Mustang Compact Excavator ME6003 Service Manual (918175) - PDF DOWNLOAD

®

ME6003 COMPACT EXCAVATOR

SERVICE MANUAL Revision A - 06/05

PART #918175

®

Mustang Manufacturing Company, Inc.

Introduction For your safety and continued proper operation, use only genuine MUSTANG® service parts.

When ordering service parts, specify the correct part number, full description, quantity required, the unit model number and serial number.

The model and serial number decal for this unit is located on the left chassis upright. “Right” and “Left” are determined from a position sitting on the seat and facing forward.

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

NOTE: Purchase equivalent, quality tires for your loader. Contact your dealer for replacement tire information.

NOTE: Replacement batteries are not provided by the Mustang Company. For battery specifications see “Engine” chapter. ALL REPLACEMENT BATTERIES MUST BE PURCHASED LOCALLY. Refer to the abbreviations table located on this page for the various fastener descriptions. Standard attaching hardware torque values are also provided on the inside back cover. If a part requires lubrication or a nonstandard torque value, it will be specified behind the part number description in parenthesis.

Items shown in the parts list that do not have part numbers are shown for reference purposes only and are NOT available for purchase.

Dimensions are in inches unless otherwise specified.

NOTE: The following abbreviations and symbols may be used herein: A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ampere AR . . . . . . . . . . . . . . . . . . . . . . . . . . As Required ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly AUX. . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary CCA . . . . . . . . . . . . . . Cold Cranking Amperage CYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder FL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flare FOPS . . . . . . Falling Object Protective Structure GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hexagon HF . . . . . . . . . . . . . . . . . . . . . . . . . . . High Flow HYD. . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic JIC . . . . . . . . . . . . . . . . . Joint Industrial Council kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilowatt LBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter MM (mm) . . . . . . . . . . . . . . . . . . . . . Millimeter NA . . . . . . . . . . . . . . . . . . . . Naturally Aspirated N/A . . . . . . . . . . . . . . . . . . . . . . .Not Applicable NEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative N•m . . . . . . . . . . . . . . . . . . . . . . . .Newton meter NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number NPT . . . . . . . . . . . . . . . . . . National Pipe Thread PN . . . . . . . . . . . . . . . . . . . . . . . . . .Part Number POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Positive PSI . . . . . . . . . . . . . . . . . Pounds per Square Inch QTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity REF . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference REQ'D.. . . . . . . . . . . . . . . . . . . . . . . . . .Required ROPS . . . . . . . . . .Roll Over Protective Structure RPM. . . . . . . . . . . . . . . . Revolutions Per Minute SAE . . . . . . . . Society of Automotive Engineers SN . . . . . . . . . . . . . . . . . . . . . . . . Serial Number SQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Square ST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Straight TURBO . . . . . . . . . . . . . . . . . . . . . Turbocharger V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volt

MUSTANG is a registered trademark of the Mustang Manfacturing Company, Inc.

Table of Contents Operation Important information about this service manual ..................................................... 1-1 Abbreviations/symbols ............................................................................................. 1-1 Identification of warnings and hazards .................................................................... 1-2 Designated use and exemption from liability ........................................................... 1-2 Type labels and component numbers ...................................................................... 1-3 Machine: overview ................................................................................................... 1-5 Cab Equipment and Controls ................................................................................... 1-6 Instrument panel, switches and indicators ............................................................... 1-8 Engine compartment .............................................................................................. 1-10 Chassis: overview .................................................................................................. 1-11 SAE/ISO operating controls selector valve ............................................................ 1-12 Tilting the cab ........................................................................................................ 1-13 SAE operating controls (standard) ......................................................................... 1-14 ISO operating controls (selectable) ....................................................................... 1-15 Boom slew/auxiliary hydraulics pedal .................................................................... 1-16 Dozer blade ........................................................................................................... 1-17 Throttle lever .......................................................................................................... 1-17 Operator’s seat adjustments .................................................................................. 1-18 Ventilation .............................................................................................................. 1-19 Cab door latch release ........................................................................................... 1-20 Interior light ............................................................................................................ 1-21 Tool kit and cab jack handle .................................................................................. 1-21 Cab heat control .................................................................................................... 1-21 Recirculated air mode ............................................................................................ 1-22 Hydraulics/swiveling and boom rotation pedal adjustment .................................... 1-22 Battery master switch ............................................................................................ 1-22 Specifications Chassis .................................................................................................................... 2-1 Engine ...................................................................................................................... 2-1 Capacities .......................................................................................................... 2-2 Engine Tightening Torques ............................................................................... 2-2 Hydraulic system ..................................................................................................... 2-3 Auxiliary hydraulics oil flow* .............................................................................. 2-3 Screwable hose burst valve ............................................................................... 2-3 Undercarriage/swivel unit ........................................................................................ 2-4 Dozer blade ............................................................................................................. 2-4 Electrical system ...................................................................................................... 2-4 Sound levels ............................................................................................................ 2-6 Fluid capacities ........................................................................................................ 2-7 Coolant compound table .......................................................................................... 2-7 Specific tightening torques ....................................................................................... 2-7 General tightening torques ...................................................................................... 2-8 Dimensions ............................................................................................................ 2-10 Lift Capacities ........................................................................................................ 2-11 Geometry ............................................................................................................... 2-15 Maintenance General information care and servicing ................................................................... 3-1 Maintenance decal symbols .................................................................................... 3-3 Maintenance decal ................................................................................................... 3-4 Maintenance schedule ............................................................................................. 3-5 General Maintenance .............................................................................................. 3-7 Cab interior ........................................................................................................ 3-8 Exterior of the machine ...................................................................................... 3-8 918175/AP0605

I-1

Engine compartment .......................................................................................... 3-8 Screw connections and attachments ................................................................. 3-8 Pivots and hinges .............................................................................................. 3-8 Lubrication ............................................................................................................... 3-9 Lubrication strip ............................................................................................... 3-10 Engine .................................................................................................................... 3-10 Changing engine oil and filter ................................................................................ 3-11 Air cleaner service ................................................................................................. 3-12 Fuel system ............................................................................................................ 3-13 Coolant system ...................................................................................................... 3-16 Electrical system .................................................................................................... 3-17 Alternator ......................................................................................................... 3-20 Checking & adjusting V-belt tension ...................................................................... 3-20 Fluids and lubricants .............................................................................................. 3-23 Pressure check ...................................................................................................... 3-24 General ............................................................................................................ 3-24 Pressure check of variable displacement pump P1 ......................................... 3-24 Pressure check of variable displacement pump P2 ......................................... 3-25 Checking the gear pump P3 pressure ............................................................. 3-26 Checking pilot control pressure ....................................................................... 3-27 Gear motor secondary pressure limiting valve ................................................ 3-28 Measuring ports: overview ............................................................................... 3-28 Primary pressure limiting valves ...................................................................... 3-29 Test report .............................................................................................................. 3-30 Hydraulic system .................................................................................................... 3-33 Cab heater filter ..................................................................................................... 3-36 Replacing the inside heater filter ..................................................................... 3-36 Engine 4TNV98 engine: overview ........................................................................................ 4-1 Fuel system .............................................................................................................. 4-3 Removing the cylinder-head cover .......................................................................... 4-4 Checking and adjusting valve tip clearance ............................................................. 4-4 Cylinder head bolt tightening order .......................................................................... 4-6 Checking the injection nozzles ................................................................................. 4-6 Pressure check .................................................................................................. 4-6 Checking the nozzle jet ............................................................................................ 4-7 Injection timing ......................................................................................................... 4-8 Adjusting engine idle ................................................................................................ 4-9 Compression ............................................................................................................ 4-9 Checking the coolant thermostat ........................................................................... 4-10 Checking the thermal switch .................................................................................. 4-10 Oil pressure switch ................................................................................................. 4-11 Checking the coolant circuit ................................................................................... 4-11 Engine troubleshooting .......................................................................................... 4-12 Hydraulic System Hydraulic pump PVD-3B-56P-21G5-4626F ............................................................. 5-1 Pump unit: exploded view .................................................................................. 5-3 Control oil unit .................................................................................................... 5-4 Main valve block ...................................................................................................... 5-5 Ports .................................................................................................................. 5-5 Legend ............................................................................................................... 5-6 Main valve block diagram .................................................................................. 5-7 Pressure limiting valves ..................................................................................... 5-8 Pump assignment .............................................................................................. 5-9 Drive counterbalancing system .............................................................................. 5-10 Pump assignment for drive counterbalancing .................................................. 5-10 I-2

918175/AP0605

Drive counter-balancing system diagram ........................................................ 5-11 Regeneration – dipper arm section ........................................................................ 5-12 Bucket pre-tension ................................................................................................. 5-12 Boom summation – raise ....................................................................................... 5-13 Check valve (load retaining valve) ......................................................................... 5-14 Flow rate adjustment of auxiliary hydraulics .......................................................... 5-15 Secondary pressure limiting valves for the auxiliary hydraulics (option) ............... 5-16 Pilot valves ............................................................................................................. 5-17 Joystick ............................................................................................................ 5-17 Pilot valve (driving) .......................................................................................... 5-18 Pilot valve for auxiliary hydraulics .................................................................... 5-20 Pilot valve for dozer blade ............................................................................... 5-21 Valves .................................................................................................................... 5-22 7/3 directional valve (changeover valve) ......................................................... 5-22 4/3 directional valve ......................................................................................... 5-23 Shuttle valve block ........................................................................................... 5-24 Changeover valve for SAE/ISO controls (option) ............................................ 5-25 Travel drive ............................................................................................................ 5-26 Function ........................................................................................................... 5-27 2nd speed range function ................................................................................ 5-27 Swivel unit .............................................................................................................. 5-29 Parking brake function ..................................................................................... 5-30 Swivel joint ............................................................................................................. 5-33 Breather filter ......................................................................................................... 5-33 Troubleshooting in the hydraulic system ............................................................... 5-34 Hydraulics diagram A4 ........................................................................................... 5-35 Hydraulics diagram (legend) .................................................................................. 5-36 Hydraulics diagram ................................................................................................ 5-37 Main valve block diagram ...................................................................................... 5-38 Hydraulics diagram with 3rd control circuit (option) .............................................. 5-39 Main valve block diagram with 3rd control circuit (option) .................................... 5-40 Electrical system Ohm's Law (current, voltage, resistance); power ..................................................... 6-1 Measuring equipment, measuring methods ............................................................. 6-1 Cable color coding ................................................................................................... 6-2 Relays ...................................................................................................................... 6-3 Use, mode of function ........................................................................................ 6-3 Electric units ............................................................................................................ 6-3 Fuse box in instrument panel ................................................................................... 6-3 Main fuse box with relays ........................................................................................ 6-4 Relays ...................................................................................................................... 6-4 Socket ...................................................................................................................... 6-5 Tip switches on joystick ........................................................................................... 6-5 Left-hand side joystick ....................................................................................... 6-5 Right-hand side joystick ..................................................................................... 6-5

918175/AP0605

I-3

Instrument panel: overview ...................................................................................... 6-6 Switches: overview .................................................................................................. 6-7 Alternator ................................................................................................................. 6-7 Starter ...................................................................................................................... 6-8 Wiring harness 1000109629: cab roof ..................................................................... 6-9 Wiring diagram version 1 ....................................................................................... 6-10 Wiring diagram version 1: legend .......................................................................... 6-11 Wiring diagram version 1 ....................................................................................... 6-12 Wiring diagram version 2: legend .......................................................................... 6-13 Wiring diagram version 2 ....................................................................................... 6-14 Wiring harness 1000109624 (legend): engine – chassis ....................................... 6-15 Wiring harness 1000109624: engine – chassis ..................................................... 6-16 Wiring harness 1000109630 (legend) version 1: switches .................................... 6-17 Wiring harness 1000109630 version 1: switches ................................................... 6-18 Wiring harness (legend) version 2: switches A4 .................................................... 6-19 Wiring harness version 2: switches ........................................................................ 6-20 Wiring harness 1000109628: armrest .................................................................... 6-21 Wiring harness 1000116138: boom working light .................................................. 6-22 Options Air conditioning ........................................................................................................ 7-1 Specific safety instructions ................................................................................ 7-1 Installation: overview ......................................................................................... 7-2 Components ...................................................................................................... 7-2 Counterweight .......................................................................................................... 7-8 Specifications ..................................................................................................... 7-8 Extended dipper arm ................................................................................................ 7-8 Specifications ..................................................................................................... 7-8 Control circuit hydraulic coupling connections ......................................................... 7-9 3rd control circuit connections ................................................................................. 7-9 Auxiliary hydraulics connections ............................................................................ 7-10 Fuel-filling pump ..................................................................................................... 7-11 Ports ................................................................................................................ 7-12 Central lubrication system ...................................................................................... 7-12 Safe load indicator D (safety valve for boom) ........................................................ 7-17 Safe load indicator F (safety valves for boom and dipper arm) ............................. 7-19 Position ............................................................................................................ 7-19

I-4

918175/AP0605

Operation

1

Operation

1.1

Important information about this service manual WARNING! •

Read and understand the excavator operator’s manual. Follow warnings and instructions for operation and maintenance in that manual. Failure to follow instructions can result serious injury.

•

Read and understand all safety decals before operating the machine. DO NOT operate the machine unless all factory-installed guards and shields are in place.

•

Be sure you are familiar with all safety devices and controls before operating the machine.

•

Know how to stop the machine before starting.

This service manual contains important information about safely servicing the machine, correctly and economically. It serves as a reference for experienced users, helps to avoid hazardous situations, and reduces repair costs and downtimes. Additionally, the reliability and the service life of the machine will be increased by following the instructions in this manual.

Proper and careful work is the best protection against accidents!

Operational safety and readiness of the machine depends not only upon operator skill, but also upon proper maintenance and service.

Always use original Mustang service parts when performing maintenance and repair work.

This ensures operational safety and readiness of the machine, and maintains its value.

1.2

Abbreviations/symbols • This symbol stands for a list.

• Subdivision within lists or an activity. Follow the steps in the sequence in which they appear.

☞ This symbol requires you to perform the activity described. ➥ Description of the effects or results of an activity. n. s. = not shown.

“Option” = optional equipment.

Stated whenever controls or other components of the machine are installed as an option.

918175/AP0605

1-1

Operation 1.3

Identification of warnings and hazards The following signal words are used throughout this manual and on decals on the machine to warn of potentially hazardous conditions.

DANGER!/WARNING!/CAUTION! Failure to follow the instructions identified by this symbol may result in personal injury or death for the operator or other persons.

☞ Measures for avoiding the hazard may be included.

IMPORTANT! Contains instructions to help use the machine more efficiently.

NOTE: Contains additional instructions and/or helpful information.

Environment!

Failure to follow the instructions identified by this symbol may result in damage to the environment. The environment is in danger if environmentally hazardous material (e.g., waste oil) is not subject to proper use or disposal.

1.4

Designated use and exemption from liability • The machine is intended for: • Moving earth, gravel, coarse gravel or ballast and rubble.

• Working with Mustang-approved implements.

• The Mustang Company is not liable for damage resulting from use other than mentioned above.

• Designated use also includes following instructions in the operator’s manual and observing maintenance and service recommendations. Read and understand the operator’s manual before starting, servicing/repairing the machine.

• The safety of the machine can be compromised by performing modifications to the machine not authorized by the Mustang Company and/or by using service parts, equipment or implements not approved by the Mustang Company. The Mustang Company is not liable for any damages resulting if this instruction is not followed.

• Follow the safety instructions in this manual, the operator’s manual, the engine manual, and any applicable instructions/manuals provided with any attachments used with the machine. The Mustang Company is not liable for personal injury and/or property damage resulting from failure to follow the safety instructions.

• The Mustang Company is not liable for personal injury and/or property damage resulting from failure to exercise care while servicing/repairing the machine.

• Do not use the machine for transportation on public roads.

1-2

918175/AP0605

Operation 1.5

Type labels and component numbers Serial number location The machine serial number plate (1), Fig. 1 is located on the front frame, below the operator’s cab. The cab/canopy serial number (2) is located on the right rear of the frame next to the rear window.

1

2

Fig. 1: Serial number locations Engine number The type label (Fig. 2) is located on the engine cylinder-head cover.

Example:

Yanmar 46557

Fig. 2: Diesel engine number

918175/AP0605

1-3

Operation Hydraulic pump identification number The hydraulic pump identification number is located on the hydraulic pump housing (Fig. 3).

Fig. 3: Hydraulic pump identification number Main valve block identification number The main valve block identification number is located on the lower side of the main valve block (Fig. 4).

Fig. 4: Main valve block identification Travel drive identification number Refer to Fig. 5 for the travel drive identification number location.

Fig. 5: Travel drive identification Swivel unit identification number Refer to Fig. 6 for the swivel unit identification number location.

Fig. 6: Swivel unit identification

1-4

918175/AP0605

Operation 1.6

Machine: overview Dipper Arm Cylinder

Dipper Arm

Operation Controls

Boom

Cab Engine Cover

Operator’s Seat Hydraulic/Fuel Tank Cover

Boom Light

Counterweight

Boom Cylinder Bucket Cylinder Swing Frame/ Superstructure Bucket

Dozer Blade Swing Cylinder

Track Frame

Travel Drive Motor

Fig. 7: Component Names

918175/AP0605

1-5

Operation 1.7

Cab Equipment and Controls

25

27

28

29

26

1

24

2

23

22

21 3

4 20 19

6

9

10 5

8

7

18

15

14

13

11

12

17

1-6

16

918175/AP0605

Operation

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

918175/AP0605

Description Auxiliary hydraulics pedal cover Auxiliary hydraulics pedal Control lever (left) Control lever (right) Control lever base (left) Control lever base (right) Armrest (left) Armrest (right) Lever – horizontal seat adjustment Lever – horizontal seat adjustment with control lever base Air vent (rear window, on the left) Air vent (rear window, on the right) Radio (option) Seat (back rest adjustment) Seat belt (lock) Cup holder Bracket (storage box for documents) Switch panel Throttle Fuse box Pre-heating/ignition switch Accessory power outlet Coolant temperature indicator Instrument cluster Drive pedal (left) Drive pedal (right) Drive lever (left) Drive lever (right) Dozer blade pedal/lever

1-7

Operation 1.8 Ref.

Description

30 31 32

Hydraulic oil filter indicator (red) – Hydraulic oil filter indicator light comes on when hydraulic oil filter is too dirty.

Air filter indicator (red) – Air filter indicator light comes on when air filter is too dirty.

Battery charge indicator (red) – Battery charge indicator light comes on when the ignition is turned on and turns off as soon as the engine runs. The alternator or the charging circuit is faulty if the indicator light comes on with the engine running. The battery is no longer charged.

Engine oil pressure indicator (red) – Engine oil pressure light comes on when the ignition is turned on and goes out as soon as the engine runs. During normal operation, this indicator should remain off. The indicator will light if the engine oil pressure drops too low. If this occurs shut on the engine IMMEDIATELY and determine the cause of the pressure drop.

Coolant temperature indicator (red) – Coolant temperature indicator light comes on when coolant temperature is too high.

Glow plug indicator (yellow) – Glow plug indicator light comes on when the ignition key is to the glow plug activation position. Indicator will go out when the glow plugs have heated sufficiently to start the engine.

Hour meter – Indicates the total operating hours of the machine. Use the hour meter to track maintenance in the maintenance log.

Fuel level gauge – The fuel level gauge shows the amount of fuel in the tank.

Indicator light – not assigned Indicator light – not assigned Hydraulic oil temperature indicator light – Hydraulic oil temperature indicator light comes on when hydraulic oil is too hot.

Coolant temperature gauge – Displays coolant temperature.

High-speed switch (transport speed) – Pressing the switch will enable high travel speed.

Windshield wiper switch (cab models only) – Pressing the two position switch to the first position turns the windshield wiper on.

Pressing and holding the switch indicator in the second position activates the washer fluid pump.

Work light switch – Press switch to the ON position to turn on the boom work light.

Roof lights (option) – Press switch to the ON position to turn on the roof light lights.

Rotating beacon (option) – Press switch to the ON position to turn on the boom work light.

Ventilation Fan (two-speed) – Press the two position switch to turn on the ventilation fan. Pressing switch to the first position is the low fan speed position and the second position is the high fan speed position. If the Summer/Winter operation valve is OPEN or HEATING position, this switch will function as the Cab Heater ON/OFF switch. The Summer/Winter operation valve is located under the hood on top of the engine behind the radiator.

Air conditioning (option) – Press the switch to turn on the air conditioning.

Not assigned Not assigned Not assigned

33

34 35 36 37 38 39 40 41 42 43 44 45 46 47

48 49 50 51

1-8

Instrument panel, switches and indicators

918175/AP0605

Operation

32

40

38

30

33

35

34 37

38 39 31

36 41

42

918175/AP0605

43

44

45

46

47

48

49

50

51

1-9

Operation 1.9

Engine compartment

52

53

54

55

56

57

Ref.

Description

52

Main valve block........................................................................................................................................................................................5-5

1-10

For more information see page

53

Measurement ports ................................................................................................................................................................................ 3-26

54

Fuel pre-filter .......................................................................................................................................................................................... 3-15

55

Engine .......................................................................................................................................................................................................4-1

56 57

Coolant tank ........................................................................................................................................................................................... 3-16 Oil/water radiator ...................................................................................................................................................................................... N/A

918175/AP0605

Operation 1.10 Chassis: overview

58

59

60

61

62

63

64

65

66

Ref.

Description

58 59

Leak oil strip ............................................................................................................................................................................................. N/A

For more information see page Swivel joint.............................................................................................................................................................................................. 5-33

60 61 62

Swivel unit .............................................................................................................................................................................................. 5-29 Opening for cleaning the hydraulic oil tank............................................................................................................................................... N/A Position of main fuse box with relays ....................................................................................................................................................... 2-4

63

Shuttle valve block.................................................................................................................................................................................. 5-24

64

Pilot valve for dozer blade ...................................................................................................................................................................... 5-21

65

Changeover valve................................................................................................................................................................................... 5-22

66 67

Pilot valve (driving) ................................................................................................................................................................................. 5-18 (NOT SHOWN) SAE/ISO Operating Controls Selector Valve (pg. 3-10 918070)

918175/AP0605

1-11

Operation 1.11 SAE/ISO operating controls selector valve Located on the lower left side of the chassis, under the cab, is the SAE/ISO selector Valve. See (1), Fig. 8. The SAE/ISO valve can be accessed through a cutout on the left side of the chassis at location (2). This machine has been set at the factory for SAE standard operation shown at position (3). If ISO operation is desired, loosen wing nut (5) and rotate valve to position (4) and tighten wing nut (5). If the machine does not function according to the decals and instructions in this manual, move the selector valve to the other position.

5 3

2

5

1

4

2 Fig. 8: SAE/ISO operating controls selector valve

1-12

918175/AP0605

Operation 1.12 Tilting the cab Refer to 1-10 (Fig. 9) to safely complete the following procedure.

6

5

2 4 1 10

3

8

9 7

11

8 Fig. 9: Tilting the cab

Tilting the cab up: 1. Follow “Mandatory Safety Shutdown Procedure” in the "Safety" Chapter of the Operator’s Manual.

2. Raise the floor mat (1) on the right, front of the cab and remove cab lockdown nut (2). Remove cab lock-down nut (3) at the right rear of the cab.

3. Securely close the cab door.

4. Locate the jack handle tubes (4) from the tool kit in the engine compartment and insert into the jack (5) and jack to the limit. The cab will be raised as far as the jack (5) will travel.

5. Pull handle (7) until the cab is completely tilted and supported by safety cables (8).

6. Remove the tilt rod (9) from the storage bracket (10) and slide the tilt rod (9) into the guide bracket (11) and secure with the split pin.

Tilting the cab down: 1. Remove the tilt rod (9) from the guide bracket (11) by removing the split pin and slide the tilt rod (10) out of the guide bracket (9) and secure with the split pin back in the storage bracket (10).

2. Use handle (7) to slowly lower the cab back onto the jack (5).

3. Remove jack handle tubes (4) from the jack (5) and insert the opposite end of the jack handle tubes (4) onto the release pin (6). Slowly turn release pin (6) counter-clockwise until the cab is lowered.

4. Turn the release pin (6) clockwise.

918175/AP0605

1-13

Operation 5. Reinstall the cab lock-down nuts (2) and (3).

6. Place the jack handle tubes (4) back in the tool kit.

1.13 SAE operating controls (standard)

WARNING! •

Always tighten cab lock-down nuts before driving or using the machine.

•

Always close the cab door before tilting the cab.

•

Stay clear from underneath the cab as it is tilted.

•

Always secure the tilt rod in the support position the when cab is tilted.

SAE boom and bucket functions are controlled by the right and left-hand joystick control levers located on the seat consoles.

Left-hand joystick 1 – Arm extend 2 – Arm retract 3 – Swing left 4 – Swing right

Fig. 10:SAE left-hand joystick

1-14

918175/AP0605

Operation SAE right-hand joystick 5 – Boom lower 6 – Boom raise 7 – Curl bucket in 8 – Curl bucket out

Fig. 11:SAE right-hand joystick

Note: The joystick controls are pilot-operated. The farther the controls are moved from center, the faster the machine will function.

1.14 ISO operating controls (selectable) ISO boom and bucket functions are controlled by the right and left-hand joystick control levers located on the seat consoles.

ISO left-hand joystick 1 – Boom lower 2 – Boom raise 3 – Swing left 4 – Swing right

Fig. 12:ISO left-hand joystick

918175/AP0605

1-15

Operation ISO right-hand joystick 5 – Arm extend 6 – Arm retract 7 – Curl bucket in 8 – Curl bucket out

Fig. 13:ISO right-hand joystick

Note: The joystick controls are pilot-operated. The farther the controls are moved from center, the faster the machine will function.

1.15 Boom slew/auxiliary hydraulics pedal The boom can be slewed, or swung, without moving the swing frame by pressing and holding the auxiliary hydraulic/changeover valve button (1) on top of the left hand joystick, and then pressing the auxiliary hydraulics pedal (2) left or right. See Fig. 14.

Pressing and holding the auxiliary hydraulic/changeover valve button (1) and pressing the auxiliary hydraulics pedal (2) to the left with your toe slews the boom to the left. Pressing and holding the auxiliary hydraulic/changeover valve button (1) and pressing the auxiliary hydraulics pedal (2) to the right with your toe slews the boom to the right.

The auxiliary hydraulics pedal (2) allows use/control of front end attachments.

