Mustang ML460 All Wheel Steer Loader Operator's Manual 918296 - PDF DOWNLOAD

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ML460 All-Wheel-Steer Loader

OPERATOR’S MANUAL PART #918296

Revision B - 12/09

®

Mustang Manufacturing Company, Inc.

MUSTANG MANUFACTURING COMPANY, INC. WARRANTY MUSTANG MANUFACTURING COMPANY, INC., hereinafter referred to as Mustang, warrants new Mustang equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date.

MUSTANG WARRANTY SERVICE INCLUDES: Genuine Mustang parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

MUSTANG MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT. ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED DELETED FROM THIS WARRANTY; ALL OTHER TERMS WILL CONTINUE TO APPLY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW.

MUSTANG WARRANTY DOES NOT INCLUDE: 1. Transportation to selling dealer’s business location or, at the option of the Original Retail Purchaser, the cost of a service call.

2. Used equipment.

3. Components covered by their own non-Mustang warranties, such as tires, batteries, trade accessories and engines.

4. Normal maintenance service and expendable, high-wear items.

5. Repairs or adjustments caused by: improper use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty.

6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment.

No agent, employee or representative of Mustang has any authority to bind Mustang to any warranty except as specifically set forth herein.

204936/AP0407

Table of contents

Table of contents I

Introduction ...................................................................................................................... 3 General Information ................................................................................................... 3 Identification of Warnings and Hazards ..................................................................... 6 Machine Overview ..................................................................................................... 7 Overview .................................................................................................................... 8 Fields of Application, Attachments ............................................................................. 9 Serial Number Plate Locations ................................................................................ 11 Safety ............................................................................................................................. 17 Additional Safety Equipment .................................................................................... 24 Safety Reminders .................................................................................................... 25 Transporting ............................................................................................................. 25 Maintenance Safety ................................................................................................. 28 Safety Instructions for Specific Hazards .................................................................. 31 Operation ....................................................................................................................... 37 Description of controls ............................................................................................. 37 Cab: Overview ......................................................................................................... 39 Instrument Panel, Multi-functional Lever and Drive Lever: Overview ...................... 41 Indicators and Warning Lights: Overview ............................................................... 42 Getting Started ......................................................................................................... 44 Battery Disconnect Switch ....................................................................................... 46 Starting the Engine .................................................................................................. 47 Air Conditioning ....................................................................................................... 62 Side Window ............................................................................................................ 69 Emergency Exit – Side Window ............................................................................... 70 Towing the Machine ................................................................................................. 72 Crane Handling the Machine ................................................................................... 74 Loading and Transporting the Machine on a Transport Vehicle .............................. 75 Working with the Machine ........................................................................................ 77 Connecting a Multi-purpose Bucket (option) ............................................................ 90 Working with the Multi-purpose Bucket ................................................................... 94 Working with Pallet Forks ........................................................................................ 99 Troubleshooting ........................................................................................................... 107 Engine trouble ....................................................................................................... 107 Maintenance ................................................................................................................ 109 Introduction ............................................................................................................ 109 Fuel System ........................................................................................................... 110 Engine Lubrication System .................................................................................... 112 Engine and Hydraulics Cooling System ................................................................. 113 Air Filter ................................................................................................................. 117 V-belt ..................................................................................................................... 119 Hydraulic System ................................................................................................... 120 Lubrication Points .................................................................................................. 124 Maintenance of Attachments ................................................................................. 125 Maintenance of the Brake System ......................................................................... 126 Tire Care ................................................................................................................ 127 Heating .................................................................................................................. 129 Air Conditioning Maintenance ................................................................................ 130 Electrical System ................................................................................................... 132 General Maintenance ............................................................................................ 135 Fluids and Lubricants ............................................................................................ 138 Maintenance Schedule .......................................................................................... 139 Maintenance Log ................................................................................................... 143 Maintenance Decal ................................................................................................ 147 Specifications ............................................................................................................... 149 Frame .................................................................................................................... 149

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Table of contents Engine ....................................................................................................................149 Power Train ............................................................................................................150 Axles ......................................................................................................................151 Brakes ....................................................................................................................151 Steering ..................................................................................................................152 Work Hydraulics .....................................................................................................152 Pilot Control ...........................................................................................................152 Payloads ................................................................................................................153 Electrical System ...................................................................................................153 Tires ......................................................................................................................156 Weights ..................................................................................................................156 Sound Levels ........................................................................................................156 Vibration ................................................................................................................156 Coolant Compound Table ......................................................................................157 Hardware Torques .................................................................................................157 Dimensions ............................................................................................................158

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Introduction

Introduction General Information Your decision to purchase Mustang equipment was a good one. We are sure that your decision was carefully considered and that you are looking forward to many years of reliable performance from the machine.

Mustang Manufacturing has invested much time and effort in developing its lines of equipment.

The equipment you have purchased is built with a great deal of pride, and designed to provide long life, efficient operation, durability and dependability.

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

This manual was developed specifically for the machine. The information within is for assistance in preparing, adjusting, maintaining and servicing the machine. More important, this manual provides an operating plan for safe and proper use of the machine. Major points of safe operation are detailed in the SAFETY chapter of this manual – see Safety on page 17.

Refer to the Table of Contents for an outline (by chapters) of this manual. Use the Index, located at the back of this manual, for specific chapter and topic/page number references.

If this machine is resold, Mustang Manufacturing recommends this manual be given to the new owner.

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

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

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

Throughout this manual information is provided that is introduced by the word NOTE or IMPORTANT. Be sure to carefully read and comply with the message or directive given. Following this information will improve operating or maintenance efficiency, help to avoid costly breakdowns and unnecessary damage, and extend the life of the machine.

Operational safety and readiness of the machine depend partially on maintenance and service.

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

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

Purchased from: ____________________________________ Date of Purchase: __________________________________ Model No.: ________________________________________ Serial No.: _________________________________________ Printed in U.S.A.

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Introduction Serial number The serial number is stamped onto the front axle attachment (on the right in driving direction) A. It is also located on the type decal.

A

Type decal information

Type decal: location

Made in Germany

00 435 12 21

Fig. 1:

Fhzg-Typ Model ModŁle Typ / Ausf.

Version Version Fg.-Nr. Serial no.

No. de sØrie Baujahr Model year AnnØe fabr.

Machine model:

347

Version:

347 04

Serial no.:

347 01 0023

Model year:

2008

Front gross axle weight rating: 9,921 lbs. (4500 kg) Rear gross axle weight rating: 9,921 lbs. (4500 kg)

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

Gross weight rating:

15,432 lbs. (7000 kg)

Output:

78 hp (58 kW)

Other information – see Specifications on page 149.

30300b0010.eps

Fig. 2:

Type decal

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

Fig. 3:

Cab type decal

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

• Working with the attachments mentioned – see Fields of Application, Attachments on page 9.

• Every other use and attachment is not designated for the machine. Mustang will not be liable for damage resulting from any other use or attachment. The user alone will bear the risk.

• Follow the instructions in the Operator’s Manual Safety, Maintenance and Service chapters, accident prevention regulations, safety and occupational regulations, and machine and traffic regulations. Mustang is not liable for damage resulting from the failure to follow these regulations.

• You can damage the machine by modifying it with parts, equipment, attachments and optional equipment that is not approved by Mustang. Mustang is not liable for damage resulting from the failure to follow these requirements.

• Mustang is not liable for personal injury and/or damage to property caused by failure to properly: • Operate, • Transport, • Service and perform maintenance, or • Repair the machine (in accordance with the Operator’s and Service Manuals).

• Read and understand the Operator’s Manual before starting, servicing or repairing the machine. Follow the safety instructions.

• The machine may not be used for transport jobs on public roads.

• In applications with lifting gear, only use the machine according to its designated use.

Abbreviations/symbols • This symbol stands for a list.

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

☞ This symbol requires you to carry out the activity described. ➥ This symbol marks the passages in the text describing the effects or results of an activity. n. s. = not shown.

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

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Introduction 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.

IMPORTANT! Failure to follow the instructions identified by this symbol may result in damage to the machine.

