases the service life of attachments. Follow the lubrication and maintenance instructions in the attachment operation manuals.

Printed in U.S.A.

3-28

918294/AP1208

3.32 Brake system Environment!

Use a suitable container to collect the brake fluid as it drains and dispose of it according to environmental laws.

Specific safety instructions

Warning!

Brakes are necessary for safety. Incorrect maintenance or repair may cause brake failure.

Important!

• All maintenance and repair work on the brakes must be completed by authorized technicians.

• The operator must check the brake fluid level in the tank daily.

• Have an authorized technician replace damaged brake lines or hoses –

Risk of accidents

Checking/adding brake fluid A

The brake fluid tank is located at the front left in the cab (next to the brake/inching pedal).

Danger!

An incorrect brake fluid grade or an insufficient brake fluid level may impair the safety of the brake system –

Accident risk

MAX MIN

Fig. 75: Checking the brake fluid level in the tank

☞ Check the brake fluid in the tank regularly. ☞ Add brake fluid up to the upper edge of the sight glass. ☞ The brake fluid must comply with the LHM SAE specification Section "Fluids and lubricants" on page 3-1.

Important!

DO NOT use brake fluid DOT 4.

☞ Replace the brake fluid every 2 years. ☞ If the brake system loses too much brake fluid, have the brake system checked and repaired by an authorized dealer.

If the level is below the upper edge of the sight glass:

☞ Clean the area around the opening with a clean cloth. ☞ Open tank cover A. ☞ Add brake fluid up to the upper edge of the sight glass (MAX). ☞ Close tank cover A. Repair work on the brake system

918294/AP1208

See Section "Brakes" on page 7-0.

3-29

Printed in U.S.A.

3.33 Tire care Danger!

Improper tire repairs are an –

Accident risk ☞ All repair work on tires and rims must be performed only by authorized personnel.

Important!

Regular tire inspection: • Improves operating safety.

• Increases tire service life.

• Can reduce machine downtime.

• Refer to the table in chapter 2 “Specifications” on pages Section "Tires for wheel loader — model AWS36" on page 2-9 and Section "Tires for wheel loader — model AWS46" on page 2-9 for the authorized tire types and the correct tire pressures. A tire table decal can also be found on the front window of the machine.

Daily tire check

☞ Complete the following maintenance work daily: • Check tire pressure Section "Tires for wheel loader — model AWS36" on page 2-9 and Section "Tires for wheel loader — model AWS46" on page 2-9.

• Check tires and rims for damage (cracks, aging, etc.).

• Remove objects from the tire tread.

• Remove oil and grease from the tires.

Weekly check

☞ Complete the following maintenance weekly: • Check tires for wear and measure tread depth.

Printed in U.S.A.

3-30

918294/AP1208

3.34 Changing wheels Danger!

Using the wrong tires or wheels –

Accident risk ☞ Use only authorized wheels and tires.

Section "Tires for wheel loader — model AWS36" on page 2-9 and Section "Tires for wheel loader — model AWS46" on page 2-9.

☞ Check the wheel nuts for tightness after every wheel or tire change.

Section "Hardware torques" on page 2-10.

Important!

The wheels are heavy and can damage the wheel stud threads if they are not handled correctly.

☞ Use the proper tools, such as covering sleeves for the studs and a jack.

Removing the wheels

☞ Proceed as follows: • Park the machine on level and firm ground.

• Block the wheels to prevent the machine from rolling.

• Slightly loosen the wheel nuts of the wheel you want to remove.

• Place a jack under the axle beam, making sure that it is secure.

• Raise the side of the axle from which you want to remove the wheel.

• Be sure the machine is firmly positioned.

• Remove the wheel nuts.

• Remove the wheel.

Fitting the wheels

☞ Proceed as follows: • Position the wheel on the wheel studs.

• Partially tighten all wheel nuts.

• Lower the raised axle.

• Tighten the wheel nuts to the correct torque.

Section "Hardware torques" on page 2-10.

918294/AP1208

3-31

Printed in U.S.A.

3.35 Heating The heating system is equipped with a fine-dust filter that must be cleaned regularly and replaced annually.

The filter is located behind the access panel, on the right on the outside of the cab.

Cleaning the dust filter of the heating system A fine-dust filter cleans the air taken in by the heater. The volume of warm air flowing out of the air vents decreases as filter contamination increases. Clean the fine-dust filter as required or annually.

☞ Clean the fine-dust filter as follows: • Open access panel A. A

• Remove fine-dust filter B. • Clean fine-dust filter B with compressed air. Replace if necessary.

• Close access panel A.

B

Fig. 76: Removing the dust filter of the heating system

Printed in U.S.A.

3-32

918294/AP1208

3.36 Electric system NOTE: The machine’s electrical system is fitted with a battery master switch. The key can be removed when in the OFF position. Remove the key: • Before working on the electrical system.

• As an antitheft precaution.

Safety instructions

Danger!

Battery acid is highly caustic –

Risk of acid burn When recharging and/or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves.

If acid is spilled:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water. ☞ Thoroughly wash any body part touched by the acid immediately with plenty of water and seek medical attention at once.

During charging, in particular, but also during normal battery operation, an oxygen-hydrogen mixture is formed in the battery cells. –

Risk of explosion ☞ Avoid open flame and sparks in the vicinity of the battery and do not smoke. ☞ Do not jump-start the machine if the battery is frozen or if the acid level is low. The battery may rupture or explode.

☞ Always disconnect the negative cable (–) from the battery before starting repair work on the electrical system.

Important! ☞ Use only 12 V power sources. Higher voltages will damage the electrical components.

☞ When connecting the battery, be sure that the poles are not inverted, otherwise sensitive electrical components will be damaged.

☞ DO NOT interrupt voltage-carrying circuits at the battery terminals because of the risk of sparking.

☞ Never place tools or other conductive articles on the battery — risk of short circuit.

☞ Disconnect the negative cable from the battery before starting repair work on the electrical system.

☞ Dispose of used batteries according to environmental laws.

918294/AP1208

3-33

Printed in U.S.A.

Service and maintenance work at regular intervals

Before driving the machine

☞ Check each time before driving the machine: • Light system.

• Signaling and warning system.

Weekly

☞ Check weekly: • Fuses Section "Fuse box" on page 2-6.

Section "Main fuse box — model AWS36" on page 2-7.

Section "Main fuse box — model AWS46" on page 2-7.

• Cable and ground connections.

• Battery charge condition.

• Condition of battery terminals.

• Wear marks on wiring harness.

Cables, bulbs and fuses

Always observe the following instructions: • Defective electric system components must always be replaced by authorized personnel, with the exception of bulbs and fuses.

• When performing maintenance on the electric system, pay particular attention to ensuring good contacts in leads and fuses.

• Blown fuses indicate overloading or short circuits. Check the electric system before installing a new fuse.

• Only use fuses with the specified load capacity (amperage) Section "Fuse box" on page 2-6.

Section "Main fuse box — model AWS36" on page 2-7.

Section "Main fuse box — model AWS46" on page 2-7.

Alternator

Always observe the following instructions: • Only test run the engine with the battery connected.

• When connecting the battery, make sure the poles (+/–) are not reversed.

• Always disconnect the battery before welding or connecting a quick battery charger.

• Replace defective charge indicators immediately.

Printed in U.S.A.

3-34

918294/AP1208

3.37 Battery maintenance Danger!

Battery acid is highly caustic –

Risk of acid burn When recharging and/or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves.

If battery acid is spilled:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water. ☞ Thoroughly wash any part of the body touched by the battery acid immediately with plenty of water and seek medical attention at once.

During charging, in particular, but also during normal battery operation, an oxygen-hydrogen mixture is formed in the battery cells –

Risk of explosion ☞ Avoid open flame and sparks in the vicinity of the battery and do not smoke. ☞ Do not jump-start the machine if the battery is frozen or if the acid level is low. The battery may rupture or explode.

☞ Always disconnect the negative terminal (–) from the battery before working on the electric system.

–

+

Battery A is located in the engine compartment, on the left next to the hydraulic oil tank.

The battery is a low-maintenance type and requires no maintenance under normal operating conditions.

A

Fig. 77: Battery

918294/AP1208

3-35

Printed in U.S.A.

3.38 General maintenance work Cleaning

Cleaning the machine consists of three separate cleaning areas: • Interior.

• Exterior.

• Engine compartment.

The wrong cleaning equipment and agents can affect machine safety and undermine the health of the persons cleaning the machine.

Follow these instructions.

When using washing solvents

• Ensure adequate room ventilation.

• Wear suitable protective clothing.

• DO NOT use flammable liquids, such as gasoline or diesel fuel.

When using compressed air

• Wear goggles and protective clothing.

• DO NOT aim the compressed air at the skin or at other people.

• DO NOT use compressed air for cleaning your clothing.

When using a high-pressure or steam jet cleaner

• Cover electrical components and damping materials.

• Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil, etc.

• Protect the following components from moisture: • Engine.

• Electric components (such as the alternator, etc.).

• Control devices and seals.

• Air intake filters, etc.

When using volatile and flammable anti-corrosion agents and sprays

• Ensure adequate room ventilation.

• DO NOT use unprotected lights or open flames.

• DO NOT smoke.

Printed in U.S.A.

3-36

918294/AP1208

3.39 Cleaning inside the cab Important!

Never use high-pressure cleaners, steam jets or high-pressure water to clean the inside of the cab. Water under high pressure may: • Penetrate into the electric system and cause short circuits.

• Damage seals and disable the controls.

Use any of the following to clean the cab: • Broom.

• Vacuum cleaner.

• Damp cloth.

• Bristle brush.

• Water with mild soap solution.

3.40 Cleaning the seat belt Clean the seat belt (do not disconnect the seat belt from the machine) with only a mild soap solution. DO NOT use chemical agents, as they may destroy the fabric.

Warning!

Debris or water on automatic seat belt may affect retraction –

Risk of personal injury ☞ Rewind the seat belt only when it is both clean and dry.

3.41 Machine exterior Use any of the following to clean the outside of the cab: • High-pressure cleaner.

• Steam jet.

918294/AP1208

3-37

Printed in U.S.A.

3.42 Engine compartment Danger!

Clean the engine only after it is turned off and stopped –

Risk of personal injury ☞ Stop the engine before cleaning. ☞ Remove the ignition key. ☞ Apply the parking brake.

Important!

When cleaning the engine with a water or steam jet:

☞ The engine must be cold. ☞ DO NOT point the jet directly at electric sensors, such as temperature and

oil pressure switches or the control valves. Any humidity penetrating these sensors can cause them to fail, which can lead to engine damage.

☞ Protect all electric parts, such as the alternator, connectors, etc., from humidity.

☞ If a water jet is unintentionally pointed at electric components, dry them with compressed air and apply contact spray to them.

3.43 Bolted connections, hinges

Important!

Check all bolted connections regularly, even if they are not listed in the maintenance schedules.

Tighten loose connections immediately. Refer to chapter “Specifications” for the tightening torques.

Important!

All mechanical pivot points on the machine (e.g., door hinges, joints) and fittings (e.g., door arresters) must be lubricated regularly, even if they are not listed in the lubrication schedule.

Printed in U.S.A.

3-38

918294/AP1208

918294/AP1208

3-39

Printed in U.S.A.

Printed in U.S.A.

Always replace complete elastic clutch

Thermostat

Starter

Fuel injection pump (separate)

Engine oil filter

Glow plug

4-0 Fuel filter

Fuel pump (maintenance can be performed)

34300s410_01.iso

F4M 2011/BF4M 2011 engine: overview

Oil pressure switch S2

4.1

Oil dipstick

Engine

Temperature switch S3

Cutoff solenoid

4

Oil drain valve

Alternator

Engine

918294/AP1208

918294/AP1208 Return

Temperature switch

☞ Replace defective seals.

4-1 Feed

34300s410_02.iso

Warm air outlet is over the engine to the left side of the machine.

Air guidance plate

Hydraulic oil cooling

Engine cooling

4.2

Check engine cover seals.

Important!

Cooling air intake from outside

Engine Engine oil cooling

Printed in U.S.A.

Printed in U.S.A.

4-2

Fig. 78: Fuel System

Remember the seal size when replacing the fuel injection pump.

Important!

Tappet

Fuel injection pump (separate)

Injection nozzle

Fuel filter

To tank

34300s410_03.iso

➥ Maintenance can be performed.

Fuel pump

• Bleed fuel system by use of the starter.

• Loosen the banjo bolt.

☞ Bleed the fuel system:

4.3

Fuel leak line (pump/nozzle)

Injection line (identical for cylinders 1–4)

Engine

Fuel system

918294/AP1208

Engine 4.4

Checking and adjusting valve clearance ☞ Set standard valve clearance when: ➥ Engine is cold, or after a warm engine has cooled down for at least 30 minutes. ➥ Oil temperature = 176°F (80°C).

NOTE: Increase valve clearance by 0.004 in. (0.1 mm) every time you replace the cylinder head gasket. Set the standard valve clearance after 1500 service hours.

Fig. 79: Turning the engine

The cylinder-head cover has been removed

☞ Turn the engine until reaching valve overlap, cylinder no. 1.

NOTE: Valve overlap means the exhaust valve is not yet closed and the intake valve is beginning to open. Both push rods cannot be turned.

Fig. 80: Valve overlap

☞ Set valve clearance at each cylinder with the feeler gauge. ➥ Inlet valve clearance: 0.012 in. (0.3 mm). ➥ Exhaust valve clearance: 0.020 in. (0.5 mm). ☞ Tighten the locknut. ➥ Tightening torque: 15 ± 1.5 lb.-ft. (20 ± 2 Nm). ➥ Check the setting again with the feeler gauge.

Fig. 81: Setting valve clearance

918294/AP1208

4-3

Printed in U.S.A.

Engine ☞ Position the gasket.

Fig. 82: Position the cylinder-head cover gasket

☞ Slide new rubber hoses onto the overflow line and the fuel injectors as far as they will go.

☞ Mount the cylinder-head cover and the overflow line. ☞ Tighten the screws. ➥ Tightening torque: 6.3 lb.-ft. (8.5 Nm).

Fig. 83: Mounting the cylinder-head cover

4.5

Replacing the fuel injection pump ☞ Loosen the crankcase screw plug.

Fig. 84: Crankcase screw plug

Printed in U.S.A.

4-4

918294/AP1208

Engine ☞ Set the adjusting lever to center position. ☞ Tighten the pin for the adjusting lever into the crankcase as far as it will go.

Fig. 85: Setting the adjusting lever

☞ Turn the camshaft until the tappet stroke of the cylinder is at lower dead center (approximately the six o’clock position).

Fig. 86: Camshaft

☞ Mount the injection pump tappet.

NOTE: Use a flexible magnetic tool.

Fig. 87: Mounting the tappets

☞ Determine the compensation gasket.

Fig. 88: Determining the compensation gasket

918294/AP1208

4-5

Printed in U.S.A.

Engine ☞ Measure dimension A from the crankcase base to the tappet base.

Fig. 89: Measuring the tappet base

☞ Dimension X of fuel injection pump = 2.4 in. (60 mm).

Important!

Dimension X is used for calculating the compensation gasket and cannot be measured with the fuel injection pump removed.

☞ Determine the difference between dimensions X and A. Example: Fig. 90: Fuel injection pump — dimension

Dimension X

= 2.4 in. (60.00 mm)

Dimension A

= 2.3 in. (59.35 mm)

Difference

= 0.03 in. (0.65 mm)

☞ Select a compensation gasket according to the table and the identification.

Difference — in. (mm) Up to 0.02 (0.4) 0.016–0.019 (0.401–0.5) 0.020–0.024 (0.501–0.6) 0.024–0.028 (0.601–0.7) 0.028–0.031 (0.701–0.8) 0.032–0.035 (0.801–0.9) 0.035–0.039 (0.901–1.0)

Identification of dimension — in. (mm) 0.40 (9.0) 0.50 (12.0) 0.59 (15.0) 0.71 (18.0) 0.83 (21.0) 0.94 (24.0) 1.06 (27.0)

Fig. 91: Compensation gaskets

Printed in U.S.A.

4-6

918294/AP1208

Engine ☞ Attach the compensation gaskets as needed.

Important!

Make sure the compensation gaskets are placed in the correct position.

Fig. 92: Placing the compensation gaskets

☞ Remove the lock pin from the fuel injection pump.

Fig. 93: Lock pin

☞ Be sure the lock wire is locked in the pivot lever before mounting the fuel injection pump.

