Mustang Compact Excavator ME1503 ME1903 ME2203 Service Manual (918174) - PDF DOWNLOAD

®

ME1503, ME1903, ME2203 COMPACT EXCAVATORS

SERVICE MANUAL Revision A - 04/05

PART #918174 ®

Mustang Manufacturing Company, Inc.

TABLE OF CONTENTS Chapter

Page

A 1 2 3 5 6 7

Technical Data Primary Dimensions ..............................................................................A2 Bucket & Geometery .............................................................................A8 Lift Capacity Charts ...............................................................................A10 Hydraulic System ..................................................................................A16 Diesel Engine ....................................................................................... A20 Tightening Torques ...............................................................................A24

B 1 2 3 4 5 6 7 8 9 10

Maintenance Maintenance Schedule ......................................................................... B3 Lubricants .............................................................................................B6 Hydraulic System ..................................................................................B8 Hydraulic Pump ..................................................................................... B15 Hose Burst Protection ...........................................................................B15 Drive Unit .............................................................................................. B16 Swivel Unit ............................................................................................ B16 Auxiliary Hydraulic System ....................................................................B17 Cab ....................................................................................................... B18 Undercarriage ....................................................................................... B19

C 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Hydraulics Hydraulic Diagram ................................................................................C1 Hydraulic Pump .................................................................................... C4 Pilot Oil Supply Unit ..............................................................................C10 Main Valve Block ..................................................................................C12 Dozer Blade Valve ...............................................................................C23 Pilot Control Valves ..............................................................................C26 Swivel Unit ............................................................................................C28 Drive Unit ..............................................................................................C31 Swivel Joint ........................................................................................... C37 Switch Valves .......................................................................................C38 Collecting Tube ..................................................................................... C39 Panel—Pilot Control Hoses ..................................................................C40 Oil Tank .................................................................................................C43 Check Valves ....................................................................................... C44

Chapter

Page

D 1 2

Diesel Engine Diesel Engine Overall............................................................................D2 Fuel Supply Line ...................................................................................D3

E 1 2 3 4 5 6 7

Electrical Electrical Diagram Legend .................................................................... E2 Cab Wiring ............................................................................................ E3 Diesel Engine Wiring .............................................................................E4 Chassis Wiring ...................................................................................... E5 Connection Cable Wiring ......................................................................E6 Relay Box—Relay Arrangement ........................................................... E7 Fuse Box ............................................................................................... E10

F 1 2 3 4 5 6 7 8

Operating Elements Major Components ................................................................................F2 Cab Equipment and Controls ................................................................F3 Instrument Panel ................................................................................... F6 Towing the Compact Excavator ............................................................F7 Lifting the Compact Excavator ..............................................................F7 Tilting the Superstructure (Model ME2203 Only) ..................................F8 Undercarriage Telescoping (Width Extension) ...................................... F8 Chassis Component Arrangement ....................................................... F9

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SERVICE MANUAL

Technical Data

ME1503—2203

C H A P T E R A:

Technical Data (Mustang Service Manual ME1503—ME2203)

Page A1

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data 1.

ME1503—2203

PRIMARY DIMENSIONS

Dimensions ME1503 R 3' 9-3/4" (1160 mm)

45 o

R 5' 1-1/4" (1555 mm)

3' 3" (990 mm) 7' 9-3/4" (2380 mm) 10" (260 mm)

9" (230 mm)

4' (1223 mm)

12' 4-3/8" (3770 mm)

8' 10-3/8" (2700 mm)

9" (230 mm)

o 80

8' 4-1/4" (2542 mm)

11' 6" (3500 mm)

Page A2

4' 10-3/4" (1490 mm)

7' 2" (2185 mm)

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

Dimensions ME1503—Long Dipper Arm 46-1/2“ (1.18 m) R 3' 8" (1160 mm)

R 5' 1" (1550 mm)

45° 80°

3' 2" (990 mm)

7' 8" (2380 mm) 14-1/8" (360 mm) 10-1/4" (260 mm)

12-5/8" (320 mm) 9" (230 mm)

8' 10" (2700 mm)

4' (1223 mm)

9" (230 mm)

11' 5" (3500 mm) 8' 7" (2665 mm)

8' 3" (2545 mm)

4' 9" (1490 mm)

13' 3/8" (3970 mm)

12' 3/4" (3675 mm)

12' 4-1/2" (3770 mm)

8" (200 mm)

7' 2" (2185 mm)

7' 9-3/4" (2380 mm)

11' 9" (3620 mm)

Page A3

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

Dimensions ME1903

Page A4

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

Dimensions ME2203

Page A5

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

1. DIMENSIONS Dimensions ME1503

ME1503

ME1503

Yanmar 3TNE68ENSR

Yanmar 3TNE74ENSR2

Yanmar 3TNV76-SNS

Starting with Serial No.

AB00440

AC00304

AE00001

Dimensions (H x W x L)

7' 9-3/4" x 3' 3" x 8' 10-3/8" (2380 x 990 x 2700 mm)

7' 9-3/4" x 3' 3" x 8' 10-3/8" (2380 x 990 x 2700 mm)

7' 9-3/4" x 3' 3" x 8' 10-3/8" (2380 x 990 x 2700 mm)

Axle Distance

48-1/4" x 63-1/4" (1223 x 1605 mm)

48-1/4" x 63-1/4" (1223 x 1605 mm)

48-1/4" x 63-1/4" (1223 x 1605 mm)

Transport Length

12' 6" (3810 mm)

12' 6" (3810 mm)

12' 6" (3810 mm)

80°/45°

80°/45°

80°/45°

5' 1-1/4" (1555 mm)

5' 1-1/4" (1555 mm)

5' 1-1/4" (1555 mm)

Boom Swing Angle (Left/Right) Minimum Front Boom Swing Radius Tilt Angle Uppercarriage

N/A

N/A

N/A

Maximum Ground Clearance

7.9" (200 mm)

7.9" (200 mm)

7.9" (200 mm)

Undercarriage Width

3' 3" x 4' 3-1/4" (990—1300 mm)

3' 3" x 4' 3-1/4" (990—1300 mm)

3' 3" x 4' 3-1/4" (990—1300 mm)

Track Width (Standard) Maximum Dump Height (Standard) Maximum Dump Height with Optional Long Dipper Arm Maximum Dig Height (Standard) Maximum Dig Height with Optional Long Dipper Arm Maximum Dig Radius (Standard) Maximum Vertical Dig Depth (Standard) Maximum Dig Depth (Standard)

9" (230 mm)

9" (230 mm)

9" (230 mm)

8' 4-1/4" (2545 mm)

8' 4-1/4" (2545 mm)

8' 4-1/4" (2545 mm)

8' 9" (2665 mm)

8' 9" (2665 mm)

8' 9" (2665 mm)

11' 6" (3500 mm)

11' 6" (3500 mm)

11' 6" (3500 mm)

11' 10-1/2" (3620 mm)

11' 10-1/2" (3620 mm)

11' 10-1/2" (3620 mm)

12' 4-1/2" (3770 mm)

12' 4-1/2" (3770 mm)

12' 4-1/2" (3770 mm)

4' 10-3/4" (1490 mm)

4' 10-3/4" (1490 mm)

4' 10-3/4" (1490 mm)

7' 2" (2185 mm)

7' 2" (2185 mm)

7' 2" (2185 mm)

3' 9-3/4" (1160 mm)

3' 9-3/4" (1160 mm)

3' 9-3/4" (1160 mm)

3' 3" x 10" (990 x 260 mm)

3' 3" x 10" (990 x 260 mm)

3' 3" x 10" (990 x 260 mm)

Dozer Blade Maximum Lift ... Ground (Above/Below) Track Rollers/Guide Rollers (Number Per Side)

10"/9" (260 mm/230 mm)

10"/9" (260 mm/230 mm)

10"/9" (260 mm/230 mm)

3 pcs.

3 pcs.

3 pcs.

Operation Weight with Cab

3759 lbs. (1705 kg)

3759 lbs. (1705 kg)

3759 lbs. (1705 kg)

Operation Weight with Canopy

3583 lbs. (1625 kg)

3583 lbs. (1625 kg)

3583 lbs. (1625 kg)

Ground Pressure (Standard)

3.8 psi (0.27 kg/cm²)

3.8 psi (0.27 kg/cm²)

3.8 psi (0.27 kg/cm²)

Minimum Tail Swing Radius Dozer Blade Dimensions (W x H) (Standard)

Gradability

30°/58%

30°/58%

30°/58%

Noise Level (LWA)

93 dB (A)

93 dB (A)

93 dB (A)

Noise Level (LPA)

77 dB (A)

77 dB (A)

77 dB (A)

Travel Speed (Drive)

1.7—3.5 mph (2,8—5,6 km/h)

1.7—3.5 mph (2,8—5,6 km/h)

1.7—3.5 mph (2,8—5,6 km/h)

252 psi (1735 kPa)

252 psi (1735 kPa)

252 psi (1735 kPa)

150 psi (1038 kPa)

150 psi (1038 kPa)

150 psi (1038 kPa)

10 rpm

10 rpm

10 rpm

Tear-Out Force Per Bucket Tooth Maximum Dipper Arm Tear-Out Force (Standard) Uppercarriage Slew (Swivel) Speed Explanation: O = Optional N = Not Available/Not Applicable

Page A6

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

Dimensions ME1903

ME2203

ME2203

Yanmar 3TNE74ENSR2

Yanmar 3TNV76-SNS

Starting with Serial No.

AB00440

AB00440

AE00001

Dimensions (H x W x L)

7' 9-1/2" x 3' 3" x 8' 11' (2375 x 990 x 2715 mm)

7' 10-3/8" x 3' 3" x 8' 11" (2395 x 990 x 2715 mm)

7' 10-3/8" x 3' 3" x 8' 11" (2395 x 990 x 2715 mm)

Axle Distance

4' 4-1/4" x 5' 7-3/8" (1325 x 1710 mm)

4' 4-1/4" x 5' 7-3/8" (1325 x 1710 mm)

4' 4-1/4" x 5' 7-3/8" (1325 x 1710 mm)

Transport Length

13' 1-1/4" (3990 mm)

13' 1-1/4" (3990 mm)

13' 1-1/4" (3990 mm)

80°/45°

80°/45°

80°/45°

5' 2" (1575 mm)

5' 2" (1575 mm)

5' 2" (1575 mm)

Boom Swing Angle (Left/Right) Minimum Front Boom Swing Radius Tilt Angle Uppercarriage Maximum Ground Clearance Undercarriage Width Track Width (Standard)

N/A

15°

15°

7" (180 mm)

7" (180 mm)

7" (180 mm)

3' 3"—5' 3-1/4" (990—1300 mm)

3' 3"—5' 3-1/4" (990—1300 mm)

3' 3"—5' 3-1/4" (990—1300 mm)

10" (250 mm)

10" (250 mm)

10" (250 mm)

Maximum Dump Height (Standard) Maximum Dump Height with Optional Long Dipper Arm Maximum Dig Height (Standard) Maximum Dig Height with Optional Long Dipper Arm Maximum Dig Radius (Standard)

9' 3/4" (2760 mm)

9' 1-1/2" (2780 mm)

9' 1-1/2" (2780 mm)

Maximum Vertical Dig Depth (Standard) Maximum Dig Depth (Standard)

9' 6" (2890 mm)

9' 7" (2915 mm)

9' 7" (2915 mm)

12' 8" (3860 mm)

12' 9" (3885 mm)

12' 9" (3885 mm)

13' 1" (3990 mm)

14' 3/8" (4275 mm)

14' 3/8" (4275 mm)

13' 5" (4090 mm)

13' 5" (4090 mm)

13' 5" (4090 mm)

5' 5-3/4" (1670 mm)

5' 5" (1650 mm)

5' 5" (1650 mm)

8' 2-1/2" (2500 mm)

8' 1-3/4" (2480 mm)

8' 1-3/4" (2480 mm)

Minimum Tail Swing Radius (Standard)

3' 9-3/4" (1160 mm)

3' 9-3/4" (1160 mm)

3' 9-3/4" (1160 mm)

Standard Dozer Blade Dimensions (W x H)

3' 3"/10-1/4" (990 mm/260 mm)

3' 3"/10-1/4" (990 mm/260 mm)

3' 3"/10-1/4" (990 mm/260 mm)

Dozer Blade Maximum Lift ... Ground (Above/Below) Track Rollers/Guide Rollers (Number Per Side)

9-3/4"/9-3/8" (245 mm/238 mm)

9-3/4"/9-3/8" (245 mm/238 mm)

9-3/4"/9-3/8" (245 mm/238 mm)

4 pcs.

4 pcs.

4 pcs.

Operation Weight with Cab

4286 lbs. (1944 kg)

4447 lbs. (2017 kg)

4447 lbs. (2017 kg)

Operation Weight with Canopy

4087 lbs. (1854 kg)

4248 lbs. (1927 kg)

4248 lbs. (1927 kg)

Ground Pressure (Standard)

3.8 psi (0.27 kg/cm²)

4.0 psi (0.28 kg/cm²)

4.0 psi (0.28 kg/cm²)

Gradability

30°/58%

30°/58%

30°/58%

Noise Level (LWA)

94 dB (A)

94 dB (A)

94 dB (A)

Noise Level (LPA)

75 dB (A)

75 dB (A)

75 dB (A)

Travel Speed (Drive)

1.2—2.5 mph (2,0—4,0 km/h)

1.2—2.5 mph (2,0—4,0 km/h)

1.2—2.5 mph (2,0—4,0 km/h)

268 psi (1846 kPa)

268 psi (1846 kPa)

268 psi (1846 kPa)

174 psi (1198 kPa)

174 psi (1198 kPa)

174 psi (1198 kPa)

10 rpm

10 rpm

10 rpm

Tear-Out Force Per Bucket Tooth Maximum Dipper Arm Tear-Out Force (Standard) Uppercarriage Slew (Swivel) Speed Explanation: O = Optional N = Not Available/Not Applicable

Page A7

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

2. BUCKET AND GEOMETERY ME1503

ME1903

ME2203

E

Bolt Diameter

1.26" (32 mm)

F

Dipper Arm Width

4.65" (118 mm)

L

Bolt Distance Bucket Carrier

5.10" (129.5 mm)

Page A8

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

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Page A9

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data 3.

ME1503—2203

LIFT CAPACITY CHARTS

Lift Capacity—ME1503

Page A10

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

LIFT CAPACITY CHART Maximum 8’ 2" (2.5 m)

9’ 8" (3.0 m)

6’ 6" (2.0 m)

4’ 9" (1.5 m)

A B 8’ 2" (2.5 m) 6’ 6" (2.0 m)

871 lbs.

(395 kg)* 871 lbs.

(395 kg)*

871 lbs.

(395 kg)* 750 lbs.

(340 kg)

849 lbs. 849 lbs.

(385 kg)* (385 kg)* 849 lbs. 849 lbs.