☞ Measures for avoiding damage to the machine.

NOTE: Contains instructions to help use the machine more efficiently.

Environment!

Failure to follow the instructions identified by this symbol may result in damage to the environment. The environment can be damaged if hazardous material (e.g., waste oil) is not properly used or disposed.

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Introduction Machine Overview 3

4

5

3

6 7

1 2

15

14

8 20 9 10 11

19

18

17

16

12

13 14

Fig. 4:

15

1

Tilt cylinder

11

Rear eye hook for tying down the machine

2

Service access (fuses, relays, recirculated air filter)

12

Door handle

3

Rearview mirror

13

Headlight with turn indicator

4

Handle

14

Position lights (white)

5

Rear work light

15

Position lights (red)

6

Eye hook (for cab removal)

16

Cab access

7

Brake, rear and turn indicator lights

17

Wheel chock

8

Door arrester

18

Loader unit

9

Towing apparatus

19

Front eye hook for tying down the machine

10

Reflectors

20

Lift cylinder

Machine overview

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Introduction Overview

The Model ML460 is a versatile and powerful helper for moving earth, gravel and debris on construction sites and elsewhere. Equip the machine with the proper safety devices when using it as a lifting accessory – see Applications with lifting gear on page 24.

The main components of the machine are:

• ROPS certified cab, enclosed version (standard), or ROPS certified cab, open version (option).

• Water-cooled, turbo-charged, Deutz four-cylinder in-line diesel engine, 78 hp (58 kW) at 2300 rpm.

• Exhaust emissions according to EC directive 97/68/EC. • Sturdy steel frame; rubber-mounted engine.

• Automotive drive, infinitely variable hydrostatic axial-piston gearbox; maximum speed 12 mph (20 km/h).

• Hydraulic four-wheel power steering with emergency steering feature. The emergency steering feature, located inside the hydraulic system, allows steering the machine if hydraulic or motor power is lost.

• Front and rear planetary axles, rear axle with oscillation.

• Service brake (mechanical and hydrostatic), mechanical disc-type parking brake.

Hydrostatic drive

The diesel engine drives a hydraulic pump, sends oil flow to a hydraulic motor connected to the rear axle. The force of the hydraulic motor is transmitted to the rear axle via the transfer gearbox. At the same time, the front axle is driven by the cardan shaft, ensuring full-time four-wheel drive.

Work hydraulics and hydrostatic fourwheel steering

The diesel engine also drives the joint gear pump for work hydraulics and hydrostatic fourwheel steering. The oil flow of this pump depends on the diesel engine speed only.

When the machine is in operation, the entire diesel engine output can be transmitted to the gear pump for work hydraulics and steering by using the inching valve. This valve responds as soon as the service brake is used, reducing or cutting off power input of the drive. Therefore, full engine output is available for the machine by pressing the accelerator pedal and the brake pedal at the same time.

Cooling system

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

The indicators on the instrument panel of the machine allow users to constantly monitor the engine and hydraulic oil temperatures, and the coolant temperature and level.

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Introduction Fields of Application, Attachments The attachments determine how the machine is used.

WARNING! In order to avoid damage to the machine, only the attachments listed below are certified for attachment to the machine.

Use: Attachment

Possible attachments and material densities.

Description of attachment

Use

Standard bucket - normal material

Loosening, picking up, transporting and loading loose or solid material (material density ≤ p = 112 lbs./ft.³ [1.8 t/m³])

Standard bucket - light weight material1

Picking up, transporting and loading very lightweight material (material density ≤p = 81 lbs./ft.³ [1.3 t/m³])

Standard bucket - super light weight material1

Picking up, transporting and loading lightweight material (material density ≤p = 56 lbs./ ft.³ [0.9 t/m³])

Multi-purpose bucket2

Grading, removing and scraping vegetation, for example; picking up and evenly spreading material; grabbing bulky material; loading trucks (material density ≤p = 112.3 lbs./ft.³ [1.8 t/m³])

Side-swing bucket1, 2

As standard bucket, however with benefits for filling and backfilling material (material density ≤p = 112 lbs./ft.³ [1.8 t/m³])

High-tilt bucket2, 3

As standard bucket, however with a 80 - 100 cm higher dump height (material density ≤p = 81 lbs./ft.³ [1.3 t/m³])

Heavy duty bucket with hydraulic clamp2, 5, 3

Picking up and transporting e.g., bulky recycling material (material density ≤p = 81 lbs./ ft.³ [1.3 t/m³])

Heavy duty forks with hydraulic clamp (silage bucket)2, 5, 3

Picking up and transporting, e.g., bulky and fibrous recycling material (e.g., grass, manure, brushwood; material density ≤p = 81 lbs./ft.³ [1.3 t/m³])

Pallet forks2, 5, 4

Picking up and transporting pallets

Pallet forks with foldable fork arms2, 4, 5

Picking up and transporting pallets

Material pusher2, 5

For moving loose bulk material

Manure forks with grab

Picking up and transporting, e.g., grass, manure, brushwood and straw

Hydraulic round bale clamp

Picking up and transporting round bales

Tree replanter2, 5

Digging and transporting nursery trees

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Introduction Description of attachment

Use

Front scarifier2, 5

Scarifying dense soil, loosening humus soil

Work platform

For repair, assembly, disassembly, maintenance and inspection work above ground

Rotary broom

Cleaning roads or facilities

Snow plough1, 2, 5, 6

Winter service

1.

2.

3.

4.

5.

6.

Use only in connection with additional lights when driving on public roads.

See the Operator's Manual of the attachment for taking the attachment into service and using it.

Use only in connection with restrictor unit.

Use only in connection with load diagrams.

Learn the legal regulations of your locality which may require specific permits, certifications, registrations etc. for use on public roads.

Only in connection with rotating beacon.

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Introduction Serial Number Plate Locations Serial number The serial number is stamped onto the front axle attachment (on the right in driving direction) A. It is also located on the type decal.

A

Type decal information Example: Model ML460 Type decal: location

Made in Germany

00 435 12 21

Fig. 5:

Fhzg-Typ Model ModŁle Typ / Ausf.

Version Version Fg.-Nr. Serial no.

No. de sØrie Baujahr Model year AnnØe fabr.

Type decal

ML460

Version:

347 04

Serial no.:

347 04 0023

Model year:

2008

Front gross axle weight rating: 9921 lbs. (4500 kg)

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

Rear gross axle weight rating: 9921 lbs. (4500 kg)

30300b0010.eps

Fig. 6:

Machine model:

Gross weight rating:

15,432 lbs. (7000 kg)

Output:

78 hp (58 kW)

Other information – see Specifications on page 149.

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

Fig. 7:

Cab type decal

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

Example:

Fig. 8:

Deutz D2011 L04 W

Diesel engine number

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Introduction Hydraulic pump number The type decal (arrow) is located on the hydraulic pump housing (next to where the pump is attached to the diesel engine).

Fig. 9:

Hydraulic pump: type decal

Hydraulic motor number The type decal (arrow) is located above the cardan shaft, on the right of the hydraulic motor.

Fig. 10: Hydraulic motor: type decal

Rear axle number The type decal (arrow) is located on the upper side of the differential housing, at the rear.

Fig. 11: Rear axle and gearbox: type decal

Front axle number The type decal (arrow) is located on the inside of the axle tube, on the right side (arrow).

Fig. 12: Front axle: type decal

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

WARNING! Safety decals must be replaced if they become unreadable.

Meaning The eye hooks on the cab are for removing the cab only and may not be used for cranelifting the machine – see Moving the Machine with a Crane on page 26.

Location Cab roof (4x).

Fig. 13: Eye hook decal

Meaning Points for tying down the machine.

The eye hooks are used for tying down the machine during loading and transport – see Loading and Transporting the Machine on a Transport Vehicle on page 75.

Location Fig. 14:

Decal for points used for tying down the machine

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

Meaning Sound levels produced by the machine.

LWA = sound power level.

Other information – see Sound Levels on page 156.

XX

Location Fig. 15: Decal:

Rear window.