Action will vary depending on the attachment and how it is connected.

1 2

Fig. 14:Boom slew

1-16

918175/AP0605

Operation

1.16 Dozer blade The dozer blade is controlled by the dozer control pedal/lever (1) located next to the travel controls. See Fig. 15.

•

Push control pedal/lever forward to lower the blade.

•

Pull control pedal/lever rearward to raise the blade.

1

Fig. 15:Dozer blade controls

1.17 Throttle lever The engine RPM is controlled by the throttle lever (1) located next to the right hand control console. See Fig. 16.

•

Push throttle lever (1) forward to lower the engine RPM.

•

Pull throttle lever (1) rearward to increase the engine RPM. 1

Fig. 16:Throttle lever

918175/AP0605

1-17

Operation 1.18 Operator’s seat adjustments Note: The operator’s seat left-hand console must be raised in order to exit the cab. In the lowered or work position, all operational functions are activated, and operator exit is blocked by the warning arm/lever. In the raised position, the all hydraulic functions of the machine are locked out.

5

2

4

3 1

6

Fig. 17:Seat adjustment

1. Seat Suspension Adjustment Rotate the knob (1), Fig. 17 to adjust the seat suspension for the operator’s weight. An indicator on the front of the seat base shows the weight adjustment in kilograms. (1 kg = 2.2 lbs.) Adjust the seat suspension correctly to ensure a comfortable ride.

2. Horizontal Seat Adjustment The seat adjustment lever (2) allows the operator to move only the seat forward and rearward.

1-18

918175/AP0605

Operation 3. Horizontal Seat & Control Adjustment The seat adjustment lever (3) allows the operator to move both the seat and the controls forward and rearward.

4. Armrest Height Adjustment The armrest height adjustment (4) allows the operator to raise or lower the armrests by turning the adjustment wheel. The rear of the left-hand armrest has a turnbuckle that may need to be adjusted to allow the left-hand armrest to rotate out of the way when the left-hand console is raised. Use the turnbuckle to adjust the armrest so it does not contact the left-hand control lever when raising the left-hand console to the lock-out position.

5. Backrest Adjustment The backrest adjustment lever (5) allows the operator to move the backrest forward and rearward.

6. Headrest Adjustment The headrest adjustment (6) allows the operator to move the headrest up and down.

7. Seat Height Adjustment The seat height adjustment allows the operator to move the seat height up and down. To raise the seat height, grasp the seat and lift up until you hear an audible click. To lower the seat, raise the seat to the highest position and then lower the seat to its lowest position.

1.19 Ventilation Windshield

WARNING! When opening the windshield, be sure to lock both latches. When closing the windshield, keep hands on handle and away from path of window.

1. The windshield can be opened for ventilation. Turn the latches (1), Fig. 18 located at the upper corners of the windshield. Grasp the handle (2) and pull the windshield up until the latches lock in the open position. For additional ventilation, the lower portion of the windshield can be removed and securely stored in the glass holder (3) located on the rear window.

2. To close the windshield, reinstall the lower windshield, and turn the latches, and then lower the windshield and lock the latches in the closed position.

918175/AP0605

1-19

Operation

2

1

1

3

3

Fig. 18:Windshield locks

1.20 Cab door latch release When fully opened, the left-hand cab door will lock in position to the side of the cab. To release the latch, use the black knob (1), Fig. 19 located on the inside of the door.

1

Fig. 19:Cab door latch release

1-20

918175/AP0605

Operation 1.21 Interior light The interior light is located on the back of the cab above the rear window. Press the switch to the right or left to turn the light ON. Move the switch to the center position to turn the light OFF.

Fig. 20:Interior light

1.22 Tool kit and cab jack handle The machine tool kit and the cab jack handle are located in the storage area under the hood in the engine compartment.

1.23 Cab heat control During the colder months, the operator’s cab heater can be turned on by opening the heater valve located under the hood on top of the engine behind the radiator (Fig. 21). Rotate the lever to either the “heat on” or “heat off” position as required.

Fig. 21:Cab heat control

918175/AP0605

1-21

Operation 1.24 Recirculated air mode When heating or cooling the cab, the recirculated air mode can be utilized to heat or cool only the air in the cab with no fresh air supply from the outside. Sliding the plate to the left will turn ON the recirculated air mode by closing the vent. Sliding the plate to the right will turn OFF the recirculated air mode by opening the vent.

Fig. 22:Recirculated air mode

1.25 Hydraulics/swiveling and boom rotation pedal adjustment The pedal operating the auxiliary hydraulics/swiveling the boom can be rotated by 90°.

1. Loosen 4 screws.

2. Rotate the pedal by 90°.

3. Tighten the 4 screws.

CAUTION! Make sure the hydraulic hoses are not squeezed as you tilt the cab.

1.26 Battery master switch

IMPORTANT! A B C

The battery power circuit is supplied with a keyswitch. Use the keyswitch to disconnect power before working on the electric system and/or as an anti-theft precaution.

Interrupting power supply

Turn key (A) of the battery master switch to position (B) and remove it.

Fig. 23:Battery master switch

Switching on power supply

1. Insert key (A) in the battery master switch.

2. Turn the key down to the notched position (C).

1-22

918175/AP0605

Specifications

2

Specifications

2.1

Chassis Sturdy steel sheet chassis, rubber-mounted engine

2.2

Engine Engine Model

Yanmar 4TNV98-VNS EPA Tier II

Engine Type

Water-cooled 4 stroke diesel engine

No. of cylinders

4

Fuel injection system

Direct injection

Aspiration

Naturally aspirated

Cooling system Lubrication system

Water-cooled/aspirating fan Force-feed lubrication with trochoidal pump

Displacement Nominal bore and stroke

202 cu. in. (3.32 L) 3.9 x 4.3 in. (98 x 110 mm)

Output Max. torque

57 hp (42.5 kW) @ 2100 rpm 184 lb.-ft. (249 Nm) @ 1400 rpm

Max. engine speed without load Idling speed

2275 +/- 50 rpm 1050 +/- 50 rpm

Valve tip clearance (intake = outlet) Injection pressure

0.006 – 0.010 in. (0.15 – 0.25 mm) (cold) 3191 – 3336 psi (220 – 230 bar)

Compression Engine oil pressure

507 +/- 14.5 psi (35 +/- 1 bar) @ 250 rpm 48 – 58 psi (3 – 4 bar)

Pressure switch for engine oil pump Opening temperature of thermostat

7.25 +/- 0.1.5 psi (0.5 +/- 0.1 bar) 157 – 163 °F (69.5 – 72.5 °C)

Thermal switch Firing order

225 – 235 °F (107 – 113 °C) 1-3-4-2-1

Direction of rotation

Counter-clockwise (as seen from the flywheel)

Starting aid Max. inclined position (engine no longer supplied with oil): Exhaust values according to

918175/AP0605

Intake manifold (pre-heating time 10 – 15 sec) 25°/46% in all directions NOTE: this is exceeded by the machine’s theoretical climbing ability (30°/58%) 97/68/EC Tier II EPA Tier II

2-1

Specifications Capacities Capacities Fuel tank

22 gal. (83 L)

Engine oil (max./effect.)1

10.7 qts. /4.7 qts. (10.2 L/4.5 L)

New engine oil (no oil)

10.7 qts. (10.2 L)

Oil Change (w/filter)

8.2 qts. (7.8 L)

Oil Change (wo/filter)

4.7 qts. (4.5 L)

Total Coolant

7.4 qts. (7.0 L)

Coolant (without radiator)

4.5 qts. (4.2 L)

Radiator

3.5 qts. (3.3L)

Expansion tank

1.6 qts (1.5 L)

1.

max: Oil quantity up to oil dipstick max mark effect\: Oil quantity between min and max oil dipstick marks

Overview of capacities: – see Fluids and lubricants on page 3-23 Engine Tightening Torques Tightening torques

2-2

Cylinder-head bolt Connecting rod bearing screw

80-83 lbf-ft (103.1 – 112.9 Nm) M11x1.25 41-44 lbf-ft (55.0 – 60.0 Nm) M10x1

Main bearing screw Flywheel screw

81-89 lbf-ft (110.0 – 120.0 Nm) M11x1.25 140-155 lbf-ft (190.0 – 210.0 Nm) M14x1.5

918175/AP0605

Specifications 2.3

Hydraulic system Hydraulic system Twin variable displacement + twin gear pump 0.12 x 1.7 + 1.3 + 0.27 in³ (2 x 28 + 21 + 4.5 cm³) PVD-2B44BP-16G5-4713F 2 x 15.1 gpm + 10.9 gpm + 3.0 gpm (2 x 57 L/min + 41.4 L/min + 11.6 L/min) at 2590 RPM 11 sections/12 sections (3rd control circuit)/ 13 sections (triple articulation boom control) 3553±73 psi (245±5 bar) 3553±44 psi (245±3 bar)

Pump

Flow rate Control valve Max. service pressure Main pressure limiting valve P1, P2 Main pressure limiting valve P3

3480±44 psi (240±3 bar)

Secondary pressure limiting valve for main valve block Main pressure limiting valve for pilot control pressure

3988-0/+7 psi (275-0/+0.5 bar) @ 20 l/min 609±15 psi (42±1 bar)

Main pressure limiting valve for swivel drive (hydraulic motor pressure restriction)

3118 psi (215 bar) Standard 22 gals. (83 L)

Hydraulic oil cooler Hydraulic tank capacity 2nd speed shift pressure Gear motor braking deceleration time

2611 psi (180 bar) 3.7±1.2 sec @122 °F (50 °C) oil temperature

Circulation pressure P1 Circulation pressure P2

239 psi (16.5 bar) 290 psi (20 bar)

Circulation pressure P3

355 psi (24.5 bar)

Auxiliary hydraulics oil flow* Pressure

P2 + P3

P2

217 psi (15 bar)

28 gpm (105 Lpm)

16 gpm (61 Lpm)

580 psi (40 bar)

27.5 gpm (104 Lpm)

15.75 gpm (60 Lpm)

870 psi (60 bar) 1325 psi (90 bar)

27 gpm (102.5 Lpm) 26.5 gpm (100 Lpm)

15.75 gpm (60 Lpm) 15.5 gpm (59 Lpm)

1740 psi (120 bar) 2175 psi (150 bar)

26 gpm (98 Lpm) 23 gpm (87 Lpm)

15.25 gpm (58 Lpm) 15 gpm (57 Lpm)

2611 psi (180 bar) 3046 psi (210 bar)

20 gpm (75 Lpm) 17 gpm (65 Lpm)

14.75 gpm (56 Lpm) 14.5 gpm (55 Lpm)

3481 psi (240 bar)

7 gpm (27 Lpm)

13.25 gpm (50 Lpm)

* Output specifications for auxiliary hydraulics with unpressurized return line

Screwable hose burst valve Location Dozer blade

918175/AP0605

Thread

Gap dimension

1/2"

0.05 in. (1.2 mm)

2-3

Specifications 2.4

Undercarriage/swivel unit Undercarriage/swivel unit 1.7/3.0 mph (2.76/4.76 km/h)

2 speed ranges

15.75 in. (400 mm)

Track width

5

No. of track rollers on either side Ground clearance

11.5 in. (290 mm)

Ground pressure

4.7 psi (0.33 kg/cm²) 9 rpm

Upper carriage swivel speed

2.5

Dozer blade Dozer blade 78.3/16.8 in. (1990/425 mm) 15.4/15.8 in. (390/400 mm)

Width/height Max. lift over/under subgrade

2.6

Electrical system Alternator Starter

12-V, 55- A 12-V, 2.3- kW

Battery Socket

12-V, 88-Ah 15-A max. - Cigarette lighter

Fuse box in instrument panel

F3 F4

2-4

F5

F6

F7

F8

F9

F10

918175/AP0605

Specifications Fuse No.

Rated Current

Protected Circuit

F3

10 Amp

Indicators, cut-off solenoid, relays

F4

10 Amp

Boom light

F5

15 Amp

Roof lights

F6

10 Amp

Valves, horn

F7

15 Amp

Heating, air conditioning

F8

10 Amp

Windshield wiper, interior light

F9

10 Amp

Rotating beacon, radio

F10

15 Amp

Socket, cigarette lighter

F4

10 Amp

Boom light

Main fuse box with relays (located under cab)

918175/AP0605

Fuse No. F1

Rated Current 40 Amp

Protected Circuit Star, pre-heat, cut-off solenoid

F2

50 Amp

Main fuse, ignition lock

Relay No. K9

Protected Circuit Cut-off solenoid

K5

Pre-heating

2-5

Specifications Relays - (located under cab)

K7

V1

K6

2.7

K8

Relay No. K6

Protected Circuit Pre-heating timer

K7 K8

Starting relay Cut-off solenoid

V1

Diode

Sound levels Sound Power

97 dB(A)

Sound Pressure

77 dB(A)

Note: Measurement of sound power level according to EC Directive 2000/14/EC. Sound level in the cab measured according to EC Directives 84/532/EEC, 89/514/EEC and 95/27/EEC. Measurements performed on asphalted surface.

2-6

918175/AP0605

Specifications 2.8

2.9

Fluid capacities Engine oil

8.2 qts. (7.8 L)

Travelling drive gearbox oil

Approx. 1.4 qts. (1.3 L)

Hydraulic oil tank

21.1 gal (80 L)

Diesel fuel tank

20.6 gal (78 L)

Engine coolant

7.4 qts. (7.0 L)

Windshield washer

2.1 qts. (2.0 L)

Coolant compound table Outside temperature Up to °C 4 -10 -20 -25 -30

Water % by volume 99 79 65 59 55

Coolant Anti-corrosion agent

Antifreeze agent

cm³/L

% by volume

% by volume

1

– 20 34 40 44

10

2.10 Specific tightening torques Live ring * Track roller * Drive pinion * Travel drive * Gear motor * Angled engine bracket Engine mounting Pump mounting Pump Swivel joint *

M14 10.9 M16 10.9 M14 10.9 M14 10.9 M16 10.9 M10 8.8 M10 8.8 M10 8.8 M12 10.9 M10 10.9

133 lbf-ft (180 Nm) 203 lbf-ft (275 Nm) 133 lbf-ft (180 Nm) 133 lbf-ft (180 Nm) 203 lbf-ft (275 Nm) 33 lbf-ft (45 Nm) 33 lbf-ft (45 Nm) 37 lbf-ft (50 Nm) 58 lbf-ft (79 Nm) 47 lbf-ft (64 Nm)

* All connections with an * must be glued with Loctite S2420 or VaryBond 12-43.

918175/AP0605

2-7

Specifications 2.11 General tightening torques Note: Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise.

Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Identification aid outside Ø

M10X1.0

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (10 mm)

M12X1.5

15 (20)

18 (25)

18 (25)

18 (25)

0.5 in. (12 mm)

M14X1.5

26 (35)

33 (45)

26 (35)

26 (35)

0.6 in. (14 mm)

M16X1.5

33 (45)

41 (55)

30 (40)

37 (50)

0.6 in. (16 mm)

M18X1.5 M22X1.5

41 (55) 48 (65)

52 (70) 92 (125)

33 (45) 44 (60)

52 (70) 92 (125)

0.7 in. (18 mm) 0.9 in. (22 mm)

M27X2.0 M33X2.0

66 (90) 111 (150)

133 (180) 229 (310)

74 (100) 118 (160)

107 (145) 155 (210)

1.0 in. (27 mm) 1.3 in. (33 mm)

M42X2.0 M48X2.0

177 (240) 214 (290)

332 (450) 398 (540)

155 (210) 192 (260)

266 (360) 398 (540)

1.7 in. (42 mm) 1.9 in. (48 mm)

G1/8A G1/4A

7 (9) 26 (35)

13 (18) 26 (35)

11 (15) 22 (30)

13 (18) 26 (35)

0.4 in. (9.73 mm) 0.5 in. (13.16 mm)

G3/8A G1/2A

33 (45) 48 (65)

52 (70) 66 (90)

33 (45) 41 (55)

37 (50) 48 (65)

0.7 in. (16.66 mm) 0.8 in. (20.96 mm)

G3/4A G1A

66 (90) 111 (150)

133 (180) 229 (310)

74 (100) 118 (160)

103 (140) 140 (190)

1.0 in. (26.44 mm) 1.3 in. (33.25 mm)

G1 1/4A G1 1/2A

177 (240) 214 (290)

332 (450) 398 (540)

155 (210) 192 (260)

266 (360) 398 (540)

1.7 in. (41.91 mm) 1.9 in. (47.80 mm)

Thread

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) Non-return valve Identification aid Thread with elastic seal outside Ø Sealing washer Elastic seal O-ring M12X1.5

15 (20)

26 (35)

26 (35)

26 (35)

0.5 in. (12 mm)

M14X1.5 M16X1.5

26 (35) 33 (45)

41 (55) 52 (70)

33 (45) 41 (55)

33 (45) 41 (55)

0.6 in. (14 mm) 0.6 in. (16 mm)

M18X1.5 M20X1.5

41 (55) 41 (55)

66 (90) 92 (125)

52 (70) 59 (80)

52 (70) 74 (100)

0.7 in. (18 mm) 0.8 in. (20 mm)

M22X1.5 M27X2.0

48 (65) 66 (90)

100 (135) 133 (180)

74 (100) 125 (170)

92 (125) 100 (135)

0.9 in. (22 mm) 1.0 in. (27 mm)

2-8

918175/AP0605

Specifications M33X2.0

111 (150)

229 (310)

229 (310)

155 (210)

1.3 in. (33 mm)

M42X2.0

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (42 mm)

M48X2.0

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (48 mm)

G1/8A G1/4A

26 (35) 33 (45)

41 (55) 59 (80)

33 (45) 44 (60)

33 (45) 44 (60)

0.5 in. (13.16 mm) 0.7 in. (16.66 mm)

G3/8A

48 (65)

85 (115)

55 (75)

74 (100)

0.8 in. (20.96 mm)

G1/2A

66 (90)

133 (180)

125 (170)

107 (145)

1.0 in. (26.44 mm)

G3/4A

111 (150)

229 (310)

229 (310)

192 (260)

1.3 in. (33.25 mm)

G1A

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (41.91 mm)

G1 1/4A

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (47.80 mm)

With coarse-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8 10.9 12.9

Threads according to DIN 7984 8.8 10.9

M5 M6

4.1 (5.5) 7 (10)

6 (8) 10 (14)

7 (10) 13 (17)

4 (5) 6.3 (8.5)

5 (7) 9 (12)

M8 M10

18 (25) 33 (45)

26 (35) 48 (65)

31 (42) 59 (80)

15 (20) 30 (40)

22 (30) 44 (59)

M12 M14

64 (87) 100 (135)

81 (110) 133 (180)

108 (147) 170 (230)

51 (69) 81 (110)

74 (100) 118 (160)

M16 M18

155 (210) 207 (280)

203 (275) 302 (410)

258 (350) 354 (480)

125 (170) 181 (245)

184 (250) 254 (345)

M20 M22

302 (410) 406 (550)

420 (570) 575 (780)

509 (690) 686 (930)

251 (340) 339 (460)

361 (490) 487 (660)

M24 M27

524 (710) 767 (1040)

738 (1000) 1092 (1480)

878 (1190) 1305 (1770)

435 (590) 642 (870)

620 (840) 922 (1250)

M30

1047 (1420)

1482 (2010)

1770 (2400)

885 (1200)

1254 (1700)

With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M8X1.0

18 (25)

27 (37)

32 (43)

16 (22)

24 (32)

M10X1.0 M10X1.25

37 (50) 36 (49)

55 (75) 52 (71)

65 (88) 61 (83)

32 (43) 31 (42)

48 (65) 46 (62)

M12X1.25 M12X1.5

64 (87) 61 (83)

96 (130) 92 (125)

111 (150) 107 (145)

55 (75) 53 (72)

81 (110) 77 (105)

M14X1.5 M16X1.5

100 (135) 155 (210)

148 (200) 229 (310)

173 (235) 266 (360)

89 (120) 133 (180)

129 (175) 195 (265)

M18X1.5 M20X1.5

232 (315) 325 (440)

332 (450) 465 (630)

391 (530) 538 (730)

199 (270) 277 (375)

284 (385) 391 (530)

M22X1.5 M24X2.0

435 (590) 546 (740)

620 (840) 789 (1070)

723 (980) 922 (1250)

369 (500) 465 (630)

524 (710) 664 (900)

M27X2.0 M30X2.0

811 (1100) 1106 (1500)

1143 (1550) 1586 (2150)

1328 (1800) 1844 (2500)

679 (920) 959 (1300)

959 (1300) 1364 (1850)

918175/AP0605

2-9

Specifications 2.12 Dimensions 13’0” (3967 mm)

8’5” (2570 mm)

8’5” (2570 mm)

4’9” (1465 mm)

1’5” (425 mm)

10’9” (3280 mm)

8’2” (2500 mm) 19’2” (5800 mm)

2’5” (745 mm)

1’9” (535 mm)

75° 51 °

(14 R4’ 65 9” mm )

6’6” (1990 mm)

2-10

1’3” (400 mm)

3’10” (1190 mm) 6’6” (1990 mm)

General Specifications Weight 12,566 lbs. (5700 kg) Height 8’5” (2570 mm) Width 6’6” (1990 mm) Transport length 19’0” (5800 mm) Dipper arm length (Standard Arm) 5’6” (1685 mm) Dipper arm length (Optional Long Arm) 6’6” (1985 mm) Max. digging depth w/ Standard Arm 12’7” (3845 mm) Max. digging depth w/ Optional Long Arm 13’7” (4140 mm) Max. vertical digging depth w/ Standard Arm 9’4” (2855 mm) Max. vertical digging depth w/ Optional Long Arm 10’3” (3135 mm) Max. digging height w/ Standard Arm 18’6” (5660 mm) Max. digging height w/ Optional Long Arm 19’2” (5850 mm) Max. dump height w/ Standard Arm 13’1” (3995 mm) Max. dump height w/ Optional Long Arm 13’8” (4185 mm) Max. digging radius w/ Standard Arm 20’ 4” (6210 mm) Max. digging radius w/ Optional Long Arm 21’3” (6490 mm) Max. reach at ground level w/ Standard Arm 19’11” (6090 mm) Max. reach at ground level w/ Optional Long Arm 20’11” (6380 mm) Max. breakout force at bucket tooth 8,925 lbf (39.7 kN) Max. tearout force (Standard Arm) 6,317 lbf (28.1 kN) Max. tearout force (Optional Long Arm) 5,642 lbf (25.1 kN) Min. tail end slewing radius 4’9” (1465 mm) Max. tail end lateral projection over tracks 1’6” (470 mm) Max. boom distance to bucket center (right-hand side) 2’5” (745 mm) Max. boom distance to bucket center (left-hand side) 1’9” (535 mm) Max. boom slew angle (left-hand side) 75° Max. boom slew angle (right-hand side) 51°

918175/AP0605

Specifications 2.13 Lift Capacities Lift Capacity Table (with short dipper arm) 16'3" (5.0 m)

13'0" (4.0 m)

9'9" (3.0 m)

6'6" (2.0 m)

3'3" (1.0 m)

0'0" (0.0 m)

13’0” (4.0 m)

16'3" (5.0 m) 13'0" (4.0 m)

9’9” (3.0 m)

6’6” (2.0 m)

A

9'9" (3.0 m)

B

6'6" (2.0 m) 3'3" (1.0 m)

0'0" (0.0 m) -3'3" (-1.0 m) -6'6" (-2.0 m) -9'9" (-3.0 m) -13'0" (-4.0 m) 16'3" (5.0 m)

13'0" (4.0 m)

9'9" (3.0 m)

6'6" (2.0 m)

3'3" (1.0 m)

0'0" (0.0 m)

13’0” (4.0 m) 9’9” (3.0 m) 6’6” (2.0 m) 3’3” (1.0 m) 0’0” (0.0 m) -3’3” (-1.0 m) -6’6” (-2.0 m)

2,337* (1060*) 2,260* (1025*) 2,304* (1045*) 2,403* (1090*) 2,524* (1145*) 2,668* (1210*) 2,767* (1255*)

1,786 (810) 1,290 (585) 1,080 (490) 1,003 (455) 1,014 (460) 1,135 (515) 1,554 (705)

2,227* (1010*) 2,612* (1185*) 3,120* (1415*) 3,428* (1555*) 3,329* (1510*)

1,720 (780) 1,609 (730) 1,477 (670) 1,378 (625) 1,345 (610)

3,483* (1580*) 4,905 (2225*) 5,368* (2435*) 5,049* (2290*) 3,924* (1780*)

2,535 (1150) 2,183 (990) 2,028 (920) 2,017 (915) 2,094 (950)

8,973* (4070*) 6,614* (3000*)

3,946 (1790) 4,101 (1860)

Maximum permissible load on extended dipper arm A Overhang from the center of the turntable.

B Height of load fixing point * Lifting capacity hydraulically limited.

All table values are in lbs. (kg) and for a machine in a horizontal position on firm ground without bucket.

With the dozer blade in driving direction

Without the dozer blade, 90° to driving direction

Calculation basis: According to ISO 10567.

The excavator's lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilizing features.

Neither 75% of the static tilt load nor 87% of the hydraulic lift capacity is exceeded.

918175/AP0605

2-11

Specifications Lift Capacity Table (with extended dipper arm)

A

16’ 3" (5.0 m)

MAX

13’ 0" (4.0 m)

9’ 9" (3.0 m)

6’ 6" (2.0 m)

B

Fig. 1:

Lift capacity table

13’ (4.0 m) 9’, 9" (3.0 m) 6,’ 6" (2.0 m) 6’, 3" (1.0 m) 13’ (0.0 m) 13’ (-1.0 m) 13’ (-2.0 m)

2623 2183 (1190*) (990)

2315 (1050*)

1907 (865)

2623 1411 (1190*) (640)

2496 (1120*)

2326 (1055)

2469 628 (1120*) (285)

2745 (1245*)

1576 (715)

3032 (1375*)

2392 (1085*)

3682 (1670*)

3682 (1670*)

2899 1168 (1265*) (530)

3042 (1380*)

1598 (725)

3726 (1690*)

2271 (1030)

5292 (2400*)

3461 (1570)

3031 1290 (1315*) (585)

3274 (1485*)

1554 (705)

4244 (1925*)

2161 (980)

6184 (2805*)

3230 (1465)

1387 (1990*)

2105 (955)

6294 (2855*)

3142 (1425)

10075 6140 (4570*) (2785)

5688 (2580*)

3175 (1440)

8774 (3980)

1466 1466 (1375*) (665) 1819 1819 (1425*) (825)

6173 (2800)

Maximum permissible load on extended dipper arm A Reach from live ring center B

Load hook height

*

Lift capacity limited by hydraulics

All table values are in lbs. (kg) and for a machine in a horizontal position on firm ground without bucket.