(385 kg)* (385 kg)*

3’ 3" (1.0 m)

882 lbs.

(400 kg)*

650 lbs. 948 lbs. 750 lbs.

(295 kg) (430 kg)* (340 kg)

1113 lbs.

(505 kg)*

937 lbs. 1444 lbs. 1334 lbs. 2260 lbs. 2083 lbs.

(425 kg) (655 kg)* (605 kg)* (1025 kg)* (945 kg)

0

970 lbs.

(440 kg)*

661 lbs. 1036 lbs. 717 lbs. 1334 lbs.

(300 kg) (470 kg)* (325 kg)* (605 kg)*

882 lbs. 1841 lbs. 1279 lbs. 2833 lbs. 1962 lbs.

(400 kg) (835 kg)* (580 kg) (1285 kg)* (890 kg)

-3’ 3" (-1.0 m) -4’ 9" (-1.5 m)

1003 lbs.

(455 kg)*

871 lbs.

(395 kg)

849 lbs. 1554 lbs. 1279 lbs. 2227 lbs. 2017 lbs.

(385 kg) (705 kg)* (580 kg) (1010 kg)* (915 kg)

981 lbs.

(445 kg)*

981 lbs.

(445 kg)*

Max. A B *

1102 lbs.

(500 kg)*

1003 lbs. 1003 lbs. 1477 lbs. 1477 lbs.

(455 kg)* (455 kg)* (670 kg)* (670 kg)*

Allowable load with extended dipper arm Overhang from the center of the turntable Height of load fixing point Lift capacity restricted by the hydraulics

All chart figures are given in lbs. (kg) rated on level, secured ground without bucket.

Dozer blade support in drive direction.

Dozer blade support 90° to drive direction.

If a bucket or other attachment is mounted, the lifting capacity, or tilting load is reduced by the empty weight of the attachment.

Position on solid subsoil and without bucket.

Design fundamentals: according to ISO 10567 The lifting power of the compact excavator is limited by the setting of the pressure controls valves and stabilizer system. Neither 75% of the static tilting load nor 87% from the hydraulic lifting capacity are exceeded.

Page A11

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

Lift Capacity—ME1903

Page A12

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

LIFT CAPACITY CHART Maximum 8’ 2" (2.5 m)

9’ 8" (3.0 m)

6’ 6" (2.0 m)

4’ 9" (1.5 m)

A B 9’ 8" (3.0 m) 6’ 6" (2.0 m)

915 lbs.

(415 kg)* 871 lbs.

(395 kg)*

915 lbs.

882 lbs. 882 lbs.

(415 kg)* (400 kg)* (400 kg)* 728 lbs. 860 lbs. 838 lbs. 882 lbs. 882 lbs.

(330 kg) (390 kg)* (380 kg) (400 kg)* (400 kg)*

3’ 3" (1.0 m)

893 lbs.

(405 kg)*

628 lbs. 1003 lbs. 816 lbs.

(285 kg) (455 kg)* (370 kg)

1213 lbs. 1047 lbs. 1664 lbs. 1433 lbs. 2436 lbs. 1676 lbs.

(550 kg)* (475 kg) (755 kg)* (650 kg) (1105 kg)* (760 kg)

0

937 lbs.

(425 kg)*

639 lbs. 1124 lbs. 750 lbs.

(290 kg) (510 kg)* (340 kg)

1466 lbs.

(665 kg)*

981 lbs. 2028 lbs. 1356 lbs. 2998 lbs. 1543 lbs.

(445 kg) (920 kg)* (615 kg) (1360 kg)* (700 kg)

-3’ 3" (-1.0 m) -4’ 9" (-1.5 m)

970 lbs.

(440 kg)*

794 lbs.

(360 kg)

1279 lbs.

(580 kg)*

981 lbs. 1753 lbs. 1345 lbs. 2524 lbs. 1499 lbs.

(445 kg) (795 kg)* (610 kg) (1145 kg)* (680 kg)

959 lbs.

(435 kg)*

959 lbs.

(435 kg)*

Max. A B *

1279 lbs. 1279 lbs. 1830 lbs. 1565 lbs.

(580 kg)* (580 kg)* (830 kg)* (710 kg)*

Allowable load with extended dipper arm Overhang from the center of the turntable Height of load fixing pint Lift capacity restricted by the hydraulics

All chart figures are given in lbs. (kg) rated on level, secured ground without bucket.

Dozer blade support in drive direction.

Dozer blade support 90° to drive direction.

If a bucket or other attachment is mounted, the lifting capacity, or tilting load is reduced by the empty weight of the attachment.

Position on solid subsoil and without bucket.

Design fundamentals: according to ISO 10567 The lifting power of the compact excavator is limited by the setting of the pressure controls valves and stabilizer system. Neither 75% of the static tilting load nor 87% from the hydraulic lifting capacity are exceeded.

Page A13

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

Lift Capacity—ME2203

Page A14

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

LIFT CAPACITY CHART

Max. A B *

Allowable load with extended dipper arm Overhang from the center of the turntable Height of load fixing pint Lift capacity restricted by the hydraulics

All chart figures are given in lbs. (kg) rated on level, secured ground without bucket.

Dozer blade support in drive direction.

Dozer blade support 90° to drive direction.

If a bucket or other attachment is mounted, the lifting capacity, or tilting load is reduced by the empty weight of the attachment.

Position on solid subsoil and without bucket.

Design fundamentals: according to ISO 10567 The lifting power of the compact excavator is limited by the setting of the pressure controls valves and stabilizer system. Neither 75% of the static tilting load nor 87% from the hydraulic lifting capacity are exceeded.

Page A15

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

5. HYDRAULIC SYSTEM

Hydraulic Settings ME1503 Model

ME1503

ME1503

Started with Serial No.:

AB00440

AC00304

Variable/Gear Pump

Variable/Gear Pump

1528401

1528401

HYDRAULIC PUMP 1

Type System

Single variable pump w ith tw o pressure ports + tw o gear pumps

3

Version A

PVD-0B-20BP-8GA5-4953(A)

4

Version B

5

Oil Flow Rate—Version A

6 + 6 + 4.9 + 2.6 gpm (23 + 23 + 18.5 + 10 L/min)

6

Oil Flow Rate—Version B

6 + 6 + 4.9 + 1.6 gpm (23 + 23 + 18.5 + 6 L/min)

2

PVD-0B-20BP-8G3-4953(B)

PRESSURE SETTING 7

Main Pressure Limiting Valve, Pump P1, P2

(2)

2900 ±44 psi (200 ±3 bar)

2900 ±44 psi (200 ±3 bar)

8

Main Pressure Limiting Valve, Pump P3

(2)

2538 ±44 psi (175 ±3 bar)

2900 ±44 psi (200 ±3 bar)

9

Pilot Oil Pressure

435 +29/-14.5 psi (30 +2/-1 bar)

435 +29/-14.5 psi (30 +2/-1 bar)

10

Secondary Pressure Limiting Valve, Main Valve Block

(3)

3553 +73/-29 psi (245 +5/-2 bar)

3553 +73/-29 psi (245 +5/-2 bar)

11 Secondary Pressure Limiting Valve, Dozer Blade Valve

(3)

N/A

N/A

12 Sw ivel Motor (SPLV) (Measuring Points Pump)

(3)

1812 -0/+334 psi (125 -0/+23 bar)

1812 -0/+334 psi (125 -0/+23 bar)

N/A (Damping Valves)

N/A (Damping Valves)

N/A

N/A

14

Drive Motor Internal Pressure Limiting Valve

15 Check Valve Boom Offset Cylinder

For correct settings: (1) General—Hydraulic Oil Temperature: 113—122°F (45—50°C) (2) Settings at Maximum Engine rpm (See Maintenance Chapter) (3) Settings at Minimum Engine rpm (See Maintenance Chapter)

CAPACITIES 16

5.5 gal. (21 L)

Hydraulic Oil Tank

17 System Filling

NOTE:

Change: Solution: Serial No.:

Higher working pressure for P1, P2 New hydraulic pump (1428407) AC01263 starting

Page A16

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

Hydraulic Settings ME1903—2203 Model

ME1903

ME2203

Started with Serial No.:

AB00440

AB00440

HYDRAULIC PUMP 1

Type

Variable/Gear Pump 1928401

2

System

Single variable pump w ith tw o pressure ports + tw o gear pumps

3

Version A

PVD-0B-20BP-8GA5-4952A

4

Version B

PVD-0B-20BP-8G3-4952B

5

Oil Flow Rate—Version A

6 + 6 + 4.9 + 2.6 gpm (23 + 23 + 18.5 + 10 L/min)

6

Oil Flow Rate—Version B

6 + 6 + 4.9 + 1.6 gpm (23 + 23 + 18.5 + 6 L/min)

PRESSURE SETTINGS 7

Main Pressure Limiting Valve, Pump P1, P2

(2)

2900 ±44 psi (200 ±3 bar)

2900 ±44 psi (200 ±3 bar)

8

Main Pressure Limiting Valve, Pump P3

(2)

2900 ±44 psi (200 ±3 bar)

2900 ±44 psi (200 ±3 bar)

9

Pilot Oil Pressure

435 +29/-14.5 psi (30 +2/-1 bar)

435 +29/-14.5 psi (30 +2/-1 bar)

10

Secondary Pressure Limiting Valve, Main Valve Block

(3)

3553 +73/-29 psi (245 +5/-2 bar)

3553 +73/-29 psi (245 +5/-2 bar)

11 Secondary Pressure Limiting Valve, Dozer Blade Valve

(3)

N/A

N/A

(3)

2176 -0/+334 psi (150 -0/+23 bar)

2176 -0/+334 psi (150 -0/+23 bar)

N/A (Damping valves)

N/A (Damping valves)

N/A

N/A

12

Sw ivel Motor (SPLV) (Measuring Points Pump)

14

Drive Motor, Internal Pressure Limiting Valve

15 Check Valve, Boom Offset Cylinder

For correct settings: (1) General—Hydraulic Oil Temperature: 113—122°F (45—50°C) (2) Settings at Maximum Engine rpm (See Maintenance Chapter) (3) Settings at Minimum Engine rpm (See Maintenance Chapter)

CAPACITIES 16

Hydraulic Oil Tank

5.5 gal. (21 L)

17 System Filling

Explanation: N/A = Not Available/Not Applicable

Page A17

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

Pressure Controlled Oil Flow—Auxiliary Hydraulics

AUXILIARY HYDRAULICS 1

Excavator

M E1503

M E1903

3TNE68ENSR

M E2203

Pressure Controlled Oil Flow —Auxiliary Hydraulics

Pressure

P2+P3

P2+P3

218 psi (15 bar)

11.1 gpm (42 L/min)

11.4 gpm (43 L/min)

435 psi (30 bar)

10.7 gpm (40.5 L/min)

11.2 gpm (42.5 L/min)

653 psi (45 bar)

10.2 gpm (38.5 L/min)

11 gpm (41.5 L/min)

870 psi (60 bar)

9.8 gpm (37 L/min)

10.6 gpm (40 L/min)

1088 psi (75 bar)

9.2 gpm (35 L/min)

10.2 gpm (38.5 L/min)

1305 psi (90 bar)

8.8 gpm (33.5 L/min)

9.6 gpm (36.5 L/min)

1523 psi (105 bar)

8.2 gpm (31 L/min)

9.1 gpm (34.5 L/min)

1740 psi (120 bar)

7.7 gpm (29 L/min)

8.7gpm (33 L/min)

1958 psi (135 bar)

7.1 gpm (27 L/min)

8.2 gpm (31 L/min)

2176 psi (150 bar)

5.7 gpm (21.5 L/min)

7.8 gpm (29.5 L/min)

2393 psi (165 bar)

2.4 gpm (9 L/min)

6.9 gpm (26 L/min)

2611 psi (180 bar)

—

5.8 gpm (22 L/min)

Conditions : 1) Pressure = Pressure setting at the tool (bucket) 2) Tolerance of the listed settings: +0.26/-0.52 gpm (+1/-2 L/min)

Clearance - Hose Burst Protection Valves (inside hose versions) Excavator ME12002 ME1503—2203 ME1503—2203 ME2203 ME2503 ME3003 ME3503, ME3703 ME2702—3602, 3802 WD ME5002 ME6002 ME6502 ME8002, ME12002

Assembled at the Triple Boom Cylinder Dozer Blade Cylinder Dozer Blade Cylinder Tilt Cylinder Dozer Blade Cylinder Dozer Blade Cylinder Dozer Blade Cylinder Dozer Blade Cylinder Dozer Blade Cylinder Dozer Blade Cylinder Dozer Blade Cylinder Dozer Blade Cylinder

Screw size 3/4" 3/8" 3/8" 1/4" 3/8" 3/8" 1/2" 3/8" 1/2" 1/2" 3/8" 1/2"

Page A18

Clearance S 0.087" (2.2 mm) 0.028" (0.7 mm) 0.039" (1 mm) 0.016" (0.4 mm) 0.031" (0.8 mm) 0.071" (1.8 mm) 0.039" (1.0 mm) 0.047" (1.2 mm) 0.047" (1.2 mm) 0.059" (1.5 mm) 0.059" (1.5 mm) 0.134" (3.4 mm)

Id.No.: 918174 AP0405

S

3) Oil flow controlled at the regular dipper arm connections

SERVICE MANUAL

Technical Data

ME1503—2203

This page intentionally left blank.