Meaning General indication of danger.

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

Location

Gefahr2.ai

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

Fig. 16: Danger decal

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

DO NOT touch any moving or turning parts.

Location On the engine cover of the machine.

Fig. 17: Prohibitory decal

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

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

Other information – see Tires on page 156.

Location Inside the cab, on left window.

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

• Observe the specific load diagrams of other attachments.

Fig. 18: Load diagram

Brake fluid label Use only LHM brake fluids. ➥ – see Maintenance of the Brake System on page 126.

➥ – see Fluids and Lubricants on page 138.

Location On the brake fluid tank.

Fig. 19: Brake fluid label

A

B

C

D E

Label: control lever (joystick) operation label • A = driving direction: (F) forward/(R) reverse and (N) neutral position • B = control lever (joystick) unlocked/locked • C = control lever (3rd control circuit for attachments) unlocked/locked • D = loader unit operation: raise, lower, dump in/out • E = 3rd control circuit operation. Pick up/set down attachment • F = loader unit operation: raise, lower with float position, dump in/out Location On the lower right on the side window.

F

Fig. 20: Label: control lever operation (overview)

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

DANGER! Read and understand the Operator's Manual before using the machine.

Location Inside the cab on the right on the pillar.

Fig. 21: Label: avoiding danger

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

Buckle up before moving or working with the machine. ➥ – see Seat belt on page 66.

Location Inside the cab on the right pillar.

Fig. 22: Seat belt label

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

☞ Location: • On the rear wall, to the left of the seat (see Fig. 23).

Fig. 23: Fire extinguisher

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Safety

Safety This manual and decals on the machine warn of safety hazards and should be read and observed closely.

Before operating the machine, first read and study the safety information in this manual.

Additionally, anyone who operates or works on the machine must be familiar with these safety precautions.

This safety alert symbol means: ATTENTION! ALWAYS BE ALERT! YOUR SAFETY IS INVOLVED! This symbol is used throughout this operator’s manual and on the decals on the machine.

DANGER! Indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

WARNING! Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

CAUTION! Indicates a potentially hazardous situation, which, if not avoided, may result in minor injury or property damage. It is also used to alert users of unsafe practices.

It is essential that operators are thoroughly trained in the safe operation of the machine and handling loads. Operators must not be physically or mentally impaired. Do not allow minors or unqualified personnel to operate the machine, or to be near the machine unless they are properly supervised. It is recommended that the operator be capable of obtaining a valid motor vehicle operator’s license.

Use of this machine is subject to certain hazards that cannot be eliminated by mechanical means, but only by exercising intelligence, care and common sense. Such hazards include: hillside operation, overloading, load instability, poor maintenance, and using the machine for a purpose for which it was not intended or designed.

Mustang Manufacturing always takes operator’s safety into consideration during the design process. Guards and shields are provided, which protect the operator and bystanders from moving parts and other hazards. Operators must be alert, however, because some areas cannot be guarded or shielded without preventing or interfering with proper operation.

Some photographs in this manual may show doors, guards and shields open or removed for the purposes of illustration only. Be sure that all doors, guards and shields are in the proper operating positions before starting the engine to operate the machine.

Different applications may require optional safety equipment. Be sure you know the work site hazards and equip the machine and the operator as necessary. The information in this manual does not replace any applicable safety rules and laws. Before operating the machine, learn the rules and laws for your area. Make sure the machine is equipped as required according to these rules/laws.

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Safety Mandatory Safety Shutdown Procedure

BEFORE cleaning, adjusting, lubricating, fueling, or servicing the machine, or leaving it unattended: 1. Bring the machine to a complete stop on a level surface. Avoid parking on an incline or hillside, but if this is not possible, park across the slope and block the tires.

2. Place forward/reverse drive switch on the top of the control lever/joystick into the neutral position.

3. Apply the parking brake.

4. Lower the lift arm and attachment completely.

5. Move the throttle to low idle position and shut off the engine.

6. Wait for all movement to stop. Move the multi-purpose joystick in all directions to verify that the hydraulic system is de-pressurized.

7. Unfasten the seat belt, remove the ignition key and take it with you. Exit the machine using the hand holds.

ONLY when these precautions have been taken can you be sure it is safe to proceed. Failure to follow this procedure could result in death or serious injury.

Before Starting

• Do not modify the Roll-Over Protective Structure (“ROPS”) unless instructed to do so in Mustang Manufacturing approved installation instructions. Modifications, such as welding, drilling or cutting, can weaken the structure and reduce the protection it provides. A damaged ROPS cannot be repaired – it must be replaced.

• To ensure safe operation, replace damaged or worn-out parts with genuine Mustang service parts.

• Mustang loaders are designed and intended to be used only with Mustang attachments and approved attachments. To avoid possible personal injury, equipment damage and performance problems, use only attachments that are approved for use on and within the operating capacity of the machine. Contact your dealer or Mustang Manufacturing for information on attachment approval and compatibility with specific machine models.

Mustang cannot be responsible if the machine is used with a non-approved attachment.

• Remove all trash and debris from the machine every day, especially in the engine compartment, to minimize the risk of fire.

• Always face the machine and use the hand holds and steps when entering and exiting the machine. Do not jump off the machine.

• Do not use starting fluid (ether).

• Walk around the machine and inspect it before using it. Look for damage, loose or missing parts, leaks, etc.

• Warn all nearby personnel before starting the machine.

• Check for proper tire pressure in all four tires before operating the machine and add air if necessary. Improperly pressurized tires adversely affect machine stability. Regularly check wheel fasteners for tightness – see Maintenance Schedule on page 139.

• Contact the proper local authorities for utility line locations BEFORE starting to dig. In North America, contact the North American One-Call Referral System at 8-1-1 in the U.S., or 1-888-258-0808 in the U.S. and Canada.

• Below-ground hazards also include water mains, tunnels and buried foundations. Know what is underneath the work site before starting to dig.

• Before working near power lines (either above-ground or buried cable-type), always contact the power utility and establish a safety plan with them.

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Safety • Be aware of height obstacles. Any object in the area of the machine could represent a potential hazard, or cause the operator to react suddenly and cause an accident. Use a spotter or a signal person when working near bridges, phone lines, work site scaffolds, or other obstructions.

• If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground.

• In cold weather, avoid sudden travel movements and stay away from even very slight slopes. The machine can slide sideways on icy slopes.

• Snow accumulation can hide potential hazards. Use care while operating and while using the machine to clear snow.

• Stay away from ditches, overhangs and other weak support surfaces. Digging under an overhang is dangerous. Know the height and reach limits of the attachment and plan ahead while working. Avoid creating dangerous situations caused by moving around the work site while working. Move to another digging area before large overhangs are formed. Working around deep pits or along high walls or trenches may require support, especially after heavy rainfalls or during Spring thaws. Park the machine away from overhangs.

• The operator’s area, steps and hand holds must be free of oil, dirt, ice and unsecured objects.

• Use warning tag/control lockout procedures during service. Alert others that service or maintenance is being performed by tagging operator’s controls — and other machine areas if required — with a warning notice.

• NEVER start the engine if there is any indication that maintenance or service work is in progress, or if a warning tag is attached to the controls.

• Replace damaged safety decals and lost or damaged operator’s manuals.

• Terrain and soil conditions at the work site, approaching traffic, weather-related hazards and any above- or below-ground obstacles and hazards should be observed and monitored by all work crew members.

• Read the operator’s manuals provided with attachments, before using those attachments.

• Check the lighting system for proper working condition before working in darkness.

• Keep the windshield and windows clean. Poor visibility can cause accidents.

During Operation

• ALWAYS fasten the seat belt securely. Never operate the machine without the seat belt fastened.

• Check indicators and displays for normal conditions after starting the engine. Listen for unusual sounds and remain alert for other potentially hazardous conditions.

• Operate the machine cautiously and gradually until you are fully familiar with all of the controls and the machine handling.

• Do not overload the machine. – see Weights on page 156 for the load limits.

• Do not raise or drop a loaded bucket or attachment suddenly. Abrupt movements under load can cause serious instability.