Fig. 94: Lock wire

☞ Mount the fuel injection pump. ☞ Evenly press the fuel injection pump in as far as it will go. ☞ Tighten the nuts. ➥ Tightening torque: 15 lb.-ft. (21 Nm).

Fig. 95: Mounting the fuel injection pump

918294/AP1208

4-7

Printed in U.S.A.

Engine ☞ Pull out the lock wire.

Fig. 96: Pulling out the lock wire

☞ Lock the bore with the lock pin.

Fig. 97: Bore with lock pin

☞ Remove the adjusting pin for the adjusting lever.

Fig. 98: Adjusting pin — adjusting lever

☞ Tighten the screw plug with a new copper sealing ring.

Tightening torque: 13 lb.-ft. (18 Nm).

Fig. 99: Screw plug

Printed in U.S.A.

4-8

918294/AP1208

Engine 4.6

Setting the charge-air pressure — model ML460 Charge air

Pos.

Description

1

Set screw aspirated volume

2

Diaphragm

3

Spring

4

Solenoid

5

Fuel injection pump adjusting lever

6

Lever

7

Set screw for spring pre-tension

8

Spring

Fig. 100: Charge-air pressure

• The charge-air pressure acts on diaphragm 2 and on spring 8 which reacts accordingly.

This turns lever 6 and sets the adjusting lever to more volume, depending on charge-air pressure.

• When the engine is stopped, the adjusting lever is blocked by the full-load stop which depends on charge pressure. In order to achieve multiple volume for starting the engine, solenoid 4 presses the mechanism even farther as the engine is started.

• Set spring pre-tension with set screw 7.

➥ Volume released depends on a number of spring features.

• Set screw 1 adjusts the intake volume.

• Spring 3 ensures proper connection of all components.

918294/AP1208

4-9

Printed in U.S.A.

Engine 4.7

Charge-pressure dependent full-load stop — model ML460 The governor is equipped with an extra charge-pressure dependent full-load stop. This avoids carbon particle emissions of supercharged engines if the load suddenly changes from (low) partial-load to full-load. Full-load stop releases only the amount of fuel needed for the available combustion air.

The full-load stop is installed on the crankcase

Turning off minus compensation

Fig. 101: Charge-air pressure: overview

4.8

Turning off minus compensation The engine receives more fuel during the start procedure, with the help of the start quantity spring.

In order to keep minus compensation from counteracting and neutralizing the additional start quantity, minus compensation is turned off with a solenoid (terminal 50).

In order to do so, the solenoid separates the reversing lever from the compensation lever.

Some injection systems receive too much fuel as engine speeds drop; i.e., the engine receives more fuel than fresh air.

➥ The engine smokes. ☞ The fuel quantity must be reduced.

Minus compensation — function

The reversing lever is loosely connected to the compensation lever. If the engine runs under load, engine speeds drop and the compensation lever moves toward extra volume.

The reversing lever inverts this movement and the adjusting lever is moved toward less volume.

Printed in U.S.A.

4-10

918294/AP1208

Engine 4.9

Switching off minus compensation — model ML360 The engine receives more fuel during the start procedure, with the help of the start quantity spring.

In order to keep minus compensation from counteracting and neutralizing the additional start quantity, minus compensation is turned off with a solenoid (terminal 50).

In order to do so, the solenoid separates the reversing lever from the compensation lever.

Switch Switch off off minus minus compensation compensation

Some injection systems receive too much fuel as engine speeds drop; i.e., the engine receives more fuel than fresh air.

➥ The engine smokes. ☞ The fuel quantity must be reduced.

Minus compensation — function

Fig. 102: Minus compensation

The reversing lever is loosely connected to the compensation lever. If the engine runs under load, engine speeds drop and the compensation lever moves toward extra volume.

The reversing lever inverts this movement and the adjusting lever is moved toward less volume.

4.10 Heating connection The heating connection feed and return line ports are located on the side of the engine.

Feed

Return

Fig. 103: Heating connection

918294/AP1208

4-11

Printed in U.S.A.

Engine 4.11 Removing/mounting the cylinder head ☞ Determine the cylinder-head gasket's identification (see Fig. 94) Piston projection — in. (mm) 0.021–0.027 (0.530–0.690) 0.027–0.029 (0.691–0.760) 0.030–0.033 (0.761–0.830)

Identification — (slot) 1 slot 2 slots 3 slots

Fig. 104: Determining the cylinder-head gasket

☞ Remove the intake and exhaust manifolds.

Fig. 105: Removing the intake manifold

☞ Remove the cylinder-head cover.

Fig. 106: Removing the cylinder-head cover

☞ Remove the rocker arm brackets.

Fig. 107: Removing the rocker arm bracket

Printed in U.S.A.

4-12

918294/AP1208

Engine ☞ Remove the push rods.

Fig. 108: Removing the valve tappets

☞ Carefully raise the cylinder head from the engine block.

Fig. 109: Removing the cylinder head

☞ Make sure the straight pins are in their positions.

Fig. 110: Straight pins

☞ Position the cylinder-head gasket, and place on the cylinder-head face.

Important!

The sealing surfaces must be clean and free of oil.

Fig. 111: Placing the cylinder-head gasket

918294/AP1208

4-13

Printed in U.S.A.

Engine ☞ Check the length of the cylinder-head bolts. ➥ 5.9 ± 0.03 in. (150 ± 0.8 mm) ☞ Install the cylinder head. ➥ Apply a thin coat of oil to the cylinder-head bolts.

Fig. 112: Placing the cylinder-head gasket

☞ Install the cylinder-head bolts. ➥ Tightening torque:

8 10

6

4 5 Manifold side 3 1 2

9 7

• 1st pass

22 lb.-ft. (30 Nm)

• 2nd pass

59 lb.-ft. (80 Nm)

• 3rd pass

118 lb.-ft. (160 Nm)

• Angle for tightening:

90°

NOTE: Follow the order for tightening the cylinder-head bolts.

See Figure 113 Installing the cylinder-head bolts

Fig. 113: Installing the cylinder-head bolts

☞ Insert the push rods.

Fig. 114: Inserting the push rods

☞ Install the rocker arm bracket and align it with the push rods. ➥ Tightening torque:15 lb.-ft. (21 Nm) ☞ Set valve clearance.

Fig. 115: Installing the rocker arm bracket

Printed in U.S.A.

4-14

918294/AP1208

Engine ☞ Place the gasket for the cylinder-head cover. ☞ Install the cylinder-head cover. ➥ Tightening torque: 6.3 lb.-ft. (8.5 Nm)

Fig. 116: Installing the cylinder-head cover gasket

918294/AP1208

4-15

Printed in U.S.A.

Engine 4.12 Sealing the bleeder valve ☞ Remove the intake and exhaust manifolds.

Fig. 117: Removing the intake manifold

☞ Remove the cover. ☞ Clean the bleed valve. ☞ Install a new O-ring. ☞ Install the cover. ➥ Tightening torque: 6.3 lb.-ft. (8.5 Nm)

Fig. 118: Bleeder valve

Intake/exhaust manifold

☞ Install new gaskets. ☞ Install the intake and exhaust manifolds.

Tightening torque

➥ Intake manifold: 15 lb.-ft. (21 Nm) ➥ Exhaust manifold: 41 lb.-ft. (55 Nm) Fig. 119: Installing the intake manifold

Printed in U.S.A.

4-16

918294/AP1208

Engine 4.13 Engine trouble Problem

Possible causes Parking brake not applied Steering-column control lever not in neutral Engine starting temperature too low Wrong SAE grade of engine lubrication oil

Engine does not start or is not easy to start

Fuel quality does not comply with specifications Defective or discharged battery Loose or oxidized cable connections in starter circuit Defective starter, or pinion does not engage Wrong valve clearance Defective fuel injector Fuel quality does not comply with specifications

Engine starts, but does not run smoothly or faultlessly

Wrong valve clearance Injection line leaks Defective fuel injector Oil level too low Oil level too high Dirty air filter Defective air filter maintenance switch or gauge

Engine overheats; temperature warning system responds Fouled oil cooler fins Defective fan, torn or loose V-belt Cooling air heats up Resistance in cooling system too high, flow capacity too low Defective fuel injector Oil level too high Fuel quality does not comply with specifications Dirty air filter Insufficient engine output

Defective air filter maintenance switch or gauge Wrong valve clearance Injection line leaks Defective fuel injector

Engine does not run on all cylinders

918294/AP1208

Injection line leaks Defective fuel injector

4-17

Printed in U.S.A.

Engine Problem

Possible causes Oil level too low

Insufficient or no engine oil pressure

Engine inclination too high Wrong SAE grade of engine lubrication oil Oil level too high

Engine oil consumption too high

Engine inclination too high Blue

Oil level too high Engine inclination too high Engine starting temperature too low

White Engine smoke

Fuel grade does not comply with specifications Wrong valve clearance Defective fuel injector Dirty air filter

Black

Defective air filter maintenance switch or gauge Wrong valve clearance Defective fuel injector

Printed in U.S.A.

4-18

918294/AP1208

Engine

918294/AP1208

4-19

Printed in U.S.A.

Power train

5

Power train

5.1

Variable-displacement pump test ports — model ML360 Y4 = forward (green/violet cable color) Y5 = reverse (white/violet cable color)

Test port HP/forward driving

Test port HP/reverse driving

Test port Pilot pressure

HP/forward HP/reverse

X2

Y4/forward

X1 Y5/reverse

Printed in U.S.A.

Test port

Test port

Steering system and work hydraulics

Boost pressure

5-0

918294/AP1208

Power train 5.2

Variable-displacement pump — model ML360

Control cartridge (starting speed)

Set screw to control initiation and control piston pressure

Transposition plug

Boost pressure valve Set screw of high-pressure cartridges (towing function)

Set screw of high-pressure cartridges

Test port

(towing function)

Steering system and work hydraulics

918294/AP1208

5-1

Printed in U.S.A.

Power train 5.3

Variable-displacement pump test ports, 12 mph (20 kph) — model ML460

Test port HP/forward driving

Test port HP/reverse driving

Test port Pilot pressure

Test port Steering system and work hydraulics

Printed in U.S.A.

Test port Boost pressure

5-2

918294/AP1208

Power train 5.4

Variable-displacement pump, 12 mph (20 kph) — model ML460

Boost pressure valve HP/forward

Control cartridge (starting speed)

(high pressure forward)

Test port Steering system and work hydraulics

Pressure cutoff (high pressure setting) HP/reverse (high pressure reverse)

918294/AP1208

5-3

Port Y5/reverse driving green/violet

Port Y4/forward driving white/violet

Printed in U.S.A.

Power train 5.5

Variable-displacement motor, 12 mph (20 kph) — all models 6.5

Control initiation test port

Return oil to cooler

Large capacity Q-max

Set screw for control initiation Allen key 3–w/f 10

Return oil to check valve 22 psi (1.5 bar)

Small capacity Q–min Y10 solenoid valve

Y2 solenoid valve 1st–2nd speed

Driving direction identification

1st speed energized

Reverse driving energized

Cable color: grey/green

75.

V a r i a b l e d i s p l a c e m e n t p u m p t e s t p o

Cable color: green/violet

Printed in U.S.A.

5-4

918294/AP1208

Power train 5.8

Inching valve overview Bleed valve for brake system

P — pilot pressure

Y — control line (master brake cylinder)

Important!

Not a bleed valve,

☞ used for venting/bleeding the piston

T — return line

Description of inching valve Pressing the brake pedal applies pressure to the inching valve and the service brake.

The machine is first braked by means of the hydraulic drive, and then with the service brake.

Functional description Actuating the master brake cylinder applies pilot pressure to port Y of the inching valve, which in turn controls the piston valve in the inching valve and establishes a connection between port P and port T. The pilot pressure of the variable-displacement pump is reduced, which reduces the flow rate of the variable-displacement pump.

The machine slows down. At the same time, the brakes engage in proportion to the brake pressure.

Warning!

Do not modify the inching valve. It is a crucial safety component.

918294/AP1208

5-5

Printed in U.S.A.

Power train 5.9

Inching valve circuit, 12 mph (20 kph)

Control line to variabledisplacement motor

Control line to variabledisplacement pump

Bleed hose

Caution!

Flexible line must be closed when measuring output with the brakes

P

Y T Bleeder valve

P from the brake

Printed in U.S.A.

Ventilation

Return line

5-6

918294/AP1208

918294/AP1208

Control initiation test port

High pressure lines (HP)

Breather filter

5-7 Control line

Return line

Return suction filter

Inching valve

Return/pilot pressure

S

1000144359_s.iso

L

Radiator exit

Suction line

Return oil

Non-return valve 22 psi (1.5 bar)

Radiator entry

Engine coolant radiator

PS

Control line

Hydraulic oil cooler

Power train

5.10 Drive circuit, 12 mph (20 kph) — model ML360

Printed in U.S.A.

Printed in U.S.A.

5-8 Pressure cutoff

Forward/reverse driving directional valve

Boost pressure valve

Servo cylinder

HP valves

To the inching valve

Work hydraulics steering

To the priority valve

Control cartridge

➥ Reverse driving energized ➥ Forward driving de-energized

Driving direction identification

Control initiation test port

Control initiation

Pressure controller

(small oil circuit)

Valve 22 psi (1.5 bar)

Vent filter

Pressure switch

Return suction filter

Oil-to-water-cooler

➥ 1st speed energized ➥ 2nd speed de-energized

Solenoid valve 1st – 2nd speed

Power train

5.11 Drive, 12 mph (20 kph): wiring diagram

918294/AP1208

Power train 5.12 Towing and transporting the machine Transporting Obey state and local over-the-road regulations. Check state and local restrictions regarding weight, width, and length of a load. The hauling machine, trailer, and load must all be in compliance with local regulations.

• Tow, load, and transport the machine only in accordance with the Operator’s Manual.

• Safely secure the machine to the transport vehicle. Use suitable mounting points and load-securing devices.

Towing C

B

• The machine may only be towed using a towing bar or a cable and towing facilities (for example, a towing coupling, hooks, and eyes).

A

• Tow slowly. Make sure no one is near the towing bar.

• Tow the machine with a cable only if the service brakes and steering are operational.

A

B C

Fig. 120: 12 mph (20 kph) hydraulic pump

Danger!

Turning the steering wheel requires greater effort if the diesel engine is off.

Remember this when towing the machine.

☞ Use a tow bar if the diesel engine breaks down.

IMPORTANT! The hydrostatic power train can be damaged when towing the machine.

☞ Turn off the engine. ☞ Tow-enable the hydraulic circuit before towing (see below). ☞ Do not tow the machine for more than 328 ft. (100 m). ☞ Do not tow the machine faster than 2–3 mph (3–4 km/h). ☞ Do not tow for longer than three minutes.

Tow the machine as follows: • Use an adequately sized towing bar.

12 mph (20 kph) hydraulic pump

☞ Switch over the HP pressure relief valves A on the hydraulic pump. To do this: • Loosen hex locknuts B on both HP valves A. • Tighten hex socket head screws C on both HP valves A until they are flush with locknuts B. • Securely tighten hex socket head screws C on both HP valves A with locknuts B. After Towing

☞ Reset the HP valves A on the 12 mph (20 kph) hydraulic pump by unscrewing each of the hex socket screws C as far as they will go and securing them with locknuts B.

☞ On the 19 mph (30 kph) hydraulic pump, remove hose D.

918294/AP1208

5-9

Printed in U.S.A.

Power train 5.13 Test report — model ML360 Model:

Prod. no. variable-displacement pump

Prod. no. variable-displacement motor

____________________

____________________

Serial no. ___________________

____________________

Test conditions:

Rated oil temperature: 122–140°F (50–6°C) Rated driving direction: Forward

See page:

Notes:

Test features:

Nominal value: (rpm)

Min. idling speed

920–980 min.

Max. idling speed

2550–2650 min.

5-12

Boost pressure

Max. engine speed

406–508 psi (28–35 bar)

5-12

Pilot pressure

Max. engine speed

363–406 psi (25–28 bar)

Min. engine speed

About 73 psi (5 bar)

5-12

Starting speed

2nd speed

1150–1250 min.

5-13

High pressure

5-14

Drive pressure

2nd speed braked max. engine speed

5366–5511 psi (370–380 bar)

5-14

Hydraulic resistance curve

2nd speed braked at 2000 rpm

Over 4642 psi (320 bar)

5-15

Engine droop

1st speed braked 3626 psi (250 bar) max. engine speed

2100–2250 min.