With the dozer blade in driving direction

Without the dozer blade, 90° to driving direction If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement dead weight.

Calculation basis: according to ISO 10567 The track excavator's lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilizing features.

Neither 75% of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.

2-12

918175/AP0605

Specifications Lift Capacity Table (with counterweight)

A

16’3" (5.0 m)

MAX

13’,0" (4.0 m)

9’,9" (3.0 m)

6’,6" (2.0 m)

B

Fig. 2:

Lift capacity table

13’ (4.0 m) 9’,9" (3.0 m) 6,’6" (2.0 m) 6’, 3" (1.0 m) 13’ (0.0 m) 13’ (-1.0 m) 13’ (-2.0 m)

2888 (1310*)

2590 (1175)

2745 (1245*)

2745 (1245*)

2866 (1300*)

2061 (935)

2789 (1265*)

2789 (1265*)

2910 (1320*)

1830 (830)

2932 (1330*)

1995 (905)

3285 (1490*)

2789 (1265)

4156 4156 (1885*) (1885*)

2998 (1360*)

1753 (795)

3164 (1435*)

1940 (880)

3913 (1775*)

2657 (1205)

5766 (2615*)

3957 (1795)

3109 (1410*)

1786 (810)

3296 (1495*)

1874 (850)

4343 (1970*)

2546 (1155)

6548 (2970*)

3781 (1715)

3230 (1465*)

1973 (895)

4332 (1965*)

2513 (1140)

6445 (2910*)

3737 (1695)

11045 7165 (5010*) (3250)

3296 (1495*)

2491 (1130)

6504 (2450*)

3792 (1720)

8830 7297 (4005*) (3310)

Maximum permissible load on extended dipper arm A Reach from live ring center B

Load hook height

*

Lift capacity limited by hydraulics

All table values are in lbs. (kg) and for a machine in a horizontal position on firm ground without bucket.

With the dozer blade in driving direction

Without the dozer blade, 90° to driving direction If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement dead weight.

Calculation basis: according to ISO 10567 The track excavator's lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilizing features.

Neither 75% of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.

918175/AP0605

2-13

Specifications Lift Capacity Table (with extended dipper arm and counterweight)

A

16’ 3" (5.0 m)

MAX

13’ 0" (4.0 m)

9’ 9" (3.0 m)

6’ 6" (2.0 m)

B

Fig. 3:

Lift capacity table

13’ (4.0 m) 9’, 9" (3.0 m) 6,’ 6" (2.0 m) 6’, 3" (1.0 m) 13’ (0.0 m) 13’ (-1.0 m) 13’ (-2.0 m)

2623 (1190*)

2491 (1130)

2315 (1050*)

2282 (1035)

2623 (1190*)

1676 (760)

2469 (1120*)

2469 (1120*)

2690 (1220*)

871 (395)

2745 (1245*)

1863 (845)

3031 (1375*)

2756 (1250)

3682 3682 (1670*) (1670*)

2789 (1265*)

1411 (640)

3042 (1380*)

1874 (850)

3726 (1690*)

2646 (1200)

5241 (2400*)

3340 (1515)

2899 (1315*)

1543 (700)

3274 (1485*)

1841 (835)

4244 (1925*)

2524 (1145)

6184 (2805*)

3770 (1710)

3031 (1375*)

1731 (785)

4387 (1990*)

2469 (1120)

6294 (2855*)

3682 (1670)

10075 7143 (4570*) (3240)

3142 (1425*)

2138 (970)

5688 (2580*)

3715 (1685)

8774 7187 (3980*) (3260)

Maximum permissible load on extended dipper arm A B

Reach from live ring center Load hook height

*

Lift capacity limited by hydraulics

All table values are in lbs. (kg) and for a machine in a horizontal position on firm ground without bucket.

With the dozer blade in driving direction

Without the dozer blade, 90° to driving direction If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement dead weight.

Calculation basis: according to ISO 10567 The track excavator's lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilising features.

Neither 75% of the static tilt load nor 87% of the hydraulic lift capacity is exceeded.

2-14

918175/AP0605

Specifications 2.14 Geometry E

Pin diameter

2 in. (50 mm)

F

dipper arm width

736 in. (195 mm)

L

Pin distance to bucket mount

9.4 in. (240 mm)

Bucket

dipper arm

Bucket

918175/AP0605

2-15

Specifications Heavy Duty Buckets Bucket (Include Esco Teeth)

Capacity

Approx. Weight

12 in. (304 mm)

2.5 cu. ft. (0.07 m3)

81 lbs. (37 kg)

16 in. (406 mm)

3.3 cu. ft. (0.09 m3)

150 lbs. (68 kg)

20 in. (508 mm)

3.7 cu. ft. (0.10 m3)

165 lbs. (75 kg)

26 in. (660 mm)

3

6.4 cu. ft. (0.18 m )

209 lbs. (95 kg)

33 in. (304 mm)

8.8 cu. ft. (0.25 m

3)

240 lbs. (109 kg)

48 in. (1219 mm) Ditching

5.9 cu. ft. (0.17 m3)

386 lbs. (175 kg)

48 in. (1219 mm) Tilting

5.9 cu. ft. (0.17 m3)

530 lbs. (240 kg)

✔ Implement designed for this excavator model (optimal excavation output) 1. Implement can be mounted but may be subject to restrictions regarding excavation forces, dump-in/out angles and productivity due to possibly reduced bucket volumes 2. Same restrictions as for 1 but in addition, mounting these implements may impair machine stability.

X Same restrictions as for 1 and 2 but in addition, subject to possible collision with the boom cylinder

2-16

918175/AP0605

Maintenance

3

Maintenance

3.1

General information care and servicing

WARNING! • Instruction is necessary before operating or servicing the machine. Read and understand this entire manual. Follow warnings and instructions for operation and maintenance. Check for correct function after adjustments or maintenance. Failure to follow instructions can result in serious injury.

• Be sure you are familiar with all safety devices and controls before operating or servicing the machine. Know how to stop before starting. This machine is designed for use only with Mustang approved accessories or attachments. The Mustang Company cannot be responsible for safety if the unit is used with non-approved attachments.

• Hydraulic reservoir is under pressure. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin and eyes.

Care and servicing Care and servicing have a significant influence on the readiness for operation and service life of the machine.

Before performing service and maintenance, always read, understand and follow the instructions provided in: •

The "Safety Instructions" section in the operator’s manual.

•

All associated attachment operator’s manuals.

For additional service information about the engine, see the engine manual provided with the machine.

Use of lubricants that do not correspond to the manufacturer’s recommendations may invalidate warranty claims.

More frequent servicing, other than the recommended intervals, may be required under extreme operational conditions (extremely dusty or hot conditions).

Always dispose of waste lubrication oils and hydraulic fluids according to local regulations or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.

DO NOT power wash the main hydraulic pumps and controls, throttle solenoids and sealed bearings. High pressure water can be forced through seals and trapped within these components, causing premature failure.

The operating pressure settings of the hydraulic system should only be adjusted by trained, qualified personnel. If malfunctions are caused by unauthorized alteration of operating pressure settings, all warranty responsibilities of the manufacturer are invalidated.

918175/AP0605

3-1

Maintenance Maintenance safety

3-2

•

Never service the machine without reading the applicable instructions.

•

Always lower bucket and dozer blade to the ground before performing any maintenance.

•

Use correct procedures to lift and support the machine. Always lift the blade fully before installing jackstands.

•

Keep engine cover and hydraulic valve cover closed except for service.

Close and latch covers before operating the machine.

•

Be sure to have the work area properly ventilated when grinding or welding parts. Wear a dust mask.

•

Exhaust fumes can kill. Exhaust system must be tightly sealed. If working in an enclosed area, vent exhaust to outside when engine must be run for service.

•

Never modify equipment or add attachments not approved by the Mustang Company.

•

Stop the engine and let it cool, then clean engine of any flammable materials before checking fluid levels.

•

Never service or adjust machine with the engine running unless the service procedure requires it.

•

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin and eyes. NEVER use your hands to search for hydraulic fluid leaks; use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin and cause serious injury. If any fluid is injected into your skin, see a doctor immediately. Injected fluid MUST be surgically removed by a doctor familiar with this procedure or gangrene may result.

•

Never fill fuel tank with engine running, while smoking or when near open flame.

•

Keep body, jewelry and clothing away from moving parts, electrical contacts, hot parts and exhaust.

•

Wear eye protection when servicing the machine.

•

Lead acid batteries produce flammable and explosive gas. Keep arcs, sparks, flames and lighted tobacco away from batteries.

•

Batteries contain acid which burns eyes and skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact, flush well with water and get immediate medical attention.

918175/AP0605

Maintenance 3.2

Maintenance decal symbols

Symbol

918175/AP0605

Assembly

Explanation

General

Visual check

General

Grease instructions

Fuel system

Drain condensation water

Fuel system

Replace the fuel filter, clean the fuel pre-filter

Radiator

Check the coolant level

Radiator

Replace coolant

Engine

Check valve tip clearance; adjust if necessary

Engine

Check the engine oil level

Engine

Replace engine oil

Engine

Replace the oil filter

Engine

Check V-belt tension

Travelling drive

Change oil

Travelling drive

Check oil

Undercarriage

Check track tension

Hydraulic system

Check oil level

Hydraulic system

Change hydraulic oil

Hydraulic system

Replace the hydraulic oil filter, replace the breather filter

3-3

Maintenance Symbol

3.3

Assembly

Explanation

Radiator fins

Clean

Heating, air conditioning

Change the recirculating air filter

Maintenance decal

Fig. 1: Maintenance decal

3-4

918175/AP0605

Maintenance 3.4

Maintenance schedule

Check, clean or inspect Service Activity

Daily

Every 50 Hours

Every 250 Hours

Every 500 Hours

Every 1000 Hours

Customer

Engine oil level

x

x

Engine coolant level

x

x

Hydraulic oil level

x

Gearbox oil level

Dealer

x x

Clean water ducts

x

x

x

x

Check engine/hydraulic oil radiator and air conditioning for contamination. Clean if necessary.

x

x

x

x

Check cooling system, heating and hoses for leaks and pressure (visual check)

x

x

x

x

Replace cab air filter for heating and air conditioning

x

Air filter (damage)

x

Inspect water separator prefilter: drain water

x

x x x

Clean water separator

x

Check V-belt condition and tension

x

Check exhaust system for damage

x

x x x

Check engine valve clearance, set if necessary

x

x

Fuel injection pump, injection and pressure, injection nozzles and valves

x

x

Empty diesel fuel tank

x

Check battery electrolyte. Fill with distilled water as necessary

x

x x

Check alternator, starter and electrical connections, bearing play and function

x

x

Preheating system and electrical connections

x

x

Air filter contamination gauge

x

x

Pressure check or primary pressure relief valves

x

x

Check tracks for cracks or cuts

x

x

Check track tension. Adjust as necessary

x

x

Bearing play on tread rollers, track carrier rollers and front idlers Check cylinders piston rods for damage

x x

x x

Check screws for tightness

x

Pin lock (bucket stick and attachment)

x

Hydraulic line clamps

x

x x x

Check indicator lights for correct function

x

x

x

Cab tilt lock components

x

x

x

Couplings, dirt build up on the hydraulic system dust caps

x

Insulating mats in the engine compartment Grease supply of the central lubrication system

918175/AP0605

x

x

x

x

x

Warning decals and operation in place Engine cover gas strut

x

x

x x x x

3-5

Maintenance Fluid and filter changes Service Activity

Daily

Every 50 Hours

Every 250 Hours

Engine oil

x*

x

Engine oil filter

x*

x

Fuel filter

x*

Every 500 Hours

Every 1000 Hours

Customer

Dealer x x

x

x

Air filter element when indicator light comes on

x

Engine coolant

x

Hydraulic oil filter insert

x*

x

x

Hydraulic oil

x

x

Breather-hydraulic oil tank Gearbox oil

x*

x x

x

x

x

*1st engine oil change only

Air conditioning Service Activity

Daily

Test air conditioning function

Every 50 Hours

Every 250 Hours

x

Replace cab air filter Check dehumidifier for corrosion

Every 500 Hours

Every 1000 Hours

Customer

x

x

x

x

x

Replace dehumidifier

x

Replace compressor oil

x

Dealer

x x

x

x

x

x

Every 500 Hours

Every 1000 Hours

Functional check Service Activity

Daily

Lights, signaling system, audible warning system

Every 50 Hours

Every 250 Hours

Customer

x

Air cleaner dust valve

x

Heating function

x

Dealer x

x

x

Leakage check Service Activity

Daily

Every 50 Hours

Every 250 Hours

Every 500 Hours

Every 1000 Hours

Customer

Engine and hydraulic system components

x

x

Cooling and heating circuit components

x

x

Traveling drive components

x

x

3-6

Dealer

918175/AP0605

Maintenance Lubrication (see Fig. 2) Service Activity

Daily

Dozer blade

Every 50 Hours

Every 250 Hours

Every 500 Hours

Every 1000 Hours

x

Customer x

Swiveling console

x

x

Boom

x

x

Dipper arm

x

x

Attachments

x

x

Chassis (front of undercarriage)

3.5

x

Dealer

x

General Maintenance Cleaning Cleaning the machine is divided into three separate areas: • Cab interior

• Machine exterior • Engine compartment For safety and health reasons, follow the following cleaning instructions: Washing solvents

• Ensure adequate room ventilation.

• Wear suitable protective clothing.

• Do not use flammable liquids, such as gasoline or diesel fuel.

Compressed air

• Work carefully.

• Wear goggles and protective clothing.

• Do not aim the compressed air at the skin or at other people.

• Do not use compressed air for cleaning your clothing.

When using a high-pressure cleaner or steam jet

• Electric components and damping material must be covered and not directly exposed to the jet.

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

• Additionally, protect the following components from moisture: • Engine.

• Electric components such as the alternator, etc.

• Control devices and seals.

• Air intake filters, etc.

When using volatile and easily flammable anti-corrosion agents and sprays:

• Ensure adequate room ventilation.

• Do not use unprotected lights or open flames.

• Do not smoke!

918175/AP0605

3-7

Maintenance Cab interior

CAUTION! Never use high-pressure cleaners, steam jets or high-pressure water to clean inside the cab. Water under high pressure may penetrate into the electric systems, cause short circuit, damage seals, and disable controls.

The following items are recommended for cleaning the cab interior:

• Broom • Vacuum cleaner • Damp cloth • Bristle brush • Water and mild soap solution Cleaning the seat belt:

• Clean the seat belt with only a mild soap solution; do not use chemical agents because they may destroy the seatbelt fabric.

Exterior of the machine

The following items are suitable for cleaning the cab exterior:

• High-pressure cleaner • Steam jet Engine compartment

Important!

Switch off the engine and allow it to cool before spraying the machine with a high-pressure cleaner or steam jet.

Important!

When cleaning the engine with a water or steam jet, do not point the jet directly at electric sensors such as the oil pressure switch. Humidity penetrating electric sensors will cause them to fail and lead to engine damage.

Screw connections, attachments, pivots and hinges Screw connections and attachments All screw connections must be checked regularly for tightness, even those not listed in the maintenance schedules. Tighten loose connections immediately.

Pivots and hinges All mechanical pivot points on the machine (e.g., door hinges, joints) and fittings (e.g., door arresters) must be lubricated regularly.

3-8

918175/AP0605

Maintenance 3.6

Lubrication D

D

D

D D D

D D

D D

W

W W

W W

W

W

D = Daily W = Weekly Fig. 2: Lubrication points

918175/AP0605

3-9

Maintenance Lubrication strip Apply grease to the lubrication strip as follows:

1. Lubrication point (A) for the offset cylinder C

A

2. Lubrication point (B) for the live ring

Important!

Apply grease to lubrication points A and B daily.

B A portable lamp can be connected to the lubrication strip's 12 V connection C. Fig. 3: Lubrication strip on the chassis

Important!

See Fluids and lubricants on page 3-23 for lubricant specifications.

3.7

Engine Important!

Be sure to read the engine manual supplied with the machine.

Checking engine oil level

Important!

See Fluids and lubricants on page 3-23 for engine oil grade. Only use engine oil specified, or equivalent quality and grade, or damage to the engine could occur.

To check the engine oil, the machine must be on a level surface and the engine turned off.

1. Run the engine until it reaches operating temperature, then stop the engine.

2. Pull the engine cover latch lever (located beneath the operator’s seat) and raise the engine cover.

3. Check the engine oil level using the dipstick (1) located at front of the engine.

See Fig. 4.

4. Add oil if required through the oil filler neck (3). See Fig. 4.

3-10

918175/AP0605

Maintenance

3 max min

1

2

Fig. 4: Oil Dipstick and Filter Locations

Note: The marks on the dipstick indicate the minimum and maximum oil levels.

3.8

Changing engine oil and filter 1. Place the machine on a level surface. Run the engine until it is at operating temperature, then turn off the engine.

2. Pull the engine cover latch handle (located beneath the operator’s seat) and raise the engine cover.

3. Position waste oil collection container under engine oil pan.

4. Remove the drain plug from the oil pan and allow oil to drain into waste oil collection container.

5. Remove the oil filter, using a filter wrench as necessary. See (2) Fig. 4.

6. Clean the filter housing surface. Put a film of clean oil on the filter gasket.

Install the new filter with gasket and hand tighten.

7. Reinstall the drain plug.

8. Remove the oil fill cap from the engine. Pour in new oil. Crankcase capacity (including the oil filter) is 8.2 qts. (7.8 L). DO NOT fill crankcase above the MAX mark on the dipstick.

9. Reinstall oil filler cap.

10. Start the engine and let it run for several minutes. Watch the engine oil light on the control panel. The light should turn off after several seconds. If it does not, shut off engine and determine cause.

11. Stop the engine and check for leaks at the oil filter and oil drain plug.

12. Check the oil level again and add oil if necessary.

918175/AP0605

3-11

Maintenance 3.9

Air cleaner service Note: The air filter indicator light illuminates when the air cleaner element needs to be replaced. See Instrument panel, switches and indicators on page 1-8

Important!

Filter cartridges degrade prematurely when used in acidic air. Acidic air is present in acid production facilities, steel and aluminium mills, chemical plants and other non-ferrous metal plants.

Do not clean air filter cartridges, replace them instead. never reuse a damaged air filter.

General air filter maintenance:

•

Store filters in original packaging in a dry place.

•

Do not strike the filter against other objects during installation.

•

Check air cleaner attachments, air intake hoses and air filters for damage. Repair or replace as necessary.

•

Frequently check clamps and screws at the induction manifold for tightness. Tighten as necessary.

•

Check the function of the dust valve weekly. Replace if necessary. See Dust valve functional check on page 3-13

1. The air cleaner is located under the engine cover. Press the engine cover release button and raise the engine cover.

2. Release the bow clips (1) to remove the air cleaner cover and gasket (2). See Fig. 5.

3. Carefully remove outer air cleaner element (3). See Fig. 5. Carefully remove inner air cleaner element (3). Clean air cleaner elements with 30 psi (200 kPa) compressed air from the inside. Clean all contamination (dust) from inside the upper and lower air cleaner housing and cover.

4. Replace both the inner and outer air cleaner elements when the indicator light comes on or according to the maintenance schedule.

5. Reinstall air cleaner elements (3, 4), gasket and air cleaner cover (2). Fasten bow clips (1).

6. Close and secure engine cover.

1

3

5 4

2

Fig. 5: Air Cleaner Service

3-12

918175/AP0605

Maintenance Important!

Do not knock the air filter element against a solid object to remove dust. The element may become distorted and damaged.

Do not operate engine without the air cleaner element installed or damage to the engine could occur.

Dust valve functional check Perform this check weekly.

1. Switch off the engine and allow it to cool.

2. Set the parking brake.

3. Squeeze the discharge slot of dust valve (B), Figure Fig. 6.

B

Fig. 6: Air Filter Dust Valve

3.10 Fuel system Filling the fuel tank

WARNING! Stop and cool the engine before adding fuel. NO SMOKING! Failure to this instruction can cause an explosion or fire.

The fuel level in the tank is indicated by the fuel gauge (1) on the console. See Fig. 7.

To fill the tank, remove the fuel filler cap (2) located on the left rear of the unit behind the cab by rotating the lock cover (3) and inserting the ignition key into the lock and unlocking the cap. See Fig. 7. Fill using clean diesel fuel with a cetane rating over 45. Re-install fuel cap.

918175/AP0605

3-13

Maintenance

3 2

1

Fig. 7: Fuel Gauge & Fuel Filler Cap

Important!

Never operate machine until fuel tank is completely empty. If this occurs, the fuel system will have to be bled of air. Always fill tank after use.

When using the machine in cold weather, make sure to use the proper fuel blend to prevent the fuel filters from “jelling” up. If this happens, the fuel filter and water separator elements will have to be replaced, and the fuel will have to be replaced with the proper fuel.

WARNING! Always clean up spilled fuel and oil. Keep heat, flames and sparks away from fuel and oil. Failure to use care around combustibles can cause explosion or fire, which can result in injury or death.

Fuel filter The fuel filter is located behind and below the engine cover.

1. Shut off fuel using the shut-off valve (2) on the water separator. See Figure Fig. 9.

2. Clean dirt from the housing and unscrew the fuel filter element. See FigureFig. 8.

3. Remove and discard old filter element properly.

4. Clean around the filter housing.

5. Put oil on the seal of the new filter element.

6. Install the fuel filter and hand tighten.

7. Open fuel valve.

The fuel system must be purged of air after changing the fuel filter, or if the fuel tank has been run dry – see Purging air from the fuel system on page 3-15.

3-14

918175/AP0605

Maintenance

1

Fig. 8: Fuel filter

Fuel shut-off valve, fuel pre-filter and water separator If water is seen in the plastic water separator bowl or the indicator ring rises to position (3), the bowl will need to be drained. See Fig. 9.

Note: The water separator is located behind the engine underneath the engine cover.

1. Shut off fuel using the fuel valve (2). See Fig. 9.

2. Unscrew plug (4) and collect the water that drains out of the hose. Allow water to drain until the indicator ring returns to the bottom of the water separator.

3. Tighten plug (4) and discard fuel/water according to local regulations. DO NOT pour it onto the ground or down a drain.

4. Open fuel valve.

Purging air from the fuel system

WARNING! DO NOT air bleed a hot engine. Spilled fuel can cause a fire.

The fuel system runs from the fuel tank, through the water separator, fuel filter, fuel injection pump and high pressure piping to the fuel injection nozzles. If the fuel tank has been run dry, or if the fuel filter, water separator or fuel lines have been replaced, trapped air will have to be removed, or bled, from the fuel system.

Bleed air from the fuel system according to the following steps: 1. Fill the fuel tank.

2. Make sure that the valve on the water separator valve (2) is in the “ON” position.

3. Turn the ignition key to the first position.

4. Wait about five minutes while the fuel system bleeds itself automatically.

5. Start the engine.

918175/AP0605

3-15

Maintenance If the engine runs smoothly and then stops, or if it does not run smoothly, switch off the engine and bleed the system again as described above.

2

3 4 Fig. 9: Fuel shut-off valve, fuel pre-filter and water separator

3.11 Coolant system Checking coolant level Important!

Insufficient coolant level reduces heat dissipation capacity which can lead to engine damage.

Note: Engine must be cold.

1. Pull the engine cover latch handle (located beneath the operator’s seat) and raise the engine cover.

2. Check the coolant level in the expansion reservoir. See Fig. 10.

3. If low, remove cap and overflow tube.

4. Fill reservoir to FULL line (1). Refer to the engine manual for correct coolant mixture for the engine. .

1 2 Fig. 10:Coolant expansion reservoir 3-16

918175/AP0605

Maintenance 3.12 Electrical system WARNING! Disconnect the negative battery terminal before working on the electrical system.

Fuses The fuse panel is located on the right-hand console, towards the rear, below the switches. See (1), Fig. 11.

To replace a fuse, remove the panel cover and pull the old fuse from the socket.

Install a new fuse of the same rating and re-install the fuse panel cover.

Important!

Determine what caused the fuse to blow and repair the defect.

See Electrical system on page 2-4 in the Specifications chapter for fuse identification.

1

Fig. 11:Fuse Panel

918175/AP0605

3-17

Maintenance Battery WARNING! • Batteries contain acid, which burns eyes and skin on contact. Wear safety goggles and protective clothing to keep acid off body.

• If battery acid is spilled, thoroughly rinse the affected surfaces immediately with plenty of water.

• Keep open flames and sparks away from the battery. Battery operation produces flammable/explosive gas.

• Do not interrupt the battery jump charging circuit at the battery terminals.

Sparking may result.

• Do not jump start the machine if the battery is frozen or battery electrolyte level is low. An explosion or ruptured battery may result.

•

Make sure the poles (+/-) are not reversed when jumping the battery.

• Never place tools/conductive items on the battery. A short circuit may result.

In case of acid contact, wash immediately with water for several minutes. In case of eye contact, get medical attention immediately.

The battery is located under the cab near the rear of the undercarriage. See (1) Fig. 12.

To access the battery (1), see Tilting the cab on page 1-13 to tilt and secure the cab to gain access to the battery (2).

Battery cables must be clean and tightly secured. Remove any acid or corrosion from the battery and cables using a sodium bicarbonate and water solution. Cover the battery terminals and cable ends with battery-saver grease.

Note: The battery is maintenance-free and requires no other service.

Using a booster battery (jump-starting)

WARNING! Keep arcs, sparks, and open flames away from batteries. When jump-starting from a booster battery, make the final connection (negative) to the machine frame away from the battery. A operating battery can create flammable gases.

Sparks or open flames can cause this gas, and the battery, to explode.

DO NOT jump-start or charge a frozen battery. Warm battery to 60°F (16°C) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

3-18

918175/AP0605

Maintenance

3

2

1

Fig. 12:Battery Location

Important!

Do not jump start using a running machine. High voltage spikes from a running machine can burn out glow plugs.

Important!

Damage to the alternator can occur if: •

Engine is operated with battery cables disconnected.

• Battery cables are connected when using a fast charger or when welding on the machine. When welding on the machine, remove both cables from the battery and ground the welder to machine frame near repair area.