• Check that attachments are securely fastened to the hitch before working.

• Never activate the float function with the bucket or attachment loaded or raised, because this will cause the lift arms and or bucket or attachment to drop rapidly.

• Make sure that no one enters the working area of the machine. Anyone standing near the machine is at risk of being caught between the moving parts of the machine.

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Safety • Machine stability is affected by: the load being carried, the height of the load, machine speed, abrupt control movements and driving over uneven terrain. DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE MACHINE TO TIP, THROWING THE OPERATOR OUT OF THE SEAT OR MACHINE, RESULTING IN DEATH OR SERIOUS INJURY. Therefore: ALWAYS operate with the seat belt fastened. Do not exceed the machine’s rated operating capacity. Carry the load low. Move the controls smoothly and gradually, and operate at speeds appropriate for the conditions.

• Never carry riders. Do not allow others to ride anywhere on the machine or attachments, because they could fall or cause an accident.

• Always look to the rear, over both shoulders, before backing up.

• Only start the engine while seated in the operator’s seat.

• Only operate the controls while seated in the operator’s seat.

• Always keep hands and feet inside the operator’s compartment while operating the machine.

• New operators must operate the machine in an open area away from bystanders.

Practice with the controls until the machine can be operated safely and efficiently.

• Wear safety goggles, ear and head protection as needed while operating the machine.

Operator must wear protective clothing when appropriate.

• Exhaust fumes can kill. Do not operate the machine in an enclosed area without adequate ventilation. Internal combustion engines deplete the oxygen supply within enclosed spaces and may create a serious hazard unless the oxygen is replaced.

• Do not drive too close to an excavation or ditch; be sure that the surrounding ground has adequate strength to support the weight of the machine and the load.

• Never allow anyone under raised lift arms. Lowering loader arms or a falling load can result in death or serious personal injury.

• Avoid slowing suddenly while carrying a load. Sudden slowing can cause the load to drop off the attachment.

• Slow down the work cycle and use slower travel speeds in congested or populated areas.

Use commonly understood hand signals so that other members of the work crew can warn the operator to slow or halt work in a potentially hazardous situation.

• Use a signal person if you cannot see the entire work area clearly, in high traffic areas and whenever the operator’s view is not clear, such as when traveling in reverse.

• Do not place limbs near moving parts. Severing of body parts can result.

• Do not use the loader to lift or transport people.

• Stay alert for people moving through the work area. When loading a truck, the operator should always know where the driver is.

• Do not load over the cab of a truck, even if the driver is in a safe spot, because someone else could have gone inside the cab.

• Exposed hydraulic hoses could react with explosive force if struck by a falling or overhead items. NEVER allow hoses to be hit, bent or interfered with during operation.

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Safety Travel Precautions

• The loader control lever should not be operated while traveling. Be sure to lock out the control lever during travel.

Do not change selected travel model (FAST/SLOW) while traveling.

• Travel with the bucket or attachment as low as possible [8”-12” (200 mm - 300 mm)] to the ground.

• Never travel over obstacles or slopes that will cause the machine to tilt severely. Travel around any slope or obstacle that would cause a tilt greater than 10°.

Avoiding Rollover Accidents

• Operate the controls smoothly to prevent jerking or bouncing. Operate on level, stable surfaces. Load, unload and turn on solid, level ground.

• Drive up and down inclines, not across them. Drive slowly on inclines. Keep the heavy end of the machine pointed uphill.

• Lifting the bucket too high while the loader unit is pointed uphill can cause tipovers.

• Evenly distribute the load on the attachment. Secure unstable loads so they do not shift or fall.

• Do not make sharp turns on inclines. Avoid steep inclines.

• Use care on loose ground. Loose, soft ground or uneven, broken terrain can cause dangerous side-load conditions and possible tipover and injury. Traveling with a suspended load or an unbalanced load can also be hazardous.

• If you must cross railroad tracks, ditches, curbs or similar surfaces, cross at an angle and drive slowly.

• Stay away from steep edges on loading docks, ramps, ditches, retaining walls and trenches.

• Avoid sharp turns and high speeds while carrying loads. The stability of the machine is greatly reduced during sharp turns. Additionally, the load may shift to the side during turns, greatly increasing the possibility of a rollover.

• To avoid tipping, keep loads as low as possible during transport and turning. Keep the bottom of the bucket or load no higher than wheel axle height during transport and turning.

• Do not turn the machine when lifting loads. As loads are lifted, a drastic shift in stability can occur, which can greatly increase the possibility of a rollover.

• If the machine becomes unstable and starts to tip, keep the seat belt fastened, hold on firmly and brace yourself. Lean away from the point of impact and stay with the machine.

If tipping occurs, DO NOT jump from the machine. The machine is equipped with rollover protection, which only protects the operator while in the operator’s seat. Trying to escape from a tipping machine can result in death or serious personal injury.

Electrical Energy

• Stay away from high-voltage lines. Serious injury or death can result from contact or proximity to high-voltage electric lines. The machine does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to keep away from power lines not clearly visible to the operator.

• Depending upon the voltage in the power line and atmospheric conditions, strong current shocks can occur if the bucket is closer than 3 m (10 ft.) to the power line. Very high voltage and rainy weather can further increase the safe operating distance.

Service Safety Practices

• Any machine modification made without authorization from Mustang could create a safety hazard, for which the machine owner would be responsible.

• For safety reasons, use only genuine Mustang parts. For example, using incorrect fasteners could lead to a condition in which the safety of critical assemblies is dangerously compromised.

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Safety • Only trained and authorized personnel, with a full awareness of safe procedures, should be allowed to operate or perform maintenance or service on the machine.

• Never attempt to bypass the keyswitch to start the engine. Use only the proper jumpstarting procedure – see Jump-starting the engine on page 49.

• Never use your hands to search for hydraulic fluid leaks. Instead, 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 at once. Injected fluid must be surgically removed by a doctor or gangrene may result.

• Always wear safety glasses with side shields when striking metal against metal. In addition, it is recommended that a softer (chip-resistant) material be used to cushion the blow, otherwise, serious injury to the eyes or other parts of the body could result.

• Do not smoke or have any spark- or flame-producing equipment or materials in the area while filling the fuel tank or working on the fuel or hydraulic systems.

• Do not attempt to loosen or disconnect any hydraulic lines, hoses, fittings, covers or caps without first relieving hydraulic circuit pressure. Relieve hydraulic pressure by performing the “Mandatory Safety Shutdown Procedure” on page 8 and slowly loosening the hydraulic reservoir filler cap. Be careful not to touch any hydraulic components that have been in recent operation, because they can be hot and cause burns.

• Do not attempt to remove the radiator cap after the engine has reached operating temperature or if it is overheated. At operating temperatures, engine coolant is extremely hot and under pressure. Always wait for the engine to cool before attempting to relieve pressure and remove the radiator cap. Failure to heed this warning could result in severe burns.

• Never rely on jacks or other similar supports if it is necessary to elevate the machine for service. Use only solid support blocking.

• Refer to the Parts Manual for information about assembly of components. Always use the correct parts and the proper torques — incorrect fastener connections can dangerously weaken assemblies.

• Exhaust fumes can kill. Do not operate the machine in an enclosed area unless there is adequate ventilation.

• Operators should also be aware of any open windows, doors or ductwork into which exhaust gases may be carried, exposing others to danger.

• Do not run the engine if repairs are being performed alone. There should always be at least two people working together if the engine must be run during service.

• Always use proper tools while working on the machine. Inappropriate tools could break or slip, causing injury, or they may not adequately perform intended functions.

• Unless necessary for servicing the engine, do not open the engine hood while the engine is running.

• Do not use the machine when maintenance is scheduled to be performed. Postponing maintenance can result in a serious reduction of the service life of the machine, more serious and costly equipment failures, and contribute to unsafe operating conditions.

• Replace hydraulic hoses every six years from the date of manufacture, even if they do not appear damaged. The date of manufacture (month or quarter and year) is indicated on hydraulic hoses.

• Only tow the machine as described in the Operator’s Manual – see Towing the machine on page 26.