✔

Hydraulic motor settings 5-15

Control piston pressure control initiation

2nd speed after braking

2756–3046 psi (190–210 bar)

5-16

Wheel speed

Max. engine speed

102–109 min.

Printed in U.S.A.

5-10

918294/AP1208

Power train 5.14 Test report — model ML460 Model:

Prod. no. variable-displacement pump

Prod. no. variable-displacement motor

____________________

____________________

Serial no. ___________________

____________________

Test conditions:

Rated oil temperature: 122–140°F (50–60°C) Rated driving direction: Forward

See page:

Notes:

5-12

Test features:

Nominal value: (rpm)

Min. idling speed

920–980 min.

Max. idling speed

2430–2470 min.

Boost pressure

Max. engine speed

406–508 psi (28–35 bar)

Pilot pressure

Max. engine speed

363–406 psi (25–28 bar)

Min. engine speed

About 73 psi (5 bar)

5-12 5-12

Starting speed

2nd speed

1050–1250 rpm

5-13

High pressure

5-14

Drive pressure

2nd speed braked max. engine speed

6817–7542 psi (470–520 bar)

5-14

Hydraulic resistance curve

2nd speed braked at 2000 rpm

Over 6092 psi (420 bar)

Engine droop

1st speed braked 3626 psi (250 bar) max. engine speed

2100–2250 min.

Control piston pressure control initiation 12 mph (20 kph)

2nd speed after braking

3481–3771 psi (240–260 bar)

Wheel speed 12 mph (20 kph)

Max. engine speed

95–100 min.

Wheel speed 19 mph (30 kph)

Max. engine speed

152–157 rpm

Control piston pressure control initiation 19 mph (30 kph)

2nd speed after braking

5-15

✔

Hydraulic motor settings 5-15

5-16

918294/AP1208

5-11

Printed in U.S.A.

Power train 5.15 Power train adjustment Important!

Run the machine up to operating temperature 140°F (60°C).

Brake the machine with the service brake when taking the measurement. Unscrew the brake-inching line from the hydraulic pump and fit a blank cover.

Set the valves only if the pressure has been released.

Tools required • High pressure gauge 8702 psi (600 bar).

• Pressure gauge 870 psi (60 bar).

• Tachometer.

5.16 Adjusting boost pressure Boost pressure valve

Set the control cartridge w/f 13 — Allen key 4 The boost pressure valve can only be set by means of washers in the boost pressure valve.

☞ Remove the complete valve. ☞ Set the pressure to 406–508 psi (28–35 bar) by adding or removing washers.

5.17 Adjusting starting speed Model ML360 = 725 psi (50 bar) high pressure, 1150–1250 rpm Model ML460 = 725 psi (50 bar) high pressure, 950–1150 rpm

☞ Safely jack up the machine at the front and rear. ☞ Move the drive lever to select the driving direction. ☞ Slowly increase the engine speed.

Set the starting speed on the control cartridge:

☞ Tighten in the control cartridge: ➥ Starts later. ☞ Loosen the control cartridge: ➥ Starts sooner.

Printed in U.S.A.

5-12

918294/AP1208

Power train 5.18 Setting high pressure/drive pressure Test port for high-pressure forward driving

Test port for high-pressure reverse driving

Connect pressure gauge 8702 psi (600 bar)

Connect pressure gauge 8702 psi (600 bar)

High-pressure valve reverse

Pressure cutoff

Important!

The pressure cutoff corresponds to the hydraulic pressure measured at the forward and reverse driving high-pressure measurement ports.

☞ Engage 1st or 2nd speed. ☞ Drive the machine against “hydraulic resistance” (wheels not allowed to spin at full power).

☞ Read the pressure on the forward driving high-pressure gauge.

Set the pressure at the pressure cutoff (w/f 13 — Allen key 4)

☞ Tighten in the pressure cutoff. ➥ Pressure increase. ☞ Loosen the pressure cutoff. ➥ Pressure reduction — model ML360= 5366–5511 psi (370–380 bar). ➥ Pressure reduction — model ML460= 6817–7542 psi (470–520 bar).

918294/AP1208

5-13

Printed in U.S.A.

Power train 5.19 Setting the secondary valves for forward/reverse driving Loosen hex socket screw 3 Apply tension to spring cap

Set w/f 8 here 1 turn corresponds to 580 psi (40 bar) 302S2214.ai

Remove valve completely (w/f 32)

Important!

Pressure setting of secondary valves is about 10% higher than pressure cutoff.

☞ Set pressure cutoff to "hydraulic resistance." ☞ Connect the forward/reverse driving high-pressure gauges. ☞ Drive the machine against hydraulic resistance. ☞ Follow the instructions in the figure to the left. ☞ Reset the pressure cutoff once the measurement is taken. ➥ Section "Test report — model AWS36" on page 5-10. ➥ Section "Test report — model AWS46" on page 5-11. ➥ w/f 13 — Allen key 4.

5.20 Setting the pump hydraulic resistance (characteristic curve) High-pressure Transposition screw (forward driving) w/f 17 — Allen key 5

Caution!

Do not modify the hydraulic resistance curve.

Important!

Transposition screw is set to 9 o'clock position (indicated by slot in the screw).

Correct the hydraulic resistance curve as required by turning the transposition screw.

Connect the pressure gauge 8702 psi (600 bar) Hydraulic resistance curve set on test rig Hydraulic resistance curve psi (bar)

7252

(500)

6527

(450)

5802

(400)

4351

(300)

2901

(200)

1450

(100)

6 o'clock

Measurement

☞ Safely jack up the machine at the front and rear. ☞ Pinch off brake inching line. ☞ Move the drive lever to select the driving direction. ☞ Increase the engine speed and drive against the hydraulic resistance. ➥ At 2000 rpm, minimum high pressure (forward) is: ➥ Model ML360: 4641 psi (320 bar). ➥ Model ML460: 6092 psi (420 bar).

Example:

9 o'clock

12 o'clock

☞ Set the transposition screw to 12 o'clock: ➥ Curve becomes flatter (machine reacts more smoothly). ☞ Set the transposition screw to 6 o'clock: ➥ Curve becomes steeper (machine reacts more abruptly).

Pilot pressure 1000

1500

2000

Speed [rpm]

Printed in U.S.A.

2500

5-14

918294/AP1208

Power train 5.21 Setting engine droop Measurement

High-pressure test port

➥ – Connect pressure gauge HP/ forward driving 8702 psi (600 bar)

➥ – Connect a tachometer (diesel) Control cartridge

☞ Safely jack up the machine at the front and rear. ☞ Pinch off brake inching line. ☞ Move the drive lever to select the 1st speed forward. ☞ Start the engine and run it at full thottle. ☞ Brake the machine until the high pressure reaches 3771 psi (260 bar). ➥ Droop speed must be: ➥ For model ML360: 2100–2250 rpm. ➥ For model ML460: 2050–2200 rpm.

If the engine droop is excessive:

☞ Check the diesel engine. ☞ Check the control cartridge.

Setting: w/f 13 — Allen key 4

5.22 Setting control initiation on the hydraulic motor High-pressure test port

➥ – Connect pressure gauge HP/forward driving 8702 psi (600 bar)

8702 psi (600 bar) pressure gauge connect (control piston)

➥ – Connect a tachometer (diesel engine)

302s2215.ai

High-pressure forward driving gauge 8702 psi (600 bar)

Adjust control initiation w/f 10 — Allen key 3 – Screw in = pressure increase – Unscrew = pressure reduction

☞ Safely jack up the machine at the front and rear. ☞ Pinch off brake inching line. ☞ Move the drive lever to 2nd speed forward. ☞ Start the engine and run it at full thottle. ☞ Slowly brake the machine with the service brake. ➥ Pressure on pressure gauge (forward driving high pressure) and control piston slowly rises.

Important!

When the pressure in the control piston drops rapidly, high pressure (forward driving) must be: • For model ML360: about 2756–3046 psi (190–210 bar).

• For model ML460: about 3481–3771 psi (240–260 bar).

918294/AP1208

5-15

Printed in U.S.A.

Power train 5.23 Setting the wheel speed Tools required • Infrared tachometer.

Label (measurement point)

Measurement and adjustment values.

➥ Section "Test report — model AWS36" on page 5-10. ➥ Section "Test report — model AWS46" on page 5-11. ☞ Safely jack up the machine at the front and rear. ☞ Move the drive lever to select the 2nd speed forward. ☞ Run the diesel engine at full thottle. ☞ Read the wheel speed with a tachometer.

Wheel speeds are adjusted at the hydraulic motor

Set screw for wheel speed

Printed in U.S.A.

☞ Loosen the set screw: ➥ Wheel speed is increased. ☞ Tighten in the set screw: ➥ Wheel speed is reduced.

5-16

918294/AP1208

Power train

918294/AP1208

5-17

Printed in U.S.A.

Axles

6

Axles

6.1

Axle overview

Printed in U.S.A.

6-0

918294/AP1208

Axles 6.2

Sealing service (joint housing/axle carrier) Tools Required: • Gear extractor.

• Soft-faced hammer.

• Tire mounting levers (2).

☞ Block the wheels. ☞ Remove screws 23 from planetary cover 25 (8 mm Allen key).

23

25

41

Environment!

Collect oil as it drains in a suitable container and dispose of it according to environmental law.

☞ Using a pry bar, remove the planetary cover 25 from the joint housing. Place a safety stand under the arm that remains connected.

25

➥ Both parts 25 and 41 are sealed on the housing with an O-ring. ☞ Remove the complete planetary cover: • There are three planetary gears in each planetary drive.

• 28 rollers per wheel are used for the planetary gear bearing.

4

30

☞ Remove circlip 30.

Caution!

To avoid injury, wear eye protection when removing snap rings and circlips.

32

☞ Remove nuts 32.

Important!

Use care to avoid damaging the gear on the double-cardan shaft 4.

918294/AP1208

6-1

Printed in U.S.A.

Axles 31

☞ Remove toothed spacer 31.

Important!

Check the condition of the toothed spacer. If toothed spacer is worn, cracked, or broken, it must be replaced.

33

35

☞ Remove tab washer 33.

☞ Remove internal-geared wheel 35 by applying pressure using an extractor or a tire mounting lever.

☞ Remove the internal-geared wheel.

41

38

Printed in U.S.A.

☞ Remove wheel hub 41 with a soft-faced hammer.

☞ Remove inner ring 38.

6-2

918294/AP1208

Axles 41

44

☞ Remove wheel hub 41.

☞ Remove cassette ring 44 with a tire mounting lever.

☞ Measure the length of the exposed screw threads on the screw restricting the steering angle.

☞ Loosen the locknut and screw in the stop screw.

☞ Remove nut securing the track rod.

14

918294/AP1208

☞ Use an extractor to remove the track rod from the joint housing 14.

6-3

Printed in U.S.A.

Axles ☞ Remove screws 19 from the lower planetary drive bearing.

19

☞ Remove the lower bearing pin 20 with the ball half.

20

☞ Remove screw 13 from the upper bearing pin.

13

☞ Remove bearing pin 10 by applying pressure with two tire mounting levers. ☞ Remove sealing ring 8.

10

8 14

☞ Remove the complete joint housing 14.

☞ Remove sealing ring 5.

5

Printed in U.S.A.

6-4

918294/AP1208

Axles ☞ Remove the double-cardan shaft 4.

8 18

☞ Remove sealing rings 8 and 18 from the pin.

Important!

Note sealing ring position for re-assembly.

☞ Remove sealing ring 3 from the axle carrier.

3

918294/AP1208

6-5

Printed in U.S.A.

Loctite 242 66–74 lb-ft (90–100 Nm)

Loctite 242 66–74 lb-ft (90–100 Nm)

Axles

CONTINU0US ROLLING TORQUE without planetary gear cover 5–15 lb-ft (7–20 Nm) PRELOAD STEERING CASE 30–59 lb-ft (40–80 Nm)

☞ Even rolling resistance of 5–15 lb-ft (7–20 Nm) (without planetary gears) ☞ Initial stress on bearing pins ➥ Torque about 30–59 lb-ft (40–80 Nm)

Printed in U.S.A.

6-6

918294/AP1208

Axles

NOTE: 6

Bushing 6 is not slotted.

☞ Use an adapter to mount the bushing.

☞ Install sealing ring 5 and cassette ring 44 into the joint housing with an adapter.

Important!

Do not use grease to insert cassette ring 44.

44

☞ Install sealing rings 8 and 18 with the larger diameter upward.

918294/AP1208

6-7

Printed in U.S.A.

Axles ☞ Install sealing ring 3 in the axle carrier with an adapter.

3

☞ Insert double-cardan shaft 4 into axle carrier 1.

1

4

☞ Carefully install joint housing 14 onto the axle carrier.

Important!

Use caution to prevent damage to the sealing ring.

4

14

☞ Install 0.016–0.028 in. (0.4–0.7 mm) spacers on the upper pin.

☞ Install the upper pin with a sealing ring with the larger diameter downward.

☞ Install the lower pin with a sealing ring with the larger diameter upward.

Printed in U.S.A.

6-8

918294/AP1208

Axles ☞ Tighten the screws securing the upper and lower bearing pins to 66–74 lb-ft (90– 100 Nm).

☞ Check vertical play with a mounting lever and a dial gauge. No play should exist.

☞ Check the tightening moment of the planetary drive bearing. ➥ The tightening moment must be 30–59 lb-ft (40–80 Nm).

☞ Hook the track rod of the steering cylinder into the joint housing and tighten to 199–221 lb-ft (270–300 Nm).

☞ Adjust the steering angle stop screw so the length of the exposed screw threads is the same as measured earlier.

918294/AP1208

6-9

Printed in U.S.A.

Axles ☞ Install the bearing and the wheel hub.

Important!

Carefully de-grease and clean all threaded parts before re-assembling internal axle components.

☞ Install the internal-geared wheel.

☞ Install the internal-geared wheel onto the seat of the planetary carrier with a soft-faced hammer.

☞ Install the lock washer.

☞ Install the fastening nuts with Loctite 243 and tighten them in two steps with a torque 4

wrench.

➥ 1st pass = 66 lb-ft (90 Nm). ➥ 2nd pass = 94–104 lb-ft (128–141 Nm).

Important!

Use care to avoid damaging the gear on the double-cardan shaft 4.

Printed in U.S.A.

6-10

918294/AP1208

Axles ☞ Install toothed spacer 31.

31 Important!

A worn or damaged tooth spacer must be replaced, or axle damage may result.

☞ Install the circlip.

☞ Without the planetary gears installed, check the wheel bearing rolling resistance: ➥ 5–15 lb-ft (7–20 Nm).

☞ Install the O-ring.

☞ Install the planetary cover.

☞ Install and tighten the fastening screws using an 8 mm Allen key. ☞ Add oil. See Chapter "Fluids and lubricants" on page 3-1. ☞ Perform a test run and check for leaks.

918294/AP1208

6-11

Printed in U.S.A.

Axles 6.3

Bevel gear shaft seals

Removal

☞ Remove the left and right side axle halves from the differential housing. ☞ Remove the differential cage from the differential housing with the crown wheel. ☞ Remove the transfer gearbox from the differential housing 5. ☞ Remove ball bearing 3. ☞ Remove threaded ring 11 with a special tool. ☞ Remove pinion shaft B, spacer ring 12 and spacers 13 and 23 from the differential housing toward the inside of the housing with a soft-faced hammer.

☞ Remove sealing ring 1.

Installation

☞ Install a new sealing ring with an adapter. ☞ Install pinion shaft B in the differential housing with the inside bearing ring. ☞ Fit spacer ring 12 and spacers 13 and 23 from the outside. ☞ Heat the inner ring of the taper roller bearing to 212°F (100°C) and install it on the pinion shaft.

☞ Screw threaded ring 11 onto the pinion shaft with Loctite 270. ☞ Tighten threaded ring 11 with a special tool to 295–369 lb-ft (400–500 Nm). ☞ Install ball bearing 3. ☞ Secure the transfer gearbox onto the differential housing. ☞ Install the left and right side axle halves.

Printed in U.S.A.

6-12

918294/AP1208

Axles Differential cage/differential lock screw connections

918294/AP1208

6-13

58–63 lb-ft (78–86 Nm)

Side crown shim 0.029 in.(0.75 mm)

19.3 lb-ft (26.2 Nm)

Side brake shim

6.4

Printed in U.S.A.

Axles

Seals (O-ring)

Overview of differential lock and differential cage

Sliding sleeve

Return spring

6.5

Printed in U.S.A.