•

Incorrectly connected booster cables.

1. Be very careful when jump starting the machine. Booster battery must be 12volt.

2. Turn ignition key to the “OFF” position.

3. Open the engine cover.

4. First, connect one end of the cable to the positive (+) terminal on the booster battery. Connect the other end of the same cable to the positive (+) terminal on the battery disconnect switch (3), on the machine you are trying to start.

See Fig. 12.

5. Connect one end of the second cable to the negative (-) terminal on the booster battery. Connect the other end of that same cable to the frame of the machine you are trying to start.

6. Start the engine. After the engine is running, remove the cable connected to the frame first. Disconnect the other cable from the battery disconnect switch (3) on the positive (+) terminal. See Fig. 12.

918175/AP0605

3-19

Maintenance Important!

DO NOT allow the cable ends to touch when removing them from the batteries. Arcs and direct short circuits can cause severe damage to the electrical system of a running machine.

Alternator

Important!

Do not test run the engine with a disconnected battery.

Replace a defective alternator immediately. An illuminated battery charge Indicator can indicate a malfunctioning alternator. See "Battery Charge Indicator" in Instrument panel, switches and indicators on page 1-8.

3.13 Checking & adjusting V-belt tension 1. Switch off engine and fold up the control lever base.

2. Open the engine cover and carefully inspect the V-belt (1) for damage. If it is damaged, replace it.

3. Press on the V-belt to check deflection. The belt deflection should be no more than 13/32” (10 mm). See Fig. 13. If deflection is more than 13/32” (10 mm), proceed to step 4.

4. Loosen adjustment bolt (2) and rotate the alternator (3) in the direction of the arrow until correct V-belt tension is established.

5. Tighten adjustment bolt (2) and re-check V-belt tension.

1

2

3 Fig. 13:Checking & adjusting V-belt tension

Checking & adjusting air conditioning V-belt tension 1. Switch off engine and fold up the control lever base.

2. Open the engine cover and carefully inspect the V-belt (1) for damage. If the V-belt (1) is damaged, replace it.

3-20

918175/AP0605

Maintenance 3. Press on the V-belt to check deflection. The belt deflection should be no more than 11/32” (9 mm). See Fig. 14. If deflection is more than 11/32” (9 mm), proceed to step 4.

4. Loosen jam nut (2) and rotate the adjustment nut (3) until the correct V-belt tension is established.

5. Tighten jam nut (2) and re-check V-belt tension. approx. 11/32” (9mm)

3

1

2

Fig. 14:Checking & Adjusting V-belt Tension

Track system Changing final drive oil 1. Position the machine on a level surface with final drive plugs positioned as shown in “Drain Position,” Fig. 15. Turn off the engine.

2. Open both plugs and drain oil into a suitable container. Re-install plugs.

3. Start the engine and move the machine slightly until plugs are positioned as shown in “Fill Position,” Fig. 15. Turn off the engine.

4. Remove both screw plugs. Pour fresh oil (Chevron Delo Gear 80W90 or BP Transgear 80W90) into the top hole until oil starts to run out of the bottom hole.

5. Re-install both plugs securely.

Environment!

Always dispose of oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.

Fig. 15:Track Final Drive Oil Change

918175/AP0605

3-21

Maintenance Checking and adjusting track tension 1. Position the machine on a level surface with mark (B), Fig. 16 of the track positioned between drive pinion (C) and the track tension roller (D).

2. Use the bucket and dozer blade to lift the machine up until tracks are just clear of the ground as shown in Fig. 17. Turn off the engine.

3. Measure the clearance at the second track roller from the drive gear. Deflection should be between 3/4”-1” (20-25 mm).

B C

D

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

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

Important!

Fig. 16:Track tension mark

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

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

5. Repeat steps 4 and 5 for the track on the other side.

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

Lifting the machine using the bucket/dozer blades

Fig. 17:Track adjustment

3-22

918175/AP0605

Maintenance 3.14 Fluids and lubricants Component/ application

Fluid

Specification

Season/temperature

Capacities1

5°F (-15°C) 113°F (+45°C)

10.8 qts. (10.2 L)

About 1.4 qts.

(1.3 L) each

Diesel engine

Engine oil

SAE 10W30 or 15W40 API classification CD (or higher, e.g., CH-4), such as BP Vanellus MG 15w40, BP Vanellus C-Extra 10W30, or Chevron Delo 400 15W40.

Final drive unit

Gearbox oil2

EP Grade conforming to API GL5, such as Chevron Delo Gear 80W90 or BP Transgear 80W90.

Year-round

ISO Viscosity Grade 46, with antiwear, anti-form and anti-oxidation additives, such as Mobil DTE 15M, Amoco Rykon 46, or BP Energol HLP-HD46.

Year-round

Mobil Delvac 1; Mobil EAL Envirosyn 68H

-4—104°F (-20—40°C)

Mobil Delvac 1300 Super 10W30, XD-3 Elite 10W-30, XD-3 10W-30

14—104°F (-10—40°C)

Mobil Delvac 1300 Super 15W40, XD-3 Elite 15W-40, XD-3 15W-40

32—104°F (0—40°C)

Gear oil

API GL5 EP Grade, such as Chevron Delo gear 80W90 or BP Transgear 80W90 is required.

Year-round

As required

Heavy-duty lithium grease

Heavy-duty 3% molybdenum disulfide lithium complex grease, such as Chevron RPM Heavy Duty Grease No. 2, Mobilgrease Moly 52 or BP Energrease Moly EP2.

Year-round

As required

Roller and friction bearings3

FINA Entergrease L21M; Mobil CMP

Year-round

As required

Open gear (live ring gears)

BP Entergrease MP-MG2

Year-round

As required

Hydraulic oil tank

Swing gear unit

Swing ring

Grease

Hydraulic oil

84.5 qts. (80 L)

Grease zerks

FINA Energrease L21 M; Mobil Multipurpose grease3 CMP

Year-round

As required

Battery terminals

Acid-proof grease4

Year-round

As required

Fuel tank

Diesel fuel

Hydraulic oil radiator Air conditioning Washer system 1.

2.

3.

4.

5.

FINA Marson L2 No. 2-D, DIN 51601 grade

Over 40°F (4°C)

No. 1-D, DIN 51601 grade

Below 40°F (4°C)

Coolant

Water + antifreeze; SP-C

Year-round

11.7 qts. (11.1 L)

Refrigerant

R134a5

Year-round

26 oz. (750 g)

Compressor oil

Sanden SP10

Year-round

4 oz. (116.5 cm³)

Cleaning agent

Water + antifreeze

Year-round

2.1 qts. (2.0 L)

20.6 gal. (78 L)

The capacities indicated are approximated values; the oil level check alone is relevant for the correct oil level Hypoid gearbox oil based on basic mineral oil (SAE85W-90 according to DIN 51502), (API GL-4, GL5) KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive Standard acid-proof grease According to DIN 8960

918175/AP0605

3-23

Maintenance 3.15 Pressure check • Run the machine until it reaches normal operating temperature before checking

General

hydraulic pressure.

Note: Hydraulic oil normal operating temperature: 122°F (50°C) minimum.

• Check pressure drop under a constant load.

• Set the primary pressure limiting valves (PPLV) with the engine at full throttle. See Hydraulic system on page 2-3 for the pressure settings.

Pressure check of variable displacement pump P1

Hydraulic supply for boom, bucket and left-hand side drive functions.

Checking primary pressure limiting valve 1 (PPLV 1)

1. Connect a pressure gauge to measuring port MP 1 (1) Fig. 18.

2. With the engine at full throttle, extend the boom cylinder as far as it will go.

3. Check and record the pressure value.

1

Fig. 18:Measuring port P1

Checking pressure prop

1. At full throttle, extend the boom cylinder as far as it will go.

2. Quickly reduce engine speed from maximum to minimum. Observe the pressure drop.

3. Check and record the pressure value. ➥ Pressure drop should not exceed the specified value by more than 10% (See Hydraulic system on page 2-3 for pressure values).

Adjusting primary pressure limiting valve 1 (PPLV 1)

1. Adjust the pressure at the primary pressure limiting valve (PPLV 1) (A) Fig. 19 on the main valve block. a. Loosen the pressure limiting valve locknut. b. Loosen the pressure limiting valve until you observe a pressure drop on the pressure gauge.

A

➥ The valve seat may be stuck and must be loosened first. c. Adjust the pressure limiting valve and tighten the locknut.

2. After completing the adjustment, check the primary pressure limiting valve 1 and the pressure drop.

3. Check the retract boom, the extend/retract bucket, and the left-hand side forward/reverse drive functions.

Fig. 19:Primary pressure limiting valve 1

3-24

918175/AP0605

Maintenance Pressure check of variable displacement pump P2

Hydraulic supply for dipper arm, right-hand side drive and auxiliary hydraulics functions.

Checking primary pressure limiting valve 2 (PPLV 2)

1. Connect a pressure gauge to measuring port MP 2 (2), Fig. 20.

2.With the engine at full throttle, extend the dipper arm cylinder as far as it will go.

3. Check and record the pressure value.

Checking pressure drop 2

Fig. 20:Measuring port P2

1. With the engine at full throttl, extend the dipper arm cylinder as far as it will go.

2. Quickly reduce engine speed from maximum to minimum. Observe the pressure drop.

3. Check and record the pressure value. ➥ Pressure drop should not exceed the by more than 10%. (See Hydraulic system on page 2-3 for pressure values).

Adjusting primary pressure limiting valve 2 (PPLV 2)

1. Adjust the pressure at the primary pressure limiting valve (PPLV 2) (B), Fig. 21, on the main valve block. a. Loosen the pressure limiting valve locknut. b. Loosen the pressure limiting valve until you observe a pressure drop on the pressure gauge.

B

➥ The valve seat may be stuck and must be loosened first. c. Adjust the pressure limiting valve and tighten the locknut.

2. After the adjustment is complete, check the primary pressure limiting valve 2 and the pressure drop.

3. Check the dipper arm retraction and the right-hand side forward/reverse drive functions.

Fig. 21:Primary pressure limiting valve 2

918175/AP0605

3-25

Maintenance Checking the auxiliary hydraulics pressure

Important!

Factory settings for auxiliary hydraulics secondary valves are possibly incorrect since the valves must be adapted to the implement.

Checking the gear pump P3 pressure

Hydraulic supply for the dozer blade, auxiliary hydraulics/boom swivel and rotate functions hydraulic supply.

Checking primary pressure limiting valve 3 (PPLV 3)

1. Connect a pressure gauge to measuring port MP 3 (3), Fig. 22.

2.With the engine at full throttle, extend the dozer blade cylinder as far as it will go.

3. Check and record the pressure value.

Checking pressure drop 3 Fig. 22:Measuring port P3

1. With the engine at full throttle, extend the dozer blade cylinder as far as it will go.

2. Quickly reduce engine speed from maximum to minimum. Observe the pressure drop.

3. Check and record the pressure value. ➥ Pressure drop should not exceed the specified value by more than 10% (See Hydraulic system on page 2-3 for pressure values).

Adjusting primary pressure limiting valve 3 (PPLV 3)

1. Adjust the pressure at the primary pressure limiting valve (PPLV 3) on the main valve block (C), Fig. 23. a. Loosen the pressure limiting valve locknut. b. Loosen the pressure limiting valve until you observe a pressure drop on the pressure gauge. ➥ The valve seat may be stuck and must be loosened first. c. Adjust the pressure limiting valve and tighten the locknut.

C

2. After the adjustment is complete, check the primary pressure limiting valve 3 and the pressure drop.

3. Check the following functions: retract dozer blade, boom swivel and rotate.

Fig. 23:Primary pressure limiting valve 3

3-26

918175/AP0605

Maintenance Checking the auxiliary hydraulics pressure

Important!

Factory settings for auxiliary hydraulics secondary valves are possibly incorrect since the valves must be adapted to the implement.

Checking pilot control pressure Checking pilot control pressure

1. Connect a pressure gauge to measuring port MP (4), Fig. 24.

2. Move the control lever base (safety switch) to the work position.

3. Acuate the joystick.

4. Check and record the pressure value.

4 Fig. 24:Pilot control pressure measuring port Adjusting pressure reducing valve 4 (PRV 4)

1. Adjust the pressure at the pressure reducing valve 4 (PRV 4) at the control oil unit (D), Fig. 25. (See Hydraulic system on page 2-3 for pressure values) 2. Check the pilot control pressure again after adjustment is complete.

D

Fig. 25:Pressure reducing valve

918175/AP0605

3-27

Maintenance Gear motor secondary pressure limiting valve Check

1. Connect a pressure gauge to measuring port MP 4.

1

2. Place the bucket, the boom, or the dozer blade firmly against the ground to prevent the machine from moving when the travel drive is engaged. Engage the travel drive, which will push against the bucket/boom/dozer blade resistance and will build up pressure in the system.

3. Check and record the pressure value.

Adjusting the gear motor secondary pressure limiting valve

1. Adjust the pressure at the secondary pressure limiting valve on the gear motor.

Fig. 26:Secondary Pressure Limiting Valve

a. Loosen the locknut of the pressure limiting valve. b. Unscrew the pressure limiting valve until you observe a pressure drop on the pressure gauge. ➥ The valve seat may be stuck and must be loosened first. c. Adjust the pressure limiting valve and tighten the locknut.

2. After the adjustment is complete, check the secondary pressure limiting valve again.

Measuring ports: overview

1

Ref.

Description

1

Measuring port for pump 1

MP 1

2

Measuring port for pump 2

3

Measuring port for pump 3

MP 2 MP 3

4

Control oil unit measuring port

MP 4

2 4

3

Fig. 27:Measurement Ports

3-28

918175/AP0605

Maintenance Primary pressure limiting valves

1

1

2

2 4

3 3

918175/AP0605

Ref.

Description

1

Pump primary pressure limiting valve 1

PPLV 1

2

Pump primary pressure limiting valve 2

3

Pump primary pressure limiting valve 3

PPLV 2 PPLV 3

4

Pressure reducing valve

PRV 4

3-29

Maintenance 3.16 Test report Pump 1 Function

Movement

Symbol

Pressure limiting valve

Measuring port

Rated value

UP

Drop

Boom

Bucket RETRACT

FORWARD

REVERSE

Rated value Drop

Measuring port MP 1 (pump)

EXTEND

Primary pressure limiting valve PPLV 1 (main valve block)

DOWN

Left-hand side drive

Specified values

Rated value Drop Rated value Drop Rated value Drop Rated value Drop

3-30

Measured

✔

3553 ±44 psi (245 ±3 bar) 363 psi (25 bar) 3553 ±44 psi (245 ±3 bar) 363 psi (25 bar) 3553 ±44 psi (245 ±3 bar) 363 psi (25 bar) 3553 ±44 psi (245 ±3 bar) 363 psi (25 bar) 3553 ±44 psi (245 ±3 bar) 363 psi (25 bar) 3553 ±44 psi (245 ±3 bar) 25 bar

918175/AP0605

Maintenance Pump 2 Movement

Function

Symbol

Pressure limiting valve

Measuring port

Specified values Rated value

EXTEND

Drop

dipper arm

Right-hand side drive REVERSE

A Auxiliary hydraulics B

Rated value Drop

Measuring port MP 2 (pump)

FORWARD

Primary pressure limiting valve PPLV 2 (main valve block)

RETRACT

Rated value Drop Rated value Drop Rated value Drop Rated value Drop

918175/AP0605

Measured

✔

3553 ±44 psi (245 ±3 bar) 363 psi (25 bar) 3553 ±44 psi (245 ±3 bar) 363 psi (25 bar) 3553 ±44 psi (245 ±3 bar) 363 psi (25 bar) 3553 ±44 psi (245 ±3 bar) 363 psi (25 bar) 3553 ±44 psi (245 ±3 bar) 363 psi (25 bar) 3553 ±44 psi (245 ±3 bar) 363 psi (25 bar)

3-31

Maintenance

Pump 3 Function

Movement

Symbol

Pressure limiting valve

Measuring port

Specified values Rated value

UP

Drop

Dozer blade

A (2) Auxiliary hydraulics B (2)

LEFT

Rated value Drop

Measuring port MP 1 (pump)

Primary pressure limiting valve PPLV 1 (main valve block)

DOWN

Rated value Drop Rated value Drop Rated value Drop

Boom swivel

Rated value

RIGHT

Drop

LEFT

Secondary pressure limiting valve Gear motor SPLV 4 (gear motor)

Rotate RIGHT

Measured

✔

Measured

✔

3480 ±44 psi (240 ±3 bar) 363 psi (25 bar) 3480 ±44 psi (240 ±3 bar) 363 psi (25 bar) 3480 ±44 psi (240 ±3 bar) 363 psi (25 bar) 3480 ±44 psi (240 ±3 bar) 363 psi (25 bar) 3480 ±44 psi (240 ±3 bar) 363 psi (25 bar) 3480 ±44 psi (240 ±3 bar) 363 psi (25 bar)

Rated value

3118 psi (215 bar)

Rated value

3118 psi (215 bar)

Pilot control Function

Joystick

3-32

Movement

ANY

Symbol

Pressure limiting valve

Pressure reducing valve PRV 4 (control oil unit)

Measuring port

Measuring port MP 4 (pump)

Specified values

Rated value

609±15 psi (42±1 bar)

918175/AP0605

Maintenance 3.17 Hydraulic system General hydraulic system service information WARNING! The hydraulic reservoir is under pressure. Never use your hands to search for hydraulic fluid leaks; use a piece of paper or cardboard to find leaks. Escaping fluid under pressure can be invisible and can penetrate the skin, causing serious injury. If any fluid is injected into your skin, see a doctor immediately.

Injected fluid MUST be surgically removed by a doctor familiar with this procedure, or gangrene may result.

Hydraulic fluid flowing out of high pressure line may cause fire, malfunction, property damage and/or personal injury. If a hydraulic leak is detected, immediately shut down the machine and repair the leak before restarting the machine.

WARNING! Insufficient, incorrect or contaminated hydraulic oil can damage the hydraulic system. Use a strainer/reflux when filling the system. Check the hydraulic oil level frequently and fill as necessary. See Checking hydraulic oil level on page 3-33. Use only authorized oils of the same type. See Fluids and lubricants on page 3-23.

Replace hydraulic hoses if any of the following are detected:

•

Damaged or leaking seals.

•

Worn/torn shells or uncovered reinforcement branches.

•

Expanded shells in several positions.

•

Entangled or crushed movable parts.

•

Debris jammed or stuck in hose casings.

Checking hydraulic oil level 1. Operate the machine until it reaches operating temperature.

2. Position the machine on a level surface.

3. Fully extend the bucket and boom, retract arm, and position as shown in Fig. 28.

4. Lower bucket and dozer blade to the ground. See Fig. 28. Turn off the machine.

918175/AP0605

3-33

Maintenance

Fig. 28:Checking and changing hydraulic oil

5. Check the hydraulic oil level indicator (1). Oil level should be visible in the sight gauge (2). See Fig. 29. If hydraulic oil is required, proceed to step 5.

6. Remove the rear cover and slowly open the breather filter (3) with a cloth to relieve pressure. Slowly open hydraulic oil filler cap (4) and then remove cap.

See Fig. 29.

Note: A short hex shaft is included in the tool kit. This tool is designed to be used with a standard ratchet wrench to open the filler cap.

7. With the filter insert (5) in place, add hydraulic oil until oil level is between the marks on sight gauge.

Important!

Do not overfill the hydraulic oil reservoir, or damage to the system/leaks can result.

1 2 FULL

4

LOW

5

3

Fig. 29:Hydraulic reservoir

8. Re-install hydraulic oil filter insert and filler cap and tighten securely.

9. Start engine and let it idle for a few minutes.

10. Check hydraulic functions. Recheck hydraulic oil level.

3-34

918175/AP0605

Maintenance Changing hydraulic oil 1. Operate the machine until it reaches operating temperature.

2. Position the machine on a level surface.

3. Fully extend the bucket and boom, and retract arm, as shown in See Fig. 28.

Lower bucket and dozer blade to the ground. Turn off the machine.

4. Slowly open the filler cap to relieve pressure (1) Fig. 29.

5. Remove the hydraulic reservoir cover (2) Fig. 29 and remove filter insert (5) Fig. 29.

Important!

The filler cap and filter assembly will be removed over the rear cover. Protect rear cover from spilled or dripping hydraulic fluid.

6. Open the reservoir drain plug and drain oil into a suitable container. Re-install drain plug and tighten securely.

Important!

Always dispose of hydraulic fluids according to environmental law or take to a recycling center for proper disposal. DO NOT pour onto the ground or down a drain.

7. Reinstall filter insert (5).

8. Fill reservoir with hydraulic oil until oil level is between marks on sight the gauge.

9. Re-install the hydraulic reservoir cover (2) and tighten securely.

10. Start engine and let it idle for a few minutes. Cycle all front attachment hydraulic functions and recheck hydraulic oil level.

Hydraulic cooling system The hydraulic system uses a hydraulic cooler to keep the hydraulic fluid at the proper temperature. The cooler is located inside the engine compartment near the engine radiator. Inspect the cooler for leaks or damage.

Hydraulic oil filter indicator See Instrument panel, switches and indicators on page 1-8.

The hydraulic oil filter indicator light illuminates when the hydraulic oil filter needs to be replaced. See Instrument panel, switches and indicators on page 1-8.

Note: In cold weather, the hydraulic oil filter indicator light may illuminate immediately when the engine is started. This is increased by increased oil viscosity. The light should go out when engine reaches operating temperature and speed.

918175/AP0605

3-35

Maintenance Checking hydraulic pressure lines Specific safety instructions

WARNING! Hydraulic reservoir is under pressure. Never use your hands to search for hydraulic fluid leaks; use a piece of paper or cardboard to find leaks. Escaping fluid under pressure can be invisible and can penetrate the skin, causing serious injury. If any fluid is injected into your skin, see a doctor immediately.

Injected fluid MUST be surgically removed by a doctor familiar with this procedure, or gangrene may result.

Release hydraulic system pressure before re-tightening leaking screwed fittings and hose connections.

Never weld or solder faulty or leaking pressure lines and connections. Replace damaged parts with new ones.

• Leaks and damaged pressure lines must be immediately repaired or replaced.

This not only increases the operating safety of your machine but also helps to protect the environment.

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

1 Q/05

In this respect, we recommend that you follow all the relevant safety regulations for hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country. Also follow DIN 20 066, part 5.

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

Example: The indication “1 Q/05” means manufactured in the 1st quarter of 2005.

3.18 Cab heater filter Replacing the inside heater filter Tilt the cab to replace the filter. See Tilting the cab on page 1-13.

The heater is located at the rear half of the cab.

Replacing the filter:

1. Open the heater cover.

2. Replace the heater filter (Fig. 29).

3. Replace and secure the heater cover.

Fig. 30: Inside heater filter

3-36

918175/AP0605

Engine

4

Engine

4.1

4TNV98 engine: overview

Air intake

Exhaust manifold Oil filler neck

Fuel injection pump

Fuel filter

Engine oil filter Oil dipstick

Oil drain Oil pressure switch

918175/AP0605

4-1

Engine

Starter

Fan blade

Clamping bracket Alternator V-belt

4-2

918175/AP0605

Engine 4.2

Fuel system

Return Feed

Fuel injection pump

Fuel filter with cutout valve

Fuel pump

918175/AP0605

Water separator with lock lever

4-3

Engine 4.3

Removing the cylinder-head cover Important!

The fuel injection lines run through the engine cylinder-head cover. Remove the cylinder-head cover with extreme care to avoid damaging the injector lines.

1. Remove all injection lines from the cylinder-head cover.

2. Carefully move the injection lines away from the engine.

3. Remove the rubber grommets from the cylinder-head cover with a screwdriver.

4. Remove the cylinder-head cover bolts and the cylinder-head cover. Remove the bolts according to the order shown in the following figure.

Fig. 1: Removing the cylinder-head cover Flywheel Side

Fan Side

Fig. 2: Cylinder-head cover bolt removal order

4.4

Checking and adjusting valve tip clearance Important!

Stop the engine and allow it to cool before checking/adjusting valve tip clearance.

Setting standard valve tip clearance is possible only on a cold engine.

1. Stop the engine and allow it to cool.

2. Remove the cylinder-head cover – See Section 4.3 Removing the cylinder-head cover on page 4-4. normal Fig. 3: Valve cap wear

4-4

abnormal

3. Crank the engine until the cylinder is at the compression cycle top dead center.

4. Check the valve cap for abnormal wear.

918175/AP0605

Engine A

5. Check valve tip clearance with a feeler gauge (see Fig. 4). Valve tip clearance should be 0.002 – 0.010 in. (0.15 – 0.25 mm).

Fig. 4: Valve tip clearance B C

6. Loosen locknut (C), Fig. 5 on the cylinder.

7. Adjust valve tip clearance by turning set screw to 0.002 – 0.010 in. (0.15 – 0.25 mm).

8. Tighten locknut (C).

9. Check the setting again with the feeler gauge.

10. Repeat the procedure for each cylinder

Fig. 5: Setting valve tip clearance

11. Position the cylinder-head cover gasket.

12. Replace and secure the cylinder-head cover – See Section 4.5 Cylinder head bolt tightening order on page 4-6.

Fig. 6: Placing the cylinder-head cover

918175/AP0605

4-5

Engine 4.5

Cylinder head bolt tightening order ☞ Tighten the cylinder-head bolts as follows: ➥ Tightening torque: • 1st pass

36.1 – 43.4 lbf-ft (49,0 – 58,8 Nm)

• 2nd pass

76 – 83.3 lbf-ft (103,1 – 112,9 Nm)

Important!

Oil the bolt threads and the contact surfaces of the cylinder-head bolts before inserting them. Tighten the cylinder-head bolts according to the order showin in the following figure.

Flywheel

4.6

Fan

Checking the injection nozzles WARNING! Keep hands away from the injector nozzle jet. Fuel exits the nozzle under extremely high pressure and can penetrate the skin and eyes. Escaping fuel under pressure can be invisible and can penetrate the skin and cause serious injury. If any fuel is injected into your skin, see a doctor immediately. Injected fluid MUST be surgically removed by a doctor familiar with this procedure or gangrene may result.

Pressure check

1. Remove the injection line and the injection nozzle.

2. Connect the injection nozzle to the high pressure line of the nozzle tester.

3. Slowly increase pressure until the nozzle ejects fuel and read the pressure indicated by the pressure gauge. Injection pressure should be 3191 – 3336 psi (220 – 230 bar).