Page A19

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

6. DIESEL ENGINE ME1503

ME1503

1 Diesel Engine Model

Yanmar 3TNE68-ENSR

Yanmar 3TNE74-ENSR2

2 Started with Serial No.: 3 Type

AB00440

AC00304

Model SPECIFICATIONS:

Vertical, 4-cycle water-cooled diesel engine Natural suction

4 Suction System 5 Combustion System 6 Glow Plug System 7 Direction of Rotation 8 Governor 9 Lubrication System

Special swirl pre-combustion chamber Glow plugs inside the pre-combustion chamber Counterclockwise (viewed from flywheel) Mechanical centrifugal govenor (all speed type) Forced lubrication with trochoid pump

10 Starting System

Electrical

11 Cooling System

Water-cooled/Pushing Fan

DATA: 12 Maximum Revolution Speed (No Load)

2350 ±50 rpm

2390 ±50 rpm 2200 ±25 rpm

14 Revolution Speed

1300 +50/-0 rpm

15 Minimum Revolution Speed (No Load) 47 cu. in. (2.68" x 283")

61.4 cu. in. (2.91" x 3.07")

784 cm 3 (68 mm x 72 mm)

1006 cm 3 (74 mm x 78 mm)

17 Output (at speed listed in item 14)

11.7 hp (8.7 kW)

15.8 hp (11.8 kW)

18 Maximum Engine Output

19.4 hp (14.5 kW)

16 Displacement (Bore x Stroke)

23.7 hp (17.7 kW) 3

19 Number of Cylinders 20 Valve Clearance (IN=OUT)

0.006—0.010" (0.15—0.25 mm)

21 Compression Ratio

23.0

22 Fuel Injection Timing

14° ±1°

23 Fuel Injection Pressure 24 Compression Pressure

1740 -0/+145 psi (120 -0/+10 bar) 479 +/- 15 psi (33 +/-1 bar) at 250 rpm

479 +/- 15 psi (33 +/-1 bar) at 250 rpm

44—58 psi (3.0—4.0 bar)

25 Engine Oil Pressure (Rev. Speed Level) 26 Pressure Switch Engine Oil Pump

5.8—8.7 psi (0.4—0.6 bar)

27 Thermostat Opening Temperature

157—163°F (69.5—72.5°C)

28 Thermostat, Fully Open

185°F (85°C)

29 Thermo Switch On/Off

225—235°F (107—113°C) and more 1-3-2-1

30 Firing Order

15 amps/12 volts

31 Generator Power (Standard)

12 volts/45 amps

32 Battery 33 V-Belt Dimensions

0.37" x 33.6" (9.5 x 855 mm)

Page A20

0.37" x 36.4" (9.5 x 925 mm)

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

Model

ME1503

ME1503

TIGHTENING TORQUES: 34 Cylinder Head Bolt

28—31 lb-ft. (38—42 Nm) (M8 x 1,25)

44—48 lb-ft. (60—65 Nm) (M9 x 1,25) N/A

35 Bonnet Screw Nut

17—21 lb-ft. (23—28 Nm)

36 Connecting Rod Bolt (M7 x 1,0) 37 Bearing Clam ping Bolt (M10 x 1,25)

39—42 lb-ft. (53—57 Nm)

59—63 lb-ft. (80—85 Nm)

38 Flywheel Bolt (M10 x 1,25)

60—65 lb-ft. (82—88 Nm)

59—66 lb-ft. (80—90 Nm)

39 Glow Plug

11—15 lb-ft. (15—20 Nm) (M10 x 1,25)

CAPACITIES 25.4 qt. (24 L)

40 Fuel Tank

2.5/1.05 qt. (2.4 L/1.0 L)

41 Engine Oil—Oil Pan (Maximum /Effective)

0.96 qt. (0.9 L)

42 Cooling System (without Radiator)

SPECIFICATIONS API grade CC class or higher

43 Engine Oil

Page A21

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

Diesel Engine Settings Model

ME1903

ME2203

SPECIFICATION: Yanmar 3TNE74-ENSR2

1 Diesel Engine Model

AB00440

2 Started with Serial No.: 3 Type

Vertical, 4-cycle water-cooled diesel engine Natural suction

4 Suction System 5 Combustion System

Special swirl pre-combustion chamber

6 Glow Plug System

Glow plugs inside the pre-combustion chamber

7 Direction of Rotation

Counterclockwise (viewed from flywheel) Mechanical centrifugal governor

8 Governor 9 Lubrication System

Forced lubrication with trochoid pump

10 Starting System

Electrical

11 Cooling System

Water cooled/pushing fan

DATA: 2390 ±50 rpm

12 Maximum Revolution Speed (No Load) 14 Revolution Speed

2200 ±25 rpm

15 Minimum Revolution Speed (No Load)

1300 +50/-0 rpm 61.4 cu. in. (2.91" x 3.07") 1006 cm 3 (74 mm x 78 mm) 15.8 hp (11.8 kW)

16 Displacem ent (Bore x Stroke) 17 Output (at speed listed in item 14)

23.7 hp (17.7 kW)

18 Maximum Engine Output

3

19 Number of Cylinders

0.006—0.010" (0,15—0,25 mm)

20 Valve Clearance (IN=OUT) 21 Compression Ratio

23.0

22 Fuel Injection Timing

14° ±1°

23 Fuel Injection Pressure

1740 -0/+145 psi (120 -0/+10 bar)

24 Compression Pressure

508 ±15 psi (35 +/-1 bar) at 250 rpm

25 Engine Oil Pressure (Rev. Speed Level)

44—58 psi (3.0—4.0 bar)

26 Pressure Switch Engine Oil Pump

5.8—8.7 psi (0.4—0.6 bar)

27 Thermostat Opening Temperature

157—163°F (69.5—72.5°C)

28 Thermostat, Fully Open

185°F (85°C)

29 Thermo Switch On/Off

225—235°F (107—113°C)/100 and more 1-3-2-1

30 Firing Order

15 amps/12 volts

31 Generator Power (Standard)

12 volts/45 amps

32 Battery

0.37" x 36.4" (9.5 x 925 mm)

33 V-Belt Dimensions

Page A22

Id.No.: 918174 AP0405

SERVICE MANUAL

Technical Data

ME1503—2203

ME1903

Model

ME2203

TIGHTENING TORQUES: 34 Cylinder Head Bolt (M9 x 1.25)

44—48 lb-ft. (60—65 Nm)

35 Bonnet Screw Nut

N/A

36 Connecting Rod Bolt (M7 x 1.0)

17—21 lb-ft. (23—28 Nm)

37 Bearing Cap Clamping Bolt (M10 x 1.25)

59—63 lb-ft. (80—85 Nm)

38 Flyw heel Clamping Bolt (M10 x 1.25)

59—66 lb-ft. (80—90 Nm)

39 Glow Plug (M10 x 1.25)

11—15 lb-ft. (15—20 Nm)

CAPACITIES 25.4 qt. (24 L)

40 Fuel Tank 41 Engine Oil—Oil Pan (Maximum/Effective)

2.5/1.05 qt. (2.4/1.0 L) 0.96 qt. (0.9 L)

42 Cooling Water Content (without Radiator)

SPECIFICATIONS API Grade CC, Class or higher

43 Engine Oil

NOTE:

Change: ME1503 Serial No.:

New diesel engine 3TNE74 for AC00304 and higher Changed technical data

Page A23

Id.No.: 918174 AP0405

Page A24

44 lb-ft. (60 Nm) 55 lb-ft. (75 Nm) 66 lb-ft. (90 Nm) 74 lb-ft. (100 Nm) 133 lb-ft. (180 Nm) 199 lb-ft. (270 Nm) 295 lb-ft. (400 Nm)

SW 24 SW 27 SW 30 SW 36 SW 41 SW 50 SW 60

M20 x 1,5 M22 x 1,5 M24 x 1,5 M30 x 2 M36 x 2 M42 x 2 M52 x 2

12S 14S 16S 20S 25S 30S 38S

08 10 12 16 20 25 32

30 lb-ft. (40 Nm) 37 lb-ft. (50 Nm) 55 lb-ft. (75 Nm) 63 lb-ft. (85 Nm) 74 lb-ft. (100 Nm) 133 lb-ft. (180 Nm) 162 lb-ft. (220 Nm)

SW 19 SW 22 SW 27 SW 32 SW 36 SW 41 SW 55

M16 x 1,5 M18 x 1,5 M22 x 1,5 M26 x 1,5 M30 x 2 M36 x 2 M45 x 2

10L

12L

15L

18L

22L

28L

08

10

12

16

20

25

Surface galvanic coated and dry (O-ring oiled). Tolerance torque -10 %

37 lb-ft. (50 Nm)

SW 22

M18 x 1,5

10S

06

15 lb-ft. (20 Nm)

SW 17

M14 x 1,5

8L

06

35L

30 lb-ft. (40 Nm)

SW 19

M16 x 1,5

8S

05

11 lb-ft. (15 Nm)

SW 14

M12 x 1,5

6L

05

32

Torque

Tool

Screw

RA

DN

Torque

Tool

Screw

RA

Heavy Type (DKOS)

DN

Light Version (DKOL)

Metric hose joints for hydraulic assembling

Tightening Torques for Hydraulic Joints and Dry Assembling

Technical Data SERVICE MANUAL

ME1503—2203

7. TIGHTENING TORQUES

Id.No.: 918174 AP0405

Page A25

Metric screw

Whitworth screw

Id.No.: 918174 AP0405

G 1-1/2A

G 1-1/4A

G 1A

Seal W asher 6.6 lb-ft.

(9 Nm) 14.8 lb-ft.

(20 Nm) 25.8 lb-ft.

(35 Nm) 33.2 lb-ft.

(45 Nm) 40.6 lb-ft.

(55 Nm) 48.0 lb-ft.

(65 Nm) 66.4 lb-ft.

(90 Nm) 110.6 lb-ft.

(150 Nm) 177.0 lb-ft.

(240 Nm) 213.9 lb-ft.

(290 Nm) 6.6 lb-ft.

(9 Nm) 25.8 lb-ft.

(35 Nm) 33.2 lb-ft.

(45 Nm) 48.0 lb-ft.

(65 Nm) 66.4 lb-ft.

(90 Nm) 110.6 lb-ft.

(150 Nm) 177.0 lb-ft.

(240 Nm) 213.9 lb-ft.

(290 Nm)

Elastic Seal 13.2 lb-ft.

(18 Nm) 18.4 lb-ft.

(25 Nm) 33.2 lb-ft.

(45 Nm) 40.6 lb-ft.

(55 Nm) 51.6 lb-ft.

(70 Nm) 92.2 lb-ft.

(125 Nm) 132.8 lb-ft.

(180 Nm) 228.6 lb-ft.

(310 Nm) 331.9 lb-ft.

(450 Nm) 398.2 lb-ft.

(540 Nm) 13.2 lb-ft.

(18 Nm) 25.8 lb-ft.

(35 Nm) 51.6 lb-ft.

(70 Nm) 66.4 lb-ft.

(90 Nm) 132.8 lb-ft.

(180 Nm) 228.6 lb-ft.

(310 Nm) 331.9 lb-ft.

(450 Nm) 398.2 lb-ft.

(540 Nm) 11.1 lb-ft.

(15 Nm) 18.4 lb-ft.

(25 Nm) 25.8 lb-ft.

(35 Nm) 29.5 lb-ft.

(40 Nm) 33.2 lb-ft.

(45 Nm) 44.3 lb-ft.

(60 Nm) 73.8 lb-ft.

(100 Nm) 118.0 lb-ft.

(160 Nm) 154.9 lb-ft.

(210 Nm) 191.8 lb-ft.

(260 Nm) 11.1 lb-ft.

(15 Nm) 22.1 lb-ft.

(30 Nm) 33.2 lb-ft.

(45 Nm) 40.6 lb-ft.

(55 Nm) 73.8 lb-ft.

(100 Nm) 118.0 lb-ft.

(160 Nm) 154.9 lb-ft.

(210 Nm) 191.8 lb-ft.

(260 Nm)

O-Ring 13.2 lb-ft.

(18 Nm) 18.4 lb-ft.

(25 Nm) 25.8 lb-ft.

(35 Nm) 36.9 lb-ft.

(50 Nm) 51.6 lb-ft.

(70 Nm) 92.2 lb-ft.

(125 Nm) 106.9 lb-ft.

(145 Nm) 154.9 lb-ft.

(210 Nm) 265.5 lb-ft.

(360 Nm) 398.2 lb-ft.

(540 Nm) 13.2 lb-ft.

(18 Nm) 25.8 lb-ft.

(35 Nm) 36.9 lb-ft.

(50 Nm) 48.0 lb-ft.

(65 Nm) 103.3 lb-ft.

(140 Nm) 140.1 lb-ft.

(190 Nm) 265.5 lb-ft.

(360 Nm) 398.2 lb-ft.

(540 Nm)

RHV with ED-seal

47.80 mm

41.91 mm

33.25 mm

26.44 mm

20.96 mm

16.66 mm

13.16 mm

9.73 mm

48 mm

42 mm

33 mm

27 mm

22 mm

18 mm

16 mm

14 mm

12 mm

10 mm

Outside Bore-Ø Seal W asher 14.8 lb-ft.

(20 Nm) 25.8 lb-ft.

(35 Nm) 33.2 lb-ft.

(45 Nm) 40.6 lb-ft.

(55 Nm) 40.6 lb-ft.

(55 Nm) 48.0 lb-ft.

(65 Nm) 66.4 lb-ft.

(90 Nm) 110.6 lb-ft.

(150 Nm) 177.0 lb-ft.

(240 Nm) 213.9 lb-ft.

(290 Nm) 25.8 lb-ft.

(35 Nm) 33.2 lb-ft.

(45 Nm) 48.0 lb-ft.

(65 Nm) 66.4 lb-ft.

(90 Nm) 110.6 lb-ft.

(150 Nm) 177.0 lb-ft.

(240 Nm) 213.9 lb-ft.

(290 Nm)

Elastic Seal 25.8 lb-ft.

(35 Nm) 40.6 lb-ft.

(55 Nm) 51.6 lb-ft.

(70 Nm) 66.4 lb-ft.

(90 Nm) 92.2 lb-ft.

(125 Nm) 99.6 lb-ft.

(135 Nm) 132.8 lb-ft.

(180 Nm) 228.6 lb-ft.

(310 Nm) 331.9 lb-ft.

(450 Nm) 398.2 lb-ft.

(540 Nm) 40.6 lb-ft.

(55 Nm) 59.0 lb-ft.

(80 Nm) 84.8 lb-ft.

(115 Nm) 132.8 lb-ft.

(180 Nm) 228.6 lb-ft.

(310 Nm) 331.9 lb-ft.

(450 Nm) 398.2 lb-ft.

(540 Nm) 25.8 lb-ft.

(35 Nm) 33.2 lb-ft.

(45 Nm) 40.6 lb-ft.

(55 Nm) 51.6 lb-ft.

(70 Nm) 59.0 lb-ft.

(80 Nm) 73.8 lb-ft.

(100 Nm) 125.4 lb-ft.

(170 Nm) 228.6 lb-ft.

(310 Nm) 243.4 lb-ft.

(330 Nm) 309.8 lb-ft.

(420 Nm) 33.2 lb-ft.

(45 Nm) 44.3 lb-ft.

(60 Nm) 55.3 lb-ft.

(75 Nm) 125.4 lb-ft.

(170 Nm) 228.6 lb-ft.

(310 Nm) 243.4 lb-ft.

(330 Nm) 309.8 lb-ft.

(420 Nm)

O-Ring

25.8 lb-ft.

(35 Nm) 33.2 lb-ft.

(45 Nm) 40.6 lb-ft.

(55 Nm) 51.6 lb-ft.

(70 Nm) 73.8 lb-ft.

(100 Nm) 92.2 lb-ft.

(125 Nm) 99.6 lb-ft.

(135 Nm) 154.9 lb-ft.

(210 Nm) 265.5 lb-ft.

(360 Nm) 398.2 lb-ft.

(540 Nm) 33.2 lb-ft.

(45 Nm) 44.3 lb-ft.

(60 Nm) 73.8 lb-ft.

(100 Nm) 106.9 lb-ft.

(145 Nm) 191.8 lb-ft.

(260 Nm) 265.5 lb-ft.

(360 Nm) 398.2 lb-ft.