6-14

918294/AP1208

Axles 6.6

Removing the differential cage with the differential lock ☞ Completely remove the axle tube (on the left in driving direction).

☞ Completely remove the differential cage with the differential lock.

☞ Use an extractor to remove the taper roller bearing.

Caution!

The sliding sleeve can be ejected upward when loosening the hex head screws.

☞ Press the sliding sleeve downward while removing the hex head screws.

☞ Remove the sliding sleeve and the spring from the differential cage.

918294/AP1208

6-15

Printed in U.S.A.

Axles 6.7

Removing the differential lock • Pos. 1: piston.

• Pos. 2: stop screw.

• Pos. 3 + 4: seals (O-rings).

☞ Remove screws 2.

2 2

☞ Remove the piston.

Printed in U.S.A.

6-16

918294/AP1208

Axles 6.8

Assembling the differential lock ☞ Guide groove A on the sliding sleeve and ball B on the differential cage must be

A

aligned during assembly.

B

☞ Insert the hex head screws of the sliding sleeve with Loctite 243 and tighten them to a torque of 19.3 lb-ft (26.2 Nm).

☞ Pre-heat the taper roller bearing to 212°F (100°C) and install it with an adapter.

A

☞ Insert the piston of the lock and tighten fastening screws 2 to a torque of 22 lb-ft (30 Nm).

☞ Clean the flange surface A on the differential housing.

2

☞ Carefully insert the differential cage with the lock in the piston.

☞ Clean the flange surface on the axle tube and install the complete axle tube.

918294/AP1208

6-17

Printed in U.S.A.

6.9

Removing the gearbox Tightening torque 89 lb-ft (120 Nm) Loctite 510 Loctite 270 tightening moment 199 lb-ft (270 Nm)

Loctite 510 tightening moment 66 lb-ft (90 Nm)

Loctite 510

Tightening torque 66 lb-ft (90 Nm)

Loctite 242 tightening moment 18 lb-ft (25 Nm) Loctite 510

Printed in U.S.A.

6-18

918294/AP1208

☞ Remove screws 33 from the gearbox.

33

☞ Remove the gearbox from the axle.

☞ Remove drain plug 22.

22

21

21

☞ Remove screws 21. Note screw location for re-assembly.

☞ Remove cover 24.

24

918294/AP1208

6-19

Printed in U.S.A.

☞ Remove nut 11 from flange 13.

11

13

☞ Remove nut 11 and O-ring 12.

11

12

☞ Remove the flange.

☞ Remove screws 15 from cover 14.

15

14

☞ Remove cover 14.

14

☞ Remove spacers 18.

18

Printed in U.S.A.

6-20

918294/AP1208

☞ Remove sealing ring 17.

17

☞ Remove shaft 26.

26

☞ Remove the oil baffle.

☞ Remove gear 31.

31

☞ Remove washer 32 and bearing 19.

32

918294/AP1208

19

6-21

Printed in U.S.A.

☞ Remove bearing shell 17.

17

☞ Remove screws 27 and remove cover 29.

29

27

☞ Remove spacers 18.

18

☞ Remove screws 9 from the adapter housing and remove the adapter housing.

9

☞ Extract bearing 4 from the adapter housing with an extractor.

4

☞ Remove upper shaft 3.

3

Printed in U.S.A.

6-22

918294/AP1208

☞ Remove outer bearing 19.

19

☞ Using a press, remove shaft 3 from the bearing.

3

19

☞ Remove gear 30 and bearing 19.

30

4

918294/AP1208

☞ Apply pressure to remove bearing 4.

6-23

Printed in U.S.A.

6.10 Input shaft version 1 sealing: overview

95–105 lb-ft (129–143 Nm)

63–66 lb-ft (86–89 Nm) 192–207 lb-ft (260–280 Nm) Loctite 242 S1 S2

26–37 lb-ft (35–50 Nm)

95–105 lb-ft (129–143 Nm) Loctite 242 18–21 lb-ft (25–28 Nm)

Printed in U.S.A.

6-24

918294/AP1208

6.11 Assembling the gearbox ☞ Install bearing 4 on shaft 3.

4

3

☞ Install gear 30 on shaft 3.

30

3

☞ Install bearing 19.

19

☞ Install the complete shaft in the housing.

☞ Press seal 4 into the adapter housing.

4

918294/AP1208

6-25

Printed in U.S.A.

☞ Install adapter housing 5.

5

☞ Tighten screws 9 to 103 lb-ft (140 Nm).

9

☞ Install bearing shell 19.

19

☞ Measure the bearing projection and make a note of it.

NOTE: Y

The dimension of the projection is shown as Y in the figure.

X

S1

Printed in U.S.A.

☞ Determine dimension X. ➥ Dimension X is the distance between the contact surface and the upper edge of the bearing.

☞ Measure both dimensions X and Y to determine the thickness of the spacers. ➥ S1 = X – Y = 0.95 mm – 0.05 mm= 0.90 mm = S

6-26

918294/AP1208

☞ Mount cover 29 with screws 27 and Loctite 510.

29 27

☞ Tighten screws 27 to 37 lb-ft (50 Nm).

27

☞ Using a soft-faced hammer, drive in the input shaft as far as it will go.

☞ Place the dial gauge on the housing.

☞ Measure the bearing play with a tire mounting lever. ➥ Bearing play 0.0008–0.0019 in. (0.02–0.05 mm)

31

918294/AP1208

☞ Install gear 31.

6-27

Printed in U.S.A.

☞ Install shaft 26 with a soft-faced hammer.

26

☞ Mount the oil driving ring.

Important!

The cut-out portion of the oil driving ring should face up.

To the inside

☞ Install bearing 19.

19

☞ Using a soft-faced hammer, install the bearing as far as it will go.

☞ Install spacer ring 32.

32

☞ Install bearing 19 onto the shaft.

19

Printed in U.S.A.

6-28

918294/AP1208

☞ Install the outer ring 19.

19

☞ Install cover 14 with washers.

14

☞ Tighten screws 15.

15

☞ Install the gearbox onto the axle.

☞ Tighten screws 33 to 55 lb-ft (75 Nm).

33

☞ Remove screws 15.

15

918294/AP1208

6-29

Printed in U.S.A.

☞ Remove washers 18 and cover 14.

14 18

☞ Using a soft-faced hammer, drive in the bearing again.

☞ Measure the bearing projection.

NOTE: The dimension of the projection is shown as Y in the figure.

Y

☞ Measure the dimension on the cover between the contact surface and the upper edge of the bearing.

To determine the spacer size:

X

➥ X–Y = 0.0019 in. (0.05 mm) (initial stress) = thickness of spacers.

☞ Install washers 18 and cover 14.

14 18

☞ Tighten screws 15 to 66 lb-ft (90 Nm).

15

Printed in U.S.A.

6-30

918294/AP1208

☞ Install the spacer washer and the flange.

☞ Install O-ring 12 and nut 11.

12

11

☞ Tighten the flange to 207 lb-ft (280 Nm).

☞ Install cover 24 with Loctite 510.

24

☞ Tighten screws 21 to 21 lb-ft (28 Nm).

21 21

☞ Install drain plug with new sealing ring in opening A and tighten securely. ☞ Fill gearbox with oil until it runs out of filler opening B. See Chapter "Fluids and lubricants" on page 3-1. Install filler opening plug with new sealing ring in opening B and tighten securely.

B A

918294/AP1208

6-31

Printed in U.S.A.

Printed in U.S.A.

7-0 Inching valve

Inching up to 116 psi (8 bar)

Brake circuit

Brake light switch (S16)

7.1 Master brake cylinder

Brakes

clearance to pedal

0.08 in. (2 mm)

7

Pressure line

• Shell LHM

• Agip LHM Super

Brake-fluid tank

Brakes

918294/AP1208

Brakes 7.2

Brake diagram

Brake pedal unit

To tank

Master brake cylinder

Inching valve Brake light switch

Brake-fluid tank • Agip LHM Super • Shell LHM

Control pressure line

Brake (front axle)

918294/AP1208

12 mph (20 kph) port

7-1

Printed in U.S.A.

Setting on cable pull

Setting on cable pull

Printed in U.S.A.

7-2

➥ Port S11 ➥ Signal (1st/2nd notch)

7.3

Handbrake switch with starting interlock

Handbrake lever

Brakes

Handbrake circuit

918294/AP1208

Brakes 7.4

Inching valve circuit, 12 mph (20 kph)

Control line to variabledisplacement motor

Control line to variabledisplacement pump

Bleed hose

Caution!

Flexible line must be closed when measuring output with the brakes

P

Y T Bleeder valve

P from the brake

918294/AP1208

Ventilation and bleeding

Return line

7-3

Printed in U.S.A.

Brakes 7.5

Service brake Warning!

For safety reasons, the brake/inching valve, the pressure accumulator and the brake caliper may only be dismantled and repaired by authorized dealer staff.

Otherwise, replace the complete unit.

To avoid damage to the seals in the brake system:

☞ Use Agip LHM Super or Shell LHM brake fluid. ☞ Be sure old brake fluid in the bleed equipment is fully replaced by the brake fluid specified above. Do not mix types of brake fluids.

Brake caliper maintenance Caution!

Be sure that no grease with metallic additives is used for maintenance work (e.g., copper paste).

☞ In combination with copper and salt water, aluminium-alloy brake calipers turn into galvanic elements producing electrical current. This produces corrosion, causing the components to “seize.”

☞ Use only PLASTILUBE or similar lubricants.

Warning!

Do not disassemble the brake piston in the brake caliper.

Risk of accidents! ☞ Replace only the complete brake caliper in case of leaks.

Replacing the brake linings

☞ Remove the safety pin. ☞ Remove the bearing pin. ☞ Remove the cable pull on the brake caliper. ☞ Fold the brake caliper up. ☞ Remove the brake linings. ☞ While applying pressure, turn the brake cylinder

Safety pin Bearing pin

piston to reset it.

☞ Insert new brake linings and install the brake caliper in the reverse order.

Printed in U.S.A.

7-4

918294/AP1208

Brakes

918294/AP1208

7-5

Printed in U.S.A.

Printed in U.S.A.

LS line

Front axle

B1

8-0 1000144594_s.iso

Steering cylinder with final position synchronization

Rear axle

Steering circuit for model ML360

To control valve

LS

Tank

8.1

A2

A1

L

T

Steering

Priority valve

B2

R

P

Pressure relief valve 2538–2611 psi (175–180 bar)

8

Test port and P line to steering system

From the pump

(in left side access)

Valve 7.3–145 psi (0.5–10.0 bar)

Check block

Steering

918294/AP1208

Steering 8.2

Steering diagram for model ML360

Pressure relief valve (adjustable to 2538–2683 psi [175–185 bar])

To control valve

From the pump

P to steering system

145 psi (10 bar) 143

7.25 psi 7.25 psi (0.5 bar) (0.5 bar)

145 psi (10 bar)

Valve block

To tank

Front axle

Rear axle

Steering cylinders

918294/AP1208

Final position synchronization

8-1

Printed in U.S.A.

Printed in U.S.A.

Check block

A

S

8-2 2538–2611 psi (175 – 180) bar

Steering system test port

R

L

LS

L

R

T

P

P

CF

Priority valve Rear axle

Tank

8.3

B

T

Front axle

Steering

Steering circuit for model ML460

918294/AP1208

Steering 8.4

Steering diagram for model ML460

Work hydraulics P

Steering

3553 psi (245 bar) 2538 psi (175 bar)

Priority valve

Check block From the pump To tank

3336 psi (230 bar)

918294/AP1208

3336 psi (230 bar)

8-3

Printed in U.S.A.

Steering 8.5

Steering system adjustment

Function

Steering is accomplished through the use of two steering cylinders. Both steering cylinders are connected together on one side of the chamber; the steering valve and the check block are located in between. Each of these components has a certain amount of leakage, which means hydraulic oil escapes between the front and rear steering cylinders. This oil is no longer replenished during steering, since pressure is applied to only one side of the front or rear steering cylinder when steering left or right. This is why synchronizing several times a day is normal, depending on how the machine is used.

Checking a steering cylinder

• Apply pressure to the steering cylinder in center position, i.e., block one side with a sleeve.

• Remove the hydraulic lines. The connecting piece to the manual pump must have a micro port and a stop cock.

• Raise pressure to 2176 psi (150 bar). Pressure is allowed to drop to about 290 psi (20 bar) in 10 minutes.

• Perform a low-pressure test at 145 psi (10 bar). No pressure drop should occur in the process.

Checking the check block

S

Pressure relief valve 3336 psi (230 bar)

A R

T Pressure relief valve 3336 psi (230 bar)

B

L

☞Testing the check block: • Connect the manual pump to port S, 3626 psi (250 bar). No pressure drop should occur in the process.

• Connect the manual pump to port A. Pressure must rise to 3336 psi (230 bar) in the process, until the pressure relief valve opens.

• Measure leakage on R < 0.5 ounce/min (15 cm³/min) – P = 3336 psi (230 bar).

• Connect the manual pump to port B. The pressure must rise to 3336 psi (230 bar) in the process, until the pressure relief valve opens.

• Measure leakage on L < 0.5 ounce/min (15 cm³/min) – P = 3336 psi (230 bar).

• Apply 218 psi (15 bar) of pressure to manual pump port T. No pressure drop should occur in the process.

Printed in U.S.A.

8-4

918294/AP1208

Steering 8.6

Hydraulic ports on servostat 17 lb-ft (23 Nm)

L

30 lb-ft (40 Nm)

L T

13 lb-ft (18 Nm)

LD

17 lb-ft (23 Nm)

R

P

30 lb-ft (40 Nm)

R

T

P

8.7

T

17 lb.-ft. (23 Nm)

LD

• P = pressure

Hydraulic pump => priority valve => servostat

• LD =

Priority valve => servostat

• L = left

Servostat => rear axle steering cylinder

• R = right

Servostat => front axle steering cylinder

• T = return

Servostat => hydraulic tank

Pressure relief valve: adjustment Pressure relief valve Steering pressure

Proceed as follows:

☞ Remove the leg room cover. ☞ Remove the side cover on the steering console. ☞ Loosen the servostat (4 screws M10) and slide downward. ☞ Adjust the steering pressure with an Allen key. ➥ 2538 psi (175 bar)

Secondary valve

918294/AP1208

8-5

Printed in U.S.A.

Steering 8.8

Steering cylinder: seals

9 5 4

3 34001e2303,eps

7 8

2

6

2

1

9

1 ☞ Proceed as follows: • Remove locknut 1 from track rod joint 2.

• Remove track rod joint 2 from the planetary carrier.

• Determine the setting value between the end of the piston rod and the track rod joint.

➥ e.g., determine the revolutions as you remove track rod joint 2.

• Remove track rod joint 2 from piston rod 3.

• Remove threaded pipe fitting 4.

• Remove the three screws 5 and complete steering cylinder from the axle carrier.

• Clamp the steering cylinder in a vise with aluminium jaws.

• Remove circlip 6.

• Slide guide bushing 7 to the inside.

• Remove circlip 8.

• Pull out piston rod 3 with guide bushing 7.

• Replace the seals and cuffs 9.

• Assemble in the reverse order.

Printed in U.S.A.

8-6

918294/AP1208

Steering 8.9

Overview of steering cylinder adjustment Adjust the steering system when servicing the axles or when necessary: • After replacing/repairing the track rods or the track-rod ends C. • After servicing the joint housing or stop screws E. • After servicing the steering cylinder, e.g., replacing the piston rod or cylinder.

The steering requires no adjustment if seal servicing does not require loosening locknut B on track-rod end C. Steering cylinders

A/ Contact surface for fork spanner

Track rod

D/ Joint

B/ Locknut

Joint housing

C/ Track-rod end

E/ Stop screw Necessary tools

1 tape measure, minimum 10 ft (3 m) 1 track measurement rod 1 screw connection G 10-L (part no. 0003632016) Standard tools

918294/AP1208

8-7

Printed in U.S.A.

Steering 8.10 How to adjust the steering cylinders The diagram shows how to follow the separate steps.

1. Check track setting Specified value = 0 (max. 0.04 in. [1 mm] toe-in)?

No

2. Correct track setting

OK

Specified value = 0 (max. 0.04 in. [1 mm] toe-in)?

3. Set the steering angle stop

4. Check synchronization Identical resistance steering in both directions

5. Set synchronization

OK

Center the piston rod (bypass)

1. Check track setting Specified value = 0 (max. 0.04 in. [1 mm] toe-in)?

OK

Printed in U.S.A.