Fig. 7: Nozzle tester

4-6

4. If the injection pressure is too low, replace the spacer in the nozzle with a thicker one. If the pressure is too high, replace the spacer with a thinner one.

See Fig. 8.

Note: Spacer thickness of 0.1 mm corresponds to a change in pressure of 276 psi (19 bar).

918175/AP0605

Engine

Upper nozzle screw fitting

Spacers

Pressure spring centring Nozzle needle Compression spring seat

Compression spring seat

Lower nozzle screw fitting

Nozzle body

Fig. 8: Injector nozzle parts breakdown

4.7

Checking the nozzle jet WARNING! Keep hands away from the injector nozzle jet. Fuel exits the nozzle under extremely high pressure and can penetrate the skin and eyes. Escaping fuel under pressure can be invisible and can penetrate the skin and cause serious injury. If any fuel is injected into your skin, see a doctor immediately. Injected fluid MUST be surgically removed by a doctor familiar with this procedure or gangrene may result.

1. Remove the injection lines and the injection nozzles.

2. Connect the injection nozzle to the high pressure line of the nozzle tester.

3. Quickly create pressure until the nozzle ejects fuel (ejection 3 – 4 times).

4. Hold a white sheet of paper about 12 in. (30 cm) away from the nozzle and let the nozzle eject fuel.

5. The nozzle jet must create a circle on the paper.

Normal atomization

6. Check the nozzle for drips after it has ejected fuel.

7. Create a pressure of about 290 psi (20 bar) below injection pressure and check whether fuel escapes from the nozzle.

Bad atomization Fig. 9: Nozzle jet

918175/AP0605

4-7

Engine 4.8

Injection timing 1. Remove the injection line for the 1st cylinder.

Note: Cylinder numbering always starts from the flywheel side.

2. Turn the engine clockwise (as seen from the radiator) by rotating the crankshaft until fuel escapes from the injection pump's base valve.

3. Remove the rubber cover from the flywheel housing and read injection time from the marks on the flywheel and flywheel housing.

4. If the marks do not coincide, adjust injection timing by turning the fuel injection pump. ➥ Injection too late: turn the pump away from the engine. ➥ Injection too early: turn the pump towards the engine.

Direction of rotation

Mark on housing

Longitudinal slots for turning the pump

4-8

918175/AP0605

Engine 4.9

Adjusting engine idle Important!

Maximum engine speed is set at the factory and cannot be modified.

Note: Adjust engine idle without load.

A

B

1. Run the engine until it reaches operating temperature.

2. Check idling speed (A) and maximum engine speed (B) with all implement functions in neutral. ➥ Idling speed: 1050 +/- 50 rpm. ➥ Max. torque: 2575 +/- 50 rpm.

3. Adjust as required.

Fig. 10:Adjusting engine revs

4.10 Compression 1. Remove the injection lines and injection nozzles.

2. Remove the plug for the cut-off solenoid to set the fuel injection pump to zero delivery.

3. Crank the engine 2 - 3 revolutions.

Note: Do not attempt to start the engine.

4. Mount the compression gauge on the cylinder you want to measure.

Fig. 11:Compression

5. Crank the engine with the starter and read the pressure indicated by the pressure gauge. ➥ Specified value: 508 +/- 14.5 psi (35 +/- 1 bar) @ 250 rpm ➥ Limit value: 406 +/- 14.5 psi (28 +/- 1 bar) @ 250 rpm

918175/AP0605

4-9

Engine 4.11 Checking the coolant thermostat 1. Remove the thermostat.

Housing cover

Thermostat Seal Housing Thermal switch Fig. 12:Coolant thermostat

Thermal switch

2. Heat the thermostat in a container filled with water.

Thermal switch

3. Using a thermometer, check whether the thermostat opens at 157 – 162.5 °F (69.5 – 72.5 °C).

4.12 Checking the thermal switch 1. Remove the thermal switch.

Thermometer

2. Heat the thermal switch in a container filled with antifreeze or oil.

3. Using an ohmmeter, measure the resistance of the thermal switch as shown.

The switch must allow the coolant to pass at a temperature of 224 – 236 °C (107 – 113 °C).

Test prods

Fig. 13:Checking the thermal switch

4-10

918175/AP0605

Engine 4.13 Oil pressure switch 1. Remove the cable connection from the oil pressure switch (in the area of the cut-off solenoid).

Measurement prod

2. Start the engine and check for correct idling speed.

3. Using an ohmmeter, measure the resistance of the oil pressure switch as shown. ➥ Infinite resistance indicates the oil pressure switch is OK. ➥ The oil pressure switch is defective if the oil can pass.

Fig. 14:Oil pressure switch

4.14 Checking the coolant circuit Coolant system leakage check:

1. Completely fill the radiator.

2. Mount an hand pump adapter on the radiator as shown.

3. Increase the pressure in the cooling circuit by means of a hand pump to about 34 psi (2.34 bar). ➥ Check the coolant circuit lines/connections for leaks if the pressure drops at the Fig. 15:Checking the radiator for leakage

pressure gauge.

Radiator cap check:

1. Remove the radiator cap and mount it onto the pressure tester as shown.

2. Increase the pressure to about 34 psi (2.34 bar) (stamped onto the radiator cap) with the pressure tester.

Radiator cap

➥ Radiator cap must open.

Fig. 16:Checking the radiator cap

918175/AP0605

4-11

Engine 4.15 Engine troubleshooting Problem

Possible causes Wrong SAE grade of engine lubrication oil Fuel grade incorrect Defective or dead battery Loose or oxidized cable connections in starter circuit Starter defective, or pinion does not engage Wrong valve tip clearance

Engine does not start or is not easy to start

Fuel injector defective Starting relay defective Glow plug defective Solenoid switch defective Cut-off solenoid does not engage starter Cut-off solenoid without current High pressure in hydraulic system preventing engine starting.

Fuel grade incorrect

Engine starts, but does not run smoothly

Wrong valve tip clearance Injection line leaks Fuel injector defective Oil level too low Oil level too high Dirty air filter

Engine overheats. Temperature warning system responds

Dirty oil cooler fins Fan defective, V-belt torn or loose Resistance in cooling system too high, flow capacity too low Fuel injector defective Oil level too high Fuel grade does not comply with specifications Dirty air filter

Insufficient engine output

Air filter maintenance switch or gauge defective Wrong valve tip clearance Injection line leaks Fuel injector defective

Engine does not run on all cylinders

Injection line leaks Fuel injector defective Oil level too low

Insufficient or no engine oil pressure

Machine inclination too steep (max. 15°) Wrong SAE grade of engine lubrication oil

4-12

918175/AP0605

Engine Problem

Possible causes Oil level too high

Engine oil consumption too high

Machine inclination too high (max. 15°) Blue

Oil level too high Machine inclination too high (max. 20°) Engine starting temperature too low Fuel grade incorrect

White

Wrong valve tip clearance Fuel injector defective

Engine smoke

Coolant combustion (defective cylinder-head gasket) Dirty air filter Air filter maintenance switch or gauge defective Black

Wrong valve tip clearance Fuel injector defective Engine oil combustion (defective cylinder-head gasket)

918175/AP0605

4-13

Engine

4-14

918175/AP0605

Hydraulic System

5

Hydraulic System

5.1

Hydraulic pump PVD-3B-56P-21G5-4626F Twin variable-displacement pump + 2 gear pumps

2 Control oil unit 3

1

10

4

9

8 6

7

Variable displacement pump unit

Gear pump unit

Ref.

Description

1 2 3

Oil flow set screw Q-max Pressure reducing valve PRV 5 Bleed screw (not active)

4

Oil flow set screw Q-min.

5

Type label

6

Port P2 Control initiation set screw Port P1 Port P3 Port P4

7 8 9 10

918175/AP0605

5

5-1

Hydraulic System

1

8

2

7

3 4

6

Variable-displacement pump unit

Gear pump unit

Ref.

5-2

5

Description

1

Control initiation set screw

2 3 4 5 6 7 8

Suction line port to variable displacement pump Oil flow set screw Q-min.

Port PR (2nd speed range) Port PV (gear motor brake bleed supply) Pilot valve supply Oil flow set screw Q-max.

Suction line port to gear pump

918175/AP0605

Hydraulic System Pump unit: exploded view 10

1

9

2 8 11

7

14

6 5 3

15

13 4 16

18

12

17

19 Ref. 1 2 3 4

918175/AP0605

Description Input shaft Shaft seal Bearing Set screw Q-min.

5

Bearing

6

Swash plate

7

Piston

8

Pressure plate

9

Cylinder drum

10

Control disc

11

Drive unit

12

Springs for control characteristics

13

Control initiation set screw

14

Gear pump

15

Set screw Q-max.

16

Governor housing

17

2nd speed range solenoid valve

18

Solenoid valve for safety valve

19

Control oil unit

5-3

Hydraulic System Control oil unit

1

2

3

4

5

6 BAR

9

8

Ref.

5

6

1

Description Gear motor brake bleed supply

2

Pilot valve supply

3

Solenoid valve for safety valve Drives/2nd speed range supply

PV

6

2nd speed range solenoid valve Pump 4 supply

Internal to P4

7

Pressure limiting valve

8

Tank line

4 5

5-4

7

9

Accumulator

10

Shuttle valve block/main valve block swiveling segment

Port PR

918175/AP0605

Hydraulic System 5.2

Main valve block

Ports

B1

A1

Bucket A2

T1

Boom

Pi1

B2 B3

A3

P1

P2

B4

A4

Dipper arm

B5

A5

Auxiliary hydraulics

B6

A6

Swivel

B7

A7

Dozer blade

A9

A8

Rotate

B9

A9

Input P3 output T2

T2

P3

Left-hand side drive Input P1 P2 Right-hand side drive Boom 2

Auxiliary hydraulics flow rate adjustment

918175/AP0605

5-5

Hydraulic System Legend

Pilot control lines Port

Legend

Controlled using

Pa1, Pb1

Bucket control

Joystick (right)

Pa2, Pb2

Boom control

Joystick (right)

Pa3, Pb3

Left-hand side drive control

Drive pedal (left)

Pa4, Pb4

Right-hand side drive control

Drive pedal (right)

Pa5, Pb5

Dipper arm control

Joystick (left)

Pa6, Pb6

Auxiliary hydraulics control

Auxiliary hydraulics pedal

Pa7, Pb7 Pa8, Pb8

Swivel control Dozer blade control

Auxiliary hydraulics pedal Dozer blade pedal

Pa9, Pb9

Rotation control

Joystick (left)

Pi1 Pi2

Boom summation control

Joystick (right)

Main control lines Port A1, B1

Legend Bucket cylinder

A2, B2 A3, B3

Boom cylinder Drive unit (left) using swivel joint

A4, B4 A5, B5

Drive unit (right) using swivel joint Dipper arm cylinder

A6, B6 A7, B7

Auxiliary hydraulics Slewing cylinder

A8, B8 A9, B9

Dozer blade cylinder Gear motor

Pump/tank lines Port P1

Legend Port for pump 1

P2 P3

Port for pump 2 Port for pump 3

P4 T1

Port for pump 4 Tank line using non-return valve and filter in tank

T2 DR1, DR2

Tank line using oil cooler and filter in tank Tank lines for boom summation

S: bucket pre-tension – see Bucket pre-tension on page 5-12

5-6

918175/AP0605

Hydraulic System Main valve block diagram

4 !

BAR

"

Bucket

0B

0A " $2

BAR

3

0I

Boom

!

0B

0A

!

0B

Left-hand side drive

" 0A

BAR

0

0B

0

0P

Input P1

0

0

!)

BAR

Input P2

0A "

Right-hand side drive

!

0I $2

Dipper arm 0B

0A " BAR

!

Auxiliary hydraulics

0B

0A "

auxiliary hydraulics flow rate adjustment

Swivel

! ! "

0B

0A

Dozer blade

!

BAR

"

0B

0A

Rotate !

0B

" 0A

Drive counter-balancing system 0

0I

BAR

0

4

918175/AP0605

5-7

Hydraulic System Pressure limiting valves

6

1

7 8

2

8

3

10

4

11 12

5

13

Ref. 1 2 3

5-8

Description Secondary pressure limiting valve (bucket base side) Primary pressure limiting valve P1 Secondary pressure limiting valve (dipper arm rod side)

4

Auxiliary hydraulics plug (secondary pressure limiting valve option see page 5-16)

5

Secondary pressure limiting valve (dozer blade base side)

6

Secondary pressure limiting valve (bucket rod side)

7

Secondary pressure limiting valve (boom base side)

8

Secondary pressure limiting valve (boom rod side)

9

Primary pressure limiting valve P2

10

Secondary pressure limiting valve (dipper arm base side)

11

Auxiliary hydraulics plug (secondary pressure limiting valve option see page 5-16)

12

Plug – see Flow rate adjustment of auxiliary hydraulics on page 5-15

13

Primary pressure limiting valve P3

918175/AP0605

Hydraulic System Pump assignment

Hydraulic supply by pump 1

• Bucket section • Boom section • Right-hand side drive section Hydraulic supply by pump 2 • Left-hand side drive section

• Dipper arm section • Auxiliary hydraulics section Hydraulic supply by pump 3 • Auxiliary hydraulics section

• Dozer blade section • Swivel unit section • Boom swivel section • Drive counter-balancing system section

Bucket Pump 1 Boom Left-hand side drive Input P1 P2 Right-hand side drive Boom 2

Pump 2

Dipper arm Auxiliary hydraulics Auxiliary hydraulics flow rate adjustment Swivel

Pump 3

Dozer blade Rotate Input P3 output T2

918175/AP0605

5-9

Hydraulic System 5.3

Drive counterbalancing system Without the drive counter-balancing system, actuating the boom as you drive causes the machine to change direction.

(P1, P2 each supply a drive, and the alarm function is also governed by P1 or P2.)

Feature If the boom is actuated as you drive straight ahead, the machine continues in a straight line and drive speed stays constant.

The drive counterbalancing system is only enabled if both drive valves are enabled.

Function

☞ The drive counterbalancing system functions by increasing pressure at both boom and

driving piston valves so function is not lost in either function when both are used simultaneously.

➥ P3 takes over all boom functions.

Pump assignment for drive counterbalancing

Hydraulic supply by pump 1

• Right-hand side drive section Hydraulic supply by pump 2

• Left-hand side drive section Hydraulic supply by pump 3

• Bucket section • Boom section • Dipper arm section • Auxiliary hydraulics section • Auxiliary hydraulics section • Dozer blade section • Swivel unit section • Boom swivel section • Drive counter-balancing system section

5-10

918175/AP0605

Hydraulic System Drive counter-balancing system diagram

4 !

BAR

"

0B

Bucket

0A

" $2

BAR

0I

Boom

3 !

0B

0A

!

0B

Left-hand side drive

" 0A

!)

BAR

0

0

0B

Input P1

0

0 BAR

0P

Input P2

0A " !

Right-hand side drive

0I $2

0B

Dipper arm

0A " !

BAR

0B

0A

Auxiliary hydraulics

" !

Swivel

! "

0B

0A

Dozer blade

!

BAR

"

0B

0A !

Rotate

"

0B

0A

0

0I

Drive counter-balancing system

BAR

0

4

918175/AP0605

5-11

Hydraulic System 5.4

Regeneration – dipper arm section Problem High loads on the dipper arm can cause the dipper arm cylinder to be “emptied” on the base side, which can cause the dipper arm to stop in vertical position.

Solution A non-return valve is integrated in the spool valve so the rod-side oil can flow to the base side.

5.5

Bucket pre-tension A nozzle is integrated in the pressure line of the bucket segment. If the bucket and the boom (both supplied with oil by the same pump) are actuated at the same time, both move simultaneously, and not the bucket (with its smaller mass) first, and then the boom with its larger mass.

– see Main valve block on page 5-5

Location:

5-12

918175/AP0605

Hydraulic System 5.6

Boom summation – raise Both P1 & P2 pumps are used to raise the boom at higher speed.

Raising the boom

• Moving the joystick also controls a second segment (boom 2).

• Pump P2 supplies the boom 2 segment with oil.

• The summation time (the time the boom 2 segment is switched) is specified by the piston spring in the boom 2 segment.

Lower the boom – see Lowering the boom: on page 5-14.

BAR

BAR

BAR

BAR

!

"

0A

!

"

0A

$2

!

"

0A

0

0

0

!

0A "

0A

0I

!

"

$2

0A "

0

!)

Boom base side

0B

0B

0I

0B

0B

0B

0P

3 0B

Joystick control

918175/AP0605

5-13

Hydraulic System 5.7

Check valve (load retaining valve) • Boom cylinder base side.

A pilot-operated load retaining valve is used to prevent spool leakage, which allows the cylinder to retain its home position.

Raising the boom: The oil opens the check valve and flows to the boom cylinder base side.

Lowering the boom: The oil is released by the piston and returns to the tank using the pilot-pressure line. This reduces the load on the check valve. This allows the base side oil to flow back using the check valve.

"

0

0A

0

0A "

!

!

0A

0I

$2

"

0A "

!

0

0

Joystick control

!)

Boom base side

BAR

BAR

BAR

BAR

4

5-14

918175/AP0605

Hydraulic System 5.8

Flow rate adjustment of auxiliary hydraulics The set screw on main valve block allows for changing auxiliary hydraulic oil flow at the ports.

Set screw – see Pressure limiting valves on page 5-8.

There are two possible positions: – see Auxiliary hydraulics oil flow* on page 2-3.

Important!

Do not position the set screws in between the two positions. This could cause the hydraulic oil to overheat.

Set screw “against hydraulic resistance” The valve seat is closed in this position.

• P2 + P3 supply the auxiliary hydraulics section with oil.

• Factory setting.

“Open” set screw Unscrew the valve seat by two turns • P2 supplies the auxiliary hydraulics section with oil

• The oil supplied by P3 flows to the tank using the open valve seat.

918175/AP0605

5-15

Hydraulic System 5.9

Secondary pressure limiting valves for the auxiliary hydraulics (option) The limiting value provides over-pressure protection for components in the secondary circuit (e.g., hydraulic hammer).

Important!

The implement manufacturer (e.g., hammer, offset bucket, etc.) is responsible for implement over-pressure protection. The Mustang Company is not be liable for damage to implements.

Problem: The secondary circuit is also protected by the primary pressure limiting valve if the spool valve is enabled. There is no protection if the spool valve is not enabled.

Ensuring protection with the spool valve disabled requires two secondary pressure limiting valves instead of the plugs.

Adjusting the secondary pressure limiting valves: The pressure limiting valves must be set at 4061 psi (280 bar) while adjusting the limiting valves.

Short-term pressure peaks can be reduced with this setting.

If the pressure limiting valves are set to less than 4061 psi (280 bar): • Have the pressure setting performed by a hydraulic systems technical specialist.

• The pump's high flow rate and the fact that the pressure peaks are now reduced by the secondary pressure limiting valve cartridges at the auxiliary hydraulics section may cause the hydraulic oil to overheat.

• Reset the pressure setting to the initial 4061 psi (280 bar) when changing implements.

Location: – see Pressure limiting valves on page 5-8.

5-16

918175/AP0605

Hydraulic System 5.10 Pilot valves • Pilot valve for bucket, boom, dipper arm and rotation • Consists of a lever and four pressure reducing valves

Joystick

2

4

1 Numbering for right-hand side joystick. Left-hand side joystick: 3-1-24

3

A

B

C

D P

T

E F

Ref. A

Description Control lever

Ref. 1

DescriptionJoystick (left) Dipper arm extension control

DescriptionJoystick (right) Boom cylinder extension control

B C

Rubber collar Linkage

2 3

Left-hand side rotation control Dipper arm retraction control

Bucket cylinder extension control Boom cylinder retraction control

D

Universal joint

4

Right-hand side rotation control

Bucket cylinder retraction control

E

Guide plate

P

Control oil unit supply

Control oil unit supply

F

Tappet

T

Tank line

Tank line

918175/AP0605

5-17

Hydraulic System Pilot valve (driving)

• Pedal with hydraulic damping.

• Consists of two pedals and four pressure reducing valves.

1

T

5-18

3

2

P

T

4

P

Ref. 1 2 3

Description Left-hand side drive segment control

4 P

Right-hand side drive segment control Pilot control pressure

T

Tank line

Left-hand side drive segment control Right-hand side drive segment control

918175/AP0605

Hydraulic System

1

6

E

2

4

3

5

Ref. 1 2 3 4

918175/AP0605

Description Bellows Shift unit (kit) Plate (kit)

5

Tappet Non-return valves

6

Damping

5-19

Hydraulic System Pilot valve for auxiliary hydraulics

• Pilot valve with pedals for remote control of directional valves • Consists of a pedal and two pressure reducing valves

1

2

A

0$

OE IW 1P

B

OE IW 0 $ 1P

C D 3

4

E

F

Ref. A

Description Pedal

B C

1

Description Auxiliary hydraulics control/offset cylinder extension control

Pedal fixture Protective caps

2 3

Auxiliary hydraulics control/offset cylinder extension control Tank line

D E

Mounting plate Tappet

4

Control oil unit supply

F

Spring

5-20

Ref.

918175/AP0605

Hydraulic System Pilot valve for dozer blade

• Pilot valve with pedal for directional valve remote control.

• Consists of a pedal and two pressure reducing valves.

1

2

A

0$ 0$

OE IW 1P

B

OE IW 1P

C

3

4

D

E

F

3 4 1

Ref.

Description

A B

Pedal Pedal fixture

1

Description Dozer blade cylinder extension control

2

Dozer blade cylinder retraction control

C D

Protective caps Mounting plate

3

Tank line

4

Control oil unit supply

E F

Tappet Springs

918175/AP0605

Ref.

2

5-21

Hydraulic System 5.11 Valves 7/3 directional valve (changeover valve)

• Switches from auxiliary hydraulics (valve de-energized) to boom swivel and vice-versa (valve energized).

• Electric control using push button on left-hand side joystick.

2

3 8

7

1

5

4

6

1

2

8

3

7

4 Ref. 1 2 3 4 5 6 7 8 5-22

5

6

Description Solenoid Main valve block for auxiliary hydraulics segment Main valve block for auxiliary hydraulics segment Pilot valve for auxiliary hydraulics Pilot valve for auxiliary hydraulics Tank line Shuttle valve block/main valve block, offset cylinder retraction control Shuttle valve block/main valve block, offset cylinder extension control 918175/AP0605

Hydraulic System 4/3 directional valve

• Used for electric auxiliary hydraulics and 3rd control circuit.

• Valve is located in pilot control branch and is controlled using tip switches on left-hand side joystick.

1

2

3

6

5

4

1

4

2 5

3

6

Ref. 1 1 2 3 4 5 6

918175/AP0605

Description Solenoid 1 Solenoid 2 Main valve block for auxiliary hydraulics segment Main valve block for auxiliary hydraulics segment Solenoid 2 Control oil unit supply Tank line

5-23

Hydraulic System Shuttle valve block

• Rotation, boom swivel and dipper arm retraction must vent the gear motor's brake.

• High forces act on the brake and destroy it if it is not vented during these operations.

2

! ! "

1

"

&

4

%

5

6

# # $ $ %

3

1 2

6

3 4 5

Ref.

Port A (-> joystick (left) 4 ->

2

main valve block, right-hand side rotation control) Port B (-> joystick (left) 2 ->

3 4 5 6

5-24

Description

1

main valve block, left-hand side rotation control) Port C (-> pedal, swivel 2 -> main valve block, offset cylinder extension control) Port D (-> pedal, swivel 1 -> main valve block, offset cylinder retraction control) Port E (-> joystick (left) 1 -> main valve block, dipper arm cylinder extension control) Port F (-> gear motor SH, brake vent)

918175/AP0605

Hydraulic System Changeover valve for SAE/ISO controls (option) The directional valve is located on the left in base plate of the chassis (I), Fig. 1.

I Fig. 1: Directional valve position

1

5

2

6

Changing the directional valve over-rides control lever operation

3

7

☞ Make sure you know which control mode is selected before starting work. ☞ Always secure wing nut J on the directional valve's changeover lever.

4

8

CAUTION!

Switching from ISO to SAE controls and vice versa with the directional valve Position • A • B

Function ➥ ISO controls ➥ SAE controls

☞ Tighten wing nut (I), Fig. 2, after changing control mode.

J A

B

Fig. 2: Directional valve

918175/AP0605

1 2 3 4 5 6 7 8

Directional valve ports Joystick (right) port 1 Main valve block, boom cylinder retraction control Joystick (right) port 3 Main valve block, boom cylinder extension control Main valve block, dipper arm cylinder extension control Joystick (left) port 1 Main valve block, dipper arm cylinder retraction control Joystick (left) port 3

5-25

Hydraulic System 5.12 Travel drive The travel drive now has an “automatic powershift” gearbox. The travel drive is in 2nd speed if the 2nd speed range switch is on (high speed). 1st speed is automatically engaged if more power is required.

2 '

8

7 6

5

1

2

3

4 6

4 1 3

5-26

Ref.

Description

1 2 3 4 5 6 7 8

Drive port (-> swivel joint 4a/7a) Brake vent piston Drive port (-> swivel joint 6a/5a) Leak oil port (-> swivel joint 8a) Brake piston 2nd speed range port (-> swivel joint 1a) 2nd speed range directional valve Brake piston

918175/AP0605

Hydraulic System Function

Driving: If high pressure is applied to one of the drive ports, the brake venting piston is actuated first and passes high pressure on to the brake cylinder, venting the brake. The throttle slowly actuates the brake piston at the same time. Brake piston control causes high pressure to be applied to the motor, which starts turning.

Stopping: The oil flows from both ports to the tank upon releasing the joystick. The brake venting, and brake pistons (slowly actuated by the throttle) return to their base positions. The slow drop of the brake piston prevents the hydraulic motor from coming to an abrupt standstill.

With the brake piston in neutral position, the ports are no longer open to the motor, which no longer turns. The pressure for venting the brake is released using both throttles shortly afterwards.

2nd speed range function

1st speed range • 2nd speed range switch: turned off The directional valve for the 2nd speed range remains in home position (position as shown in diagram), and the hydraulic motor's swash plate is in maximum capacity position.

➥ The motor turns at low speed.

2nd speed range

• 2nd speed range switch: turned on The directional valve for the 2nd speed range is enabled, and the hydraulic motor's swash plate is in minimum capacity position.

➥ The motor turns at high speed.

If the pressure rises in the travelling drive, the directional valve for the 2nd speed range is forced back to home position and hydraulic motor's swash plate returns to maximum capacity.