• Use the battery disconnect switch to disconnect the battery before performing electrical service or electrical welding on the machine.

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Safety • Turn off all electrical equipment before connecting leads to the battery, including electrical switches on the battery charger or jump-starting equipment.

• When disconnecting at the battery terminals, remove the cable connected to the negative terminal first. When installing a battery, connect the positive terminal cable first.

• Sparks and open flames can set off explosive battery gas from incidental contact or static discharge. Turn off all switches and the engine when working on batteries. Keep battery terminals tight. Contact between a loose terminal and post can create an explosive spark.

• When jump-starting from another machine, do not allow the machines to touch. Wear safety glasses or goggles while battery connections are made.

• Connect positive cable first when installing jumper cables. The final cable connection, at the metal frame of the machine being charged or jump-started, should be as far away from the batteries as possible.

• Never jump-start the machine if it has a frozen battery. The battery could explode. Thaw a frozen battery before charging it or attaching jumper cables.

• Flush eyes with water for 10-15 minutes if battery acid is splashed in the face. Anyone swallowing battery acid must have immediate medical aid. Call the Poison Control Center at 1-800-222-1222 in the United States.

Fire Hazards

• The machine must be cleaned on a regular basis to avoid the buildup of flammable debris, such as leaves, straw, etc. Accumulated debris, particularly in the engine compartment, creates a fire hazard.

• The machine has several components that operate at high temperatures under normal operating conditions, primarily the engine and exhaust systems. Also, the electrical system, if not properly maintained or if damaged, can arc or produce sparks. These conditions make it extremely important to avoid circumstances where explosive dust or gases can be ignited by arcs, sparks or heat.

• Add fuel, oil, antifreeze and hydraulic fluid to the machine only in well ventilated areas.

The machine must be parked with controls, lights and switches turned off. The engine must be turned off before fueling.

• Do not smoke while filling the fuel tank, while working on the fuel or hydraulic systems, or while working around the battery.

• Static electricity can produce dangerous sparks at the fuel-filling nozzle. In very cold, dry weather or other conditions that could produce static discharge, keep the tip of the fuel nozzle in constant contact with the neck of the fuel-filling nozzle, to provide a ground. Be sure that the ground is connected from the machine to the service truck before fueling begins.

• Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured

• It is recommended that a 2.27 kg (5 lbs.) or larger, multi-purpose “A/B/C” fire extinguisher be mounted within reach of the operator. Check the fire extinguisher periodically and be sure that work site crew members are trained in its use.

• Oil leaks can ignite on hot components. Repair any damaged or leaking components before using machine.

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Safety Applications with lifting gear

Definition: Applications with lifting gear are used for raising, transporting and lowering loads with the help of load-securing devices (e.g., slings, chains). In doing so, the help of persons is necessary for securing and detaching the load. For example, get help from other people when lifting and lowering pipes, culverts or containers.

• The machine may only be used with lifting gear if the necessary safety devices are in place and functional.

• The load must be secured to prevent it from falling or slipping.

• Persons guiding the load or securing it must stay in visual contact with the operator.

• The operator must guide the load to the ground as soon as possible and avoid any oscillating or swinging movements.

• The machine may be moved with a raised load only if the path of the machine is as level as possible.

• Persons attaching or securing loads may only approach the machine from the side, after the operator has given permission. The operator may only give permission after the machine is at a standstill and the attachment no longer moves.

• Do NOT use any damaged or incorrectly dimensioned lifting attachments (slings, chains).

• Always wear protective gloves when working with lifting attachments.

Additional Safety Equipment WARNING! Severe operation may require use of additional safety equipment.

Work in mines, tunnels, deep pits or on loose or wet surfaces could produce the hazard of falling rock, roll over or falling objects.

Any operator protective system installed on the machine must comply with applicable safety standards and carry appropriate decaling and rating information.

Never attempt to alter or modify the protective structure by drilling holes, welding or re-locating fasteners. Any serious impact or damage to the system requires a complete integrity reevaluation, and replacement of the system may be necessary.

Install additional safety equipment if conditions require

When working with a hydraulic breaker, a front guard over the windshield may be required.

Laminated glass or polycarbonate protection for the front, side or rear windows may also be recommended depending upon particular work conditions.

Contact your Mustang dealer for available safety guards and/or recommendations if there is any risk of being hit by objects that could strike the operator’s cab.

Keep a fire extinguisher at hand

It is recommended that a 5 lb. (2.27 kg) or larger, multi-purpose “A/B/C” fire extinguisher be mounted in the cab. Check the fire extinguisher periodically and be sure that work site crew members are trained in its use.

Seat belt must be used at all times

When the engine is running, the operator must be seated at the control station with the seat belt fastened.

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Safety Safety Reminders Exposure to crystalline silica

Exposure to crystalline silica (found in sand, soil and rocks) has been associated with silicosis, a debilitating and often fatal lung disease. A Hazard Review (Pub. No. 2002-129) by the U.S. National Institute for Occupational Safety and Health (NIOSH) indicates a significant risk of chronic silicosis for workers exposed to inhaled crystalline silica over a working lifetime. NIOSH recommends an exposure limit of 0.05 mg/m3 as a time-weighted average for up to a 10-hr. workday during a 40-hr. work week. NIOSH also recommends substituting less hazardous materials when feasible, using respiratory protection and regular medical examinations for exposed workers.

Maintain safety equipment in good condition

Machinery guards and body panel covers must be in place at all times. Keep clear of rotating parts, such as cooling fan and alternator belts, which could catch hair, jewellery or loose clothing.

Safety-critical parts must be replaced periodically

Replace the following potentially fire-related components as soon as they begin to show signs of deterioration: • Fuel system flexible hoses, fuel tank overflow drain hose and the fuel filler cap.

• Hydraulic system hoses, especially the pump outlet lines.

Keep mounting brackets, hose, and cable routing ties tight. Hose routings should have gradual bends.

High-pressure hydraulic lines can store energy

Exposed hydraulic hoses on the lift arm could react with explosive force if struck by a falling rock, overhead obstacle or other job site hazard. Extra safety guards may be required.

NEVER allow hoses to be hit, bent or interfered with during operation.

Operator’s cab should be kept clean

Cleaning off accumulations of grease and dirt helps extend equipment service life. Cleaning also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result.

Wear eye protection and safety clothing

Full eye protection, a hard hat, safety shoes and gloves may be required at the job site.

Breathing masks, ear protection may be required

Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause permanent injuries.

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

• Only tow, load and transport the machine in accordance with the Operator’s Manual.

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

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Safety Towing the machine • The machine may only be towed using a tow bar or a cable and towing apparatus (for example, a towing coupling, hooks and eyes).

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

• Only tow the machine with a cable if the service brakes and steering are fully operational.

WARNING! Turning the steering wheel requires greater effort if the engine is off. Remember this when towing the machine.

☞ Use a tow bar if the engine breaks down.

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

☞ Turn off the engine. ☞ Short-circuit the hydraulic circuit before towing (see next page). ☞ Do not tow the machine for more than 328 ft. (100 m), and do not tow it faster than 1 – 2 mph (3 – 4 km/h).

Moving the Machine with a Crane Safety instructions

• The crane and lifting gear must have sufficient capacity – see Specifications on page 149.

• Crane handling requires lifting gear of four equal lengths.

• Secure the machine against unintentional movement.

Crane handling

WARNING! Incorrect crane handling of the machine –

Accident risk. ☞ Do not carry passengers. ☞ The person instructing the crane operator must be within sight or sound of the crane operator.

☞ Make sure that the lifting capacities of the crane and the lifting gear (cables, chains) are sufficient.

☞ Only load the machine if the standard bucket is empty and in the transport position

– see Use: Attachment on page 9.

☞ Avoid suspended loads.

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Safety ☞ Lift the machine as follows: • Install and lock the standard bucket – see Installing attachments on page 81.

• Empty the standard bucket.

• Set the drive to neutral – see Changing direction on page 54.

• Tilt in the standard bucket and lower it into the transport position – see Control lever (joystick) on page 78.