No

6. Test run

8-8

No

END

918294/AP1208

Steering 8.11 Checking the track setting Check the track as follows:

A

☞ Jack up the machine in the front and rear and prop it safely. Make sure there is enough

Front axle B

☞ Set the steering to straight ahead. Check with a tape measure. ☞ Determine dimension A and dimension B. To do this, measure with the track meas-

Rim flange

➥ Rated dimension B – A = 0, max. + 0.04 in. (1 mm). ➥ i.e. dimension A may be a max. 0.04 in. (1 mm) smaller than dimension B on the

space for steering at the full steering angles for the front and rear axles.

Measuring

urement rod on the inside on the rim flange at the center of the wheels.

same axle.

Important!

A

Check and set the tracks of front and rear axles separately.

The front and rear axle dimensions may differ slightly due to production tolerances.

Rear axle

B

8.12 Correcting the track setting A/ Contact surface for fork spanner

X

C/ Track-rod end

B/ Locknut

If the track setting does not correspond to the specified value 0 (max. 0.04 in. [1 mm] toein), set the track as follows:

☞ Loosen locknut B on either side. ☞ Slightly and evenly tighten or loosen the threaded rod on track-rod end C on either side.

➥ Make sure dimension X is approximately identical on both sides. ☞ Check the track setting again. ☞ Repeat this procedure until the track setting corresponds to the specified value. ☞ Tighten locknut B. ☞ Check dimension X again on either side of the steering cylinder.

918294/AP1208

8-9

Printed in U.S.A.

Steering 8.13 Setting the steering limit Specified value: steering angle = 40° (front and rear axles) The steering synchronization will not operate correctly unless the steering angles of all wheels are exactly the same.

The exact adjustment of the steering angles and stops is set during manufacturing.

F/ Locknut

E/ Stop screw

Adjust the steering limit as follows:

☞ Loosen locknuts F on stop screws E. ☞ Fully unscrew all stop screws E on either side of the front and rear axles. ☞ Actuate the steering cylinder to the left as far as it will go. ➥ Stop screw E should not touch the limit stop on the axle. ☞ Turn stop screw E against the limit stop by hand, then unscrew it again one-and-onehalf revolutions. Secure screw by tightening locknut F.

☞ Actuate the steering cylinder to the right as far as it will go. ➥ Stop screw E should not touch the limit stop on the axle. ☞ Turn stop screw E against the limit stop by hand, then unscrew it again one-and-onehalf revolutions. Secure screw by tightening locknut F. Important!

Perform these basic settings on both joint housings of the front and rear axles.

Limiting the maximum steering angle ensures steering angles of about 40°.

Printed in U.S.A.

8-10

918294/AP1208

Steering 8.14 Checking steering synchronization The axles are synchronized through a bypass in the final positions of the steering cylinders. In the final position of the piston, oil flows from one side of the cylinder to the other.

Bypass In the axle that reaches the steering limit first, the oil flows through a bypass in the steering cylinder and on to the other side if the wheels do not run synchronously.

If the steering wheel is turned further, the steering cylinder of the other axle moves on as far as it will go, causing the wheels on the inside curve to have the same steering angle.

R L

Checking the bypass

If the steering is set to straight ahead again, the wheels (or the axles) run in the same track. This only works optimally, however, if the bypass position to the left and right of the piston (and with regard to the front and rear axles) is the same in the limit positions.

This is true only if the same resistance can be felt at the steering limits to the left and right when evenly turning the steering wheel at the same speed, because the force required to turn the steering wheel at the limit stops on the left and right must be identical.

The steering cylinders (or the bypasses) of the front and rear axles must be centered separately, as follows, to ensure this.

When checking the front axle

☞ Remove both flexible lines from the rear axle steering cylinder and connect them with an intermediate screw connection G 10-L.

When checking the rear axle

☞ Remove both flexible lines from the front axle steering cylinder and connect them with an intermediate screw connection G 10-L. Important!

Make sure there is no air in the steering circuit otherwise synchronization cannot be checked or set correctly.

☞ Bleed the steering system after servicing the steering cylinders. Section "Bleeding the steering cylinders" on page 8-12.

918294/AP1208

8-11

Printed in U.S.A.

Steering Bleeding the steering cylinders

☞ Start the engine. ☞ Turn the steering wheel to the left until a resistance can be felt. ☞ Continue turning the steering wheel 5 to 10 revolutions until the resistance no longer

Front axle

changes.

Bypass

☞ Turn the steering wheel to the right until a resistance can be felt. ☞ Continue turning the steering wheel 5 to 10 revolutions until the resistance no longer changes.

If there is no more air in the steering circuit:

☞ Turn the wheels to the left as far as they will go. ☞ Continue turning the steering wheel against the limit. ➥ You must be able to feel a certain resistance (oil flows through the bypass). ☞ Turn the wheels to the right as far as they will go. ☞ Continue turning the steering wheel against the limit. ➥ You must be able to feel the same resistance as when turned to the left. ➥ If the resistance is stronger (when turning the steering wheel at the same speed),

Front axle

move the piston of the piston rod to the left until reaching the same resistance.

Bypass

☞ Perform Section "Setting steering synchronization" on page 8-13.

Important!

The steering cylinders of the front and rear axles are checked in the same way.

Printed in U.S.A.

8-12

918294/AP1208

Steering 8.15 Setting steering synchronization A/ Contact surface for fork spanner

X

C/ Track-rod end

B/ Locknut

Important!

Always move the piston in the direction with the stronger resistance.

Proceed as follows:

☞ Set the steering system to straight-ahead position. ☞ Stop the engine and turn off the ignition. ☞ Loosen locknut B on either side. Keep the rod from turning with a fork spanner on contact surface A.

☞ Move the piston gradually (half revolutions), until the resistance felt on the steering wheel is identical.

☞ Loosen the threaded rod half a revolution on track-rod end C on the left side. ☞ Tighten the threaded rod the same number of revolutions on track-rod end C on the right side.

☞ Tighten locknut B on either side. Keep the rod from turning with a fork spanner on contact surface A.

☞ Check the track again as soon as the piston rod is centered.

NOTE: Dimension X will no longer be identical on the left and right.

☞ Remove the intermediate screw connection G 10-L between the flexible lines on the

steering cylinder and mount the flexible lines correctly onto the steering cylinder connections.

Important!

The steering cylinders of the front and rear axles are set in the same way.

Final check/test run

☞ Tighten all flexible lines and screw connections. ☞ Lower the machine back onto the wheels. ☞ Carry out a test run. Turn the steering wheel to the left and right as far as it will go to check the synchronous position of the wheels.

918294/AP1208

8-13

Printed in U.S.A.

Hydraulic system

9

Hydraulic system

9.1

Test report for model ML360

Model:

Serial no.

_______________________________

____________________________________

Test conditions:

Rated oil temperature:122–140°F (50–60°C) Rated driving direction: Forward

Test features:

Notes:

Nominal value: (rpm)

Diesel engine idling speed

Measured on crankshaft

Lower

920–980 rpm

Upper

2550–2650 rpm

Work hydraulics 3rd control circuit

Measured on the hydraulic pump (max. engine rpm)

✔

3191–3481 psi (220–240 bar)

Work hydraulics Lift cylinder (secondary)

3481 psi (240 bar)

Work hydraulics Tilt cylinder (dump out) (secondary)

1668–1958 psi

Minimum idling speed

(100 bar)

Work hydraulics Tilt cylinder (dump in)

3481 psi (240 bar)

(secondary) Load stabilizer

Measured on the hydraulic pump

2031 psi (140 bar)

Steering pressure

At maximum engine speed

2538–2828 psi (175–195 bar)

Loader unit lowered

T oil = 122°F (50°C)

Lift cylinder max.

0.59 in. (15 mm)

P cylinder = 1450 psi (100 bar)/t = 10 min

Printed in U.S.A.

9-0

Tilt cylinder max.

0.67 in. (17 mm)

918294/AP1208

Hydraulic system 9.2

Test report for model ML460

Model:

Serial no.

_______________________________

____________________________________

Test conditions:

Rated oil temperature:122 – 140°F (50 – 60°C) Rated driving direction: Forward

Test features:

Notes:

Nominal value: (rpm)

Diesel engine idling speed

Measured on crankshaft

Lower

1000–1050 rpm

Upper

2430–2470 rpm

Work hydraulics 3rd control circuit

Measured on the hydraulic pump (max. engine rpm)

✔

3698–3916 psi (255–270 bar)

Work hydraulics Lift cylinder (secondary)

3481 psi (280 bar) 1668–1958 psi

Work hydraulics Tilt cylinder (dump out) (secondary)

(115–135 bar)

Minimum idling speed

Work hydraulics Tilt cylinder (dump in)

3481 psi (280 bar)

(secondary) Load stabilizer

Measured on the hydraulic pump

2031 psi (140 bar)

Steering pressure

At maximum engine speed

2538–2828 psi (175–195 bar)

Loader unit lowered

T oil = 122°F (50°C)

Lift cylinder max.

0.37 in. (9.5 mm)

P cylinder = 1450 psi (100 bar)/t = 10 min

918294/AP1208

9-1

Tilt cylinder max.

0.43 in. (11 mm)

Printed in U.S.A.

Priority valve

Control valve

Test port for work hydraulics

Suction and return filter

Printed in U.S.A.

9-2

• Model ML460 = 22.2 gpm (84 L/min)

• Model ML360 = 18.6 gpm (71 L/min)

9.3

Work hydraulics:

Test port for steering system

Hydraulic system

Work hydraulics oil supply

918294/AP1208

Hydraulic system 9.4

Control valve ports 1668–1958 psi (115–135 bar)

Plug

Primary 3046 psi (210 bar)

26 lb-ft (35 Nm)

B1 = Tilt in

B3

B2

B1

A3

A2

A1

B2 = Lower B3 = Unlock

A1 = Dump out

T

A2 = Raise

P

A3 = Lock 3481 psi (240 bar)

9.5

3481 psi (240 bar)

Priority valve ports Control line from the steering system

LS

P from the pump

CF

P

Steering system test port 2538–2828 psi (175–195 bar)

EF

Work hydraulics test port Model ML360 = 3191–3481 psi (220–240 bar) Model ML460 = 3698–3916 psi (255–270 bar)

918294/AP1208

9-3

Printed in U.S.A.

Hydraulic system 9.6

Priority valve diagram To control valve

To the steering system

Control line from the steering system

From the pump

9.7

Load stabilizer ports Pressure accumulator 290 psi (20 bar) (pre-tensioning pressure)

Pressure relief valve 2031 psi (140 bar)

Y20

Y21

Y20/Y21 Both energized

Printed in U.S.A.

9-4

918294/AP1208

Hydraulic system 9.8

Load stabilizer circuit

A2 T B2 To the pressure accumulator

Valve block

Y21

Pressure relief valve 2031 psi (140 bar)

9.9

Y20

Load stabilizer diagram

Lift cylinder

Solenoid valve

Pressure accumulator

Control valve 918294/AP1208

9-5

Printed in U.S.A.

Hydraulic system 9.10 Lift cylinder: seals

Seals (included in seal kit)

Joint bearing

34300s910_11.iso

Cylinder head 295 lb.-ft. (400 Nm)

Piston 443 lb.-ft. (600 Nm)

Removing/installing

☞ Unscrew cylinder head with special key. ☞ Pull out piston rod. ☞ Remove threaded pin on piston. ☞ Unscrew piston from piston rod. ☞ Replace complete seal kit. ➥ Seal kit includes all seals, sleeves and threaded pins. ➥ Calibrate the piston seal when replacing it. ☞ Install in the reverse order. ➥ Tighten to the torque values shown in the figure.

Important!

Special tools are required for sealing the cylinder.

Printed in U.S.A.

9-6

918294/AP1208

Hydraulic system 9.11 Tilt cylinder: seals

Seals (included in seal kit)

Joint bearing

34300s910_12.iso

Cylinder head 295 lb.-ft. (400 Nm)

Piston 443 lb.-ft. (600 Nm)

Removing/installing

☞ Unscrew cylinder head with special key. ☞ Pull out piston rod. ☞ Remove threaded pin on piston. ☞ Unscrew piston from piston rod. ☞ Replace complete seal kit: ➥ Seal kit includes all seals, sleeves and threaded pins. ➥ Calibrate the piston seal when replacing it. ☞ Install in the reverse order: ➥ Tighten to the torque values shown in the figure.

Important!

Special tools are required for sealing the cylinder.

918294/AP1208

9-7

Printed in U.S.A.

Hydraulic system 9.12 Control cylinder (quick-hitch frame): seals

Piston seal Rod seal Circlip

Seal between cylinder and guide bushing

36eh3610.iso

Removing/installing

☞ Release the pressure in the quick-hitch cylinder control circuit. ☞ Remove the circlip. ☞ Drive out the piston with an impact extractor M8. ☞ Replace the seal between piston rod and guide bushing: ➥ Replace complete seal kit. ☞ Install in the reverse order.

Important!

Special tools are required for sealing the cylinder.

Printed in U.S.A.

9-8

918294/AP1208

Hydraulic system

918294/AP1208

9-9

Printed in U.S.A.

9.13 Work hydraulics diagram 7

8

9

Pressure line from priority valve EF

Return from case flushing (variable-displacement pump)

10

Return from hydraulic motor T2 Return from hydraulic motor T

3

Return (variabledisplacement pump S)

Ref.

2 P1 1

4 B1

B2

1450 psi (100 bar)

3481 psi (240 bar)

21.8 psi (1.5 bar) 5 6

1

Return suction filter

2

Pressure switch

3

Oil-to-water-cooler

4

Vent filter

5

Non-return valve 21.8 psi (1.5 bar)

6

Hydraulic oil tank

7

Tilt cylinder

8

Lift cylinder

9

Control cylinder (3rd control circuit)

10

Quick couplers (3rd control circuit)

11

Control valve (3-fold)

11 Support Return from inching valve, steering system 72.5 psi (5 bar)

3046 psi (210 bar) Return from control valve

Printed in U.S.A.

9-10

918294/AP1208

918294/AP1208

9-11

Printed in U.S.A.

Electrical system

10 Electrical system 10.1 Ohm’s Law (current, voltage, resistance determines power) Ohm’s law describes how current, voltage and resistance combine to determine power.

Current “I” — Ampere (A) Voltage “U” — Volt (V) Resistance “R” — Ohm (Ω)

Mnemonic:

U R

I

Output Power "P" — Watt (W) P = U x I = R x I² = U²/R

10.2 Measuring equipment and methods Multi-function measuring device • Measurements of values (P, U, R, I).

• Continuity test.

• Diode test.

Calculate measuring range using known data (P, U, R, I) and set before measuring.

Follow AC/DC basic setting.

➥ AC = alternating current/voltage. ➥ DC = direct current/voltage.

Test device with acoustic and optical signal output • Continuity test in de-energized machine electric system and of wiring harnesses.

Printed in U.S.A.

10-0

918294/AP1208

Electrical system Measuring methods — multi-function measuring device Measuring current (ignition switched on):

• Black cable in COM socket (ground).

• Red cable in A socket or mA socket; connect in series to load.

Measuring voltage (ignition turned on):

• Black cable in COM socket (ground).

• Red cable in V socket.

• Connect in parallel to load (see measuring voltage).

Measuring resistance (ignition switched off): • Black cable in COM socket (ground).

• Red cable in Ω socket.

• Connect in parallel to load (see measuring voltage).

918294/AP1208

10-1

Printed in U.S.A.

Electrical system 10.3 Terminal description Terminal and cable descriptions are not the same because equipment with different terminal can be connected to both ends of a cable. If there are not enough terminal descriptions (multiple plug and socket connections), the terminals are marked with continuous number or letter codes and do not have any standardized function assignment.

Terminal

Meaning

1

Ignition coil, ignition distributor Low voltage

1a 1b

Ignition distributor with two separate electric circuits to ignition contact breaker I to ignition contact breaker II

2

Short-circuit terminal (magneto ignition)

4

Ignition coil, ignition distributor High voltage

4a 4b

Ignition distributor with two separate electric circuits from ignition coil I, terminal 4 from ignition coil II, terminal 4

15

Switched plus behind battery (output ignition [drive] switch)

15a

Output at dropping resistor to ignition coil and starter

17 19

Pre-heating start switch Start Pre-heating

30

Battery Input from + battery terminal, direct

30a

12/24 V battery change-over relay Input from + terminal of battery II

31

Return line to battery Minus terminal or ground, direct

31b

Return line to battery Minus terminal or ground, via switch or relay (switched negative)

31a 31c

12/24 V battery change-over relay Return line to minus terminal of battery II Return line to minus terminal of battery I

32 33 33a 33b 33f 33g 33h 33L 33R

Electric motors Return line Main terminal connection Self-parking switch (off) Shunt field For second lower speed range For third lower speed range For fourth lower speed range Counterclockwise rotation Clockwise rotation

45

Printed in U.S.A.