(540 Nm)

RHV with ED-seal

Torque tolerance: ±10%; Installed in Steel/Aluminium

G 1-1/2A

G 1-1/4A

G 1A

G 3/4A

G 1/2A

G 3/8A

G 1/4A

M48 x 2,0

M42 x 2,0

M33 x 2,0

M27 x 2,0

M22 x 1,5

M20 x 1,5

M18 x 1,5

M16 x 1,5

M14 x 1,5

M12 x 1,5

Screw

Heavy Version Straight pipe fitting with thread and screwed plug

47.80 mm

41.91 mm

33.25 mm

26.44 mm

20.96 mm

16.66 mm

13.16 mm

48 mm

42 mm

33 mm

27 mm

22 mm

20 mm

18 mm

16 mm

14 mm

12 mm

Outside Bore-Ø

SERVICE MANUAL

G 3/4A

G 1/2A

G 3/8A

G 1/4A

G 1/8A

M48 x 2,0

M42 x 2,0

M33 x 2,0

M27 x 2,0

M22 x 1,5

M18 x 1,5

M16 x 1,5

M14 x 1,5

M12 x 1,5

M10 x 1,0

Screw

Light Verison

Whitworth screw

Straight pipe fitting with thread and screwed plug

Metric screw The indicated values are to be used as approximate values.

Screws with different seal types for hydraulic use

Tightening Torques for Hydraulic Screw Joints and Dry Assem bling

ME1503—2203

Technical Data

The indicated values are to be used as approximate values.

Page A26

8 (10.9) 10 (12.9) 7 (8.8)

8 (10.9)

4.1 lb-ft.

5.9 lb-ft.

7.4 lb-ft.

3.7 lb-ft.

5.2 lb-ft.

(5.5 Nm) (8 Nm) (10 Nm) (5 Nm) (7 Nm) 7.4 lb-ft.

10.3 lb-ft.

12.5 lb-ft.

6.3 lb-ft.

8.9 lb-ft.

(10 Nm) (14 Nm) (17 Nm) (8.5 Nm) (12 Nm) 18.4 lb-ft.

25.8 lb-ft 31.0 lb-ft.

14.8 lb-ft.

22.1 lb-ft.

(25 Nm) (35 Nm) (42 Nm) (20 Nm) (30 Nm) 33.2 lb-ft.

47.9 lb-ft.

59.0 lb-ft.

29.5 lb-ft.

43.5 lb-ft.

(45 Nm) (65 Nm) (80 Nm) (40 Nm) (59 Nm) 64.2 lb-ft.

81.1 lb-ft. 108.4 lb-ft. 50.9 lb-ft.

73.8 lb-ft.

(87 Nm) (110 Nm) (147 Nm) (69 Nm) (100 Nm) 99.6 lb-ft. 132.8 lb-ft. 169.6 lb-ft. 81.1 lb-ft. 118.0 lb-ft.

(135 Nm) (180 Nm) (230 Nm) (110 Nm) (160 Nm) 154.9 lb-ft. 202.8 lb-ft. 258.1 lb-ft. 125.4 lb-ft. 184.4 lb-ft.

(210 Nm) (275 Nm) (350 Nm) (170 Nm) (250 Nm) 206.5 lb-ft. 302.4 lb-ft. 354.0 lb-ft. 180.7 lb-ft. 254.5 lb-ft.

(280 Nm) (410 Nm) (480 Nm) (245 Nm) (345 Nm) 302.4 lb-ft. 420.4 lb-ft. 509.0 lb-ft. 250.8 lb-ft. 361.4 lb-ft.

(410 Nm) (570 Nm) (690 Nm) (340 Nm) (490 Nm) 405.7 lb-ft. 575.3 lb-ft. 685.9 lb-ft. 339.3 lb-ft. 486.8 lb-ft.

(550 Nm) (780 Nm) (930 Nm) (460 Nm) (660 Nm) 523.7 lb-ft. 737.6 lb-ft. 877.7 lb-ft. 435.2 lb-ft. 619.6 lb-ft.

(710 Nm) (1000 Nm) (1190 Nm) (590 Nm) (840 Nm) 767.1 lb-ft. 1091.6 lb-ft. 1305.5 lb-ft. 641.7 lb-ft. 922.0 lb-ft.

(1040 Nm) (1480 Nm) (1770 Nm) (870 Nm) (1250 Nm) 1047.3 lb-ft. 1482.5 lb-ft. 1770.1 lb-ft. 885.1 lb-ft. 1253.8 lb-ft.

(1420 Nm) (2010 Nm) (2400 Nm) (1200 Nm) (1700 Nm)

7 (8.8)

Screw with DIN 912, DIN 931, Screws DIN 7984 DIN 933, usw.

Id.No.: 918174 AP0405

Size 7 (8.8)

23.6 lb-ft.

(32 Nm) 47.9 lb-ft.

(65 Nm) 45.7 lb-ft.

(62 Nm) 81.1 lb-ft.

(110 Nm) 77.4 lb-ft.

(105 Nm) 129.1 lb-ft.

(175 Nm) 195.5 lb-ft.

(265 Nm) 283.9 lb-ft.

(385 Nm) 390.9 lb-ft.

(530 Nm) 523.7 lb-ft.

(710 Nm) 663.8 lb-ft.

(900 Nm) 958.9 lb-ft.

(1300 Nm) 1364.5 lb-ft.

(1850 Nm)

8 (10.9)

Screws DIN 7984

8 (10.9) 10 (12.9) 7 (8.8)

Screws with DIN 912, DIN 931, DIN 933, usw.

With Fine Screw

18.4 lb-ft.

27.3 lb-ft.

31.7 lb-ft.

16.2 lb-ft.

M8 x 1,0 (25 Nm) (37 Nm) (43 Nm) (22 Nm) 55.3 lb-ft.

64.9 lb-ft.

31.7 lb-ft.

36.9 lb-ft.

M10 x 1,0 (50 Nm) (75 Nm) (88 Nm) (43 Nm) 36.1 lb-ft.

52.5 lb-ft.

61.2 lb-ft.

30.9 lb-ft.

M10 x 1,25 (49 Nm) (71 Nm) (83 Nm) (42 Nm) 64.2 lb-ft.

95.9 lb-ft. 110.6 lb-ft. 55.3 lb-ft.

M12 x 1,25 (87 nm) (130 Nm) (150 Nm) (75 Nm) 61.2 lb-ft.

92.2 lb-ft. 106.9 lb-ft 53.1 lb-ft.

M12 x 1,5 (83 Nm) (125 Nm) (145 Nm) (72 Nm) 99.6 lb-ft. 147.5 lb-ft. 173.3 lb-ft. 88.5 lb-ft.

M14 x 1,5 (135 Nm) (200 Nm) (235 Nm) (120 Nm) 154.9 lb-ft. 228.6 lb-ft. 265.5 lb-ft. 132.8 lb-ft.

M16 x 1,5 (210 Nm) (310 Nm) (360 Nm) (180 Nm) 232.3 lb-ft. 331.9 lb-ft. 390.9 lb-ft. 199.1 lb-ft.

M18 x 1,5 (315 Nm) (450 Nm) (530 Nm) (270 Nm) 324.5 lb-ft. 464.7 lb-ft 538.4 lb-ft. 276.6 lb-ft.

M20 x 1,5 (440 Nm) (630 Nm) (730 Nm) (375 Nm) 435.2 lb-ft. 619.6 lb-ft. 722.8 lb-ft. 368.8 lb-ft.

M22 x 1,5 (590 Nm) (840 Nm) (980 Nm) (500 Nm) 545.8 lb-gt. 789.2 lb-ft. 921.9 lb-ft. 464.7 lb-ft.

M24 x 2,0 (740 Nm) (1070 Nm) (1250 Nm) (630 Nm) 811.3 lb-ft. 1143.2 lb-ft. 1327.6 lb-ft. 678.6 lb-ft.

M27 x 2,0 (1100 Nm) (1550 Nm) (1800 Nm) (920 Nm) 1106.3 lb-ft. 1585.8 lb-ft. 1843.9 lb-ft. 958.8 lb-ft.

M30 x 2,0 (1500 Nm) (2150 Nm) (2500 Nm) (1300 Nm)

All values are based on a coefficient of friction of µ = 0,12 and are as appropriate values to be used.

DIN 7984 Socket-head screw s w ith female hexagon and low head.

DIN 931/DIN 933 Hexagon screw s w ith/w ithout shank.

DIN 912 Socket-head screw s w ith female hexagon.

M30

M27

M24

M22

M20

M18

M16

M14

M12

M10

M8

M6

M5

Size

With Standard Screw

Source: KB-Defaults/Kramer Company

Tightening torque MA for high quality screw joints

Tightening Torques for High Quality Screws

Technical Data SERVICE MANUAL

ME1503—2203

Source: KB-Defaults/Kramer Company

Page A27 47.2 lb-ft. (64 Nm)* 36.9 lb-ft. (50 Nm) 36.9 lb-ft. (50 Nm)

M10 x 10.9 M10 x 8.8 M10 x 10.9

Cab Fixing Screw

Engine Carrier

Id.No.: 918174 AP0405 36.9 lb-ft. (50 Nm) 58.3 lb-ft. (79 Nm)

M10 x 8.8 M12 x 8.8

Pump Carrier

Pump

M12 x 8.8

M10 x 8.8

M8 x 8.8

58.3 lb-ft. (79 Nm)

36.9 lb-ft. (50 Nm)

18.8 lb-ft. (25.5 Nm)

36.9 lb-ft. (50 Nm)

36.9 lb-ft. (50 Nm)

47.2 lb-ft. (64 Nm)*

88.5 lb-ft. (120 Nm)

88.5 lb-ft. (120 Nm)

47.2 lb-ft. (64 Nm)*

47.2 lb-ft. (64 Nm)*

47.2 lb-ft. (64 Nm)*

47.2 lb-ft. (64 Nm)*

88.5 lb-ft. (120 Nm)

M12 x 8.8

M10 x 8.8

M8 x 8.8

M10 x 10.9

M10 x 8.8

M10 x 10.9

M12 x 12.9

M12 x 10.9

M10 x 10.9

M10 x 10.9

M10 x 10.9

M10 x 10.9

M12 x 10.9

58.3 lb-ft. (79 Nm)

36.9 lb-ft. (50 Nm)

18.8 lb-ft. (25.5 Nm)

36.9 lb-ft. (50 Nm)

36.9 lb-ft. (50 Nm)

47.2 lb-ft. (64 Nm)*

88.5 lb-ft. (120 Nm)

88.5 lb-ft. (120 Nm)

47.2 lb-ft. (64 Nm)*

47.2 lb-ft. (64 Nm)*

47.2 lb-ft. (64 Nm)*

47.2 lb-ft. (64 Nm)*

88.5 lb-ft. (120 Nm)

ME2203

*Note: Mustang reserves the right to make changes. Always check the actual torque values in the Parts Manual.

18.8 lb-ft. (25.5 Nm)

M8 x 8.8

M10 x 10.9

M10 x 8.8

M10 x 10.9

M12 x 12.9

M12 x 10.9

M10 x 10.9

M10 x 10.9

M10 x 10.9

M10 x 10.9

M12 x 10.9

ME1903

SERVICE MANUAL

Engine Bearings

88.5 lb-ft. (120 Nm)

88.5 lb-ft. (120 Nm)

M12 x 12.9

Swivel Unit

M12 x 10.9

47.2 lb-ft. (64 Nm)*

M10 x 10.9

Sprocket 47.2 lb-ft. (64 Nm)*

47.2 lb-ft. (64 Nm)*

M10 x 10.9

Swivel Joint

M10 x 10.9

47.2 lb-ft. (64 Nm)*

M10 x 10.9

Track Roller

Drive Unit

88.5 lb-ft. (120 Nm)

M12 x 10.9

Turntable

ME1503

Tightening torque MA for ME1503—2203

Type Relative Tightening Torques for High Quality Screw Joints

ME1503—2203

Technical Data

Source: Defaults/Mustang Parts Manu

SERVICE MANUAL

Technical Data

ME1503—2203

This page intentionally left blank.

Page A28

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

C H A P T E R B:

Maintenance (Mustang Service Manual ME1503—2203)

Page B1

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

Maintenance - General (according to Operator‘s Manual) The reliability and service-life of machines are to a great extent influenced by care and maintenance.

Cleaning: In the first 3 months wash the machine only with cold water (do not use high-pressure or steam-jet cleaning). After the first three months the minimum distance between the spraying nozzles and the vehicle must be 12 inches (30 cm), and the water temperature shall not be higher than 140°F (60°C). Do not use aggressive cleaning agents.

Performing specified maintenance is of primary advantage to the owner of a machine.

Perform maintenance as specified by the manufacturer. Failure to perform the specified maintenance will result in exclusions of warranty.

For engine maintenance requirements, refer to the engine operating instructions.

Using lubricants that are not in compliance with the manufacturer’s recommendation will void the warranty.

Before starting machine maintenance or repair, please read all procedures and all warnings and cautions to avoid injury and equipment damage.

Before starting maintenance or repair work, lower the working equipment to the ground. Apply locking and safety levers.

- Bleed residual pressure off the hydraulic system.

- Let the engine cool down.

If work must be done with the machine lifted, it must be securely supported.

Provide for sufficient ventilation when performing maintenance or repair work in a closed room.

Dispose of oil filters (oil, etc.) as required by environmental law.

When working on and/or below the compact excavator, place a warning sign on the operator’s seat and/or someplace clearly visible and legible at the compact excavator. Remove the ignition key.