➥ The motor now turns at low speed.

The directional valve returns to 2nd speed range as soon as the pressure in the travelling drive drops again.

➥ The motor turns at high speed again.

Note: Switch operating point of the 2nd speed directional valve: 2611 psi (180 bar)

918175/AP0605

5-27

Hydraulic System

Ref. 1 2

Description Circlip Plug

3 4

Thrust washer Cover with fittings

5

O-ring Sun gear

6 7 8 9 10 11 12 13 14 15 16

5-28

Gear reduction Circlip Planetary gears Gear housing Circlip Bearing Circlip Lifetime seal Centering Hydraulic motor

918175/AP0605

Hydraulic System 5.13 Swivel unit Hydraulically controlled swash-plate piston motor with maintenance-free swivel gearbox and mechanical motor brake.

X

2 '

9

8

2

1

3

X

X

7

4

5

6

1 2

7

Ref. 1 2 3 4 5 6 7 8 9

Description SH brake vent port (-> shuttle valve block) Pilot control pressure port (-> control oil unit) Parking brake valve Right-hand side rotation port (-> main valve block) Anti-cavitation line port (-> main valve block/tank) Left-hand side rotation port (-> main valve block) Shock anti-cavitation valves Leak oil port (-> tank) Brake piston

Note: The shock anti-cavitation valves are dampened for smooth braking.

918175/AP0605

5-29

Hydraulic System Parking brake function Opening the brake The shuttle valve block directs the pilot control pressure to the SH input if rotation, boom swivel or dipper arm retraction is carried out. The pilot control pressure at the SH input causes the piston in the parking brake valve to shift to active state (brake vent). This directs the pilot control pressure at the PG input to the brake cylinder and vents the brake.

• Movement: rotation, boom swivel or dipper arm retraction.

• Pilot control pressure is present at the SH input.

• The piston of the parking brake valve moves to work position.

• Pilot control pressure is directed to the brake piston.

• Brake is vented.

Closing the brake The shuttle valve block causes the pilot control pressure to drop and the SH input is not pressurized upon termination of rotation, boom swivel or dipper arm retraction. The piston in the parking brake valve switches to home position (brake) if there is no pressure at the SH input. The pressure in the brake cylinder escapes using the parking brake valve to the leak oil system. This enables the brake with some delay (depending on oil viscosity and brake valve leakage).

• End of movement: rotation, boom swivel or dipper arm retraction.

• The pilot control pressure at the SH input drops.

• The piston of the parking brake valve moves to home position.

• No more pilot control pressure on the brake piston.

• The oil in the brake piston flows to the tank using a throttle orifice.

• The brake is enabled.

Time for venting the brake: 3.7 sec +/-1.2 @ 122 °F (50 °C) oil temperature

5-30

918175/AP0605

Hydraulic System

Ref. 1 2

918175/AP0605

Description Pinion shaft Spacer washer

3

Bearing seal ring

4

Bearing

5

Gear housing

6

Sealing ring

7

Bearing

8

Round nut

9

Complete drive

10

Spacer washer

11

O-ring

12

Ring gear

13

Gear reduction

14

Gear reduction

15

Sun gear

16

Motor flange

17

Hydraulic motor

18

Bolt

19

Bolt

20

Plug

5-31

Hydraulic System

Ref.

Description

Ref.

Description

Ref.

Description

1 2

O-ring

Motor housing

15 16

Spring Plate

29 30

Motor head Anti-cavitation valve

3 4

O-ring Plug

17 18

Circlip Control disc

31 32

Spring O-ring

5 6

O-ring Bearing

19 20

Parking brake steel ring Brake disc

33 34

Plug O-ring

7 8

Motor shaft Plate

21 22

O-ring Spacer washer

35 36

Shock valve O-ring

9 10

Piston Plate

23 24

O-ring O-ring

37 38

O-ring Plug

11 12

Bush Pin

25 26

Parking brake piston Brake piston spring

39 40

Bolt O-ring

13 14

Cylinder block Plate

27 28

Bearing Pin

41 42

Parking brake valve block Bolt

5-32

918175/AP0605

Hydraulic System 5.14 Swivel joint 8-port swivel joint Ref.

Description

1 2 3 4 5 6 7 8

High speed Blade (base side) Blade (rod side) Drive (upper right) Drive (upper left) Drive (lower right) Drive (lower left) Leak oil

5.15 Breather filter The breather filter: • Prevents the oil tank from pressurizing.

• Pre-pressurizes the oil tank to 5.8 psi (0,4 bar) (aids the variable displacement pump's suction)

• Intake air filtering.

The breather filter is located under the tank cover, between the hydraulic filler inlet and the fuel filler inlet.

Replace the breather filter as instructed in the maintenance schedule – see Maintenance schedule on page 3-5.

Fig. 3: Breather filter position

918175/AP0605

5-33

Hydraulic System

Ref. 1 2

Description Filter fabric Bleeder valve

1 2 Fig. 4: Breather filter

5.16 Troubleshooting in the hydraulic system Problem

Possible causes Safety switch on control lever base defective Safety switch on control lever base improperly set Solenoid valve on control oil unit defective

Hydraulic system inoperative

Solenoid valve on control oil unit contaminated Hydraulic oil level too low Defective valve fuses Plug and socket connection towards solenoid valve defective/interrupted Quickhitch couplings not connected properly

Hydraulic hammer malfunctioning

Hydraulic oil quantity too high/too low Hydraulic oil pressure too high/too low Switch for 2nd speed range defective Solenoid valve on control oil unit defective

Excavator runs in 1st speed only

Solenoid valve on control oil unit contaminated Defective valve fuses Plug and socket solenoid valve connection defective/interrupted Counter-pressure in travelling drive does not drop below control pressure

5-34

918175/AP0605

# # $ $ %

0A

%

0A

OPTION: auxiliary electr. hydraulics 0A

&

0B

Swivel

0B "

0

! ! "

0B

Auxiliary hydraulics

47MAX

0A

4

0B

BAR BAR BAR

BAR

BAR

0

0B

0B

0B

0I

0I

!

0A "

!

0A "

!

0A "

"

!

0A

BAR

Rotate

X X

Blade Swivel Auxiliary hydraulics ! " 0A

$2 !

0P

0B

0B

0B

2(: 0,2 %$ "!2

4 0 0

2 ' 2 '

X

$"

2 '

Gear motor

Dozer blade cylinder Slewing cylinder

Auxiliary hydraulics

Dipper arm Right-hand side drive

" 0A

0

!)

0

!

0A "

!

0A

3

02

Left-hand side drive Boom

0I $2

0B

dipper arm cylinder

Travelling drive (right)

Travelling drive (left)

"

!

-

0B 0B

! '

' " 0' 3(

5-35

918175/AP0605

9

9

0A

Blade 9

Rotate

Joystick (right)

Joystick (left)

0 0 0 06

02

0A "

4

0A

dipper arm

Righthand side drive

Lefthand side drive Boom

! !

Auxiliary hydraulics Swivel Bucket

0A 0A 0A 0A

0B 0B

0A

Bucket

!

A

0A A

!

0 !

A !

0A 0A A

!

0 A

0A A

0A 0A

0 A

!

0A

$"

0A A

Boom cylinder Bucket cylinder

BAR

Hydraulic System 5.17 Hydraulics diagram A4

06

0

0A

4

Hydraulic System 5.18 Hydraulics diagram (legend)

5-36

Ref. 1 2 3 4 5 6 7 8 9 10

Description Diesel engine Variable displacement pump and gear pump Control oil unit Left-hand side joystick pilot valve Right-hand side joystick pilot valve Main valve block Left-hand side drive pilot valve Boom swivel pilot valve

11 12

Oil cooler Oil filter

13 14

Shuttle valve block Swivel unit

15 16

Remote drive Travelling drive

17 18

Slewing cylinder Dipper arm cylinder

19 20

Boom cylinder Bucket cylinder

21 22

Dozer blade cylinder Hose burst valve

23 24

Electric pilot valve: auxiliary hydraulics (option) Pilot valve: 3rd control circuit (option)

25 26

Change-over valve: dozer blade/triple articulation boom Counterbalance valve: triple articulation boom

27

Triple articulation boom

Dozer blade pilot valve Changeover valve: boom swivel/auxiliary hydraulics

918175/AP0605

5.19 Hydraulics diagram

! '

X

X

0

-

0B

$"

& 0A

2 '

'

0

"

Swivel ! ! " " # # $ $ % %

4

0A

Gear motor

$"

OPTION: auxiliary electr. hydraulics

BAR

X

0A

0B

0A

0A

0

02

0'

0B

0B

0I

Auxiliary hydraulics

9

4

0B

!

0A

A A

!

Auxiliary hydraulics Swivel

! !

Auxiliary hydraulics

"

2(: 0,2 %$ "!2

0A "

0A

0B BAR

!

0A "

Swivel

0B

0A

0

Left-hand side drive

0B

0A

-

0B

!

0I BAR

3

9

$2

0B

!

0B

0A

0A

!

A

0

A

0A "

!

2 '

Right-hand side drive

0

0P

0

0A

0

!)

0A

0

0

0B

0

Boom

Travelling drive (left)

0A

2 '

0B

4

Bucket

5-37

06

! !

A A

Bucket cylinder

9

02

BAR

Bucket

Joystick (right)

Boom

!

06

0A

0A "

0A

0A

"

Boom cylinder

!

! "

0A

A

!

4

Lefthand side drive

Joystick (left)

Dipper arm

0I

BAR

Travelling drive (right)

0A

$2

A

Right-hand side drive

0B

BAR

0A

Rotate

BAR

"

0 0

!

Dipper arm

47MAX

0A

Dipper arm cylinder

0A

Blade

0A

!

Blade Auxiliary hydraulics

0A "

Rotate

Slewing cylinder

0B

0A

3(

Dozer blade cylinder

918175/AP0605

5.20 Main valve block diagram

0B

3

0B

0B

0P

0B

0I

0B

0B

0B

0B

0B

BAR

BAR

BAR

BAR

BAR

4 BAR

4

BAR

0

!

"

" 0A

!

0A

0A

!

"

$2

$2 Pump/tank lines

Main control lines

Pilot control lines

0I

0

0

!)

0

0A

0A

0A

0A

0A

0A

0

"

!

"

!

"

!

!

"

!

"

!

"

0I 0

Port

Legend

Controlled via

Port

Legend

Port

Legend

Pa1, Pb1

Bucket control

Joystick (left)

A1, B1

Bucket cylinder

P1

Port for pump 1

Pa2, Pb2

Boom control

Joystick (left)

A2, B2

Boom cylinder

P2

Port for pump 2

Pa3, Pb3

Left-hand side drive control

Drive pedal (left)

A3, B3

Drive unit (left) via swivel joint

P3

Port for pump 3

Drive unit (right) via swivel joint

P4

Port for pump 4

Pa4, Pb4

Right-hand side drive control

Drive pedal (right)

A4, B4

Pa5, Pb5

Dipper arm control

Joystick (right)

A5, B5

Dipper arm cylinder

T1

Tank line via non-return valve and filter in tank

Pa6, Pb6

Auxiliary hydraulics control

Auxiliary hydraulics pedal

A6, B6

Auxiliary hydraulics

T2

Tank line via oil cooler and filter in tank

Pa7, Pb7

Swivel control

Auxiliary hydraulics pedal

A7, B7

Slewing cylinder

DR1, DR2

Tank lines for boom summation

Dozer blade cylinder Gear motor

Pa8, Pb8

Dozer blade control

Dozer blade pedal

A8, B8

Pa9, Pb9

Rotation control

Joystick (right)

A9, B9

Pi1 Pi2

Boom summation control

Joystick (right)

918175/AP0605

S: bucket pre-tension – see Bucket pre-tension on page 5-12

5-38

4

-

0

X

X

BAR

2 '

3rd control circuit

0A

4

9 0A

!

BAR

Rotate

0B

0B

Joystick (left)

0

0I

Dipper arm

!

"

0

0B

Right-hand side drive

0B

Left-hand side drive

0A " !

0

Boom

0A 0A

0A

-

0A

!

0

!

A

0P

2 '

0

!)

0A

0

A

0B

0A

0

4

Left-hand side drive

!

A

!

0A

A

$2

0

Right-hand side drive

0A

47MAX

0A

" 0A

BAR

3rd control circuit

0B

0A !

BAR

3rd control circuit

Auxiliary hydraulics Swivel

0A

0 0

dipper arm

0B

2(: 0,2 %$ "!2

0A

"

0B

!

"

!

Travelling drive (left)

BAR

0I

4

Bucket

9

06

! !

A A

Bucket cylinder

06

Joystick (right)

02

!

Bucket

Boom cylinder

0A

Boom BAR

0A

0B

"

0A

2 '

0A

9

3

$2

"

5-39

0A

0B

0A

0B

0A 0A

Blade

A

! !

0A

0B

!

Auxiliary hydraulics

Dipper arm cylinder

Travelling drive (right)

0B

0 02

!

Swivel

Auxiliary hydraulics

' " 0'

A

BAR

3(

0B

0A "

0A "

Slewing cylinder

0B

X

Blade

0B

0A " !

Rotate

Dozer blade cylinder

! ! " " # # $ $ % %

0I

0A

Gear motor

&

! '

$"

$"

5.21 Hydraulics diagram with 3rd control circuit (option)

918175/AP0605

5.22 Main valve block diagram with 3rd control circuit (option)

0B

3

0B

0B

0P

0B

0I

0B

0B

0B

0B

0B

0B

BAR

BAR

BAR

BAR

BAR

4 BAR

4

0 BAR

0A

$2 0I

0A

0A

Port

Legend

Controlled via

Port

Legend

Port

Legend

Pa1, Pb1

Bucket control

Joystick (left)

A1, B1

Bucket cylinder

P1

Port for pump 1

Pa2, Pb2

Boom control

Joystick (left)

A2, B2

Boom cylinder

P2

Port for pump 2

Pa3, Pb3

Left-hand side drive control

Drive pedal (left)

A3, B3

Drive unit (left) via swivel joint

P3

Port for pump 3

Drive unit (right) via swivel joint

P4

Port for pump 4

Pa4, Pb4

Right-hand side drive control

Drive pedal (right)

A4, B4

Pa5, Pb5

Dipper arm control

Joystick (right)

A5, B5

Dipper arm cylinder

T1

Tank line via non-return valve and filter in tank

Pa6, Pb6

Auxiliary hydraulics control

Auxiliary hydraulics pedal

A6, B6

Auxiliary hydraulics

T2

Tank line via oil cooler and filter in tank

Pa7, Pb7

Swivel control

Auxiliary hydraulics pedal

A7, B7

Slewing cylinder

DR1, DR2

Tank lines for boom summation

3rd control circuit

Pa8, Pb8

3rd control circuit (control)

Joystick (left)

A8, B8

Pa9, Pb9

Dozer blade control

Dozer blade pedal

A9, B9

Dozer blade cylinder

Pa10, Pb10

Rotation control

Joystick (right)

A10, B10

Gear motor

Pi1 Pi2

Boom summation control

Joystick (right)

918175/AP0605

!

"

"

!

"

!

0

0A

$2

0A

0A

0A

0A

0A

0A

0

Pump/tank lines

Main control lines

Pilot control lines

!)

0 "

!

"

!

"

!

"

!

!

"

!

"

!

"

0I

0

S: bucket pre-tension – see Bucket pre-tension on page 5-12

5-40

Electrical system

6

Electrical system

6.1

Ohm's Law (current, voltage, resistance); power It describes the interrelation between current, voltage and resistance.

Current “I” – Ampere (A) Voltage “E” – Volt (V) Resistance “R” – Ohm (ΩW)

Mnemonic:

E R

I

Output Power "P" – Watt (W) P = U x I = R x I² = U²/R

6.2

Measuring equipment, measuring methods Multi-function measuring device

• Measurements of values (E, R, I, f) • Continuity test • Diode test Calculate measuring range using known data (P, E, R, I) and set before measuring.

Use AC/DC basic setting. ➥ AC = alternating current/voltage;

➥ DC = direct current/voltage Test device with acoustic and optical signal output

• Continuity test of de-energized machine electrical system and wiring harnesses

918175/AP0605

6-1

Electrical system Measuring methods – multi-function measuring device

• Measuring current (ignition turned on): • Black cable in COM socket (ground) • Red cable in A socket or mA socket; connect in series to load

• Measuring voltage (ignition turned on): • Black cable in COM socket (ground) • Red cable in V socket • Connect in parallel to load • Measuring resistance (ignition turned off): • Black cable in COM socket (ground), • Red cable in Ω-socket; • Connect in parallel to load (see measuring voltage).

Test lamp The test lamp is used to test lines and functions with the ignition turned on.

• Line test (testing voltage): Connect test lamp between the live cable and machine ground • Functional check (testing current): Connect test lamp between a connection on the load to be tested and the connection line

6.3

Cable color coding Color Black Brown Red Orange Yellow Green Blue Violet Grey White Pink

6-2

Code blk brn red org yel grn blu vio gry wht pnk

918175/AP0605

Electrical system 6.4

Relays

Use, mode of function

Relays are used for switching electric loads (high currents) where the control power of the relay coil is relatively low. Because of this, relays can be controlled by microelectronics or microswitches (e.g. touchpad keyboards, sensors). The switch contacts can be make-contact, break-contact or changeover switches. These perform the actual switching function.

Zero-center relay

86

30

86 = Start of coil

(control line)

85 = End of coil

(ground)

30 = Input

(load line)

87 = Make-contact switch output (load line) 87 a = Break-contact switch output (load line) 85

87 87a

Fig. 5: Terminal description on relay

6.5

Electric units Units Alternator Starter

12 V, 55 A 12 V, 2.3 kW

Battery

12 V, 88 Ah Accessory power outlet (e.g., for cigarette lighter) 15 A max.

Socket

6.6

Fuse box in instrument panel Fuse no.

Rated current (A)

Protected circuit

F3

10 A

Indicators, engine relay

F4

10 A

Boom working light

F5

15A

Cab working light

F6

10 A

Valves, horn

F7

15A

Heating, air conditioning

F8

10 A

Wiper, interior light

F9

10 A

Rotating beacon, radio, drive interlock

F10

15A

Accessory power socket (cigarette lighter)

F3 F4 F5 F6 F7 F8 F9 F10 Fig. 6: Fuse box

918175/AP0605

6-3

Electrical system 6.7

Main fuse box with relays The main fuse box is located under the cab.

K9

K5

F1 F2

Fuse no.

Rated current (A)

Protected circuit

F1

40 A

Start, pre-heat, cut-off solenoid

F2

50 A

Fuel-filling pump, main fuse, ignition lock

Relay no.

Fig. 7: Relay box under the cab

6.8

K9

Cut-off solenoid switching relay

K5

Preheating high current relay

Relays Relays are located in the relay box under the cab, next to the swiveling console

K7

Switching relay no.

Protected circuit

K6

Pre-heating timer (indicator only); black plug

K7

Starting relay

K8

Cut-off solenoid timer; white plug

V1

Cut-off solenoid recovery diode

V1

K6

K81

Fig. 8: Relays

6-4

918175/AP0605

Electrical system 6.9

Socket The socket, (A) Fig 9, is located above the lubrication strip (B).

A

B

Fig. 9: Lubrication strip on the chassis

6.10 Tip switches on joystick Left-hand side joystick 2

3

Ref. 1 2 3

1

Description Changeover or boom swivel and auxiliary hydraulics (S27) Tip switch for additional control circuit (S30) Tip switch for additional control circuit (S31)

1

Fig. 10:Left-hand side joystick (standard and option)

Right-hand side joystick 2

3

Ref. 1 2 3

1

Description Horn (S55) Not assigned Automatic idling speed feature (S48)

1

Fig. 11:Right-hand side joystick (standard and option)

918175/AP0605

6-5

Electrical system 6.11 Instrument panel: overview

1

2

7

3

5

6

Ref. 1 2 3 4 5 6 7

6-6

7

6

5

4

4

3

2

1

Description Indicator (X10) Temperature indicator – diesel engine (X13) Accessory power socket (cigarette lighter) (E15) Pre-heating start switch (S1) Fuse box (– see Fuse box in instrument panel on page 6-3) Switch panel Radio option (A1)

918175/AP0605

Electrical system 6.12 Switches: overview

8

10

9

12

11

Ref. 8 9 10 11 12 13 14 15 16 17

13

14

15

16

17

Description Switch – high speed (S21) Switch – wiper/washer (S20) Switch – boom working light (S16) Switch – cab working light (S17) Switch – rotating beacon (S18) Switch – ventilation (S15) Switch – air conditioning system option (S51) Switch – safe load indicator option (S42) Not assigned Not assigned

6.13 Alternator The alternator charges the battery and supplies rectified -phase alternating current to electric components.

Ref. 1 2

1

Description Connection B (battery) Connection P starting relay Connection IG indicator (12V) Connection L indicator (ground)

2

Fig. 12:Alternator

918175/AP0605

6-7

Electrical system 6.14 Starter 2

Ref. 1

1

2

Description Connection S starting relay Connection B battery

Fig. 13:Alternator

6-8

918175/AP0605

Electrical system

Electrical system 6.15 Wiring harness 1000109629: cab roof

B11

B12

10

12

11

Radio

A1

13 8

Loudspeaker

6

X X 7

Interior light E14 Rear roof light

E7

Rotating beacon H28

13

X X

8A

E9

11

6

15

Front roof light

12

5

8

7

4

10

5

2

X X

3

1

4

2

X X

8 8A

X 3

1

Cab connection

5 7 9 2

1

1

6

6

2

2

7

7

3

3

4

4

8

8

5

5

9

9

X12

14 15 3

14

GND1

GND2

grn/yel (X12/1) grn/yel

blu (X12/6)

blu

brn (X12/4) l 50

blk (GND1)

M2 Wiper blk

No. 1 2 3 4 5

6-9

From X12 (1) 9 pole plug and socket connector – cab X12 (2) 9 pole plug and socket connector – cab X12 (3) 9 pole plug and socket connector – cab X12 (4) 9 pole plug and socket connector – cab X12 (5) 9 pole plug and socket connector – cab

brn

To M2 wiper motor

Color mm² grn/yel 0.75

No. 6

H28 rotating beacon

vio

1

7

GND1

blk

1

8

M2 wiper motor

brn

0.75

8A 9

E9 front roof light

grn/red

1 10

From X12 (6) 9 pole plug and socket connector – cab X12 (7) 9 pole plug and socket connector – cab X12 (8) 9 pole plug and socket connector – cab A1.1/4 radio X12 (9) 9 pole plug and socket connector – cab A1/6 radio

To M2 wiper motor

Color mm² blu 0.75

E14 interior light

blu

1

A1.1/4 radio

red

1

A1.1/7 radio E7 rear roof light

red grn/blu

1 1

B11 loudspeaker

wht

0.5

No. 11 12 13 14 15 16

From A1/5 radio A1/4 radio A1/3 radio GND1 GND1 GND1

To B11 loudspeaker B12 loudspeaker B12 loudspeaker GND2 A1.1/8 radio M2 wiper motor

Color wht/blk wht wht/blk blk blk blk

mm² 0.5 0.5 0.5 1.5 1 0.75

918175/AP0605

Electrical system 6.16 Wiring diagram version 1

918175/AP0605

6-10

Electrical system 6.17 Wiring diagram version 1: legend No. A1 B1 B2 B6 B11 B12 E7 E9 E10 E11 E14 E15 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 G1 G2 H2 H3 H4 H5 H6 H7 H9 H28 H33 H30 K5 K6 K7 K8

6-11

Description Radio Fuel indicator Horn Engine oil temperature sensor Loudspeaker Loudspeaker Rear roof light Front roof light Front roof light Boom light Interior light Cigarette lighter Main fuse: starter, pre-heating Main fuse + fuel-filling pump Indicators, engine relay Boom working light Cab working light Valves, horn Fan, air conditioning Wiper, interior light Rotating beacon, radio, drive interlock Socket, accessory Alternator Battery Pre-heating indicator Engine temperature indicator Engine oil pressure indicator Alternator charge function indicator Air filter indicator Hydraulic oil filter indicator Safe load indicator Rotating beacon Spare indicator Spare indicator Pre-heating high current relay Pre-heating time lag relay High current relay – start Cut-off solenoid time lag relay

Section E14 F6 D/E10 E6 E15 E15 F14 F13 F8/9 E/F13 A14 E2 E1 A4 A7 A8 A9 A10 A12 A13 A14 F3 F1 B3 B3 B3 B3 B3 B3 C3 F13 B3 C3 E4 D5 E2 D3

Loc. Opt

Opt Opt Opt Opt Opt

Opt Opt

No. K9 M1 M2 M4 M5 M7 M9 P1 P2 P3 R1 S1 S2 S3 S4 S5 S8 S15 S16 S17 S18 S20 S21 S21.1 S27 S28 S30 S31 S41 S42 S48 S51 S52 S54 S55 V1 X1 X2

Description Cut-off solenoid switching relay Starter Wiper motor Fan Washer pump Fuel-filling pump Fuel pump Hour meter Fuel level indicator Engine oil temperature gauge Glow plug Pre-heating start switch Engine oil pressure switch Engine temperature switch Air filter pressure switch Hydraulic oil pressure switch Battery master switch Ventilation switch Boom working light switch Cab working light switch Rotating beacon switch Wiper/washer switch High speed switch High speed tip switch (prepared) Additional hydraulics/swivel tip switch Safety switch Additional control circuit tip switch Additional control circuit tip switch Safe load indicator pressure switch Safe load indicator switch Automatic idling speed tip switch Air conditioning switch Air conditioning pressure switch Air conditioning thermostat Horn tip switch Recovery diode 13 pole connection – engine/chassis 11 pole connection – engine/chassis

Section E3 F2 F13 C12 F8 F1 F3 B3 B3 A3 F4 A1 F5 E5 F6 F7 F1 A10 A7 A8 A13 A20 A9 E9 D10 C28 D9 D9 E8 A7 C9 A11 E12 D12 C10 E4 D4-6 D7-9

Loc.