Starter Separate starter relay, output; Starter, input (main current)

10-2

918294/AP1208

Electrical system Terminal

Meaning

45a 45b

Two-starter parallel operation Starting relay for engagement current Output starter I, Input starters I and II Output starter II

48

Terminal on starter and on start-repeating relay (to monitor starting)

49 49a 49b 49c

Turn indicator unit (pulse generator) Input Output Output, 2nd turn indicator circuit Output, 3rd turn indicator circuit

50

Starter Starter control (direct)

50a

Battery change-over relay Output for starter control

50b

Starter control with parallel operation of 2 starters with sequential control

50c 50d

Starting relay for sequential control of the engagement current during parallel operation of 2 starters Input at starting relay for starter I Input at starting relay for starter II

50e 50f

Start locking relay Input Output

50g 50h

Start repeat relay Input Output

51 51e

AC alternator Direct current voltage at rectifier Direct current voltage at rectifier with choke coil for daytime driving

52

Trailer signals Signals from trailer to towing machine

53 53a 53b 53c 53e 53i

Wiper motor, input (+) Wiper (+), self-parking switch (off) Wiper (shunt winding) Electric window washer pump Wiper (brake winding) Wiper motor with permanent magnet and third brush (for higher speed)

54g

Trailer signal For lamp combinations and trailer plug connections Brake lights Pneumatic valve for additional retarding brake, electromagnetically actuated

55

Fog lights

56 56a 56b 56d

Headlight High-beam and high beam indicator Low-beam Headlight flasher contact

57 57a 57L 57R

Side marker light for motorcycles (also for cars, trucks, etc., in other countries) Parking light Parking light, left Parking light, right

54

918294/AP1208

10-3

Printed in U.S.A.

Electrical system Terminal

Meaning

58 58b 58c 58d 58L 58R

Side marker, rear, license plate and instrument panel lights Rear light change-over for single-axle tractors Trailer plug-and-receptacle assembly for single-conductor rear light cable with fuse in trailer Variable-intensity instrument panel lights, side marker and rear light Left Right, license plate light

59 59a 59b 59c

AC alternator (magneto alternator) Alternating voltage, output, rectifier, input Charging armature, output Rear light armature, output Brake light armature, output

61

Alternator charge indicator

71 71a 71b

Tone sequence control device Input Output to horns 1 + 2 low Output to horns 1 + 2 high

72

Alarm switch (rotating beacon)

75

Radio, socket (e.g., cigarette lighter)

76

Loudspeaker

77

Door valve control

81 81a 81b 82 82a 82b 82z 82y 83 83a 83b 83L 83R

Switches (break contact and change-over switches) Input 1st output, break side 2nd output, break side Make-contact switch Input 1st output 2nd output 1st input 2nd input Multiple-position switch Input Output, position 1 Output, position 2 Output, left side position Output, right side position Current relay

84

Input, actuator and relay contact

84a 84b

Output, actuator Output, relay contact

84a

84b

84

Printed in U.S.A.

10-4

918294/AP1208

Electrical system Terminal

Meaning

85 86 86a 86b

Switching relay — output, actuator (end of winding negative or ground) Input, actuator Start of winding Start of winding or 1st winding Winding tap or 2nd winding 86

87a 88a 87a 88a 87a 88a 88b

85

87

88

87

87

87 87a 87b 87c 87z 87y 87x

Relay contact for break and change-over contacts Input 1st output (break side) 2nd output 3rd output 1st input 2nd input 3rd input

88

Relay contact for make-contact Input

88a 88b 88c

Relay point for make-contact and change-over contacts (make side) 1st output 2nd output 3rd output

88z 88y 88x

Relay contact for make-contact 1st input 2nd input 3rd input

Alternator and governor B+ B– D+ D– DF DF1 DF2

Battery positive Battery negative Dynamo positive Dynamo negative Dynamo field Dynamo field 1 Dynamo field 2

U, V, W

Three-phase alternator — three-phase terminals

Turn indicator (turn indicator unit) C C0 C2 C3 L R

918294/AP1208

First indicator Main terminal connection for separate indicator circuits actuated by the turn indicator switch Second indicator Third indicator Indicator light, left Indicator light, right

10-5

Printed in U.S.A.

Electrical system 10.4 Cable color coding The cables are color-coded. Refer to the 21-pin cab/frame interface or the explanation in the wiring harness drawings for other colors not listed in this table.

Line From

To

Identification color

Basic color

Ignition coil I

Ignition distributor (low-voltage ignition lead)

Green

-

Ignition coil II

Ignition distributor (low-voltage ignition lead)

Green

Red

Battery

Starter

Black

-

Battery

Ground (if bare ground lead is not used)

Black

-

Starter

Alternator

Red

-

Starter

Control panel (30)

Red

-

Light switch (30)

Ignition switch (30)

Red

-

Control panel (30) or light switch (30)

Fuse

Red

-

Fuse

Hand lamp, radio, clock, etc.

Red

-

Control panel (15/54)

Heater plug and starter switch; heater-plug indicator

Black

-

Heater plug and starter switch; heater-plug indicator

Glow plugs

Black

-

Ignition switch (15/54)

Ignition coil

Black

-

Ignition switch or control panel (54/15/61a)

Indicators

Black

-

Control panel or ignition switch (15/54)

Fuse

Black

-

Fuse box

Brake light

Black

Red

Fuse box

Turn indicator switch

Black

White-green

Turn indicator switch

Turn indicator, left

Black

White

Turn indicator switch

Turn indicator, right

Black

Green

Indicator

Turn indicator

Light blue

-

Fuse

Cigarette lighter

Black

-

Fuse

Heated window

Black

Yellow-red

Fuse

1st horn

Black

Yellow

Fuse

2nd and 3rd horn

Black

Yellow-light blue

Horns

1 pole horn push button (ground)

Brown

-

Fuse

Wipers

Black

Purple

Battery charge indicator

Terminal 61 of alternator or reverse current cutout Light blue

-

Fuse

Main beam indicator

Light blue

White

Oil pressure gauge (indicator)

Oil pressure switch

Light blue

Green

Fuel level indicator

Fuel tank

Light blue

Black

Tire-pressure warning device

Tire-pressure drop indicator

Light blue

Yellow

Control panel and light switch

Low-beam switch

White

Black

Low-beam switch (a)

Fuse

White

-

Printed in U.S.A.

10-6

918294/AP1208

Electrical system Line From

To

Identification color

Basic color

Fuse

Main headlight, left

White

-

Fuse

Main headlight, right

White

-

Low-beam switch (b)

Fuse

Yellow

-

Fuse

Low-beam, left

Yellow

-

Fuse

Low-beam, right

Yellow

-

Control panel or light switch (58)

Fuse

Gray

-

Fuse

Rear light, side light and parking light left

Gray

Black

Fuse

License plate light (combined with rear left light) Gray

Black

Fuse

Rear light, side light and parking light, right

Gray

Red

Fuse

License plate light (combined with rear right light)

Gray

Red

Fuse

License plate light (only if special line is laid)

Gray

-

Fuse

Dome light

Red

-

Control panel (57)

Fuse

Gray

Green

Control panel and light switch

Instrument panel light

Gray

Red

All consumers except the battery ground lead if Ground the use of bare lines is not possible

Brown

-

Battery change-over switch (50)/starter push button or heater plug and starter switch

Black

-

918294/AP1208

Starter

10-7

Printed in U.S.A.

Electrical system Other color codes Abbreviation

Abbreviation

old

new

Black

sw

BK

Brown

br

BN

Red

rt

RD

Orange

or

OG

Yellow

ge

YE

Green

gn

GN

Blue

bl

BU

Violet

vi

VT

Gray

gr

GY

White

ws

WH

Pink

rs

PK

Gold

-

GD

Turquoise

tk

TQ

Silver

-

SR

Color

10.5 Relays Use, mode of function

Relays are used for switching electric loads (high currents) where the control power of the relay coil is relatively low. Relays can therefore be controlled by micro-electronics or microswitches (e.g., touchpad keyboards, sensors). The switch contacts can be make-contact, break-contact or change-over switches. These undertake the actual switching function.

Terminal description on relay

Zero-center relay

86

86 = Start of coil (control line)

30

85 = End of coil (ground) 30 = Input (load line) 87 = Make-contact switch output (load line)

85 87

Printed in U.S.A.

87a

87a = Break-contact switch output (load line)

10-8

918294/AP1208

Electrical system 10.6 Starter, battery, alternator Electric system Alternator

12 V, 95 A

Starter

12 V, 3.0 kW

Battery

12 V, 88 Ah

10.7 Fuse box The fuse box is located on the instrument panel to the right of the parking brake lever.

Fig. 121: Fuse box

918294/AP1208

No.

Rated current

Protected circuit

F1

7.5

High beam, left

F2

7.5

High beam, right

F3

5

Left parking and rear lights, front socket

F4

5

Switch assignment: 4th control circuit S11, front/rear working light, front implements (option), rotating beacon (option) Switch lights: lights, heating S5, load stabilizer S8, 3rd control circuit Right parking and rear lights, front socket (option)

F5

7.5

High-current relay — pre-heating and starting, high-current relay, interior light, relays — minus compensation, pre-heating indicator, hazard warning light

F6

25

Cigarette lighter, rotating beacon (option), front/rear working light

F7

25

High-beam indicator

F8

7.5

Low-beam, left

F9

7.5

Low-beam, right

F10

5

Switching relays — front implement (option), instrument panel, cutoff solenoid

F11

15

Washer pump, rear wiper, relays — wiper, front wiper, horn

F12

5

1st/2nd-speed solenoid valve

F13

7.5

Relays — forward/reverse, solenoid valve — forward/reverse, backup warning system

F14

20

Front implement (option), heating fan

F15

7.5

Relays — turn indicator, brake lights

F16

5

Radio (option)

10-9

Printed in U.S.A.

Electrical system 10.8 Main fuse box with relays for model ML360 F18

The main fuse box with the power relays and the pre-heating time control unit is located in the engine compartment, on the left, under the battery. .

F17

K5 K7

F19

K29

Fuse no.

Rated current (A)

Protected circuit

F17

80 A

Main fuse

F18

40 A

Pre-heating/start fuse (starter)

F19

10 A

Minus compensation

Relay no.

Protected circuit

K5

Pre-heating: power relay

K7

Start: starter relay

K29

Minus compensation

10.9 Main fuse box with relays for model ML460 K6

F17

F18

F20

K5 K7

F19

Printed in U.S.A.

K29

Fuse no.

Rated current (A)

Protected circuit

F17

80 A

Main fuse

F18

40 A

Pre-heating/start fuse (starter)

F19

10 A

Minus compensation

F20

50 A1

Pre-heating (2nd glow plug, intake-air pre-heating)

Relay no.

Protected circuit

K5

Pre-heating: power relay

K6

Pre-heating time control unit

K7

Start: starter relay

K29

Minus compensation 10-10

918294/AP1208

Electrical system 10.10 Switching relays The switching relays are located under the switch panel (board), on the right in the side console. (accessed through the maintenance cover on the right, on the outside of the cab).

Switching relay no.

K10 X7 X2

K3

X4 X1

K4 K16

Protected circuit

K1

High-current relay 70 A

K3

Reverse driving switching relay 40/60 A

K4

Forward driving switching relay 40/60 A

K10

Switching relay — turn indicator

K16

Switching relay — front socket (option)

K23

Wiper switching relay

X1

X6 V10 K1

X2

K23 X3 X5

X3 X4

Plug socket

X5 X6 X7 V10

918294/AP1208

10-11

Printed in U.S.A.

Electrical system 10.11 Description of blocking diodes Blocking diodes V8, V9

Function • V9 has no function.

• V8 only for model ML460 for the differential lock function.

Location • On the board.

Blocking diode V10

Function • V10 has no function.

Location • On the board.

Blocking diode V11

Function • V11 has the function of preventing the engine from starting with the parking brake released.

➥ Relay K7 is grounded via the indicator if V11 is defective.

Location • On X1 Blocking diodes V16, V17

Function • V16/V17 for the lights (S15 switch for fan).

➥ Switch S15 is not lit if V16/V17 are defective.

Location • On the board.

Blocking diodes V20, V21

Function • V20, V21 are used for the float position with hose burst valve and load stabilizer.

• V20 is used for the load stabilizer.

➥ The hose burst valve is not switched if V20 is defective.

• V21 is used for the float position with hose burst valve.

➥ The hose burst valve does not open if V21 is defective.

Location • On the board.

Printed in U.S.A.

10-12

918294/AP1208

Electrical system 10.12 Overview of switch assignment 1

2

3

4

5

Important!

Mount the switches as shown and affix symbols on them to avoid damage due to malfunctions.

☞ Remove the switch panel blank cover. ☞ Insert the switch (rocker switch) in the board.

6

7

8

9

10

Switch position

1

2

3

4

5

Abbreviation

S14

Not assigned

Not assigned

S15

S17

Function

Lights

–

–

Heating/fan

Only with 2 rear working lights

Switch position

6

7

8

9

10

Abbreviation

S44

S16

S18

S56

S27

Load stabilizer

Working light

Rotating beacon

4th control circuit

Front socket

Function

NOTE: See parts manual for switch/symbol service parts numbers.

918294/AP1208

10-13

Printed in U.S.A.

Electrical system 10.13 Installing a rotating beacon A

OG

☞ Install bracket A for the rotating beacon at the rear left of the cab. ☞ The cable for the rotating beacon is located at the rear left in the cab frame. ➥ Cable colors OG (orange) for power.

BK (black) for ground.

☞ Insert the switch with the symbol in switch console S18. ➥ Section "Overview of switch assignment" on page 10-13. ☞ Check the electric system.

OG BK

10.14 Installing the backup warning system ☞ Install the backup warning system B on the bracket at the rear left of the cab. ☞ The cable for the rotating beacon is located at the rear left in the cab frame: ➥ Cable colors VT/WH (violet/white) for power.

B

BK (black) for ground.

☞ Check the electric system.

VT/WH BK

Printed in U.S.A.

10-14

918294/AP1208

Electrical system 10.15 Installing two front work lights GN/VT

☞ Mount the work lights on the brackets at the front left and right. ☞ The cables for the front work lights are located in the wiring harnesses at the upper left and right in the cab frame.

➥ GN/VT (green/violet) for power and BK (black) for ground. ☞ Insert the switch in switch console S16. ➥ Section "Overview of switch assignment" on page 10-13. ☞ Connect both cables GN/VT (green/violet with white connectors). ➥ The cables are located underneath the board and are accessed through the outside maintenance cover on the right.

➥ Check the electric system.

10.16 Installing two front work lights and one rear work light Cable connection (white connector)

☞ Install the front work lights (see description above). ☞ Install the work light on the bracket at the rear right and connect it with the cable for the rear work light.

➥ The cables for the rear work light are located in the wiring harness at the upper right in the cab frame.

➥ GN/VT (green/violet) for power and BK (black) for ground. ☞ Insert the switch in switch console S16. ➥ Section "Overview of switch assignment" on page 10-13. ☞ Connect the plug and socket connection (white connector and green/violet cable).

Important!

Only three additional lights can be operated with switch S16.

☞ An additional switch is required in the switch panel when mounting a 4th work light.

☞ Check the electrical system.

918294/AP1208

10-15

Printed in U.S.A.

Legend: electric diagram for model ML360 Equipment

Equipment

A1 B1 B2 B3 B8 B11 B12 E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E14 E15 F1–F16 F17 F18 G1 G2 H1 H3 H4 H5 H7 H8 H10 H11 H18 H20 H21 H22 H23 H24 H25 H26 H27 H28 K1 K3 K4 K5 K7 K10 K16

Radio Fuel level sensor Horn Backup warning system Safe load indicator sensor Loudspeaker Loudspeaker Front right parking light Rear right light Front left parking light Rear left light High, low-beam (right) High, low-beam (left) Rear working light Rear working light Front working light Front working light Interior light with switch Cigarette lighter with light Fuses Main fuse Pre-heating/start fuse Alternator Battery High-beam indicator Engine temperature indicator Engine oil pressure indicator Alternator charge indicator Hydraulic oil filter indicator Hydraulic oil temperature indicator (not used) 3rd control circuit indicator Hand brake indicator Brake lights Brake lights Machine turn indicator Rear implement turn indicator Front right turn indicator Rear right turn indicator Front left turn indicator Rear left turn indicator Rotating beacon High-current relay 70 A Reverse driving 40/60 A Forward driving 40/60 A High-current relay pre-heating Start high-current relay Turn indicator relay Front socket 40/60 A

Printed in U.S.A.