Page B2

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

1. MAINTENANCE SCHEDULE

Servicing activity component

Mustang ME1503—2203

Every 10 h

Every 50 h

Every 250 h Every 500 h Every 1000 h

(daily)

(w eekly)

(6 months)

(12 months)

(18 months)

Annually

ENGINE Oil Level

O

Fuel Level

O

Leakage

O

Visual Check

O

Air Filter

O/X

Seating of Mounting Bolts Coolant

<>

<>

O O

Engine Speed Regulation

O

Exhaust System

O

Engine Oil

O

Oil Filter

<>(1)

<>

<>

<>(1)

<>

<>

V-Belt: Condition and Tension

O

Cooler Fins

X

Valve Clearance

O

O

Alternator, Starter

O

Fuel Tank

X

Water Pump

O

Fuel Filter

O

<>

<>

Cooling System and Hoses

O

Electrical Connections

O

Glow Plug System

O

Coolant Thermostat

O

Battery Fluid

O X

O

- Check - Clean

<> - Change/Replace <> (1) - Change/Replace the first time

Page B3

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

Servicing activity component

Every 10 h Every 50 h Every 250 h Every 500 h Every 1000 h (daily)

(w eekly)

(6 months) (12 months)

(18 months)

Annually

HY DRAUL IC S YS T EM Hydraulic Pump Fastening Bolts

O

Leakage (Lines, Pumps, Cylinders)

O

Hydraulic Oil Level

O

Oil Cooler Fins

X

Filter Insert

<>(1)

O

Primary and Secondary Pressure Limiting

<>

<>

O

Valves Hydraulic Oil

O

<>(1)

Breather Filter Filling Strainer

<>

<>

O

ELECT RICAL Indicator Lamps

O

System Function

O

Connections

O

T RAVEL GEAR Chain After Working

O

Chain Tension

O

Bearing Play—Tread Rollers, Track Carrier

O

Rollers, Front Idlers

TRAVEL G E A R U N I T Leakage

O

Gear Oil

<>(1)

<>

G EAR RING Bearing System

O

Gearing

O X

<>

- Check - Clean

<> - Change/Replace <> (1) - Change/Replace the first time

Page B4

Id.No.: 918174 AP0405

<>

SERVICE MANUAL

Maintenance

ME1503—2203

Servicing activity component

Every 10 h Every 50 h Every 250 h Every 500 h Every 1000 h (daily)

(w eekly)

(6 months)

(12 months)

(18 months)

HE AT ING Function

O

Leakage (Cooling and Heating Circuit)

O

Seals

O

Fan

O

WO RKING EQ UIP M E NT Lubricate Lubricating Points

O

Bucket Teeth (Fastening and Wear)

O

Pin Fastening

O

Line Fastenings

O

Piston Rods

O

Operation of Hydraulic Cylinder Under Load

O

O

Bushing Play

O

Bearing Play

O

GENERAL Operating Elements

O

Hydraulic Fittings

O

Bolts

O

Lights

O

Windshield Washing System Leakage Check—Visual Inspection

O X

- Check - Clean

O O

<> - Change/Replace <> (1) - Change/Replace the first time

Page B5

Id.No.: 918174 AP0405

Annually

SERVICE MANUAL

Maintenance

ME1503—2203

2. LUBRICANTS LUBRICATION FILLINGS—EXCAVATORS USED AS

EXCAVATOR

10W40 (Norm) BP Vanellus FE APISF-CD + SAE 10W 40 FINA Kappa SE10W40 Q8 T660-10W40

Engine Oil

Hydraulic Oil

LUBRICATION TYPE

Synthetic

HVLP 46 (Norm) BP Energol SHF 46 Mobil DTE 15M Amoco Rykon 46

Swing Ring

Chevron RPM Heavy Duty Grease No. 2 Mobilgrease Moly 52 BP Energrease Moly EP2

Drive Motors

EP 90 API GL 5 Chevron RPM Heavy Duty Grease No. 2 BP Transgear 80W 90

Boom, Dipper Arm

BP Energrease L 21 M Gleitmo 805 (For the first greasing of the bolts.)

Track Tension Cylinder

BP Energrease L 21 M

Planetary Gear Fix and Float Axles Distribution Gear All Lubrication Points

Wheeled Excavator

API GL 5 Chevron Delo Gear 80W 90 BP Transgear 80W 90 BP Energrease L 21 M

Conditions: Engine Oil at -13—104°F (-25—40°C) Outside Temperature.

Grease at -13—104°F (-25—40°C) Outside Temperature.

Page B6

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

3. HYDRAULIC SYSTEM Pressure Test > General Instructions: -

Always bleed the hydraulic system before performing maintenance and repair work.

For hydraulic settings, please refer to the Technical Data chapter.

Before each pressure test the device must be at operating temperature—hydraulic oil temperature at least 122°F (50°C).

Primary pressure limiting valves (PPLV) must be adjusted at maximum engine speed. (Refer to Technical Data chapter).

The pressure drop (delta P between maximum and minimum diesel engine speed) is tested at unloaded condition.

3.1 Pressure Test of Variable Displacement Pump P1 Functions: boom, bucket, driving right 3.1.1 Check Setting PPLV 1: a) Connect pressure gauge to measuring port MP 1. b) With the engine at maximum speed, move boom cylinder at bottom side to stop. c) Check and record the pressure.

3.1.2 Check Pressure Drop: a) Move boom cylinder at bottom side to stop at maximum diesel engine speed (item b). b) Reduce diesel engine speed quickly from maximum to minimum speed—check and record the pressure. c) Calculate the pressure drop: maximum speed pressure minus the minimum speed pressure. The pressure drop should not exceed more than 10% of the setting (approximate value—only applicable to primary pressure limiting valves). An excessive pressure drop could indicate leakage. d) Check the setting and pressure drop of function boom rod side, bucket bottom side/rod side, driving right forward/reverse. e) If any settings deviate from factory settings, set the correct pressure at the primary pressure limiting valve (PPLV 1) at the main valve block and repeat items 3.2.1 and 3.2.2, a—c. f) An excessive pressure drop might indicate leakage (example: defective O-ring in secondary valve, etc.).

3.2 Pressure Test of Variable Displacement Pump 2 Functions: dipper arm, driving left, auxiliary hydraulics

Page B7

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

3.2.1 Check Setting PPLV 2: a) Connect pressure gauge to measuring port MP 2. b) With the engine at maximum speed, move dipper arm at bottom side to stop. c) Check and record the pressure.

3.2.2 Check Pressure Drop: a) Check and note pressure drop of indvidual functions similar to 3.1.2, a—e. b) Check the settings and pressure drop of functions dipper arm rod side and driving right , and note the result. c) If any settings deviate from factory settings, set the correct pressure at the primary pressure limiting valve (PPLV 2) at the main valve block and repeat items 3.1.1 and 3.2.2, a—c. d) Note: Pressure test for additional hydraulic system: - With ball valve opened — unpressurized return flow (measurement: system banking-up pressure).

- If there are secondary valves AH installed, the factory specifications may be invalid, as SPLV are set individually.

- The auxiliary hydaulics function shows the setting of the primary pressure limiting valve PPLV 2, PPLV 3 at measuring ports MP 2, MP 3, if there are no secondary valves installed.

3.3 Pressure Test—Gear Pump P3 Functions (ME1503 and ME1903): dozer blade, offset, swivelling, undercarriage telescoping, auxiliary hydraulics Functions (ME2203): hydraulics, tilt cylinder

dozer blade, offset, swivelling, undercarriage telescoping, auxiliary

3.3.1 Check Setting PPLV 3: a) Connect pressure gauge to measuring port MP 3. b) With the engine at maximum speed, move the dozer blade at bottom side to stop. c) Check and record the pressure and pressure drop. d) The swivelling function is supplied by pump P3, though the operating pressue is limited by the secondary pressure limiting valves (SPLV 4) at the swivel motor—See Swivel Motor.

NOTE: Check of pressure drop is admissible only with primary pressure control valves.

3.4 Pilot Pressure Test: Functions: hydraulic pilot control 3.4.1 Check Setting PRV 5: a) Connect pressure gauge to measuring port MP 4. b) Actuate joystick. c) Check pressure and/or set it at the pressure reducing valve (PRV 5) at the oil control unit.

Please also refer to the Pressure Checklist on the following pages.

Page B8

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

Measuring Ports at the Measuring Strip MP4 Oil Control Unit/Pump

MP 3 MP 2 MP 1

PRV 5 (MP4)

PPLV 3 (MP3)

PPLV 1 (MP1)

PPLV 2 (MP2) Page B9

Mounting Position

Id.No.: 918174 AP0405

Page B10

Id.No.: 918174 AP0405

Drive Left

Dipper Arm

PUMP 2

Drive Right

Bucket

Boom

PUMP 1

Functions

Mustang

BACKWARD

FORWARD

IN

OUT

BACKWARD

Setting 2901 ±44 psi (200 ±3 bar) > Fall > 290 psi (20 bar)

Primary Pressure Measuring Point Setting 2901 ±44 psi (200 ±3 bar) > Limiting Valve Fall > 290 psi (20 bar) PPLV 2 MP 2 Setting 2901 ±44 psi (200 ±3 bar) > (Main Valve Block) (Main Valve Block) Fall > 290 psi (20 bar)

Setting 2901 ±44 psi (200 ±3 bar) > Fall > 290 psi (20 bar)

SEE TECHNICAL DATA CHAPTER

Setting 2901 ±44 psi (200 ±3 bar) > Fall > 290 psi (20 bar)

FORWARD

Primary Pressure Measuring Point Setting 2901 ±44 psi (200 ±3 bar) > Fall > 290 psi (20 bar) Limiting Valve MP 1 PPLV 1 Setting 2901 ±44 psi (200 ±3 bar) > (Main Valve Block) (Main Valve Block) Fall > 290 psi (20 bar) Setting 2901 ±44 psi (200 ±3 bar) > Fall > 290 psi (20 bar)

IN

OUT

Checked

SEE TECHNICAL DATA CHAPTER

Settings (1)

DOWN

Press.limit.valve Measuring point

Setting 2901 ±44 psi (200 ±3 bar) > Fall > 290 psi (20 bar)

Symbol

Mustang Excavators

PRESSURE CHECKLIST

UP

Motion

Prüfer:

Serial.No: AC 01264 Work hrs/Date 50 Std / 20

Setting 2901 ±44 psi (200 ±3 bar) > Fall > 290 psi (20 bar)

ME1503

X

X

OK?

Maintenance SERVICE MANUAL

ME1503—2203

PLV = Pressure Limiting Valve PRV = Pressure Reducing Valve

(1) Note: Pressure settings correspond to the serial no. of your excavator. Always compare with the pressure setting in Technical Data chapter.

(2) Note: Setting correct only without secondary pressure limiting valves.

(3) Function Swivel: see Technical Data and Maintenance chapters.

(4) See Technical Data chapter, Different Settings.

Page B11 RIGHT

LEFT

DOWN/IN

All (Pilot Oil Supply Unit)

PRV 5

Valve

Pressure Reducing

Pilot Oil Supply Unit

Measuring Point MP 4

(Sw ivel Motor) (3)

Limiting Valve

SPLV 4

/

290 psi (20 bar)

2901 ±44 psi (200 ±3 bar)

290 psi (20 bar)

2901 ±44 psi (200 ±3 bar)

N/A

2901 ±44 psi (200 ±3 bar)

N/A

2901 ±44 psi (200 ±3 bar)

Settings (1)

>

>

> >

> >

> >

Fall

Setting

N/A

435 ±29 psi (30 ±2 bar)

Setting (4): 1813 +334/-0 psi (125 +23/-0 bar) > Fall > N/A

Setting (4): 1813 +334/-0 psi (125 +23/-0 bar) > Fall > N/A

Fall

Setting Measuring Point Fall MP 3 Setting

Secondary Pressure

( Sw ivel Motor)

Setting (2):

Setting (2): Fall:

(Main Valve Block) Fall:

MP 2

Measuring Point

(Dozer Blade Valve) (Main Valve Block)

PPLV 3

Limiting Valve

Primary Pressure

(Main Valve Block)

PPLV 2

Limiting Valve

Primary Pressure

Press.limit.valve Measuring point

Mustang Excavators Checked

PRESSURE CHECK

X

X

X

OK?

SERVICE MANUAL

Joystick

B

A

UP/OUT

PILOT SYSTEM

Swivel Motor

Dozer Blade Cylinder Telescopic Cylinder

PUMP 3

Auxiliary Hydraulics/ Boom Offset

PUMP 2

Symbol

Function

Motion

Checked by

Serial No: AC 01264 Work hrs/Date 50 Std /

Mustang

ME1503

ME1503—2203

Maintenance

PLV = Pressure Limiting Valve PRV = Pressure Reducing Valve

(1) Note: Pressure settings correspond with the serial no. of your excavator. Always compare with the pressure setting in the Technical Data chapter.

(2) Note: Setting correct only without secondary pressure limiting valves.

(3) Function Swivel: See Technical Data and Maintenance chapters.

(4) See Technical Data chapter, Different Settings.

Id.No.: 918174 AP0405

Page B12

Drive Left

Dipper Arm

PUMP 2

Drive Right

Bucket

Boom

PUMP 1

Functions

BACKWARD

FORWARD

IN

OUT

> >

Setting Fall

BACKWARD

Setting Fall

(Main Valve Block) Fall

> >

> >

> >

Primary Pressure Measuring Point Setting Limiting Valve Fall PPLV 2 MP 2 Setting (Main Valve Block)

> >

Setting Fall

SEE TECHNICAL DATA CHAPTER

> >

> >

Setting Fall

IN (Main Valve Block) Fall

> >

Primary Pressure Measuring Point Setting Fall Limiting Valve PPLV 1 MP 1 Setting (Main Valve Block)

> >

Setting Fall

DOWN OUT

Checked

SEE TECHNICAL DATA CHAPTER

Settings (1)

> >

Press.limit.valve Measuring point

Setting Fall

Symbol

Mustang Excavators

X

X

OK?

PRESSURE CHECKLIST

UP

Motion

Checked by:

FORWARD

Mustang ME1503—2203

Serial No: Work hrs/Date

Maintenance SERVICE MANUAL

ME1503—2203

PLV = Pressure Limiting Valve PRV = Pressure Reducing Valve

(1) Note: Pressure settings correspond with the serial no. of your excavator. Always compare with the pressure setting in the Technical Data chapter.

(2) Not: Setting correct only without secondary pressure limiting valves.

(3) Function Swivel: See Technical Data and Maintenance chapters.

(4) See Technical Data chapter, Different Settings.

Id.No.: 918174 AP0405

Page B13

Joystick

All

RIGHT

LEFT

DOWN/IN

UP/OUT

B

A

Motion

Symbol

Checked by

Setting (2):

Setting (2): Fall:

Id.No.: 918174 AP0405 (Pilot Oil Supply Unit)

PRV 5

Valve

Pressure Reducing

(Swivel Motor)

Fall

Pilot Oil Supply Unit

Fall

Measuring Point Setting MP 4

( 3)

(Main Valve Block) Fall:

MP 2

Measuring Point

N/A

N/A

Settings (1)

Setting Measuring Point Fall MP 3 PPLV 3 (Main Valve Block) Setting (Dozer Blade Valve) Fall / Setting (4): Secondary Pressure Fall Limiting Valve (Swivel Motor) SPLV 4 Setting(4): Limiting Valve

Primary Pressure

(Main Valve Block)

PPLV 2

Limiting Valve

Primary Pressure

Press.limit.valve Measuring point

> >

> > > >

> >

> >

> >

Checked

Mustang Excavators

PRESSURE CHECK

X

X

X

OK?

SERVICE MANUAL

PILOT SYSTEM

Swivel Motor

Dozer Blade Cylinder Telescopic Cylinder

PUMP 3

Auxiliary Hydraulics/ Boom Offset

PUMP 2

Function

Mustang ME1503—2203

Serial No: Work hrs/Date

ME1503—2203

Maintenance

PLV = Pressure Limiting Valve PRV = Pressure Reducing Valve

(1) Note: Pressure settings correspond with the serial no. of your excavator. Always compare with the pressure setting in the Technical Data chapter.

(2) Note: Setting correct only without secondary pressure limiting valves.

(3) Function Swivel: See Technical Data and Maintenance chapters.