Opt Opt Opt Opt

Opt Opt Opt Opt

No. X3 X4 X5 X6 X7 X8 X10 X11 X12 X13 X14 X15 X16 X19 XE11 XS41 Y1 Y3 Y13 Y14 Y15 Y16 Y17 Y31

Description Section 2 pole main connection D0 9 pole connection – drive interlock C/D1 7 pole connection – armrest/chassis D11/12 5 pole connection – armrest switch C11/12 6 pole connection – joystick (right) C11 6 pole connection – joystick (left) D11 15 pole connection – indicator B/C3 2 pole connection – (unused) B6 9 pole connection – cab C13/14 5 pole connection – engine temperature A3 2 pole connection – automatic revs setting D3 1 pole connection – drive alarm D1 3 pole connection – drive alarm E2 1 pole connection – socket F7 2 pole connection – boom working light E9 2 pole connection – safe load indicator E8 Cut-off solenoid F4 high speed solenoid valve F9 Solenoid valve for safety valve F13 Solenoid valve – automatic idling speed F9 setting Solenoid valve – auxiliary hydraulics/swivel F10 Solenoid valve – additional control circuit F10 Solenoid valve – additional control circuit F11 Solenoid valve – air conditioning F12

Loc.

Opt

Opt Opt Opt

Opt Opt Opt Opt Opt Opt Opt Opt

918175/AP0605

Electrical system 6.18 Wiring diagram version 1

918175/AP0605

6-12

Electrical system 6.19 Wiring diagram version 2: legend No. A1 B1 B2 B6 B11 B12 B14 E7 E9 E10 E11 E14 E15 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 G1 G2 H2 H3 H4 H5 H6 H7 H9 H28 H33

6-13

Description Radio Fuel indicator Horn Engine oil temperature sensor Loudspeaker Loudspeaker Warning buzzer Rear roof light Front roof light Front roof light Boom light Interior light Cigarette lighter Main fuse: starter, pre-heating Main fuse + fuel-filling pump Indicators, engine relay Boom working light Cab working light Valves, horn Fan, air conditioning Wiper, interior light Rotating beacon, radio, drive interlock Socket, cigarette lighter Alternator Battery Pre-heating indicator Engine temperature indicator Engine oil pressure indicator Alternator charge function indicator Air filter indicator Hydraulic oil filter indicator Safe load indicator Rotating beacon Spare indicator

Section E14 F6 D/E10 E6 E15 E15 C2 F14 F13 F8/9 E/F13 A14 E2 E1 A4 A7 A8 A9 A10 A12 A13 A14 F3 F1 B1 B1 B1 B1 B1 B1 C3 F13 B1

Loc. Opt

Opt Opt Opt Opt Opt .

Opt Opt

No. H30 K5 K6 K7 K8 K9 M1 M2 M4 M5 M7 M9 P1 P2 P3 R1 S1 S2 S3 S4 S5 S8 S15 S16 S17 S18 S20 S21 S21.1 S27 S28 S30 S31 S41

Description Spare indicator Pre-heating high current relay Pre-heating time lag relay High current relay – start Cut-off solenoid time lag relay Cut-off solenoid switching relay Starter Wiper motor Fan Washer pump Fuel-filling pump Fuel pump Hour meter Fuel level indication Engine oil temperature gauge Glow plug Pre-heating start switch Engine oil pressure switch Engine temperature switch Air filter pressure switch Hydraulic oil pressure switch Battery master switch Ventilation switch Boom working light switch Cab working light switch Rotating beacon switch Wiper/washer switch High speed switch High speed tip switch (prepared) Additional hydraulics/swivel tip switch Safety switch Additional control circuit tip switch Additional control circuit tip switch Safe load indicator pressure switch

Section C3 E4 D5 E2 D3 E3 F2 F13 C12 F8 F1 F3 B1 B1 A3 F4 A1 F5 E5 F6 F7 F1 A10 A7 A8 A13 A20 A9 E9 D10 C28 D9 D9 E8

Loc.

Opt

No. S42 S48 S51 S52 S54 S55 V1 X1 X2 X3 X4 X5 X6 X7 X8 X10 X11 X12 X13 X14 X15 X16 X19 XE11 XS41 Y1 Y3 Y13 Y14

Opt Opt Opt

Y15 Y16 Y17 Y31

Opt Opt Opt Opt

Opt Opt Opt

Description Section Safe load indicator switch A7 Automatic idling speed tip switch C9 Air conditioning switch A11 Air conditioning pressure switch E12 Air conditioning thermostat D12 Horn tip switch C10 Recovery diode E4 13 pole connection – engine/chassis D4-6 11 pole connection – engine/chassis D7-9 2 pole main connection D0 9 pole connection – drive interlock C/D3 7 pole connection – armrest/chassis D11/12 5 pole connection – armrest switch C11/12 6 pole connection – joystick (right) C11 6 pole connection – joystick (left) D11 15 pole connection – indicator B/C1 2 pole connection – (unused) B6 9 pole connection – cab C13/14 5 pole connection – engine temperature A3 2 pole connection – automatic revs setting D3 1 pole connection – drive alarm D1 3 pole connection – drive alarm E2 1 pole connection – socket F7 2 pole connection – boom working light E9 2 pole connection – safe load indicator E8 Cut-off solenoid F4 high speed solenoid valve F9 Solenoid valve for safety valve F13 Solenoid valve – automatic idling speed set- F9 ting Solenoid valve – auxiliary hydraulics/swivel F10 Solenoid valve – additional control circuit F10 Solenoid valve – additional control circuit F11 Solenoid valve – air conditioning F12

Loc. Opt Opt Opt Opt Opt

Opt

Opt Opt Opt

918175/AP0605

Electrical system 6.20 Wiring diagram version 2

918175/AP0605

6-14

Electrical system 6.21 Wiring harness 1000109624 (legend): engine – chassis No. 1 2 3 4 5 6 7 8 9 10 11 12

16A 17

From G1/B alternator G1/B alternator M1 starter F1 main fuse K5/30 pre-heating relay F1 main fuse F2 main fuse F2 main fuse GND K7/B start high current relay K5/87 pre-heating relay K9/87 cut-off solenoid switching relay M9/1 fuel pump GND K8 cut-off solenoid time lag relay K8 cut-off solenoid time lag relay V1 blocking diode M9/1 fuel pump

18

G1/2 alternator

19

K6 pre-heating time lag relay

20 21

K6 pre-heating time lag relay K6 pre-heating time lag relay

22 23

K6 pre-heating time lag relay K6 pre-heating time lag relay

24

K8 cut-off solenoid time lag relay K8 cut-off solenoid time lag relay K7/6 start high current relay GND K5/85 pre-heating relay K6 pre-heating time lag relay

13 14 15 16

25 26 27 28 29 30

6-15

K8 cut-off solenoid time lag relay

To M1 starter F1 main fuse F2 main fuse K5/30 pre-heating relay K9/30 cut-off solenoid relay K7/A start high current relay X3/A main connection M7 fuel-filling pump M7 fuel-filling pump M1 starter R1 glow plug Y1/1 cut-off solenoid

Color red red red red red red red red blk wht/red brn wht

Y1/2 cut-off solenoid Y1/3 cut-off solenoid X1/2 engine/chassis connection V1 blocking diode

blu blk blu blu

K7/1 start high current relay blu X1/2 engine/chassis connec- blu tion X1/1 engine/chassis connec- blu tion X1/3 engine/chassis connec- brn tion K5/86 preheating relay brn X1/4 engine/chassis connec- wht/blk tion K7/3 start high current relay wht/blk X1/5 engine/chassis connec- gry/red tion K9/86 cut-off solenoid switch- blu/blk ing relay K9/85 cut-off solenoid switch- pnk/blk ing relay G1/3 alternator blk/blu K5/85 pre-heating relay blk K6 pre-heating time lag relay blk K8 cut-off solenoid time lag blk relay V1 blocking diode blk

No. From 30A V1 blocking diode 31 G1/1 alternator 32 33 34 35 36 37 38 38A 39 40 41 44 45 46 47 48 49 50 51 52 53 54 55 56

To Color K7/5 start high current relay blk X1/6 engine/chassis connec- pnk tion S2 engine oil pressure switch X1/7 engine/chassis connec- wht/grn tion S3 engine temperature switch X1/8 engine/chassis connec- blk/grn tion S3 engine temperature switch X1/9 engine/chassis connec- grn/wht tion S4 air filter pressure switch X1/10 engine/chassis congry/blu nection S4 air filter pressure switch GND blk B1 fuel level indicator X1/11 engine/chassis connec- vio/blk tion GND X16/2 drive alarm connection blk B1 fuel level indicator X16/2 drive alarm connection blk B1 fuel level indicator S5 pre-heating start switch blk S5 pre-heating start switch X2/1 engine/chassis connec- org/wht tion X16/1 drive alarm connection X1/1 engine/chassis connec- blu tion S21.1 high speed tip switch X2/2 engine/chassis connec- gry (prepared) tion S21.1 high speed tip switch B2 horn gry (prepared) B2 horn X5/5 armrest/chassis connec- org tion X19 socket X2/4 engine/chassis connec- red/blk tion X19 socket GND blk M5 washer pump X2/5 engine/chassis connec- blk/wht tion M5 washer pump GND blk XS41/1 safe load indicator X2/6 engine/chassis connec- vio/blu tion XS41/2 safe load indicator GND blk XE11/1 boom working light X2/7 engine/chassis connec- grn/yel tion XE11/2 boom working light GND blk S21.1/1 high speed tip switch X2/8 engine/chassis connec- brn/blk (prepared) tion Y3 high speed solenoid valve X2/8 engine/chassis connec- brn/blk tion

No. From 57 Y3 high speed solenoid valve 58 Y13 solenoid valve for safety valve 60 GND 61 62 63 64 65 66 67 68 69 70 71 72 73 79 80

To Color GND blk X5/4 armrest/chassis connec- brn/wht tion Y13 solenoid valve for safety blk valve M9/2 fuel pump blk X5/1 armrest/chassis connec- blu/yel tion GND blk

GND Y15/1 auxiliary hydraulics/ swivel solenoid valve Y15/2 auxiliary hydraulics/ swivel solenoid valve Y16/1 electr. auxiliary hydrau- X5/2 armrest/chassis connec- gry/yel lics solenoid valve tion Y16/2 electr. auxiliary hydrau- GND blk lics solenoid valve Y17/1 electr. auxiliary hydrau- X5/3 armrest/chassis connec- gry/grn lics solenoid valve tion Y17/2 electr. auxiliary hydrau- GND blk lics solenoid valve S52 air conditioning pressure X5/7 armrest/chassis connec- yel/red switch tion S52 air conditioning pressure X2/11 engine/chassis connec- yel/red switch tion X2/11 engine/chassis connec- Y31 air conditioning solenoid yel/red tion valve Y14/1 changeover valve sole- X2/9 engine/chassis connec- brn/grn noid valve tion Y14/2 changeover valve sole- GND blk noid valve GND X5/6 armrest/chassis connec- blk tion X15 drive alarm connection X16/3 drive alarm connection gry/blk GND X3/B main connection blk

918175/AP0605

Electrical system 6.22 Wiring harness 1000109624: engine – chassis

AH/swivel changeover valve

Changeover valve

Y14

1

Y15

1

2

Electr. AH valve

1

2

Electr. AH valve

Y16

Y17

1

2

Preheating

Cut-off solenoid

K6

K8

2

Starting relay

Cut-off solenoid

K7

K9

6 16A A

X1

8

33

41

9

34

15

10

35

19 3

11

37

12

X

23 5 31 6

13

X

32 7

71

21 4

53

40

1

8 55 56

44

2

71

X

3

47

4

X

49

5

11 69 70

51

6

7

X2

3

18 1 17 2

9

10

1

3 2

72

62

3

1

2

63

64

1

3 2

66

65

1

V1

67

2

21 22

23

24

25

19 20

28 29

15 16

29 30

B

X

30A

22

2

3

4

5

6

30A

26

12

85

25

K5

6

11

87 86

85

24

27 28

30

16 22 30 26

25

12

87 86

20 4 5

5

24

27 28

F2

50A

30

5

10 10

Blocking diode

X 1

Main fuses

F1

40A

Preheat

11

4

2 4 5

6

7

3

8

20

30

16A 16

Wiring harness connection 1000124173 45

46

B2

50

M5

49

Horn

Washer pump 47

A

7

55

79

44

X15

62

1

6

73

64

2

7

68

58 4

Wiring harness connection 1000124101

S5

GND

high speed valve

Y3

Safety valve

Y13

36

41 79

1

Fuel pump

M9

52

51

54

Air filter pressure switch

2

1

XE11

53

Boom working light

26

3

18

2

31

1

Alternator

13

38 38A 3

61

2

2

S52

S4 35

1

17

Drive alarm

M7

XS41

Socket

39

Hydraulic oil pressure switch

X16

Fuel-filling pump

Air conditioning pressure switch

X19

60 58

40

57 60 61 63 65 67 72 73 80

X

Safe load indicator

S21.1

57 56

9 14 27 36 38 48 50 52 54

66 3

X

48

8

46

9

X5

5

69

45

high speed switch (prepared)

Drive alarm

68

G1

X3

B

80

1 2

37

1

32

70

Starter 12 3

Air conditioning valve

Y31

918175/AP0605

1 3

10

38A 39

11

B1

Fuel level indicator

Preheating system

R1

Engine oil pressure

S2

13

2

14

M1

34 33

Cut-off solenoid

Water temperature switch

Y1

S3

6-16

Electrical system 6.23 Wiring harness 1000109630 (legend) version 1: switches No.

From

To

Color

No.

From

To

Color

No.

From

To

Color

7

X3/A main connection

S1/1 pre-heating start switch

red

71

X2/9 engine/chassis connection

X6/1 armrest switch connection

brn/grn

112

F3 indicators and engine relay fuse

X13 engine temperature connection

blu

7A

S1/1 pre-heating start switch

F10 socket and cigarette lighter fuse

red

76

F6 valves and horn fuse

X4/6 drive interlock connection

gry

113

X10/1 indicator connection

X13 engine temperature connection

blu

15

X1/2 engine/chassis connection

X4/9 drive interlock connection

blu

78

X4/3 drive interlock connection

X12/3 cab connection

blk

114

F3 indicators and engine relay fuse

blu

15A

X4.1/9 drive interlock connection

X4.1/5 drive interlock connection

blu

82

S51/5 air conditioning switch

X6/2 armrest switch connection

yel/red

X14/1 automatic revs setting connection

19

X1/3 engine/chassis connection

S1/8 pre-heating start switch

brn

83

S15/3 ventilation switch

X6/3 armrest switch connection

yel/blk

115

S18/10 rotating beacon switch

X14/1 automatic revs setting connection

blu

19A

S1/3 pre-heating start switch

S1/6 pre-heating start switch

brn

84

S15/6 ventilation switch

X6/4 armrest switch connection

yel/blu

116

S18/10 rotating beacon switch

S42/10 safe load indicator switch

vio/blu

21

X1/4 engine/chassis connection

X4/8 drive interlock connection

wht/blk

86

X4/4 drive interlock connection

S1/7 pre-heating start switch

wht/blk

117

S16/B boom working light switch

E15 cigarette lighter

grn/yel

21A

X4.1/4 drive interlock connection

X4.1/8 drive interlock connection

wht/blk

87

F6 valves and horn fuse

S21/5 high speed switch

gry

118

X13 engine temperature connection

E15 cigarette lighter

grn/yel

23

X1/5 engine/chassis connection

X10/10 indicator connection

gry/red

88

S21/10 high speed switch

S21/5 high speed switch

gry

119

X13 engine temperature connection

X10/2 indicator connection

grn/yel

31

X1/6 engine/chassis connection

X10/7 indicator connection

pnk

89

F8 wiper and interior light fuse

S20/2 wiper/washer switch

blu

120

F10 socket, cigarette lighter

E15 cigarette lighter

red/blk

32

X1/7 engine/chassis connection

X10/8 indicator connection

wht/ grn

90

S20/10 wiper/washer switch

S20/2 wiper/washer switch

blu

121

red

X12/4 cab connection

S20/6 wiper/washer switch

blu/wht

F9 rotating beacon, radio and drive interlock fuse

X12/8 cab connection

91 92

S20/7 wiper/washer switch

S20/6 wiper/washer switch

blu/wht

122

X11/1 (unused)

X2/3 engine/chassis connection

brn/blu

93

S20/5 wiper/washer switch

X12/1 cab connection

blu/red

123

X10/5 indicator connection

X11/2 (unused)

blk

94

F4 boom working light fuse

S16/5 boom working light switch

grn

124

X13 engine temperature connection

X11/2 (unused)

blk

94A

S16/10 boom working light switch

S16/5 boom working light switch

grn

125

X13 engine temperature connection

X13 engine temperature connection

blk

95

F5 cab working light fuse

S17/1 cab working light switch

grn

126

X13 engine temperature connection

blk

96

S17/1 cab working light switch

S17/2 cab working light switch

grn

X14/2 automatic revs setting connection

127

X14/2 automatic revs setting connection

S21/9 high speed switch

blk

128

S20/9 wiper/washer switch

S21/9 high speed switch

blk

129

S20/9 wiper/washer switch

S16/9 boom working light switch

blk

130

S17/9 cab working light switch

S16/9 boom working light switch

blk

131

S17/9 cab working light switch

S18/9 rotating beacon switch

blk

132

S15/9 ventilation switch

S18/9 rotating beacon switch

blk

133

S15/9 ventilation switch

S51/9 air conditioning switch

blk

134

S42/9 safe load indicator switch

S51/9 air conditioning switch

blk

135

S42/9 safe load indicator switch

X3/B main connection

blk

136

E15 cigarette lighter

X3/B main connection

blk

137

X12/3 cab connection

X3/B main connection

blk

138

S1/5 pre-heating start switch

F4 boom working light fuse

blu

139

S1/6 pre-heating start switch

F7 fan and air conditioning fuse

blu

33

X1/8 engine/chassis connection

X10/9 indicator connection

blk/grn

34

X1/9 engine/chassis connection

X13 engine temperature connection

grn/ wht

35

X1/10 engine/chassis connection

X10/6 indicator connection

gry/blu

37

X1/11 engine/chassis connection

X10/4 indicator connection

vio/blk

40

X2/1 engine/chassis connection

X10/12 indicator connection

org/ wht

41

X1/1 engine/chassis connection

F3 indicators and engine relay fuse

blu

97

S17/1 cab working light switch

S17/10 cab working light switch

grn

42

X1/1 engine/chassis connection

X4/5 drive interlock connection

blu

98

F8 wiper and interior light fuse

X12/7 cab connection

blu

42A

X4/7 drive interlock connection

X4/5 drive interlock connection

blu

98A

X12/7 cab connection

X12/8 cab connection

blu

43

X4/5 drive interlock connection

F9 rotating beacon, radio and drive interlock fuse

red

99

S17/1 cab working light switch

X12/5 cab connection

grn/red

101

S17/3 cab working light switch

X12/9 cab connection

grn/blu

102

F9 rotating beacon, radio and drive interlock fuse

S18/5 rotating beacon switch

red

44

X2/2 engine/chassis connection

F6 valves and horn fuse

gry

47

X2/4 engine/chassis connection

F10 socket and cigarette lighter fuse

red/blk

49

X2/5 engine/chassis connection

S20/3 wiper/washer switch

blk/wht

103

S18/1 rotating beacon switch

X12/2 cab connection

vio

51

X2/6 engine/chassis connection

S42/5 safe load indicator switch

vio/blu

105

F7 fan and air conditioning fuse

S15/2 ventilation switch

yel

53

X2/7 engine/chassis connection

S16/1 boom working light switch

grn/yel

106

S15/1 ventilation switch

S15/2 ventilation switch

yel

55

X2/8 engine/chassis connection

S21/1 high speed switch

brn/blk

107

S15/1 ventilation switch

S15/10 ventilation switch

yel

58A

X4.1/1 drive interlock connection

X4.1/6 drive interlock connection

brn/ wht

108

S51/10 air conditioning switch

S15/10 ventilation switch

yel

109

S15/3 ventilation switch

S51/1 air conditioning switch

yel/blk

110

S42/1 safe load indicator switch

X10/14 indicator connection

vio/blu

59

6-17

X4/1 drive interlock connection

X6/5 armrest switch connection

gry

918175/AP0605

Electrical system 6.24 Wiring harness 1000109630 version 1: switches Boom working light switch

3

3

3

8

8

8 8 8 8

!

8 8

8

8

8

8 8 8 8

!

8 8 8 8

8

8

High speed switch

3

8

8

3

8 8

3

8

Wiper/washer switch

8 8 8 8

3

8

8

Cab working light switch

3

8 8

8

8 8

8 8 8

8

Preheating start switch

3

Automatic revs setting connection

!

%

Indicator connection

8

8

8

Engine temperature connection

!

8

8

Accessory power socket

!

Rotating beacon switch

Ventilation switch

Air conditioning switch

37&

Safe load indicator switch

8

8

8

8

8

8

8

Engine/chassis connection

918175/AP0605

8

8

!

"

8

Main connection

8 Engine/chassis connection

!

!

8 Armrest switch connection

8

!

!

Drive interlock connec-

tion

8

Cab connection

!

" &

"

# &

#

$ &

$

% &

%

& &

&

' &

'

!

!

!

!

8

! &

8

8

8

8

8

8

8

8

8

8

8

(

Indicators, controls, engine and cut-off solenoid holding contact

Boom working light

Cab working light

Valves

Heating, air conditioning

Wiper, interior light

8

8

8

8

!

( & 8

Rotating beacon, radio, drive interlock Socket, cigarette lighter

6-18

Electrical system 6.25 Wiring harness (legend) version 2: switches A4 No. From 7 X3/A main connection 7A S1/1 pre-heating start switch 15 X1/2 engine/chassis connection 15A X4.1/9 drive interlock connection 19 X1/3 engine/chassis connection 19A S1/3 pre-heating start switch 21 X1/4 engine/chassis connection 21A X4.1/4 drive interlock connection 23 X1/5 engine/chassis connection 31 X1/6 engine/chassis connection 32 X1/7 engine/chassis connection 32A X10/10 indicator connection 33 X1/8 engine/chassis connection 33A X10/14 indicator connection 34 X1/9 engine/chassis connection 35 X1/10 engine/chassis connection 37 X1/11 engine/chassis connection 40 X2/1 engine/chassis connection 41 X1/1 engine/chassis connection 42 X1/1 engine/chassis connection 42A X4/7 drive interlock connection 43 X4/5 drive interlock connection 44 X2/2 engine/chassis connection 47 X2/4 engine/chassis connection 49 X2/5 engine/chassis connection 51 X2/6 engine/chassis connection 53 X2/7 engine/chassis connection 55 X2/8 engine/chassis connection 58A X4.1/1 drive interlock connection 59 X4/1 drive interlock connection 71 X2/9 engine/chassis connection 76 F6 valves and horn fuse 78 X4/3 drive interlock connection 82 S51/5 air conditioning switch 83 S15/3 ventilation switch 84 S15/6 ventilation switch 86 X4/4 drive interlock connection 87 F6 valves and horn fuse 88 S21/10 high speed switch 89 F8 wiper and interior light fuse 90 S20/10 wiper/washer switch 91 X12/4 cab connection 92 S20/7 wiper/washer switch 93 S20/5 wiper/washer switch 94 F4 boom working light fuse 94A S16/10 boom working light switch 95 F5 cab working light fuse 96 S17/1 cab working light switch 97 S17/1 cab working light switch 98 F8 wiper and interior light fuse 98A X12/7 cab connection

6-19

To S1/1 pre-heating start switch F10 socket and cigarette lighter fuse X4/9 drive interlock connection X4.1/5 drive interlock connection S1/8 pre-heating start switch S1/6 pre-heating start switch X4/8 drive interlock connection X4.1/8 drive interlock connection X10/10 indicator connection X10/8 indicator connection B14/5 warning buzzer connection B14/5 warning buzzer connection B14/6 warning buzzer connection B14/6 warning buzzer connection X13 engine temperature connection X10/3 indicator connection X10/4 indicator connection X10/6 indicator connection F3 indicators and engine relay fuse X4/5 drive interlock connection X4/5 drive interlock connection F9 rotating beacon, radio and drive interlock fuse F6 valves and horn fuse F10 socket and cigarette lighter fuse S20/3 wiper/washer switch S42/5 safe load indicator switch S16/1 boom working light switch S21/1 high high speedspeed switch X4.1/6 drive interlock connection X6/5 armrest switch connection X6/1 armrest switch connection X4/6 drive interlock connection X12/3 cab connection X6/2 armrest switch connection X6/3 armrest switch connection X6/4 armrest switch connection S1/7 pre-heating start switch S21/5 high speed switch S21/5 high speed switch S20/2 wiper/washer switch S20/2 wiper/washer switch S20/6 wiper/washer switch S20/6 wiper/washer switch X12/1 cab connection S16/5 boom working light switch S16/5 boom working light switch S17/1 cab working light switch S17/2 cab working light switch S17/10 cab working light switch X12/7 cab connection X12/8 cab connection

Color red red blu blu brn brn wht/blk wht/blk gry/red pnk wht/grn wht/grn blk/grn blk/grn grn/wht gry/blu vio/blk org/wht blu blu blu red gry red/blk blk/wht vio/blu grn/yel brn/blk brn/wht gry brn/grn gry blk yel/red yel/blk yel/blu wht/blk gry gry blu blu blu/wht blu/wht blu/red grn grn grn grn grn blu blu

No. From 99 S17/1 cab working light switch 101 S17/3 cab working light switch 102 F9 rotating beacon, radio and drive interlock fuse 103 S18/1 rotating beacon switch 105 F7 fan and air conditioning fuse 106 S15/1 ventilation switch 107 S15/1 ventilation switch 108 S51/10 air conditioning switch 109 S15/3 ventilation switch 110 S42/1 safe load indicator switch 111 X10/13 indicator connection 112 F3 indicators and engine relay fuse 113 B14/1 warning buzzer connection 113 B14/1 warning buzzer connection A 114 F3 indicators and engine relay fuse 115 S18/10 rotating beacon switch 116 S18/10 rotating beacon switch 117 S16/B boom working light switch 118 X13 engine temperature connection 119 X13 engine temperature connection 120 F10 socket, cigarette lighter 121 F9 rotating beacon, radio and drive interlock fuse 122 X11/1 (unused) 123 X10/5 indicator connection 124 X13 engine temperature connection 125 X13 engine temperature connection 126 X14/2 automatic revs setting connection 127 X14/2 automatic revs setting connection 128 S20/9 wiper/washer switch 129 S20/9 wiper/washer switch 130 S17/9 cab working light switch 131 S17/9 cab working light switch 132 S15/9 ventilation switch 133 S15/9 ventilation switch 134 S42/9 safe load indicator switch 135 S42/9 safe load indicator switch

To X12/5 cab connection X12/9 cab connection S18/5 rotating beacon switch

Color grn/red grn/blu red

X12/2 cab connection S15/2 ventilation switch S15/2 ventilation switch S15/10 ventilation switch S15/10 ventilation switch S51/1 air conditioning switch B14/3 warning buzzer connection B14/3 warning buzzer connection X13 engine temperature connection X13 engine temperature connection X10/1 indicator connection

vio yel yel yel yel yel/blk vio/blu vio/blu blu blu blu

X14/1 automatic revs setting connection X14/1 automatic revs setting connection S42/10 safe load indicator switch E15 cigarette lighter E15 cigarette lighter X10/2 indicator connection E15 cigarette lighter X12/8 cab connection

blu

vio/blu grn/yel grn/yel grn/yel red/blk red

X2/3 engine/chassis connection X11/2 (unused) X11/2 (unused) X13 engine temperature connection X13 engine temperature connection

brn/blu blk blk blk blk

S21/9 high speed switch

blk

S21/9 high speed switch S16/9 boom working light switch S16/9 boom working light switch S18/9 rotating beacon switch S18/9 rotating beacon switch S51/9 air conditioning switch S51/9 air conditioning switch X3/B main connection

blk blk blk blk blk blk blk blk

blu

918175/AP0605

Electrical system 6.26 Wiring harness version 2: switches Rotating beacon switch

Cab working light switch

S42

S51

S15

S18

S17

1 110

X 5 51 7 X

X X X X

135 134

116 10

3

1 109

4

3

6 8

2

1 107 106 106 105 2

1 103

4

3

84 5 X 7 X

3

X 5 82 7 X

X X X X

133 134

108 10

9

6 8

9

X 83

4

109 6

X

133 132

8

107 10 108

1 95 96

96 97 2

1 53 117

4

3 101

4

3

6

5

6

5 94 94A

8

7

X X

X 99 X

8

7

X

X X X X

115 10 116

9

131 130

97 10

9

129 130

94A 10

X X X X

131 132

9

High speed switch

S20

S21

S16

2

X 5 102 7 X

Wiper/ washer switch

X

X 89 90 2 49 X 4 5 93 91 92 6 7 92 X 8

2

1

4

3

6 8

9

129 128

90 10

1 55

2

X

X X 5 87 88 X 7 X X

4

3

9

127 128

Preheating start switch

6 8

88 10

S1

Automatic revs setting connection

3

19A

4

9

2

Boom working light switch

5

7A

X

X14

9.