34101b330_01.iso

• Turn off the engine.

• Apply the parking brake – see Prevent rolling away on page 54.

• Remove the ignition key.

• Do not allow anyone to stay in the cab.

• Close the doors and engine cover.

• Fasten the loader at the four points provided by using proper lifting gear – see Machine Overview on page 7.

Fig. 24: Crane handling

WARNING! Do not use the eye hooks on the cab for loading the machine.

• Carefully lift the machine.

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Safety Loading and Transporting the Machine Safety instructions

• The transport vehicle must support the height and weight of the machine – see Specifications on page 149.

• Remove any dirt, snow or ice from the loader tires.

• Secure the machine to prevent unintentional movement.

Loading the machine

DANGER! The machine must be loaded and transported properly –

Accident risk. ☞ – see Loading and Transporting the Machine on a Transport Vehicle on page 75.

Maintenance Safety ☞ Use proper tools.

• While working on the machine, never use improper tools. They could break or slip, causing injury, or they may not adequately perform intended functions.

☞ Battery electrolyte and explosive gases can be lethal.

• Flush eyes with water for 10-15 minutes if battery acid is splashed on the face. Anyone who swallows acid must have immediate medical aid. Call the Poison Control Center listing in the telephone directory.

• Sparks can set off explosive battery gas from incidental contact or static discharge.

Turn off all switches and the engine when working on batteries. Keep battery terminals tight. Contact between a loose terminal and post can create an explosive spark.

☞ Disconnect batteries for electrical service and before electrical welding.

• Remove cable to negative terminal first when disconnecting a battery. Connect positive terminal cable first when installing a battery.

☞ Use warning tag/control lockout procedures during service.

• Alert others that service or maintenance is being performed and tag operator’s cab controls — and other machine areas if required — with a warning notice.

☞ Do not run the engine if repairs or work is being performed alone.You should always have at least two people working together if the engine must be run during service.

☞ Always use adequate equipment supports and blocking.

• Lower bucket to the ground before leaving the operator’s seat. Do not work under any equipment supported solely by a lift jack.

☞ Do not work on hot engines, cooling or hydraulic systems.

• Wait for the engine to cool after operation. Park the machine on a firm, level surface and lower all equipment before shutting down and switching off controls. When engine lube oil, gearbox lubricant or other fluids require changing, wait for fluid temperatures to decrease to a moderate level before removing drain plugs.

IMPORTANT! Engine oil will drain more quickly and completely if it is warm. Do not drain hot fluids, e.g., 200° F (95° C), but do not wait for full cool-down either.

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Safety ☞ Cool-down is required prior to radiator or hydraulic reservoir checks.

• Stop the engine and allow it to cool before performing service on the engine radiator or hydraulic reservoir. Both assemblies have pressure vents at the filler cap for venting pressure. LOOSEN CAPS SLOWLY. Vent the pressure before removing the filler caps.

• Release hydraulic system pressure by cycling controls and releasing hydraulic reservoir pressure before removing hydraulic reservoir access cover. The hydraulic reservoir is pressurized. Vent the system pressure by rotating the filler cap.

LOOSEN CAP SLOWLY prior to removal.

• Make sure to release stored hydraulic pressure in lines by cycling the operator’s controls in each direction after the engine has been shut down.

☞ Pressurized hydraulic oil leaks can be hazardous.

• Fluid leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury.

• Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands. Obtain immediate medical attention if pressurized oil pierces the skin.

Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

☞ Use correct replacement fasteners tightened to proper torque.

• Refer to the Parts Manual for information on torques and assembly of components.

Always use the correct parts – incorrect fastener connections can dangerously weaken assemblies.

☞ Dispose of all petroleum-based oils and fluids properly.

• Used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. Never drain any petroleum-based product on the ground or dispose of used oil in municipal waste collection containers, or in metropolitan sewer systems or landfills. Check state and local regulations for other requirements.

Safety instructions for maintenance • Perform the Mandatory Safety Shutdown Procedure before performing any service,

maintenance or repair work – see Mandatory Safety Shutdown Procedure on page 18.

• If you must have the engine running while performing service, maintenance or repair work: • Only work in groups of two or more.

• Both persons must maintain visual contact with each other.

• Follow the safety instructions in the Operator’s Manual.

• Keep a safe distance away from all rotating and moving parts (e.g. fan blades, V-belt drives, etc.).

• Perform service, maintenance and repair work only if: • Machine is positioned on firm and level ground.

• Lever for selecting the travel direction is in neutral.

• Parking brake is applied.

• Hydraulic attachments and working equipment are lowered to the ground.

• Machine is secured against unintentional movement.

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Safety

WARNING! Avoid the risk of accidents by securing parts and large assemblies being moved to the lifting tackle. Stay clear of suspended loads.

WARNING! Never use machine parts, attachments or superstructures as a climbing aid.

Wear a safety harness when completing maintenance work at greater heights.

Keep all handles, steps, handrails, platforms, landings, and ladders free from dirt, snow and ice.

IMPORTANT! Before cleaning the machine with water, a steam jet (high-pressure cleaning) or detergents, cover or tape any openings that must be protected against water, steam or detergent penetration. Special care must be taken with the electrical system.

• After cleaning, examine all fuel, lubricant and hydraulic oil lines for leaks, chafe marks and damage.

• Tighten any loose connections.

• Avoid contact with hot parts, such as the engine block or the exhaust system during the operation of the machine and for some time afterwards – risk of burns.

• Retainer pins can fly out or splinter when struck with force – risk of personal injury.

• Do not use ether starting aids. This especially applies to those cases in which a heater (intake-air preheating) is used at the same time – risk of explosion.

Service and maintenance work on ROPS superstructures (ROPS bar)

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• DO NOT do any straightening or welding on ROPS structures. Damaged ROPS structures must be replaced with original Mustang service parts.

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Safety Safety Instructions for Specific Hazards Electric energy

• Only use proper, original equipment fuses with the specified current rating. Turn off the machine immediately if there are any problems with the electrical system.

DANGER! When working with the machine, maintain a safe distance from overhead electric lines. If work must be performed close to overhead lines, keep the equipment/ attachments as far away from them as possible.

DANGER! If your machine comes into contact with a live wire: • Do not leave the machine.

• Drive the machine out of the area of danger.

• Warn others against approaching and touching the machine.

• Have the live wire de-energized.

• Do not leave the machine until the damaged line has been safely de-energized.

• Work on the electrical system may only be done by a trained technician.

• Inspect and check the electrical equipment of the machine at regular intervals. Defects such as loose connections or scorched cables must be corrected immediately.

• Follow the operating voltage of the machine/attachments.

• Always remove the ground strap from the battery when working on the electrical system or during welding.

• Jump-starting with a battery cable can be hazardous if carried out improperly. Follow the safety instructions regarding the battery.

Gas, dust, steam, smoke

• Only operate the machine in adequately ventilated premises.

• Perform welding, flame-cutting and grinding work on the machine only if it has been authorized. Before performing welding, flame-cutting and grinding, clean the machine and its surroundings from dust and other flammable substances.

Hydraulic equipment

• Check all lines, hoses and connections regularly for leaks and damage. Repair any damage and leaks immediately. Spilled oil may cause injury and fire.

• Depressurize all system and pressure lines (hydraulic system) to be opened before performing any repair work.

• Hydraulic lines must be routed and fitted properly. Make sure no connections are interchanged. Use only genuine Mustang replacement parts to ensure that the fittings, lengths and quality of the hoses comply with the technical requirements.

Noise

• Maintain the muffler and exhaust system in good condition.

• Wear hearing protection if necessary.

Oil, grease and other chemical substances

• When handling oil, grease and other chemical substances (e.g., battery electrolyte –

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sulphuric acid), follow the product-related safety requirements (material safety data sheet) carefully to prevent burning or scalding yourself or other persons.

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Safety Battery

• When handling the battery, follow the specific safety instructions. Batteries contain sulphuric acid and are caustic.

DANGER! A hydrogen-air mixture, which creates a risk of explosion, is formed in the battery cells during normal operation, and especially during charging.