(4) See Technical Data chapter, Different Settings.

SERVICE MANUAL

Maintenance

ME1503—2203

4. HYDRAULIC PUMP Bleeding -

Shut down the device.

Open breathing/bleeding filter.

Open bleeding hose stopper.

Drain a small amount of hydraulic oil via the bleeding hose (hose down).

Lift the bleeding hose a little above the level of the hydraulic pump, drain a small amount of hydraulic oil and reseal the bleeding hose.

Re-attach bleeding hose at the rear wall of the engine compartment.

Position of bleeding hose on hydraulic pump

5. HOSE BURST PROTECTION

S

Clearance dimension check Safety regulations provide for the installation of hose burst protection facilities in dozer blade cylinders and in tilting cylinders. If such valves are missing, the person who authorized the modification is responsible for the consequences in case of an accident.

SETTING GAP DIMENSION “S”: 1. Loosen the two nuts.

2. Adjust the gap “S” by means of a gauge for the relevant type of excavator (see Technical Data chapter).

3. Tighten the nuts lightly by hand and secure the jam nuts together.

Page B14

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

6. DRIVE UNIT Gear Box > Check: - Open the oil level plug.

- The oil level must be at the oil level inspection hole. > Change: - Open the oil filler and drain plug.

- Drain oil and collect it in an appropriate container.

- Close drain plug and open oil level plug.

- Fill in fresh oil via the filler orifice until the gear oil emerges from the level inspection hole.

- Close oil level plug and filler hole.

Warning: It is recommended (as specified in the maintenance schedule) to check the drive unit for leakage and proper oil level often.

Dispose of waste oil in compliance with environmental laws.

For gear oil specifications—see Technical Data chapter, List of Lubricants.

Position of Drive Unit: > Filling/Check 1 Gear Oil Level

2

> Draining 2 = Bleeding /Oil Level Plug 1 = Screw Plug/Filler Plug

2 1

7. SWIVEL UNIT As described in the Hydraulics System chapter, the swivel unit gearbox is “maintenance free” (lubricated with hydraulic oil).

Page B15

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

8. AUXILIARY HYDRAULICS Check activation of auxiliary hydraulic system:

Auxiliary Hydraulics System Pedal

Verify that the piston of the auxiliary hydraulics system (operated mechanically via cable pull) can be operated fully in both directions to prevent the hydraulics system from overheating.

To Adjust: a) Adjustment of cable pull in both operating directions: Note: If this adjustment is not successful, further service of other associated auxiliary hydraulics system components may be required.

Auxiliary Hydraulics Pedal Adjusting Screws

1) Actuate pedal by hand and push the cylinder all the way into the main valve block. If pedal travel is limited by the adjusting screws, loosen the adjusting screws.

Warning: Actuate pedal only by hand. An improperly adjusted pedal may result in cable damage.

2) 3) 4) 5)

Tighten the adjusting screw until it contacts the pedal.

Loosen the adjusting screw one half turn (stop clearance).

Hold the adjusting screw and tighten the jam nut.

Check activation. The pedal must not rest on the floor mat.

Note: This adjustment must be performed for both adjusting screws.

Page B16

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

9. CAB Removal Feature: Removal of frame of operator’s cab can be done by removing the 4 cab bolts and the central connector. The excator functions remain active; the cab cable system is disabled.

Removal: - Remove cab bolts “A”.

- Loosen washing container hose at non-return valve (valve compartment).

- Loosen cab connector (right beside the seat).

- Lift the cab at the lugs provided for this purpose.

Tightening torque of cab bolts A : M12 x 10.9—89 lb-ft. (120 Nm) (glued in with blue grade Loctite® 242) 4 Cab Bolts “A”

Tilting Up Feature: It is possible to lift the cab, including the seat bracket, approximately 4” (10 cm) to the back, without having to dismantle the pilot control hoses and the electrical equipment.

This feature allows access to the swivel drive and the rotary transmission for minor repair work without having to remove the cab.

Page B17

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

10. UNDERCARRIAGE > CHECK AND ADJUST TRACK TENSION 1. Position the machine on a level surface.

2. Use the bucket and dozer blade to lift the unit up until the tracks are clear of the ground as shown.

Turn off the engine.

3. Measure the clearance at the center of the track frame. Deflection should be between 0.6—0.8” (15—20 mm).

4. Using a grease gun, pump grease into the fitting unitl the track is properly tensioned.

NOTE: A grease gun is supplied with machine tool kit.

IMPORTANT! Do not over-tension the track. If the track is too tight, loosen the grease fitting to relieve pressure.

Grease Gun

WARNING! Do not loosen grease fitting more than two turns or the grease fitting could be ejected under pressure and cause injury.

5. Repeat steps 3 and 4 for the right side track.

6. Start the engine. Lower the unit to the ground.

Adjustment Fitting

Wrench

Page B18

Id.No.: 918174 AP0405

SERVICE MANUAL

Maintenance

ME1503—2203

This page intentionally left blank.

Page B19

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

C H A P T E R C:

Hydraulics (Mustang Service Manual ME1503—2203)

Page C1

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

1. HYDRAULIC DIAGRAM Legend—Hydraulic Diagram ME1503/1903/2203 1 Diesel Engine 2 Variable Displacement Pumps + Gear Pump Unit + Oil Supply Unit 3 Pilot Control Valves—Drive 4 Joystick, Left 5 Joystick, Right 6 Main Valve Block 7 Dozer Blade Valve 8 Hose Burst Protection Valve 10 Switch Valve 11 Hose Burst Protection Valve 12 Oil Cooler 13 Hydraulic Oil Return Filter 14 Ball-Type Stop Valve 15 Swivel Unit 16/17 Drive Unit 18 Boom Offset Cylinder 19 Dipper Arm Cylinder 20 Boom Cylinder 21 Bucket Cylinder 22 Dozer Blade Cylinder 23 Tilting Cylinder (Model ME2203 Only) 24 Telescopic Cylinder 26 Non-Return Valve (Bypass) 28 Check Valve—Boom Offset Cylinder (Serial No.: AC01800 and higher)

Page C2

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

DRIVE UNIT LEFT

TELESCOPING CYLINDER

24

DOZER BLADE CYLINDER

TILT CYLINDER

BOOM OFFSET CYLINDER

DIPPER ARM CYLINDER

SWIVEL UNIT

RIGHT

17

16

BOOM CYLINDER

BUCKET CYLINDER

15

23

18

21 2176 ps1 (150 bar)

22

8

19

20

28

11

T3 PR

9

LIFT ARM

RV2

25

A8 Pa8

B6

A7

RV1

2900 psi (200 bar)

Ø1.4 mm

Pa5

Pa6

B5

Pa7 B8

DRIVE RIGHT

BUCKET

Pa6

A5

Pa5

A4

B4

P1

Pa4

Pa1

7

P2

Pa4

A3

B3

Pa3

Pa3

B2

P3

B1

A1

Pa1

A2

TURN

AUXILIARY HYDRAULICS/ SWIVEL

10

DRIVE LEFT

BUCKET HANDLE

T5

Pb8

Pb6

Pb5

Pb4

Pb3

Pb1

6

2900 psi (200 bar)

T1

Pa1

TURN/ SWIVEL

PP

Pa4

BUCKET HANDLE

DRIVE RIGHT

Pa6

LIFT ARM

Pa7

BUCKET

4

T2

RIGHT JOYSTICK

T

DRIVE PEDAL

T4

SOL B

Pa3

3

2

5

LEFT JOYSTICK

PP

DRIVE LEFT

3

4

PB1

Pb7 T2

Pa3

1

P B1 P B2

Pb6

Pb1

Pb3

T4

PB1

T1

T3

PR

PP

12

2

PR

26 14

SOL A

PD

P2

29

13

P2 P1

508 psi (35 bar)

T5

P1

P3

M 1

S1

Page C3

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

2. HYDRAULIC PUMP

Mustang ME1503: Type: (PVD-0B-20BP-8GA5-4952A—Oil Pump Control 4.5) (PVD-0B-20BP-8G3-4952B—Oil Pump Control 2.7) - Double Axial and Double Gear Pump - Technically identical with pump ME1903/2203 - Differences in regulating characteristic - Visual difference: black laquered

Regulating Characteristics of Double Variable Displacement Pump ME1503

Page C4

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Mustang ME1903/2203: Types:

(PVD-0B-20BP-8GA5-4953A—Oil Pump Control 4.5) (PVD-0B-20BP-8G3-4953B—Oil Pump Control 2.7)

Variable Displacement Pump Unit

Air-Bleed Screw (Not Active)

(M12 8.8)

Anschluß Port P2 P2 Port P3 Port Counterbalancing System— Main Valve Block

TT

= 58 lb-ft. (79 Nm)

Double Axial and Gear Pump ME1903/2203 (Pressure Side View)

Port Air-Bleeding Hose (Engine Compartment)

Port P1 Gear Pump Unit

Page C5

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Double Axial and Gear Pump ME1903/2203 (Suction Side View)

Adjusting Screw for Start of Regulation

Adjusting Screw for Start of Regulation

Suction Pipe Port

Page C6

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Regulating Characteristics ME1903/2203

Page C7

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Legend—Double Variable Displacement and Gear Pump ME1503/1903/2203 1 Case 2 Case Cover 3 Primary Shaft 4 Cylinder Drum 5 Distribution Plate 6 Piston 7 Sliding Block 8 Sliding Block Bracket 9 Centering Ring 10 Swash Plate 11 Spacer Pins 12 Ball 13 Sealing 14 Spring 15 Spring 18 Spring Receptacle 19 Spring Guide 20 Centering Pin 21 Pin 24 Spacer Ring 25 Piston 26 Piston 27 Centering Pin 30 Ball Bearing 31 Needle Bearing 32 Shaft Sealing Ring

33 Spacer Ring 34 Seeger Circlip Ring 35 Seeger Circlip Ring 36 Seeger Circlip Ring 39 O-Ring 40 O-Ring 42 Stopper 44 Screw 49 Stopper 56 Dowel Pin 60 Screw 61 Hexagon Nut 62 Packing Ring 65 Gear Pump 66 Coupling 67 Ring 68 Screw 69 O-Ring 70 Washer 71 O-Ring 72 O-Ring 73 Pilot Control Case 74 Screw 75 Washer 76 Solenoid Valve 77 Solenoid Valve

Page C8

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Exploded View—Double Axial and Gear Pump ME1503/1903/2203

Page C9

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

3. PILOT OIL SUPPLY UNIT Control Oil Unit

Control Oil Unit

Hydraulic Diagram Pump/Control Oil Unit Port C ( 2 )

AP

MP

(1)

Port A: Supply of pilot control valves (joystick, etc.) via the safety solenoid valve in combination with the sensitive micro-switch in each arm rest (solenoid valve B).

Port B/C: Supply of control valves “second driving speed” in the driving motors, in combination with the push-button at the driving lever (solenoid valve A).

( 1 ) Pressure Reducing Valve pilot control system (see Technical Data) > AP ( 2 ) Measuring Port MP 4 (control oil unit > joystick) > MP Page C10

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Oil Control Unit Cable Assignment:

Solenoid Valve Arrangement Oil Control Unit

Solenoid Valve A Solenoid Valve B

Pilot Control System—Pressure Adjustment Points

AP Pressure Reducing Valve Pilot Control Pressure (1) Solenoid Valve A Solenoid Valve B

Page C11

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

4. MAIN VALVE BLOCK Type: BCV35/7 Function: Regeneration function section dipper arm drive counterbalancing system, seats for auxilliary hydraulics secondary shock valves.

13

12

11 view B

Pa5

Pa6

Pa4

Pa1

T2 A8

A7

B8

B6

A5

P2

A4

A3

A2

B5

P1

B4

B3

B2

P3

A1

B1

T1

PP

Pb7

9

Pb5

Pb6

14

8

7

Pb4

6

5

Pb1

Pb3

4

3

15

Main Valve Block 1 2 3 4 5 6 7 8 9

Swivelling Counterbalancing System Auxiliary Hydraulics/Offset Dipper Arm Driving Left Input Section, P1 Driving Right Boom 1 Bucket

10 11 12 13 14 15

T1, Collector P3 Blade Valve Input Section, P2 T, Hydraulic Oil Cooler Boom 2 Port PP, to Pilot Oil Supply Unit

Page C12

10

2

1

view A

Mounting Position

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Main Valve Block—View A

6 1.

2.

3.

4.

5.

6.

5

4

3 AP

2

1

Port A for counterbalancing system (pilot control pressure) Secondary pressure limiting valve dipper arm cylinder bottom side Primary pressure limiting valve—P1 Secondary pressure limiting valve boom cylinder rod side Secondary pressure limiting valve boom cylinder bottom side Secondary pressure limiting valve bucket cylinder rod side

Main Valve Block—View B

1

2 AP

3

1. Secondary pressure limiting valve dipper arm cylinder rod side 2. Primary pressure limiting valve—P2 3. Secondary pressure limiting valve bucket cylinder bottom side

Page C13

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Circuit Diagram: Main Valve Block ME1503—2203 Mounting Position

Page C14

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Section Swivel (Swing)

2

Check Valve

Section Auxilliary Hydraulics

2 3 4

Plug—Can Be Exchanged to Secondary-Pressure Limiting Valve Check Valve Plug

Page C15

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Section Drive Left/Drive Right

2

Check Valve (Long)

Section Inledge P1/P2

2 3

Primary-Pressure Llimiting Valve Plug

Page C16

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Section Boom 1

2 3

Check Valve (Load Holding Valve) Secondary-Pressure Limiting Valve Boom Cylinder Rod Side with Suction Function

Section Boom 2

2 3 4

Check Valve Plug Secondary-Pressure Limiting Valve Boom Cylinder Bottom Side with Suction Function

Page C17

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Section Bucket

2 3

Check Valve Secondary-Pressure Limiting Valve Bucket Cylinder with Suction Function

Page C18

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Regeneration—Dipper Arm Section Regeneration

Situation: Because of heavy loads at the dipper arm the dipper arm cylinder may become “evacuated” on the bottom side, which might lead to a dipper arm standstill in vertical position.

Solution: Regeneration of the rod-side dipper arm cylinder oil to the cylinder bottom side. To this end the spool valve is provided with a non-return valve.

Dipper Arm Section

2 3 5

Check Valve Secondary-Pressure Limiting Valve Regeneration Valve

Page C19

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Drive Counterbalancing System General: All Mustang ME1503—2203 models are equipped with drive counterbalancing function.

If an arm function is activated when driving straight, the device keeps track—the driving speed remains constant. The drive counterbalancing system is activated only if both driving valves are active.

NOTE: If couterbalacing is not functioning properly, the unit will not track straight if the arm function is activated.

Section View—Drive Counterbalancing System

2 3 4

Plug Long Check Valve (P1/P2) Drive Counterbalancing Valve with Prefilter

Page C20

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

See circuit diagram drive counterbalancing system: -

Both piston valves for driving and one arm function must be actuated.