1

Accessory power socket

Engine temperature connection

E15

X13

86 7

Indicator connection

19A

2

6

138 139

Ventilation switch

7

Air conditioning switch

SWF: 593.757

Safe load indicator switch

126 127

X

19

115

10

8

114

120

136

117 118

126 125

125 124

112 113

34

8

119 118

!

8

8

8 !

!

8

!

!

8

8

!

"

13 12

X X

11 37

32

7

44

55 8

23

3 122

71 9

5

35

19 3

9

34

15 2 41

42 1

X1 Engine/chassis connection

918175/AP0605

53 7

2

10

33

40

31 6

21 4

8

1

A

B

7

135 136 137

47

5

49

X 10

X3 Main con-

6

51

X

nection

X2

Engine/chassis connection

71 1 82 2

5 59

4

11

4 84

6 98A 7 98

98A

Armrest switch connection

1

103 2 137 78 3

83 3

X6

93 1

2

X4

91 4

8

121

9

101 99 5

3

78

4

86

6

76 6

Drive interlock connection 21 8

43 42A 7

5 42 42A

X12

Cab connection

59

58

15 9

A

" &

B

# &

C

$ &

D

% &

E

& &

F

' &

G

58 1

7

2

8

21A 21A 4

X4.1

! &

3

41

X

112

1

114

X

94

138

X

X

95

X

X

2

X

76

X

44

X

105

139

X 89

X

98

X

43

X

102

7A

120

121

47

122

Warning buzzer

123 124

X11

Indicators, controls, engine and cut-off solenoid holding contact Boom working light

3

Cab working light

4

Valves

5

Heating, air conditioning

6

Wiper, interior light

87

X

( & X H

9 15A

X

7

Rotating beacon, radio, drive interlock

8

Socket, cigarette lighter

15A 5

6-20

Electrical system

Electrical system 6.27 Wiring harness 1000109628: armrest

Heater fan M4 84

83

X

74 75

Air conditioning thermostat S54

Safety switch S28

68

Armrest switch connection 5 76

X6 4

68

83

3

82

2

71

1

58

4

66

3

6 73 74

64

2

46

62

1

7

X5

81

84

5

82 76 77

58

64 3 66

6

62 2 85

5

77 1 75

4

X8

Joystick (left)

Armrest/chassis connection

Joystick (right) connection 85 3 X

6

71 2 46

5

81 1 73

4

X7

No. From 46 X5/5 armrest/chassis connection 58 X5/4 armrest/chassis connection 62 X5/1 armrest/chassis connection 64 X5/2 armrest/chassis connection 66 X5/3 armrest/chassis connection 68 X5/7 armrest/chassis connection 71 X6/1 armrest switch connection 73 X5/6 armrest/chassis connection 74 X5/6 armrest/chassis connection

918175/AP0605

To X7/85 joystick (right) connection S28 safety switch

Color org

No. From 75 M4/2 fan

brn/wht

76

X8/2 joystick (left) con- blu/yel nection X8/3 joystick (left) con- gry/yel nection X8/6 joystick (left) con- gry/grn nection S54 air conditioning yel/red thermostat X7/2 joystick (right) con- brn/grn nection X7/4 joystick (right) con- blk nection M4/2 fan blk

77 81 82 83 84 85

X6/5 armrest switch connection S28 safety switch X6/5 armrest switch connection X6/2 armrest switch connection X6/3 armrest switch connection X6/4 armrest switch connection X8/5 joystick (left) connection

To X8/4 joystick (left) connection S28 safety switch

Color blk gry

X8/1 joystick (left) con- gry nection X7/1 joystick (right) con- gry nection S54 air conditioning yel/red thermostat M4/1 fan yel/blk M4/3 fan

yel/blu

X7/3 joystick (right) con- gry/blk nection

6-21

Electrical system 6.28 Wiring harness 1000116138: boom working light

XE11

53 54 1

53

2

54

No From .

53 XE11/1 boom working light 54 XE11/2 boom working light

6-22

E1

To

Color

E1 boom working light E1 boom working light

grn/yel blk

918175/AP0605

Options

7

Options

7.1

Air conditioning

Specific safety instructions

WARNING! Avoid contact with the heat exchanger, the condenser, and the supply lines. Lines and hoses carrying refrigerants or coolants can be pressurized and hot.

Risk of burns! ☞ Before servicing air conditioning, do the following.

• Stop the machine and allow it to cool.

• Drain the cooling circuit.

• Avoid contact with parts carrying coolant.

• Service air conditioning.

Important!

Make sure the cooling system does not come into contact with chlorine, acidic substances, oil, grease or high humidity. Use drain and fill systems for R134a only.

Important!

The air conditioning system is most efficient when using “outside” air.

– see Cab heat control on page 1-21

918175/AP0605

7-1

Options Installation: overview

Dehumidifier

Air conditioning unit

Condenser

Engine

Compressor

Components

Air conditioning unit The air conditioning unit consists of: • Evaporator: This is where the liquid refrigerant evaporates, and the air taken in by the fan is cooled

• Expansion valve: Installed in the evaporator and controls the quantity of liquid refrig•

erant injected.

Ice guard: A fixed-setting thermostat with sensors placed between the evaporator fins prevents them from icing up due to freezing condensation water. The thermostat switches the evaporator's refrigerant supply off at –1.1 °C +/-0.8 °C and on again at +2.2 °C +/-0.8 °C as required.

• Heat exchanger • Twin radial fan: Can be controlled in steps and is overload-protected by means of a temperature microfuse.

7-2

918175/AP0605

Options

5

2

1

Ref. 1 2 3 4 5

3

4

Description Thermostat cable Fan cable Expansion valve Service cover Intake/outlet direction

Compressor The compressor takes refrigerant from the evaporator and passes it under pressure into the condenser. The engine drives the compressor using a V-belt and an electro-magnetic clutch.

Condenser The refrigerant vapor is condensed into liquid by the condenser.

Fig. 1: Compressor

918175/AP0605

7-3

Options Dehumidifier/pressure switch The dehumidifier consists of a collector/integrated dryer, a sight glass, and a pressure switch.

The dehumidifier serves as an expansion receptacle and tank for the refrigerant. It binds water chemically, withdrawing it from the circuit.

A sight glass on the dehumidifier is used to check the level of the circuit.

Important!

The cooling system is malfunctioning if gas bubbles appear in the sight glass.

Replace the dehumidifier if the sight glass is cloudy or shows traces of corrosion.

Fig. 2: Dehumidifier/pressure switch

Important!

Do not open the dehumidifier. Humidity in the room will saturate the dehumidify and disable it.

Filling the air conditioning system Important!

Air conditioning system should be filled only by technicians trained to use air conditioning fill equipment.

• Only use refrigerant R134a according to DIN 8960 – see Fluids and lubricants on page 3-23.

• Fill up the system in accordance with the fill equipment documentation.

• Fill the system to the proper level. No bubbles should appear in the sight glass.

7-4

918175/AP0605

Options

Start evacuation 20 minutes min. < .3 psi (20 mbar)

Interrupt evacuation Check connections Check for stable vacuum Pressure gauge rises Wait 5 minutes min.

or rectify

System is full

Evacuate for a further 25 minutes min.

Fill in gaseous refrigerant to a pressure of 3 bar

Check for leakage

Pressure gauge rises

System is pressurized

Fill in required quantity of refrigerant

Important!

Do not overfill the system.

☞ Overfilling can damage the system and reduces cooling capacity.

Air conditioning maintenance Important!

When performing air conditioning maintenance: • The cooling circuit may be pressurized even if the system is empty. Carefully release this pressure whenever disconnecting components.

• Close all openings tightly to prevent humidity from penetrating into the system.

• Do not open the cooling circuit outdoors in humid weather or rain.

918175/AP0605

7-5

Options Checking the compressor oil Check the oil level if:

• a system component has been replaced • the system leaks oil • the maintenance interval is due – see Maintenance schedule on page 3-5 Proceed as follows:

1. With the engine at idle, operate the air conditioning for 10 minutes.

2. Open the oil filler opening.

3. Push the oil dipstick all the way into the oil filler opening.

Fig. 3: Oil filler inlet for the air conditioning

4. Withdraw the oil dipstick from the compressor and read the oil level at the grooves on the oil dipstick. ➥ The oil level must reach 5 – 7 grooves on the dipstick.

5. Fill as required with the proper grade of oil– see Fluids and lubricants on page 3-23 for the proper oil grade.

Fresh/recirculated air filter replacement 1. Tilt the cab to replace the filter 1.12 Tilting the cab on page 1-13. The air conditioning system filter is located at the rear half of the cab.

2. Remove the cover between the air conditioning unit and the front air duct.

3. Remove the inside filter.

4. Insert a new inside heater filter.

5. Replace the cover between the air conditioning unit and the front air duct.

Troubleshooting Problem

Defective or loose fuse

Check the fuse's seat, insert correctly if necessary. Replace a defective fuse. Re-occurring trouble within short time indicates there is a short circuit or obstruction in the system.

Check the fan for obstruction or a defect and rectify the cause

Line interruption

Check the wiring for loose contacts or breaks

Defective fan motor

Replace the fan

Defective fan switch

Check or replace the switch

Short circuit in wiring or fan switch

Eliminate the short circuit. Install a new cable and/or switch if necessary

Contaminated contacts

Carefully clean the pins. Proceed with extreme care to avoid short circuits.

Heat exchanger heavily contaminated

Clean carefully and avoid damage that could cause leaks.

Fan does not work

Fan cannot be turned off

Reduced fan output

7-6

Remedy

Possible causes

918175/AP0605

Options Problem

Heater inoperative or output insufficient

Coolant leaks from the unit

Compressor does not work

Condenser overflow Iced condenser

Flow temperature too low

Wait for the engine to warm up

Defective thermostat

Replace the thermostat

Heat exchanger fins contaminated

Check and/or clean the heat exchanger

Folded or pinched line

Remove the cause of the folding/pinching and/or reroute the hoses

Loose hose connection

Check the seat of the flexible lines and tighten the clamps

Damaged hose

Replace hose

Damaged heat exchanger

Replace the heat exchanger

Loose or torn V-belt

Adjust V-belt tension/replace the V-belt

Compressor's solenoid coil interruption

Check the current to the clutch

V-belt pulley does not turn when electromagnetic clutch is activated

Check compressor. Replace if defective

Compressor clutch slips

Repair the clutch or replace the compressor

Expansion valve is blocked or stuck in open Replace the expansion valve position Thermostat sensor in wrong position

Place the sensor to proper position

Defective expansion valve/thermostat

Replace the expansion valve/thermostat

Interruption of refrigerant line

Check all lines for external damage or chafing

System leak

Replace refrigerant, check for leaks and repair as necessary

Fan duct obstructed

Check air intake and outlet for obstruction.

Remove obstruction

Refrigerant level too low

Fill as required

Humidity in system

Empty the air conditioning system, replace the dehumidifier, evacuate and fill up

Dehumidifier saturated or clogged

Replace the dehumidifier

Condenser fins contaminated

Clean the fins Important: Do not use a high-pressure cleaner

Line interruption

Check, repair and/or replace the lines

Defective fan motor

Replace the fan

Loose/excessively worn V-belt

Tighten/replace the V-belt as required

Loose compressor bracket/worn internal compressor parts

Repair the bracket/replace compressor

Worn fan motor

Replace fan motor

System over-filled

Bleed refrigerant to proper level

Not enough refrigerant in the system

Check for leaks. Fill as required

Loss of refrigerant

Insufficient cooling output

System cools with interruptions

System runs very loudly

918175/AP0605

Remedy

Possible causes

7-7

Options 7.2

Counterweight

Specifications Counterweight Weight

1168 lbs. (340 kg)

Max. tail end lateral projection over tracks

2.4 in. (60 mm)

Important!

Refer to the lift capacity table when using a counterweight Lift Capacity Table (with counterweight) on page 2-13.

7.3

Extended dipper arm

Specifications Extended dipper arm Length

69 in. (1750 mm)

Important!

Refer to the lift capacity tables when using an extended dipper arm. See Lift Capacity Table (with extended dipper arm) on page 2-12 and Lift Capacity Table (with extended dipper arm and counterweight) on page 2-14.

7-8

918175/AP0605

Options 7.4

Control circuit hydraulic coupling connections Connect and disconnect the grab couplings as follows:

Disconnecting the couplings: 1. Park the machine on firm and level ground.

2. Extend dipper arm cylinder (A) halfway.

3. Switch off the engine.

A

4. Release the pressure on the dipper arm cylinder by moving the right-hand side control lever to the left and right.

5. Fold the control lever base up.

6. Turn lock sleeve (C), Fig. 4, towards lock ball (B).

7. Pull lock sleeve (C) upwards. The coupling opens.

Connecting the coupling: B C

1. Connect the coupling onto the dipper arm cylinder connection making sure it is straight. a. Wait until you hear a hissing sound from the connection. b. Fully connect the coupling on the connection.

Fig. 4: Hydraulic couplings

2. Turn the lock away from lock ball (B).

Flat-seal couplings (can be coupled under residual pressure) Plug Sleeve

ISO designation 12.5 12.5

Thread 1/2 BSP 1/2 BSP

Couplings according to ISO 16028

7.5

3rd control circuit connections

Important!

See the implement operator’s manual for instructions about connecting the 3rd control circuit to the implement.

Standard connections: Port Standard Quick coupler option

918175/AP0605

Coupling Bulkhead coupling 1/2" Quick coupler 12.5 1/2"

7-9

Options 7.6

Auxiliary hydraulics connections

Important!

See the implement operator’s manual for instructions about connecting the auxiliary hydraulics to the implement.

Standard connections:

T U

V

Port T

Fig. 5: Connections for auxiliary hydraulics

dipper arm (left) Pressure line bulkhead coupling 1/2"

dipper arm (right)

Pressure line bulkhead coupling 1/2" Unpressurized return line (hammer) bulkhead coupling 3/4"

U V

Quick coupler options: Port T

dipper arm (left) Pressure line quick coupler 12.5 1/2"

U V

dipper arm (right)

Pressure line quick coupler 12.5 1/2" Unpressurized return line (hammer) quick coupler 17 3/4"

Couplings according to ISO 16028 -- US equivalent

Note: Couplings cannot be coupled under pressure.

7-10

918175/AP0605

Options 7.7

Fuel-filling pump Note: On units with serial numbers below AC02650: Use the sight glass instead of the indicator.

Refuel with the fuel-filling pump (A), Fig. 6 as follows:

1. Place the machine on level ground.

B

2. Switch off the engine.

A

3. Open the engine cover.

4. Insert the hose of fuel-filling pump (A) into the container with the fuel – see Filling the fuel tank on page 3-13.

5. Press button (B) to switch on fuel-filling pump (A). ➥ The fuel tank is full as soon as indicator (C) comes on.

6. Press button (B) to switch off fuel-filling pump (A).

Fig. 6: Fuel-filling pump

Important!

Switch off the fuel-filling pump as soon as indicator (C) comes on, otherwise the fuel tank may overflow and can be damaged.

C

• Fuel tank capacity: 22 gals. (83 L).

Fig. 7: Fuel-filling pump indicator A float switch (Fig. 8) screwed into the fuel tank triggers the indicator.

Fig. 8: Float switch

918175/AP0605

7-11

Options Ports

The electric connection for the fuel-filling pump is already installed.

The indicator has its own wiring harness, connected to the engine/chassis wiring harness by means of plug X16.

;

8

;

6 No. From 38 XE16/2 drive alarm connection 41 XE16/1 drive alarm connection 100 X17 float switch

7.8

To X17 float switch S60/1 indicator S60/2 indicator

Color blk blu vio

Central lubrication system The central lubrication system is a grease-based central lubrication system with 12 lubrication points

Position The electric pump for the central lubrication system is installed over the hydraulic pump.

The electric pump presses the grease through the lubrication line towards the distributing block on the boom.

From the distributing block, the grease passes on to the lubrication points.

Fig. 9: Central lubrication system pump

7-12

918175/AP0605

Options Ports 1 2 3 4 5

Ref. 1 2 3 4 5

918175/AP0605

Description – Ground (brown) + Intermediate lubrication tip switch connection (orange) + Ignition (black) – Error indicator (red) + Lubrication indicator (green)

7-13

Options Function

1

3

Ref.

Description

1 2 3

Push button on motor housing Red LED Green LED

2

The green LED comes on for about 1.5 seconds after ignition is turned on to indicate readiness.

Pressing the push button on the pump's motor housing switches on the pump and starts the lubrication cycle. The pump drive motor is turned off and cycle time begins after lubrication time is over.

All further lubrication starts automatically according to the cycle time set.

Lubrication time is stopped and saved if ignition or lubrication is turned off during cycle time. The data is read from the memory upon switching ignition on again, and lubrication is resumed where it was interrupted.

Pressing the push button on the motor housing or on the instrument panel starts intermediate lubrication at any give time if ignition is turned on.

Status LEDs Fig. 10:Central lubrication system push button

Indication

Meaning

Green LED 1.5 sec

Ignition on (operational readiness)

Steady green light

Comes on during lubrication Grease level error indicator Remains lit until grease tank is refilled

Steady red light Blinking red light

7-14

Over-pressure error indicator

918175/AP0605

Options Adjusting breaks and lubrication times Adjust breaks and lubrication times with potentiometers.

Lubrication time Break 1 min to 16 min 0.5 h to 8 h 1

0.5

16

8

Repair in case of clogging Clogging indication Over-pressure beyond service pressure means the system is clogged and is indicated as follows:

• Grease escapes by the pressure relief valve • Blinking red LED on the pump housing Causes for clogging in the system

• Crushed or clogged lubrication line • Bearing overfilled or clogged with lubricant • Inadequate lubricant for central lubrication systems • Clogged distributor output • Clogged distributor Detecting clogging ☞ Unscrew the main line off the main distributor. ☞ Activate the pump with the push button and check whether lubricant is delivered correctly.

☞ Screw the main line onto the main distributor. ☞ Unscrew the lines one after another and activate the pump every time.

Repairing a clogged distributor

• Remove the distributor from the system • Unscrew the screw plugs of the piston bore • Move the piston back and forth (do not remove) • Screw the screw plugs back in again You can remove the piston of the defective distributor and check it for scratches or damage. If there are traces of hardened grease on the piston or the bores, remove the grease with compressed air or by washing the piston.

Important!

Traces of hardened grease are a sign that the grease is not suitable for central lubrication systems.

918175/AP0605

7-15

Options

Problem

Pump does not work

Pump works but does not supply grease

No grease rims on all lubrication points

Integrated electronic controls defective

Replace the controls and the cap

Electric line interrupted

Replace the electric line

Defective pump

Replace the pump

Air inclusions in piston

Vent the pump

Level too low

Fill the tank

Pump element defective

Replace the pump element

Pump does not work

See “Pump does not work”

Breaks too long or lubrication time too short Shorten breaks or increase lubrication time System clogged

No grease rims on some lubrication points

No grease rim on one lubrication point

Reduced pump speed

Grease escapes by the pressure relief valve

7-16

Remedy

Possible causes

See “Grease escapes by the pressure relief valve”

Burst or leaky supply lines to secondary disReplace the lines tributor Leaky screw connections

Re-tighten or replace the screw connections

Burst or leaky lubrication line to lubrication point

Replace the line

Leaky screw connections

Tighten or replace the screw connections

High system pressure

Check system bearings

Low ambient temperatures

No damage (intermediate lubrication once or twice if necessary)

System pressure too high

Detect and eliminate clogging

System pressure too high

Detect and eliminate clogging

Clogged distributor

Replace the distributor

Clogged system

Repair clogged/stuck bearings

Defective valve spring

Replace the pressure relief valve

918175/AP0605

Options 7.9

Safe load indicator D (safety valve for boom) Position

2

1

6

5

3

4

Ref. 1 2 3 4 5 6

Description Boom segment pilot control port Joystick connection Boom pressure line port Hose burst valve Pressure switch Oil strip return port

Function The valve is mounted directly on the base-side port of the boom cylinder.

“Extend cylinder” function:

• cylinder can be extended normally ( “free flow” towards the cylinder always possible) Note: The built-in non-return valve safely holds the load in rest position.

918175/AP0605

7-17

Options “Retract cylinder” function:

• Pilot control pressure moves valve (1) to work position (free oil return from the base side)

• The valve moves back to home position if the pilot control pressure drops In addition, a safety valve (2) protects the hydraulic cylinder from overload.

Note: The valve settings are sealed.

Diagram

1 2

2 1

C2

7-18

V2

918175/AP0605

Options 7.10 Safe load indicator F (safety valves for boom and dipper arm) Position

2

1 3

4

5

6

8

7

Ref. 1 2 3 4 5 6 7 8

918175/AP0605

Description Boom segment pilot control port Joystick connection Joystick connection Dipper arm pressure line port Oil strip return port Pressure switch Hose burst valve Boom pressure line port

7-19

Options Function One valve is mounted directly on the base-side port of the boom cylinder, the other valve is mounted on the rod-side port of the dipper arm cylinder.

“Extend boom cylinder” function: • cylinder can be extended normally (“free flow” towards the cylinder always possible).

Note: The built-in non-return valve safely holds the load in rest position.

“Retract boom cylinder” function:

• Pilot control pressure moves valve (1) to work position (free oil return from the base side).

• The valve moves back to home position if the pilot control pressure drops “Retract dipper arm cylinder” function:

• The cylinder can be retracted as usual (always “free flow” from the cylinder) Note: The built-in non-return valve safely holds the load in rest position.

“Extend dipper arm cylinder” function: • Pilot control pressure moves valve (1) to work position (free oil flow to the base side)

• The valve moves back to home position if the pilot control pressure drops In addition, a safety valve (2) protects the hydraulic cylinder from overload.

Note: The valve settings are sealed.

7-20

918175/AP0605

Options Diagram

1 2

2 1

C2

918175/AP0605

V2

7-21

Options This page intentionally left blank

7-22

918175/AP0605

TORQUE SPECIFICATIONS Use these torque values when tightening hardware (excluding locknuts, and self-tapping, thread-forming, and sheet metal screws) unless otherwise specified.

UNIFIED NATIONAL THREAD

GRADE 2

GRADE 5

GRADE 8

DRY

LUBED

DRY

LUBED

DRY

LUBED

8-32 8-36 10-24 10-32

19* 20* 27* 31*

14* 15* 21* 23*

30* 31* 43* 49*

22* 23* 32* 36*

41* 43* 60* 68*

31* 32* 45* 51*

1/4-20 1/4-28 5/16-18 5/16-24

66* 76* 11 12

50* 56* 9 9

9 10 17 19

75* 86* 13 14

12 14 25 25

9 10 18 20

3/8-16 3/8-24 7/16-14 7/16-20

20 23 32 36

15 17 24 27

30 35 50 55

23 25 35 40

45 50 70 80

35 35 55 60

1/2-13 1/2-20 9/16-12 9/16-18

50 55 70 80

35 40 55 60

75 90 110 120

55 65 80 90

110 120 150 170

80 90 110 130

5/8-11 5/8-18 3/4-10 3/4-16

100 110 175 200

75 85 130 150

150 180 260 300

110 130 200 220

220 240 380 420

170 180 280 320

7/8-9 7/8-14 1-8 1-12

170 180 250 270

125 140 190 210

430 470 640 710

320 360 480 530

600 660 900 1000

460 500 680 740

METRIC COARSE THREAD

GRADE 8.8

GRADE 10.9

GRADE 12.9

DRY

LUBED

DRY

LUBED

DRY

LUBED

M6-1 M8-1.25 M10-1.5

8 19 37.5

6 14 28

11 27 53

8 20 39

13.5 32.5 64

10 24 47

M12-1.75 M14-2 M16-2

65 103.5 158.5

48 76.5 117.5

91.5 145.5 223.5

67.5 108 165.5

111.5 176.5 271

82 131 200

*All torque values are in ft-lbs except those marked with an * which are in lbs.

For metric torque value (N·m) multiply ft-lbs value by 1.355 or the in-lbs value by 0.113.

®

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

918175/AP0605

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

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