In the case of a frozen battery or of an insufficient electrolyte level, do not try to start the machine with battery jumper cables. The battery can burst or explode.

Tires

• Repair work on tires and rims must be carried out only by technical staff or an authorized dealer.

• Damaged tires and/or wrong tire pressure reduce the operational safety of the machine.

Therefore, carry out regular checks of the tires for: • Proper tire pressure.

• Damage.

DANGER! DO NOT inflate tires with flammable gas – this creates a risk of explosion.

• Perform regular checks of the wheel nuts for tightness. After changing tires, check the wheel nuts after 10 service hours.

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Safety

NOTES

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CHECKLISTS I acknowledge the pre-delivery procedures were performed on this unit as outlined on this page.

Pre-Delivery Checklist The following checklist is an important reminder of valuable information and inspections that MUST be made before delivering the machine to the customer. Check off each item after the prescribed action is taken.

_______________________________________________ Dealership Name _______________________________________________ Dealer Representative’s Name _______________________________________________ Date Checklist Filled Out

CHECK THAT: R

Unit has not been damaged in shipment. Check for such things as dents and loose or missing parts; correct or replace components as required.

R

Battery is securely mounted and not cracked. Be sure cable connections are tight.

R

Cylinders, hoses and fittings are not damaged, leaking or loosely connected.

R

Filters are not damaged, leaking or loosely secured.

R

Machine is properly lubricated and no grease fittings are missing or damaged.

R

Hydraulic system reservoir, engine crankcase and drive axles are filled to their proper levels.

R

All adjustments are made to comply with settings provided in the Maintenance chapter of this manual.

R

All guards, shields and decals are in place and secured.

R

Model and serial numbers for this unit are recorded in the space provided on this page.

IMPORTANT Start the engine and test run the unit while checking that all controls operate properly.

CHECK THAT:

_______________________________________________ Model & Serial Number

Delivery Checklist The following checklist is an important reminder of valuable information that MUST be passed on to the customer at the time of delivery. Check off each item as you explain it to the customer.

EXPLAIN: R

Safety Instructions and Operation chapters of this manual, regarding the safe operation of this machine.

R

Maintenance and Troubleshooting chapters for information regarding the proper maintenance of this machine. Explain that regular lubrication and maintenance is required for continued safe operation and long machine life.

R

A copy of the product warranty is included on the inside front cover of this Operator’s Manual.

R

Give the Operator’s Manual to the customer and instruct the customer to read and completely understand the contents before operating the unit.

R

Completely fill out the Owner’s Registration, including customer’s signature and return it to Mustang Manufacturing.

R

Drive controls and lift arm/bucket/steering controls operate properly and are not damaged or binding.

R

Drive controls are properly adjusted for correct neutral position.

_______________________________________________ Customer’s Signature

R

The parking brake, along with the lock-out devices, are activated with the unit stationary (no pilot control pressure).

_______________________________________________ Date Delivered

R

All hydraulic functions are NOT operational with the control lever lock in the lock-out position.

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RETAIN FOR CUSTOMER’S RECORDS

918296/BP1209

CHECKLISTS I acknowledge the pre-delivery procedures were performed on this unit as outlined on this page.

Pre-Delivery Checklist The following checklist is an important reminder of valuable information and inspections that MUST be made before delivering the machine to the customer. Check off each item after the prescribed action is taken.

_______________________________________________ Dealer Representative’s Name _______________________________________________ Date Checklist Filled Out

CHECK THAT:

Remove dealer’s file copy at perforation.

_______________________________________________ Dealership Name

R

Unit has not been damaged in shipment. Check for such things as dents and loose or missing parts; correct or replace components as required.

R

Battery is securely mounted and not cracked. Be sure cable connections are tight.

R

Cylinders, hoses and fittings are not damaged, leaking or loosely connected.

R

Filters are not damaged, leaking or loosely secured.

R

Machine is properly lubricated and no grease fittings are missing or damaged.

R

Hydraulic system reservoir, engine crankcase and drive axles are filled to their proper levels.

R

All adjustments are made to comply with settings provided in the Maintenance chapter of this manual.

R

All guards, shields and decals are in place and secured.

R

Model and serial numbers for this unit are recorded in the space provided on this page.

IMPORTANT Start the engine and test run the unit while checking that all controls operate properly.

CHECK THAT:

_______________________________________________ Model & Serial Number

Delivery Checklist The following checklist is an important reminder of valuable information that MUST be passed on to the customer at the time of delivery. Check off each item as you explain it to the customer.

EXPLAIN: R

Safety Instructions and Operation chapters of this manual, regarding the safe operation of this machine.

R

Maintenance and Troubleshooting chapters for information regarding the proper maintenance of this machine. Explain that regular lubrication and maintenance is required for continued safe operation and long machine life.

R

A copy of the product warranty is included on the inside front cover of this Operator’s Manual.

R

Give the Operator’s Manual to the customer and instruct the customer to read and completely understand the contents before operating the unit.

R

Completely fill out the Owner’s Registration, including customer’s signature and return it to Mustang Manufacturing.

R

Drive controls and lift arm/bucket/steering controls operate properly and are not damaged or binding.

R

Drive controls are properly adjusted for correct neutral position.

_______________________________________________ Customer’s Signature

R

The parking brake, along with the lock-out devices, are activated with the unit stationary (no pilot control pressure).

_______________________________________________ Date Delivered

R

All hydraulic functions are NOT operational with the control lever lock in the lock-out position.

Printed in U.S.A.

35

RETAIN FOR DEALER’S RECORDS

918296/BP1209

INTENTIONALLY BLANK (To be removed as dealer’s file copy)

Printed in U.S.A.

36

918296/BP1209

Operation

Operation Description of controls This chapter describes the indicators and controls in the cab.

The pages listed in the table refer to the description of the controls.

Number/letter combinations describe the controls. For example 40/18 or 40/A means figure number 40/item number 18, or figure number 40/position A. The following symbols are used:

• This symbol stands for a list.

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

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

n. s. = not shown.

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

Printed in U.S.A.

37

918296/BP1209

Operation

1 2 2

5

3

34

4 5 6 7 33 8 32 9 31 10 30 11 I0

29

12

11

13

28 27

14

26

15 16 25

24

17

23

18

22

19

20

20 21

Fig. 25: Cab overview Printed in U.S.A.

38

918296/BP1209

Operation Cab: Overview Pos.

Description

For more information see page

1 2 3

Sun visor Air vent(s) – front window Wiper motor – front window

4

Cab light

5

Air vent(s) – floor

6

Accelerator pedal ....................................................................................................................................................................................... 53

7

Instrument cluster....................................................................................................................................................................................... 42

8

Window lock ............................................................................................................................................................................................... 69

9

Joystick-style control lever ......................................................................................................................................................................... 78

10

Control lever – 3rd control circuit................................................................................................................................................................ 79

11

Cab door arrester ....................................................................................................................................................................................... 68

12

Speed range switch panel .......................................................................................................................................................................... 55

13

Lever – horizontal seat adjustment ............................................................................................................................................................ 65

14

Parking brake lever .................................................................................................................................................................................... 54

15

Switch panel ............................................................................................................................................................................................... 41

16

Fuse box................................................................................................................................................................................................... 153

17 18

Instrument panel......................................................................................................................................................................................... 41 Storage / Radio (option)

19

Rear wiper switch/motor............................................................................................................................................................................. 63

20 21

Left cab door arrester / right side window arrester .............................................................................................................................. 68, 69 Storage pocket for operator’s manual

22

Lever – backrest adjustment ...................................................................................................................................................................... 65

23

Operator's seat........................................................................................................................................................................................... 64

24

Air conditioning........................................................................................................................................................................................... 62

25

Air conditioning control ............................................................................................................................................................................... 62

26

Seat belt ..................................................................................................................................................................................................... 66

27

Lever – weight adjustment ......................................................................................................................................................................... 64

28

Hydrostatic steering.................................................................................................................................................................................... 56

29

Multi-functional lever .................................................................................................................................................................................. 60

30

Outside door handle ................................................................................................................................................................................... 68

31

Hydrostatic service brake / inching pedal................................................................................................................................................... 53

32

Windshield washer fill................................................................................................................................................................................. 63

33

Brake fluid fill ............................................................................................................................................................................................ 126

34

Front window defroster vents ..................................................................................................................................................................... 61

Printed in U.S.A.