Location (section) X6/2 X1/2 X3/2 X3/2 X6/2 X6/2 X6/2 X3/2 X3/2 X3/2 X3/2 X3/2 X3/2 X6/2 X6/2 X6/2 X6/2 X6/2 X5/2

2 2 X4/2 X4/2 X4/2 X4/2 X4/2 X4/2 X2/2 X4/2 X4/2 X5/2 X5/2 X2/2 X4/2 X3/2 X3/2 X3/2 X3/2 X6/2 1 X1/1 X1/1 2 2 X2/1 X3/1

Remarks

Equipment

Equipment

Option

K17 K18 K23 K27 M1 M2 M3 M4 M5 P1 P2 P6 R1 R2 S1 S2 S3 S5 S6 S9 S11 S12 S14 S15 S16 S18 S 19 S21 S27 S30 S31 S32

Unlock 40/60 A Lock 40/60 A Wiper speed 1 40/60A Time lag relay 5 min Starter Front wiper motor Rear wiper motor Engine fan Washer pump Hour meter Fuel level indication Safe load indicator Glow plug Heated rear window Pre-heating start switch Engine oil pressure switch Engine temperature switch Hydraulic oil pressure switch Hydraulic oil temperature switch Brake light switch Parking brake switch Steering-column control lever (left) Light switch Heating switch Working light switch Rotating beacon switch Hazard warning switch 1st/2nd speed switch Front socket switch “Unlock” tip switch “Lock” tip switch 3rd control circuit switch Continuous operation switch for 3rd control circuit Forward switch Reverse switch Quick-hitch lock tip switch Load stabilizer switch Tilt cylinder lock key-operated switch 4th control circuit switch Heated rear window switch (not used) Suppressor diode Blocking diode Blocking diode Blocking diode Suppressor diode Blocking diode Suppressor diode

Option Option Option

Option Option Option Option

S33

Option

Option

S34 S35 S40 S44 S47 S56 S59 S63 V1–V7 V8,V9 V10 V11 V13–V15 V16,V17 V18,V19

10-16

Location (section) X1/1 X1/1 X5/1 X2/1 2 X6/2 X6/2 X5/2 X6/2 X4/2 X4/2 X6/2 2 X6/2 X4/2 X1/2 X1/2 X1/2 X1/2 X5/2 X2/2 X2/2 X6/1 X5/1 X6/1 X6/1 X2/2 X2/2 X2/1 X2/2 X2/2 X1/1 X1/1 X2/2 X2/2 X5/2 X1/1 X5/2 X1/1 X2/1 X2/2 X1/2 X1/1 X6/1 X1/2 X1/2 X5/1 X5/2

Remarks

Equipment

Equipment

Option Option

V20,V21 V22 W1

Blocking diode Suppressor diode Radio aerial

X1

Connector engine/valves

X2

Drive input connector

X3

Lights connector

X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16 X17 X18 Y10 Y2 Y4 Y5 Y10 Y20 Y21 Y23 Y24 Y22 Y25 Y26 Y27 Y30 Y33 Y34

Instrument panel connector Power supply connector Roof connector Min. 13-pole drive interlock connector Control lever connector (drive) Control lever connector (auxiliary hydraulics) 12-pole steering column connector (left) Front socket Rear socket Radio connection gray Radio connection brown Instrument panel connection Front wiper connection Clearance lights connection Safe load indicator sensor connection Cutoff solenoid 1st/2nd speed solenoid valve Reverse driving solenoid valve Forward driving solenoid valve Driving direction identification solenoid valve Load stabilizer solenoid valve Load stabilizer solenoid valve “Retract telescopic unit” solenoid valve “Extend telescopic unit” solenoid valve Hose burst valve solenoid (OFF) Quick-hitch lock solenoid valve Tilt cylinder lock solenoid valve Tilt cylinder lock solenoid valve Minus compensation valve (motor II) (not used) (not used)

Option

Tele Option

Option Option

Option Option Option Option Option

Tele Option Option Option Option

Location (section) X2/2 X5/2 X6/2

Remarks Option Tele (natural colored) (natural colored)

X2/2 X2/2 X3/2 X3/2 X5/2 X5/2 X4/2 X6/2 X4/2 X6/2 X1/2 X1/2 X1/2 X1/2 X1/2 X1/2 X1/2 X1/2 X1/2 X1/2 X5/2 X5/2 X5/2 2 X1/2 X1/2

Option Option

Tele

Option Option Tele Tele Option Tele Option Option

Legend: electrical diagram for model ML360

918294/AP1208

10.17 Electric diagram (sheet 1) for model ML360 1

2

3

A

4

F14 20A

1

F11 15A

5

6

7

8

F12 5A

9

10

11

12

13

14

1 2

F15 7,5A

F13 7,5A

3 4 5 6 B

5

S32

6 10

2 9

30

86

30

86

87

85

87

85

30

15 (86) K3

K4

1

K27

86

30

85

87

K16

31 (85)

87

F2 7,5A

F3 5A

F4 5A

7 8 9

F8 F9 7,5A 7,5A

F1 7,5A

10 11 12

C

13

Board

S44

5

9

14 15 16

10 6

2 B

17

1

D

9 5

S56

K1

S33 9

V9

9

10

31

B

S59 10

S27 10

R2

G

R

18 19 20 21 22 23 24

K10

+

C

3

5

9

B

25

10

26 27

B

28

5

V8

1 B

1

1

1

E 86

30

30

86

85

87

87

85

K18

29 30

K17

31 32 X2

BK/GN 1,0

BK/GN 1,0

BK/GN 1,0

BK/WH 1,0

YE/BK 1,5

BK/WH 1,0

BK/WH 1,0

15 21 12 16 14 19 17 22 WH/BK 1,5

BN/YE 1,5

20 13 11 YE 1,5

7

WH 1,5

9 10

WH/VT 1,0

8

GY/BK 1,0

2

GY/BK 1,0

GY/RD 1,0

RD/YE 1,5

GY/RD 1,0

GY/BK 1,0

6 18 3 4

GY/BK 1,0

RD/BK 1,0

5 GY/RD 1,0

1

GY/RD 1,0

10 BN/VT 1,0

WH/RD 1,0

S63

1

5 3 BK/RD/YE 1,0

7

BK/WH/GN 1,0

1

V21

14 RD/BK 1,5

8 WH/BU 1,0

RD/YE 1,0

BN 1,0

13 6 12 2 WH/VT 1,0 GN/VT 1,0

V20

X3

WH/GN 1,0

9 11

GY/GN 1,0

BU 1,0

4

18

BN/YE 1,0 BN/BK 1,0

17 RD/GN 1,0

5 15

WH/RD 1,0

BK 1,0

12 11 13

BK/WH 1,5

7

VT/BU 1,0

BU/YE 1,0

9

BU/GY 1,0

10 8

BU/GN 1,0

16

BU/WH 1,0

6

BU/RD 1,0

GN/VT 1,0

3

PINK 1,0

4

BU/BK 1,0

14

GY/GN 1,0

2

WH/VT 1,0

2

1

BN/BK 1,0

F

BN/YE 1,0

X1

S9

2

33

RD 1,0

+ R1

49

49a

X11

7/58L

BK 1,0

BK 1,0

BK 1,0

BK 1,0

BK 1,5

4/R

1/L

37

BN/BK 1,0

38

B C A

X9

2

3 4 1 X8 S35

S30

BU 1,0

D+ B+ 3 G G1 50 RD 10,0 B30 M M1

S31

39

40 S34

41

Electrical diagram (sheet 1) for model ML360

L

M 2

3

4

5

10-17

6

7

8

9

10

11

12

13

L

M

1000133956_d_li.iso 1

918294/AP1208

BK 1,5 3/31

30 RD/YE 1,5

BK/WH 1,0

RD/BK 1,5

L

BK/GN 1,0

5

15 R

X12 5/58R

31 58L 54 58R

BK 1,5

36 BK 1,0

WH/VT 1,0

S19

H21 S11

BK 50

-

2

WH/BK 1,0 GN/WH 1,0

85

H26

H24

BN/YE 1,0 BN/BK 1,0

RD/BK 1,0

BU 6,0 BK 1,0 BK 50

B S21

10

K29

Y30

K

7

1

9

86

56a 56b

B3

BK 1,5

Y21

GN 1,0 YE 1,0

85 87

K7 85 87

56b

35

H27

H25

Y22

BU/YE 1,0

F19 10A 30 86

E4

E6

E5

BK 1,0

BK 1,0 BK 1,0

86 30

K5 87

V11

RD/BK 4,0

RD 6,0 30

BK 50

Y20

F18 40A RD 1,0

G2

T

E2

H20

BK 1,0

T

Y34

1

3

V15

RD 6,0

RD 6,0

RD 10,0

Wiring harness

J

F17 80A RD 6,0

B2

BK 1,0

Y4

V14 V13

BK 1,0

Y10

E3

BK 1,0

Y5

E1

56a Y1

S3

S6

V7

BK 1,0

Y23

V6

BK/WH/GN 1,0

Y24

V3 Y2

BK/WH/RD 1,0

V2

BK 1,5

V18

Q

BK 1,0

V1

BK 1,0

V5

BK 1,0

BK 1,0

BK 1,0

BK 1,0

BK 1,0

BK 1,0

V4

34

B1 P

P

Y33

H

S2

S5 BK 1,0

G

BK 10,0

RD 10,0

3

14

Printed in U.S.A.

10.18 Electric diagram (sheet 2) for model ML360 14

15

16

17

18

19

20

21

22

1 2

F16 5A

1

23

F7 25A

F10 5A

24

F6 25A

A

F5 7,5A

3 4 5 6 3 6 10

B 2 9

7 8 9

B

1

86

K23 30

85

87

S14

10 11 12

C

Board

13 14 15 16 17 18 19 20 21 22 23 24

9

3

10

5

S16

9

10

S15 B

B 1

5

5

1

V16

25

B

V10

D

9 10

S18

1

V17

26 27

29 30

X7

2 1

31 32 X5

H7

BK 1,0

BK 1,0

36 9

1

V18

V19

Y26

Y27

OG 1,0

VT/GN 1,5

GY 1,0 P6 to 18 15

10

22 6

H

W1

B

X13

V22

8 7

Y25

38

G

H28

E9

M2

S40 3

VT/GN 1,5

VT/GN 1,5 M

M5

E14 E10

53 31b 31

53a

M

1

3 4 2

BK 1,0

S47

37

RD/BK 1,0

BU 1,5 BK/BU 1,5 GN/BK 1,5

BU/GN 1,0 VT/GN 1,0

RD/YE 1,5

GN/BK 1,0

RD/BK 1,5

BU/GN 1,0

X16

4

5

2

1

2

1

J X18

A1 3

BU 1,0

H8

H4

E7

E15

RD/GN 1,0

H3

F

BK 1,0

H22

E8

Q

BU/BK 1,0

RD 1,0 RD/GN 1,0 BU 1,0

H18

GY/GN 1,5

M

1

BK 1,0

h

5 7 8 14 4 nc nc

BK 1,5

H1

P2

P1

12

13

BK 1,5

H5

M4

M

8

11

BK 1,5

H23

M3

X15

11

BK 1,5

H11

2

BK 2,5

H10

13

BK 1,0

3

9 3 10 nc nc 12 6 1

2

GN 1,0 GN 1,0

X17

5

WH/BK 1,0

6

35

BK/WH/BU 1,0

7

RD/WH 2,5 RD/YE 2,5

10

RD 1,0

BK/GN 1,0

14

S1

33 34

E

X6

1 13 19 20 17 15 4 9 18

8 11 10 12 16 14 2122 7 5

6

BN/YE 1,5 RD/BK 1,0 OG 1,0

3

YE 1,5

2

11

WH 1,5

13

BK/WH 1,0

9

17

BU/YE 1,0

15

14

BU/RD 1,0

4

15

BU/GN 1,0

10

BU/WH 1,0

1

BN/WH 1,0

BU 1,0

RD 1,5

BK/BU 1,0

GY/BK 1,0

VT 1,0

12

WH 1,0

15

50a 30

GY/RD 1,0

BU/BK1,0

RD/BK 1,0 BU/GY 1,0

2

19

5 6

VT/BU 1,0

X4

2 9 16 8 7 4 3 18

Wiring harness

BK/WH 1,0

4 3

28

6

X14

BN BU

39

to B8

40

B4

B5

K

41

11

8

7

2

6

H

53c

53

31b

9

10

5 R

L

3

4 1

Electrical diagram (sheet 2) for model ML360

X10

56b 56a L

S2 15

49

30

56

M

Printed in U.S.A.

M

1000133956_d_re.iso 14

15

16

17

18

19

20

10-18

21

22

23

24

918294/AP1208

10.19 Legend: electric diagram for model ML460 Equipment A1 A1 B1 B2 B3 B11 B12 E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E14 E15 F1–F16 F17 F18 F19 F20 G1 G2 H1 H3 H4 H5 H7 H8 H10 H11 H18 H20 H21 H22 H23 H24 H25 H26 H27 H28 S35 K1 K3 K4 K5 918294/AP1208

Equipment Radio Radio Fuel level sensor Horn Backup warning system Loudspeaker Loudspeaker Front right parking light Rear right light Front left parking light Rear left light High, low-beam (right) High, low-beam (left) Rear working light Rear working light Front working light Front working light Interior light with switch Cigarette lighter with light Fuses Main fuse Pre-heating/start fuse Minus compensation fuse 2nd pre-heating fuse Alternator Battery High-beam indicator Engine temperature indicator Engine oil pressure indicator Alternator charge indicator Hydraulic oil filter indicator Hydraulic oil temperature indicator Hose burst valve indicator 3rd control circuit indicator Parking brake indicator Brake lights Brake lights Machine turn indicator Rear implement turn indicator Front right turn indicator Rear right turn indicator Front left turn indicator Rear left turn indicator Rotating beacon Reverse switch High-current relay 70 A Reverse driving 40/60 A Forward driving 40/60 A High-current relay pre-heating

Loc. X6/2 X6 X1/2 X3/2 X3/2 X6/2 X6/2 X3/2 X3/2 X3/2 X3/2 X3/2 X3/2 X6/2 X6/2 X6/2 X6/2 X6/2 X5/2

2 2 X4/2 X4/2 X4/2 X4/2 X4/2 X4/2 X2/2 X4/2 X4/2 X5/2 X5/2 X2/2 X4/2 X3/2 X3/2 X3/2 X3/2 X6/2 1 X1/1 X1/1 2

Remarks Option Option

Option Option Option

Option Option Option Option

Option

Equipment K6 K7 K10 K16 K17 K18 K23 K27 M1 M2 M3 M4 M5 P1 P2 R1 R8 S1 S2 S3 S5 S6 S9 S11 S12 S14 S15 S16 S18 S 19 S21 S27 S30 S31 S32 S33

Option

S34 S35 S44 S47 S56 S59 S63 V1–V7 V8,V9 V10 V11 V13–V15

Equipment Pre-heating time control unit Start high-current relay Turn indicator relay Front socket 40/60 A Unlock 40/60 A Lock 40/60 A Wiper speed 1 40/60A Time lag relay 5 min Starter Front wiper motor Rear wiper motor Engine fan Washer pump Hour meter Fuel level indication Glow plug 2nd glow plug Pre-heating start switch Engine oil pressure switch Engine temperature switch Hydraulic oil pressure switch Hydraulic oil temperature switch Brake light switch Parking brake switch Steering-column control lever (left) Light switch Heating switch Working light switch Rotating beacon switch Hazard warning switch 1st/2nd speed switch Front socket switch “Unlock” tip switch “Lock” tip switch 3rd control circuit switch Continuous operation switch for 3rd control circuit Forward switch Reverse switch Load stabilizer switch Tilt cylinder lock key-operated switch 4th control circuit switch Heated rear window switch (not used) Suppressor diode Blocking diode Blocking diode Blocking diode Suppressor diode 10-19

Loc. X1/2 2 X2/1 X3/1 X1/1 X1/1 X5/1 X2/1 2 X6/2 X6/2 X5/2 X6/2 X4/2 X4/2 2 X1/2 X4/2 X1/2 X1/2 X1/2 X1/2 X5/2 X2/2 X2/2 X6/1 X5/1 X6/1 X6/1 X2/2 X2/2 X2/1 X2/2 X2/2 X1/1

Remarks

X1/1

Option

X2/2 X2/2 X1/1 X5/2 X1/1 X2/1 X2/2 X1/2 X1/1 X6/1 X1/2 X1/2

Option Option Option Option

Equipment V16,V17 V18,V19 V20,V21 V22 W1

Equipment Blocking diode Suppressor diode Blocking diode Suppressor diode Radio aerial

X1

Connector engine/valves

X2

Drive input connector

X3

Lights connector

X4 X5 X6 X7 X8

Instrument panel connector Power supply connector Roof connector Min. 13-pole drive interlock connector Control lever connector (drive) Control lever connector (auxiliary hydraulics) 12-pole steering column connector (left) Front socket Rear socket Radio connection gray Radio connection brown Instrument panel connection Front wiper connection Clearance lights connection Cutoff solenoid 1st/2nd speed solenoid valve Reverse driving solenoid valve Forward driving solenoid valve Differential lock solenoid valve Driving direction identification solenoid valve Load stabilizer solenoid valve Load stabilizer solenoid valve Hose burst valve solenoid (OFF) Tilt cylinder lock solenoid valve Tilt cylinder lock solenoid valve Minus compensation valve (motor II) (not used) (not used)

X9

Option Option

Option Option Option Option

Option Option Option Option Option

X10 X11 X12 X13 X14 X15 X16 X17 Y10 Y2 Y4 Y5 Y9 Y10 Y20 Y21 Y22 Y26 Y27 Y30 Y33 Y34

Loc. X5/1 X5/2 X2/2 X5/2 X6/2

Remarks

Option Tele (natural colored) (natural colored)

X2/2 X2/2 X3/2 X3/2 X5/2 X5/2 X4/2 X6/2 X4/2 X1/2 X1/2 X1/2 X1/2 X1/2

Option Option

X1/2 X1/2 X1/2 X1/2 X5/2 X5/2 2 X1/2 X1/2

Option Option Option Option Option

Legend: electrical diagram for model ML460

Printed in U.S.A.