The main valve block of the drive counterbalancing system is activated because of an increased banking-up pressure.

P3 — assumes supply of arm functions.

Auxiliary hydraulics section:

Pump assignment when drive counterbalancing system is active: supplied by P1 section driving left supplied by P2 section driving right section bucket section boom supplied by P3 section dipper arm section flow rate AH section dozer blade section swivel unit section drive counterbalancing Drive Counterbalancing System Section

PP

Port Drive Counterbalancing System PP >> P4 Page C21

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Counterbalancing System

Page C22

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

5. DOZER BLADE VALVE

1

ME1503/1903

5

6

2

1

ME2203

3

7

1 2 3 4 5 6 7

Primary Pressure Limiting Valve P3 Blade Section Telescoping Undercarriage Section Cab Level Section (Model ME2203 Only) Transmission Pressure Control Block P3 Tank—Collector

5 6

2

3

4 Page C23

7 Id.No.: 918174 AP0405

AP

SERVICE MANUAL

Hydraulics

ME1503—2203

Position of Blade Valve

Can be reached from cab — blade valve cover

Blade Valve

Section Design

1 2 3 4 5

Directly Controlled Pressure Reducing Valve Screw Plug Tapered Stopper Hand Lever Spring Reset

Page C24

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Switching Symbol

T

A

P

B

Blade Valve Diagram

T B

B

B

A

A

A

HC- D10/ 3

P

Page C25

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

6. PILOT CONTROL VALVES

Pressure Regulation P.C. 363 +36/-0 PSI (25 +2.5/-0 bar)

Operating Angle on 1 Port

87 +0/-10 PSI (6 +0/-0.7 bar)

0

2° ±1°

18° 25‘ 20° 10‘ ±1° 35‘ ±1°

Manual Control Valve (Joystick) 1 Control Lever 3 Rod Assembly 4 Rubber Collar 6 Joint 7 Guide Plate 10 Tappet

Page C26

Id.No.: 918174 AP0405

Degree

SERVICE MANUAL

Hydraulics

ME1503—2203

Drive Pedal with Hydraulic Damper

Page C27

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

7. SWIVEL UNIT Swivel Motor Port Assignment (OMS H250): TT

= 55—59 lb-ft. (75—80 Nm)

A

B

S

S

T A B T S

Port Switch Valve Port Switch Valve Suction Line Shock Suction Valves (Not Adjustable)

Page C28

AP

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Swivel Motor Diagram

10 11 12

13

14

1 2 3 4 5

Bearing Housing Primary Shaft Cardan Shaft Gear Rim Gear Wheel

6 Roller 7 Valve Cardan Shaft 8 Movable Distributor Head 9 Valve Chamber 10 Control Valve

11 Stationary Distributor Head 12 Oil Leakage Pipe 13 Centering Bore 14 Oil Leakage Bore

Page C29

Id.No.: 918174 AP0405

Setup: A B C D E F

Output Shaft Cardan Shaft Gear Wheel Set Cardan Shaft Valve Return Valve Poppet Valve

SERVICE MANUAL

Hydraulics

ME1503—2203

Swivel Motor Assembly OMS H250: 1. Align valve chamber with the oil ports pointing toward the body.

2. Insert stationary distributor head into chamber.

3. Insert movable distributor head so that the inside duct is placed exactly above the inside of the oil port oil duct (the chamber bottom must be visible).

4. Mount the stationary distributor head so that the oil leakage bore is placed above the oil leakage duct.

5. Insert cardan shaft valve.

6. Mount toothed rim, so it is aligned with the distributor head by means of fixing pin (the inner oil duct at the chamber bottom must still be visible).

7. Move toothed wheel as far right as possible; insert roller.

8. Mount cardan shaft and bearing housing.

9. Secure the motor by tightening to 55—59 lb-ft. (75—80 Nm).

Circuit Diagram OMS 250 H

Suction Line Collector

Control Block Output

Page C30

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

8. DRIVE UNIT Type: ME1503: MAG 12-V ME1903—2203: MAG 16-V

Tank

PR (Control Oil Unit) Brake Piston

A

Damping Valves

B

Driving Motor Port Assignment

Driving Mode Port Left Side—Top Right Side—Bottom

Oil Leakage Ports (Always Use the Top Port)

Ports A and B

Damping Valve/Brake Piston

Page C31

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Gear Box—Drive Unit 700/2C2 1 Snap Ring 2 Stopper 3 Washer 4 Cover 5 Thrust Washer 6 O-Ring 7 Planet Wheels 8 Locking Ring 9 Sun Wheel 10 Gear Reduction Complete 1st Stage 11 Gearbox Case 12 Locking Ring 13 Bearing 14 Locking Ring 15 Lifetime Sealing 16 Hydraulic Motor

Page C32

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Drive Motor MAG 12V/MAG 16V

M1 Complete Motor M2 Main Drive Pinion M3 Bearing M4 Spring M5 Piston M6 O-Ring M7 Packing Ring M8 Bearing M9 Motor Shaft M10 Swash Plate M11 Piston M12 Plate M13 Bushing M14 Pin M15 Cylinder Block M16 Compensating Washer M17 Spring M18 Compensating Washer M19 Locking Ring M20 Distributor Head M21 Bearing M22 Centering Pin M23 O-Ring M24 Screws

Page C33

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Drive Motor/Hydraulic Brake Valve T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 T11 T12 T13 T14 T15 T16 T17 T18 T19

Stopper Plug O-Ring Compensating Washer Spring Compensating Washer Brake Piston Throttle Valve Piston (2nd Driving Stage) Spring O-Ring Stopper Throttle Valve Stopper Connecting Screw Pin O-Ring Stopper Stopper O-Ring

Page C34

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Port Assignment ME1503/1903:

Driving Left Top Driving Left Bottom Blade Rod Side

Driving Right Top Driving Right Bottom

Telescoping Cylinder Bottom Side Telescoping Cylinder Rod Side

Dozer Blade Bottom Side EVT Leak Oil EVT Driving Fast Sealed Passage for Rotating Shaft — 152

Swivel Joint 1 Internal Part 2 External Part 3 Cover 5 Hex Head Cap Screws 6 Split Washer 7 PU-Supporting Ring 8 Lip Seal 9 Turcon Roto Glyd Ring 10 V-Packing Ring

TT Tightening torque Item 5: M8 x 20 - 8.8 = 18 lb-ft. (24 Nm)

Page C35

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Port Assignment ME2203:

Telescoping Cylinder, Bottom Side

Driving Left Bottom Driving Left Top

EVW Driving Right Bottom Telescoping Cylinder, Rod Side Blade Bottom Side

Driving Right Top Blade Rod Side Tilting Cylinder Rod Side Driving Fast Tilting Cylinder, Bottom Side

Page C36

Leak Oil

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Swivel Joint — ME2203

1 Internal Part 2 External Part 3 Cover 5 Hex Head Cap Screws 6 Split Washer 7 PU-Supporting Ring 8 Lip Seal 9 Turcon Roto Glyd Ring 10 V-Packing Ring

TT - Tightening Torque Item 5: M8 x 20 - 8.8 = 18 lb-ft. (24 Nm) Page C37

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

10. SWITCH VALVE Switch Valve Port Assignment

2a 2

1

3

4

6

7

5

1 Control Block Section Auxiliary Hydraulics 2 Control Block Section Auxiliary Hydraulics 2a Unpressurized Return Flow via Reversing Cock for Hammering Mode (Collector) 3 Tank 4, 5 Output Auxiliary Hydraulics 6, 7 Output Offset Cylinder

Position of Switch Valve Switch Valve Switching Symbol

Page C38

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

11. COLLECTING TUBE Collecting Tube—Tank Return Flow Port Assignment 1

2

3 5

4 6

7

1 2 3 4 5 6 7

Port Hydraulic Oil Cooler Collecting Tube—Return Filter Port Blade Valve 3-Bar Non-Return Valve Ball Valve for Unpressurized Return Flow—Auxiliary Hydraulics Port Fuel Pipe Swivel Motor Port Fuel Pipe Control Block

Page C39

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

12. PANEL— PILOT CONTROL HOSES

ME1503—2203

Collector Strip Port Assignment

LÖ 4

HU 3

LÖ 2

DR 4

LST 1

DL 2

LST 3

HU 1

Right Joystick

Left Joystick

Right

Left Main Valve Block Left Joystick LST 3 Dipper Arm -> Joystick Position 3 LST 1 Dipper Arm -> Joystick Position 1 DL 2 Turning Left -> Joystick Position 2 DR 4 Turning Right -> Joystick Position 4

Joystick Positions Left/Right

Right Joystick

2

HU 3 Boom -> Joystick Position 3 HU 1 Boom -> Joystick Position 1 LÖ 4 Bucket-> Joystick Position 4 LÖ 2 Bucket-> Joystick Position 2

1

3 P Page C40

4

T

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

12. PANEL—PILOT CONTROL HOSES Function: Pos. 1: Pos. 2:

Option: Switch Valve JCB

Joystick assignment can be changed via the selector lever at the directional control valve Joystick Right—Boom Joystick Left—Dipper Arm Joystick Right—Dipper Arm Joystick Left—Boom

Directional Control Valve Port Assignment

Directional Control Valve— Selector Lever (Position 1)

Optional Switch Valve—Changed Assignment of Joysticks

Joystick Left

Selector Lever 1 2 3 4 5 6 7 8

Joystick Right

Position 1

Position 2

Dipper Arm Out Dipper Arm in Swivelling Left Swivelling Right Boom Down Boom Up Bucket In Bucket Out

Boom Down Boom Up Swivelling Left Swivelling Right Dipper Arm Out Dipper Arm In Bucket In Bucket Out

Page C41

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

Directional Control Valve Port Assignment

LÖ 4

LÖ 2

HU 1

LST 1

LST 3

DL 2

DR 4

HU 3

Joysticks

Valve Pos 1 / Pos 2

Position 1

Position 2

HU 1

LST 1

LST 3

HU 3

Selector Lever

Main Valve Block Left/Right Joystick Positions Left Joystick LST 3 LST 1 DL 2 DR 4

Dipper Arm ->Joystick Position 3 Dipper Arm-> Joystick Position 1 Turning Left -> Joystick Position 2 Turning Right -> Joystick Position 4

2

Right Joystick HU 3 HU 1 LÖ 4 LÖ 2

Boom -> Joystick Position 3 Boom -> Joystick Position 1 Bucket-> Joystick Position 4 Bucket-> Joystick Position 2

Page C42

1

3 P

4

T

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

13. OIL TANK—Hydraulic System A) Breather Filter

>> Also refer to Maintenance chapter

The breather provides the following functions: -

Pressure compensation in the hydaulic tank (varying oil level) by sucking and pressing air in and out of the tank — protection of oil tank against swelling.

Pressurizing the oil tank to the defined overpressure -> to support intake of the variable displacement pump.

Intake air filtering.

Initial Pressure: 6 psi (0.4 bar) Breather (Hydraulic Tank)

Return Filter (Hydraulic Tank)

Change: NOTE: 2203 Serial No.:

New oil tank breathing filter ME1503— AC00985 and higher Note: old/new not interchangeable

Page C43

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

14. CHECK VALVES

Type: Function:

BOOM OFFSET CYLINDER Pilot-controlled double check valve Leakage of switch valve does not permit blocked position of offset cylinder Change: Solution: Serial No.:

NOTE:

Fixing the position of boom offset cylinder.

Check valve block Start at AC01800

Solution: Note: A modification kit — check valve block is available.

2

V1

V2

C2

C1

1 1. Check Valve Boom Offset Cylinder 2. Boom Offset Cylinder C1. To Boom Offset Cylinder Bottom Side C2. To Boom Offset Cylinder Rod Side V1, V2. To Switch Valve

Page C44

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

14. CHECK VALVES TILT CYLINDER—ME2203 ONLY Pilot-controlled double check valve Leakage of switch valve doesn’t permit blocked position of tilt cylinder Serial No. AC02074 and higher

Type: Function: Series :

(Swivel Joint) — Tilt Cylinder, Rod Side

Tank

C1

0.6

V1

Dozer Blade Valve Tank

0.6

V2

Dozer Blade Valve

C2

(Swivel Joint) — Tilt Cylinder Bottom Side

Page C45

Id.No.: 918174 AP0405

SERVICE MANUAL

Hydraulics

ME1503—2203

This page intentionally left blank.

Page C46

Id.No.: 918174 AP0405

SERVICE MANUAL

Diesel Engine

ME1503—2203

C H A P T E R D:

Diesel Engine (Mustang Service Manual ME1503—2203)

Page D1

Id.No.: 918174 AP0405

M E 3703

M E 3503

D 1703

D 1703 4 TN E 8 8 E N S R

K UB O T A

3 TN E 8 8 E N S R 2

K UB O T A

M E 3003

D 1403

3 TN E 8 8 E N S R 1

K UB O T A

M E 2503

M E 2203

M E 1903

Page D2 M E 12002

ME 8002

ME 6502

ME 6002

ME 5002

ME 3602 F

ME 3402 F

ME 2902 F

ME 2702 F

ME 2202 F

4 TN E 1 0 6 TN S

4 TN E 9 8 N S R

4 TN E 8 8 N S W 4 TN E 8 8 E N S W

4 TN E 8 8 N S R 4 TN E 8 8 E N S R

3 TN E 8 8 N S R 3 TN E 8 8 E N S R

3 TN E 7 4 N S R -2 3 TN E 7 4 E N S R -2

ME 1402 RD

ME 5001 RD

ME 3802 RD

ME 3602 RD

ME 3402 RD

ME 2902 RD

ME 2702 RD

ME 2202 RD

ME 1902 RD

ME 1702 RD

3 TN E 7 4 E N S R 2 ( 0 3 S e )

M E 1503

3 TN E 6 8 N S R 3 TN E 6 8 E N S R

ME 1902 F

ME 1402 F

3 TN E 6 8 N S R 3 TN E 7 4 E N S R 2 ( 0 3 S e )

M u s ta n g

ME 1502 RD

M E 1402 P F

3 TN E 6 8 E N S R ( 0 3 S e )

M E 1403

Typ e

ME 1502 F

M u s ta n g

Typ e

M u s ta n g

D I E S E L E N G I N E S O v e r a ll

3 TN 1 0 0 T E N S

4 TN E 8 8 N S W

4 TN E 8 8 N S R

3 TN E 8 8 N S R

3 TN E 7 4 N S R (2 )

Typ e s

Diesel Engine SERVICE MANUAL

ME1503—2203

Diesel Engine Overall

Id.No.: 918174 AP0405

SERVICE MANUAL

Diesel Engine

ME1503—2203

NOTE:

Change: Serial No.:

New Yanmar diesel engine for ME1503 AC00304 and higher

Fuel Supply Line

1

2

3

4 5 6

7 8 1 2 3 4 5 6 7 8

Fuel Injector Valves Fuel Injector Pump Non-Return Valve Throttle Main Fuel Filter Fuel Pump (with Mechanical Pump Function) Water Seperator Fuel Tank

Page D3

Id.No.: 918174 AP0405

SERVICE MANUAL

Diesel Engine

ME1503—2203

A) RADIATOR Position Diesel Engine Fan/Air Circulation Guide Cover: Pressing fan -> 1/3 of the fan width inside the fan air circulation guide cover.

Sucking fan -> 2/3 of the fan width inside the fan air circulation guide cover.

Page D4

Id.No.: 918174 AP0405

SERVICE MANUAL

Electrical

ME1503—2203

C H A P T E R E:

Electrical (Mustang Service Manual ME1503—2203)

Page E1

Id.No.: 918174 AP0405

SERVICE MANUAL

Electrical

ME1503—2203

Electrical Diagram Legend (Starting with Serial No. AC01876)

Name AB1

Description Stop Soleniod

Name R1

Description Preheating

B2 B3

Horn Fuel Level Sensor

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11

Lights Arm, Cab 12V/30 Cab Rotating Beacon Plug Socket Res Windshield Wiper 12V/15 Cab Light Switch High Speed Valve Valves Heating Fan, Horn

FG

Main Fuse

G1

Alternator

H3 H12 H13 H14 H15 H16 H17 H18 H19 H20 H21 H22

Arm Light Preheat Light Load Control Light Engine Temperature Light Engine Oil Pressure Light Air Filter Restriction Light Hydraulic Oil Filter Restriction Light Overload Warning Light Interior Cab Lighting Cab Roof Light, Front Cab Roof Light, Rear Rotating Beacon

S2 S4 S5 S6 S7 S8 S10.1 S10.2 S11 S12 S14 S15 S16 S17 S18 S19 S20 S21 S22 S23

Water Temperature Switch Air Filter Restriction Switch Engine Oil Pressure Switch 3rd Hydraulic Circuit Button Boom Swing/Extend Hydraulics Button 3rd Hydraulic Circuit Button Right Safety Switch Left Safety Switch High Gear Switch Overload Warning System Pressure Switch Hydraulic Oil Filter Restriction Switch Windshield Washer System Heater Fan Switch High Gear Switch Roof Light Switch Front/Side Light Switch Ignition Switch Rotating Beacon Switch Overload Warning System Switch Roof Light Switch

K2 K4 K5 K6

Glow Plug Relay (10 second) Start Relay Engine Stop Timer Soleniod Engine Stop Soleniod

X0 X1 X2 X4 X5 X6 X9 X10 X17 X18 X19 X26 X27 X28 X29

Cigarette Lighter Main Connector, Engine Wiring Harness Main Connector, Engine Wiring Harness Engine Relay Alternator Load Control Alternator Main (Positive) Starter Main (Positive) Starter Soleniod Main Connector, Arm Rest Wiring Harness Ground Plug Socket Horn Button Connector Anti-Theft Device Connector Cab Connector Instrument Panel Connector

M1 M5 M6 M7

Heater Fan Starter Motor Windshield Wiper Windshield Washer

Y2 Y3 Y4 Y5 Y6

Boom Swing/Extend Hydraulic Valve 3rd Hydraulic Circuit 3rd Hydraulic Circuit Safety Valve High Speed Valve

Page E2

Id.No.: 918174 AP0405

SERVICE MANUAL

Electrical

ME1503—2203

Cab Wiring (Starting with Serial No. AC01876)

Brown Brown

Green

Cab Roof Light, Front

-31

Connection Bus

LS LLS L+

Radio LS RLS R+

Red

+30

+30

Cab Roof Light, Front

Yellow / Green +15 31b -31

M

I

Windshield Wiper Motor

Blue

Black

Ground +15

Interior Lighting -31

Violet

Rotating Beacon

Ground

Connection Bus

Blue / Red

-31

Yellow / Black

Cab Roof Light, Rear

Page E3

Ground

Id.No.: 918174 AP0405

SERVICE MANUAL

Electrical

ME1503—2203

Deisel Engine Wiring (Starting with Serial No. AC01876)

Page E4

Id.No.: 918174 AP0405

SERVICE MANUAL

Electrical

ME1503—2203

Chassis Wiring (Starting with Serial No. AC01876)

Page E5

Id.No.: 918174 AP0405

SERVICE MANUAL

Electrical

ME1503—2203

Connection Cable Wiring (Starting with Serial No. AC01876)

Page E6

Id.No.: 918174 AP0405

SERVICE MANUAL

Electrical

ME1503—2203

Relay Box—Relay Arrangement

2

Black 1 2 3 4 5

3

Yellow Loop

1

4

5

Position of Relay Box (Engine Compartment)

Starting Relay (Terminal 50) Preheating Time Relay (only for pilot lamp; approximatelty 15—18 sec.)

Timing Relay for Pulling Contact; switching time 1.5 seconds Switching Relay for Pulling Contact Main Fuse (50 amp.)

Stopping Solenoid (Cable Assignment) Black: Dimensions Red: Locking Contact White: Pulling Contact

Page E7

Id.No.: 918174 AP0405

SERVICE MANUAL

Electrical

ME1503—2203

Preheating Timer Relay Plug-In Connection (Black Connector)

1 2 3 4 5 6 7 8

1

5

2

6

3

7

4

8

2x Black/White Red/Gray 2x Black Brown Red/White Yellow Black Red

Ignition Lock Terminal (50A) and Starting Relay Preheating Pilot Lamp Stopping Solenoid and Starting Relay Diode Preheating Pilot Lamp

Timer Relay Plug-In Connection for Pulling Contact (White Connector) 1

5

2

6

3

7

4

8

1 2 3 4

Black/Pink Black/Blue 2x Black 2x Blue

5 6 7 8

Red/White Yellow Black Red

Switching Relay Pulling Contact Switching Relay Pulling Contact Preheating Timer Relay Switching Relay Pulling Contact and 30A fuse (Terminal 54, Ignition Lock)

Page E8

Id.No.: 918174 AP0405

SERVICE MANUAL

Electrical

ME1503—2203

Switching Relay Stopping Solenoid Pulling Contact Connection

1 2

1 2 3

3

Blue 30A Fuse (Terminal 54 Ignition Lock) and Timer Relay Pulling Contact Red Stopping Solenoid Black/Blue and Black/Pink of Timer Relay Pulling Contact

Starting Relay Connection 1 2 4

1 2 3 4

Black Red/White Red White

3

Diode and Preheating Timer Relay Ignition Lock (Terminal 50A and Diode) Ignition Lock (Terminal 30) Starter (Terminal 50)

Page E9

Id.No.: 918174 AP0405

SERVICE MANUAL

Electrical

ME1503—2203

Fuse Box The fuses are integrated into the instrument panel.

The main fuse 50 amps for ignition and glow plug.

No. Capacity (A) 1 10 2 15 3 10 4 15 5 10 6 10 7 10 8 Reserved 9 10 10 10 11 10

Application Switch Lights Lights Arm, Cab 12-V/15 Cab Heating, Horn Valves Windshield Wiper and Washer Generator Reserved 12-V/30 Cab Socket Reserved

Page E10

Id.No.: 918174 AP0405

SERVICE MANUAL

Operating Elements

ME1503—2203

C H A P T E R F:

Operating Elements (Mustang Service Manual ME1503—2203)

Page F1

Id.No.: 918174 AP0405

SERVICE MANUAL

Operating Elements

ME1503— 2203

Major Components:

1

2

4

3

5 20

8, 9

7

16, 17

10

12

11

13

19

1 Dipper Arm 2 Dipper Arm Cylinder 3 Boom 4 Cab 5 Operator’s Seat 6 Engine Cover 7 Bucket Cylinder 8 Left Control Lever 9 Right Control Lever 10 Bucket 11 Boom Cylinder

15

14

21

18

12 Control Lever Bracket 13 Dozer Blade 14 Undercarriage 15 Chassis 16 Left Driving Lever 17 Right Driving Lever 18 Drive Unit 19 Track Tension Cover 20 Lifting Suspension Lugs 21 Transportation Towing Lugs

Page F2

Id.No.: 918174 AP0405

6

SERVICE MANUAL

Operating Elements

ME1503—2203

Cab Equipment and Controls

1

2

3

4

5

Page F3

Id.No.: 918174 AP0405

SERVICE MANUAL

Operating Elements

ME1503— 2203

Right Control Lever Bracket 6

7

Left Control Lever Bracket 11

18

16

Cab—Foot Area 14

10

Cab Interior 17 8, 9 13 12 15

Page F4

Id.No.: 918174 AP0405

SERVICE MANUAL

Operating Elements

ME1503—2203

Cab Equipment and Controls Legend: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Dozer Blade Operation Lever Undercarriage Telescoping Lever Uppercarriage Tilt Lever (Model ME2203 Only) Uppercarriage Locking Piston Hydraulic Oil Level Inspection Glass Rocker Switches Ignition Key Switch Dashboard Arm Rests with Joystick (Version III) Auxiliary Hydraulics and/or Boom Offset Foot Pedal (Simultaneous Actuation of Pushbutton at Left Joystick) Throttle Lever Heater Engine Cover Release Driving Pedals (Hydraulically Piloted) Glove Box Heater Control Cigarette Lighter Fuse Box

NOTE:

Idea: Solution:

NOTE:

Idea: Solution:

Change: Solution: Serial No.:

More space in feet and knee area.

Joystick consoles IV — short AC01876 and higher

More space for the feet and knees Joystick consoles short (IV), Due to this modification the position of the instruments and the wiring have been changed.

Change: Solution: Serial No.:

Joystick consoles IV — Modification Strengthening cover joystick consoles AC01876 and higher

Precautionary strengthening cover for the joystick console fixing point Modification kit for joystick console IV (mandatory modification)

Page F5

Id.No.: 918174 AP0405

SERVICE MANUAL

Operating Elements

ME1503— 2203

Instrument Panel 1 2 3 4 5 6 7 8

9 Headlight Control 10 Hourmeter 11 Ignition Key Switch 12 Windshield Wiper/Washer Switch 13 Cab Light Switch 14 Overdrive 15 Headlight Switch 16 Not Used

Fuel Gauge Charge Indicator Engine Oil Pressure Indicator Water Temperature Warning Light Air Filter Restriction Indicator Light Glow Plug Indicator Hydraulic Filter Restriction Indicator Light Overload Warning Light

1 6 7 8 9 10 11 12 13 14 15 16

2 3 4 5

Page F6

Id.No.: 918174 AP0405

SERVICE MANUAL

Operating Elements

ME1503—2203

Towing the Compact Excavator Use only the towing lugs for towing the compact excavator.

Secure the towing lug shackle pin with the locking pin.

Lifting the Compact Excavator Warning!: The lifting hoist must be able to support, at minimum, the dead weight of the compact excavator.

Move the boom and dozer blade all the way up and apply the uppercarriage locking piston.

Attach and secure lifting aids (ropes, chains, etc.) at the two lifting lugs on the cab roof.

Keep the compact excavator level while lifting.

Excavator Lifting Lugs

Minimum Length of Cable: 4 feet (1200 mm)

Page F7

Id.No.: 918174 AP0405

SERVICE MANUAL

Operating Elements

ME1503— 2203

Tilting the Superstructure (Model ME2203 Only) In order to facilitate vertical digging on a slope, the superstructure of the ME2203 crawler excavator can be hydraulically tilted 15° by means of a lever. This helps keep the chassis horizontal.

Superstructure Tilting Hydraulic Cylinder

Undercarrige Telescoping (Width Extension) For better stability, it is possible to hydraulically change the track gauge of the compact excavator from 39—51” (980—1300 mm).

WARNING!: Narrow track gauge (39” [980 mm]) results in reduced stability.

38.6″″ (980 mm)

51.2″″ (1300 mm)

Page F8

Id.No.: 918174 AP0405

SERVICE MANUAL

Operating Elements

ME1503—2203

Chassis Component Arrangement

12

2

3

4

5

14

6 11

7 1

8 13 9 10

1 2 3 4 5 6 7

Auxiliary Hydraulics/Boom Offset Electric Switch Valve Diesel Engine/Pump Unit Fuel Tank Breathing and Bleeding Filter (Port) Return Filter Hydraulic Oil Tank Hydraulic Oil Level Inspection Glass

8 Swivel Unit 9 Main Valve Block 10 Swivel Joint 11 Hydraulic Oil Cooler 12 Radiator 13 Offset Cylinder 14 Collecting Tube Hydraulic Oil Return Flow

Page F9

Id.No.: 918174 AP0405

TORQUE SPECIFICATIONS Note: Use these torque values when tightening MUSTANG 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. (13 mm)

M14X1.5

26 (35)

33 (45)

26 (35)

26 (35)

0.6 in. (15 mm)

M16X1.5

33 (45)

41 (55)

30 (40)

37 (50)

0.6 in. (15 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. (25 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. (43 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. (10 mm)

G1/4A

26 (35)

26 (35)

22 (30)

26 (35)

0.5 in. (13 mm)

G3/8A

33 (45)

52 (70)

33 (45)

37 (50)

0.7 in. (18 mm)

G1/2A

48 (65)

66 (90)

41 (55)

48 (65)

0.8 in. (20 mm)

G3/4A

66 (90)

133 (180)

74 (100)

103 (140)

1.0 in. (25 mm)

G1A

111 (150)

229 (310)

118 (160)

140 (190)

1.3 in. (33 mm)

G1 1/4A

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (43 mm)

G1 1/2A

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (48 mm)

Thread

918174/AP0405

6-1

Printed in U.S.A.

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

Identification aid outside Ø

M12X1.5

15 (20)

26 (35)

26 (35)

26 (35)

0.5 in. (13 mm)

M14X1.5

26 (35)

41 (55)

33 (45)

33 (45)

0.6 in. (15 mm)

M16X1.5

33 (45)

52 (70)

41 (55)

41 (55)

0.6 in. (15 mm)

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. (25 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. (43 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 mm)

G1/4A

33 (45)

59 (80)

44 (60)

44 (60)

0.7 in. (18 mm)

G3/8A

48 (65)

85 (115)

55 (75)

74 (100)

0.8 in. (20 mm)

G1/2A

66 (90)

133 (180)

125 (170)

107 (145)

1.0 in. (25 mm)

G3/4A

111 (150)

229 (310)

229 (310)

192 (260)

1.3 in. (33 mm)

G1A

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (43 mm)

G1 1/4A

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (48 mm)

Thread

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)

Printed in U.S.A.

6-2

918174/AP0405

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)

918174/AP0405

6-3

Printed in U.S.A.

®

Mustang Manufacturing Co., Inc. 1880 Austin Road, P.O. Box 547, Owatonna, Minnesota, 55060-0547 USA www.mustangmfg.com

918174/AP0405

© 2005 MUSTANG MANUFACTURING COMPANY, INC. All Rights Reserved.

PRINTED IN USA