10.20 Electric diagram (sheet 1) for model ML460 1

2

3

4

5

6

7

8

9

10

11

12

13

14

1 2

A F11 15A

F14 20A

1

F13 7,5A

F12 5A

F15 7,5A

3 4 5 6

B

S32 2 9

5 6 10

30 K4

86

30

86

87

85

87

85

1

15 (86)

K3

30

K27

86

30

85

87

7 8 9

K16 87

31 (85)

F3 5A

F4 5A

F2 7,5A

F8 7,5A

F1 F9 7,5A 7,5A

10 11 12

C

Board

13 S44

9 2 B

5

14 15 16

10 6

17

1

D 5 S56

K1

B S33

30

R2

G

R

K10 C

+

3

25

10

26 27

B

28

1

E 86

5

31 B

18 19 20 21 22 23 24

1

9

V9

9 S59 10

B

1

9

5

V8

9 S27 10

10

1

29 30

86

30

K17

K18 87

31 32

85

V20

BK/GN 1,0

BK/GN 1,0

BK/GN 1,0

YE 1,5

BK/WH 1,0 BK/WH 1,0

WH/BK 1,5

YE/BK 1,5

15 21 12 16 14 19 17 22 BK/WH 1,0

20 13 11 WH 1,5

7 BN/YE 1,5

GY/BK 1,0

9 10 GY/BK 1,0

8

GY/BK 1,0

RD/BK 1,0

2

GY/RD 1,0

BN/VT 1,0

5

GY/RD 1,0

WH/RD 1,0

6 18 3 4 GY/RD 1,0

1

GY/RD 1,0

10

GY/BK 1,0

1

RD/YE 1,5

5 3 BK/RD/YE 1,0

7

BK/WH/GN 1,0

S63 1

V21

14 RD/BK 1,5

8

WH/GN 1,0

13 6 12 2 BN 1,0

GY/GN 1,0

9 11

X3

WH/VT 1,0 GN/VT 1,0

4

RD/YE 1,0

18

BN/YE 1,0 BN/BK 1,0

17

RD/GN 1,0

BU/YE 1,0

5 15 BU 1,0

PINK 1,0

12 11 13

WH/RD 1,0

GY/GN 1,0

7

BK 1,0

GN/VT 1,0

9

BK/WH 1,5

10 8

VT/BU 1,0

16

BU/GN 1,0

6

BU/WH 1,0

3

BU/RD 1,0

4

BU/BK 1,0

2

14 WH/VT 1,0

2

GY/GN 1,0

1 F

X2

WH/VT 1,0

X1

WH/BU 1,0

87

85

S9

2

33 RD 1,0

85

BK 1,0 BK 50 R1

GN 1,0 YE 1,0 S31

X12 5/58R

BK 1,0

BK 1,0

BK 1,0

BK 1,0

BK 1,5

BK 1,5

36

BK 1,5

BK 1,0

X11

7/58L

3/31

4/R

1/L

37

38

X8 2

3

S35

S30

BU 1,0 D+ RD 10,0 3G G1 B+ 50 30 M BM1

4 1

39

40 S34

41

Electrical diagram (sheet 1) for model ML460

R8

BK 50

BK 50

+

B C A

30

H26

H21

31 58L 54 58R

5

X9

49a

L

15

56b H24

RD/YE 1,5

9

49 R

BK/WH 1,0

V11

Y30

K

35 H27

WH/BK 1,0 GN/WH 1,0

31 L 50 BN/BK 1,0

BN/YE 1,0 BN/BK 1,0

K29

B S21

BU/YE 1,0

RD/BK 1,0

H

86

10

BU/BK 1,0

85 87

K7 85 87

30 15 TK

BU 6,0

86 30

K6

7

RD/BK 1,5 BK/GN 1,0

1

BK/WH 1,0

WH/VT 1,0

S19

RD 1,0

RD/BK 4,0

RD 6,0

RD 6,0 BU 6,0

F20 50A

F19 10A 86 30

RD 6,0 30 K5 87

- G2

S11

BK 1,0

BK 1,0

Y21

2

BK 1,5

Y22

BK 1,0

V15

56b 56a

B3

BK 1,0

Y34

V13 Y20

RD 6,0

RD 6,0

F18 40A

T

BK 1,0

T

F17 80A

RD 10,0

Wiring harness

J

V7

E4

E2

BK 1,0

V6

H20

BK 1,0

Y2

BK/WH/GN 1,0

Y4

1

3

BK/WH/RD 1,0

Y10

B2 56a

V14

BK 1,5

Y5

E3

H25 Y1

BK 1,0

V2

Y9

E1

E6

E5

Q

S3

S6

BK 1,0

V18

V3

BK 1,0

BK 1,0

BK 1,0

BK 1,0

BK 1,0

BK 1,0

V4

V1

34

B1 P

P

Y33

H

S2

S5

BK 1,0

G

BK 10,0

RD 10,0

3

L

L

M

M 1000155885_li.iso 1

Printed in U.S.A.

2

3

4

5

10-20

6

7

8

9

10

11

12

13

14

918294/AP1208

10.21 Electric diagram (sheet 2) for model ML460 15

14

16

17

18

19

20

21

22

23

24

1 2 F16 5A

1 3

F10 5A

A

F5 7,5A

F6 25A

F7 25A

4 5 6 3 6 10

B 2 9

7 8 9

B

86

K23 30

85

87

1 S14

10 11

Board

12 C

13 14 15 16 17

3

10

18 19 20 21 22 23 24

S15 B 1

5

9 S16 10

9

B 1

5

5 V16

S18 10

B

V10

25

D

9

1

V17

26 27

4 3

28 29 30

X7

E

2 1 BU/BK 1,0

31 32

13

5 7 8 14 4 nc nc

RD/BK 1,0

VT/GN 1,5

GY 1,0

11

BU 1,5 BK/BU 1,5 GN/BK 1,5

BU/GN 1,0

BU/GN 1,0

RD/YE 1,5 GN 1,0 GN/BK 1,0

RD/BK 1,5

F

h

H18

H22

H3

H4

H8

H7

E7 X16

Q

53a M

BK 1,0

S47

M5

3 4 2

VT/GN 1,5

E8

VT/GN 1,5

E15

M

E14

G

E10

1

H28

53 31b 31 M

E9

M2

36

BK 1,0

H1

P2

P1

M4

1

BK 1,5

H5

12

BK 1,5

H23

M3

M

8

BK 1,5

X15

11

BK 1,5

H11

2

BK 1,0

13

BK 2,5

X17

3

GN 1,0

35

VT/GN 1,0

BK/WH/BU 1,0

34

H10

GY/GN 1,5

6

9 12 6 1 3 10 nc nc

2

30

33

5

WH/BK 1,0

7

RD/WH 2,5 RD/YE 2,5

10

RD 1,0

BK/GN 1,0

14

X6

1 13 19 20 17 15 4 9 18

6 8 11 10 12 16 14 21 22 7 5 RD/BK 1,0 OG 1,0

3

YE 1,5

2

11

WH 1,5 BN/YE 1,5

13

BK/WH 1,0

BN/WH 1,0

9

17

BU/YE 1,0

WH 1,0

15

14

BU/RD 1,0

VT/BU 1,0

4

15

BU/GN 1,0

10

BU/WH 1,0

1

BU 1,0

BK/BU 1,0

GY/RD 1,0

VT 1,0

S1

12

RD 1,5

15

50a

GY/BK 1,0

BU/BK1,0

BU/GY 1,0

RD/BK 1,0

2

19

X5

5 6

OG 1,0

X4

2 9 16 8 7 4 3 18

Wiring harness

BK/WH 1,0

37

BK 1,0

BK 1,0

H

W1

V18

V19

Y26

Y27 X13

8 7

J A1

38

3

4

5

6 X14

39

40

B4

B5

K

41

11

8

7

2

6

9

10

H

53c

53

31b

L

R

56b 56a

49

30

5 3 41

Electrical diagram (sheet 2) for model ML460

X10 L

S2 15

56

M

M 1000155885_re.iso 14

918294/AP1208

15

16

17

18

19

20

21

10-21

22

23

24

Printed in U.S.A.

TORQUE SPECIFICATIONS Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise Hydraulic fittings with various seals (light application). All torque values are in lb-ft (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Identification aid outside Ø

M10x1.0

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (10 mm)

M12x1.5

15 (20)

18 (25)

18 (25)

18 (25)

0.5 in. (12 mm)

M14x1.5

26 (35)

33 (45)

26 (35)

26 (35)

0.6 in. (14 mm)

M16x1.5

33 (45)

41 (55)

30 (40)

37 (50)

0.6 in. (16 mm)

M18x1.5

41 (55)

52 (70)

33 (45)

52 (70)

0.7 in. (18 mm)

M22x1.5

48 (65)

92 (125)

44 (60)

92 (125)

0.9 in. (22 mm)

M27x2.0

66 (90)

133 (180)

74 (100)

107 (145)

1.0 in. (27 mm)

M33x2.0

111 (150)

229 (310)

118 (160)

155 (210)

1.3 in. (33 mm)

M42x2.0

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (42 mm)

M48x2.0

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (48 mm)

G1/8A

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (9.73 mm)

G1/4A

26 (35)

26 (35)

22 (30)

26 (35)

0.5 in. (13.16 mm)

G3/8A

33 (45)

52 (70)

33 (45)

37 (50)

0.7 in. (16.66 mm)

G1/2A

48 (65)

66 (90)

41 (55)

48 (65)

0.8 in. (20.96 mm)

Thread

G3/4A

66 (90)

133 (180)

74 (100)

103 (140)

1.0 in. (26.44 mm)

G1A

111 (150)

229 (310)

118 (160)

140 (190)

1.3 in. (33.25 mm)

G1 1/4A

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (41.91 mm)

G1 1/2A

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (47.80 mm)

Hydraulic fittings with various seals (heavy application). All torque values are in lb-ft (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

M12x1.5

15 (20)

26 (35)

26 (35)

26 (35)

0.5 in. (12 mm)

M14x1.5

26 (35)

41 (55)

33 (45)

33 (45)

0.6 in. (14 mm)

M16x1.5

33 (45)

52 (70)

41 (55)

41 (55)

0.6 in. (16 mm)

Thread

Identification aid outside Ø

M18x1.5

41 (55)

66 (90)

52 (70)

52 (70)

0.7 in. (18 mm)

M20x1.5

41 (55)

92 (125)

59 (80)

74 (100)

0.8 in. (20 mm)

M22x1.5

48 (65)

100 (135)

74 (100)

92 (125)

0.9 in. (22 mm)

M27x2.0

66 (90)

133 (180)

125 (170)

100 (135)

1.0 in. (27 mm)

M33x2.0

111 (150)

229 (310)

229 (310)

155 (210)

1.3 in. (33 mm)

M42x2.0

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (42 mm)

M48x2.0

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (48 mm)

G1/8A

26 (35)

41 (55)

33 (45)

33 (45)

0.5 in. (13.16 mm)

G1/4A

33 (45)

59 (80)

44 (60)

44 (60)

0.7 in. (16.66 mm)

G3/8A

48 (65)

85 (115)

55 (75)

74 (100)

0.8 in. (20.96 mm)

G1/2A

66 (90)

133 (180)

125 (170)

107 (145)

1.0 in. (26.44 mm)

G3/4A

111 (150)

229 (310)

229 (310)

192 (260)

1.3 in. (33.25 mm)

G1A

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (41.91 mm)

G1 1/4A

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (47.80 mm)

With coarse-pitch thread. All torque values are in lb-ft (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M5

4.1 (5.5)

6 (8)

7 (10)

4 (5)

5 (7)

M6

7 (10)

10 (14)

13 (17)

6.3 (8.5)

9 (12)

M8

18 (25)

26 (35)

31 (42)

15 (20)

22 (30)

M10

33 (45)

48 (65)

59 (80)

30 (40)

44 (59)

M12

64 (87)

81 (110)

108 (147)

51 (69)

74 (100)

M14

100 (135)

133 (180)

170 (230)

81 (110)

118 (160)

M16

155 (210)

203 (275)

258 (350)

125 (170)

184 (250)

M18

207 (280)

302 (410)

354 (480)

181 (245)

254 (345)

M20

302 (410)

420 (570)

509 (690)

251 (340)

361 (490)

M22

406 (550)

575 (780)

686 (930)

339 (460)

487 (660)

M24

524 (710)

738 (1000)

878 (1190)

435 (590)

620 (840)

M27

767 (1040)

1092 (1480)

1305 (1770)

642 (870)

922 (1250)

M30

1047 (1420)

1482 (2010)

1770 (2400)

885 (1200)

1254 (1700)

With fine-pitch thread. All torque values are in lb-ft (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M8x1.0

18 (25)

27 (37)

32 (43)

16 (22)

24 (32)

M10x1.0

37 (50)

55 (75)

65 (88)

32 (43)

48 (65)

M10x1.25

36 (49)

52 (71)

61 (83)

31 (42)

46 (62)

M12x1.25

64 (87)

96 (130)

111 (150)

55 (75)

81 (110)

M12x1.5

61 (83)

92 (125)

107 (145)

53 (72)

77 (105)

M14x1.5

100 (135)

148 (200)

173 (235)

89 (120)

129 (175)

M16x1.5

155 (210)

229 (310)

266 (360)

133 (180)

195 (265)

M18x1.5

232 (315)

332 (450)

391 (530)

199 (270)

284 (385)

M20x1.5

325 (440)

465 (630)

538 (730)

277 (375)

391 (530)

M22x1.5

435 (590)

620 (840)

723 (980)

369 (500)

524 (710)

M24x2.0

546 (740)

789 (1070)

922 (1250)

465 (630)

664 (900)

M27x2.0

811 (1100)

1143 (1550)

1328 (1800)

679 (920)

959 (1300)

M30x2.0

1106 (1500)

1586 (2150)

1844 (2500)

959 (1300)

1364 (1850)

®

Mustang Manufacturing Co., Inc. 1880 Austin Road, P.O. Box 547, Owatonna, Minnesota, 55060-0547 USA www.mustangmfg.com

918294/AP0605

© 2008 MUSTANG MANUFACTURING COMPANY, INC. All Rights Reserved.

PRINTED IN USA