39

918296/BP1209

Operation

Instrument Panel Detail

39

41

40

42 43

38 37

Multi-functional Lever Detail

44 1

50

49

48

45

36 72

35 46 47

52

51 Right Joystick Detail

Right Console

Switch Detail

53

73

54

59 60 61 62 74 Console Switches Detail 63 67 64 65 66

55 70 56 57

68

69

70

71

16

58 Fig. 30: Instruments, Multi-functional and drive levers overview

Printed in U.S.A.

40

918296/BP1209

Operation Instrument Panel, Multi-functional Lever and Drive Lever: Overview Pos.

Description

For more information see page

Instrument panel 35

Indicator (red) coolant level ........................................................................................................................................................................43

36

Indicator (green) – right/left turn indicator for rear attachments..................................................................................................................60

37

Indicator (green) – right/left turn indicator...................................................................................................................................................60

38

Indicator (red) – hydraulic oil filter............................................................................................................................................................ 121

39

Indicator (red) – hydraulic oil temperature ..................................................................................................................................................42

40

Indicator (red) – alternator charge function.................................................................................................................................................43

41

Indicator (red) – parking brake....................................................................................................................................................................42

42

Indicator (red) – engine oil pressure ...........................................................................................................................................................43

43

Indicator (red) – engine coolant temperature..............................................................................................................................................43

44 45 46 47

Indicator (blue) – high beam .......................................................................................................................................................................43 Not assigned Fuel level indicator Hourmeter

Multi-functional lever 48

Tip switch – horn

49

Tip switch – front/rear windshield washer pump.........................................................................................................................................63

50

Rotary switch – front wiper .........................................................................................................................................................................63

Switches and control lever (side console) 51

Loader unit control lever with lock ..............................................................................................................................................................78

52

Rocker switch with lock – 3rd control circuit ...............................................................................................................................................78

53

Toggle switch – drive range selection.........................................................................................................................................................55

54

Not assigned

55

Ignition keyswitch........................................................................................................................................................................................46

56 57

Switch – hazard warning system Socket/cigarette lighter

58

Rotary switch – heater temperature control................................................................................................................................................61

59

Indicator (green) – forward driving direction ...............................................................................................................................................54

60

Tip switch – driving direction selection switch ............................................................................................................................................54

61

Indicator (green) – reverse driving direction ...............................................................................................................................................54

62

Tip switch – neutral speed range................................................................................................................................................................55

63 64

Rocker switch – lights .................................................................................................................................................................................58 Not assigned

65

Not assigned

66

Heater fan switch ........................................................................................................................................................................................61

67

Rocker switch – rear working light ..............................................................................................................................................................60

68

Rocker switch – front working light (option) ................................................................................................................................................60

69 70

Rocker switch – rotating beacon (option) ...................................................................................................................................................61 Not assigned

71

Rocker switch – front socket for electrically operated attachments (option)

72

Differential lock indicator.............................................................................................................................................................................56

73

Tip switch – differential lock........................................................................................................................................................................56

74

Tip switch – differential lock........................................................................................................................................................................56

Printed in U.S.A.

41

918296/BP1209

Operation Indicators and Warning Lights: Overview 35 Indicator (red) – coolant level

35

Comes on if the coolant level is too low:

☞ Check the coolant system for leaks, have possible damage repaired by an authorized workshop.

☞ Add coolant.

36 Indicator (green) – right/left turn indicator on rear attachment

36

Flashes repeatedly: • When the turn indicators are used.

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

37 Indicator (green) – right/left turn indicators

37

Flashes repeatedly when the turn indicators are used.

38 Indicator (red) – hydraulic oil filter

38

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

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

39 Hydraulic oil temperature indicator

39

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

Risk of hydraulic damage as soon as temperature indicator 39 comes on.

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

• Move control lever 25/9 to neutral.

• Select neutral by using tip switch 30/62.

• Run the engine at increased speeds until temperature indicator 39 goes out.

40 Indicator (red) – alternator charge function

40

Comes on after the ignition is switched on and goes out after the engine runs.

Comes on while the engine is running if: • The V-belt or charging circuit for the alternator is faulty.

• The battery is discharged (➠ page 119).

41

Printed in U.S.A.

P

41 Indicator (red) – parking brake Comes on when parking brake lever 25/14 is applied.

42

918296/BP1209

Operation

42

42 Indicator (red) – engine oil pressure Comes on if the engine oil pressure is too low. If the oil pressure is to low:

☞ Stop the machine. ☞ Turn off the engine immediately and check the oil level (➠ page 112).

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

43

44

43 Temperature indicator – engine coolant Indicates if the engine temperature is too high.

44 Indicator (blue) – high beam Comes on if high beam is turned on or during headlight flashing.

72

72 Telltale (green) – differential lock Indicates that the differential lock is switched on

Printed in U.S.A.

43

918296/BP1209

Operation Getting Started Safety instructions • Only use the steps and handles provided when entering and leaving the cab.

• Face the machine as you enter and leave it.

• Keep the footholds and the handles clean to ensure a safe hold at all times.

• Never use the controls or cables as handles.

• Never climb onto or jump off a moving machine.

• Refer to the load diagrams for the loader unit pallet forks – see Picking up loads with the pallet forks on page 104.

Important information

• The machine may only be used in good operating condition in accordance with its designated use and the instructions in the Operator’s Manual, and only by persons who are properly trained and fully aware of the risks involved in operating the machine – see Checklists on page 45.

Run-in period

The performance and service life of the machine is heavily dependent on using the machine carefully during its first 100 operating hours.

• Do not overload the machine.

• Do not run the engine at a high speed for extended periods of time.

• Increase the load gradually while varying the engine speed.

• Follow the maintenance schedule – see Maintenance Schedule on page 139.

Printed in U.S.A.

44

918296/BP1209

Operation Checklists Use the checklists in this section to help you check and monitor the machine before, during and after operation.

Start-up checklist

Complete the checklist below before starting the engine or putting the machine into service: ✔

No. Question

Printed in U.S.A.

1

Sufficient fuel in the tank? (➠ 110)

2

Engine oil level OK? (➠ 112)

3

Oil level in hydraulic reservoir OK? (➠ 120)

4

Water level in washer reservoir OK? (➠ 63)

5

V-belt condition and tension checked? (➠ 119)

6

Loader unit lubricated? (➠ 125)

7

Brake system (including parking brake) OK? (➠ 51)

8

Tire condition and inflation pressure OK? (➠ 127)

9

Wheel nuts securely tightened (especially after a wheel change)? (➠ 128, 157)

10

Lights, signals, indicators, warning lights and indicators OK? (➠ 58, 60, 42)

11

Windows, mirrors, lights and steps clean?

12

Is the attachment on the loader unit correctly locked? (➠ 81)

13

Is the engine cover firmly locked? (➠ 71)

14

Especially after cleaning, maintenance or repair work: Rags, tools and other loose objects removed?

15

Approved warning triangle, hazard warning light and first aid kit in the machine?

16

Seat position and rearview mirror correctly adjusted? (➠ 64)

16

Seat belt fastened? (➠ 67)

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918296/BP1209

Operation Operation checklist

Complete the checklist below after starting the engine, during operation, and when driving on public roads: ✔

No. Question After starting and during operation: 1

Indicators for engine oil pressure and alternator went out? (➠ 42)

2

Braking effect sufficient? (➠ 51)

3

Temperature indicator for engine coolant in normal range? (➠ 42)

4

Steering working properly? (➠ 51)

5

Is anyone hazardously close to the machine? (➠ 17)

6

3rd control circuit locked? (➠ 79)

When driving on public roads:

Parking checklist

7

Bucket and attachments in the transport position? (➠ 50)

8

Transport locks installed? (➠ 78)

9

Control lever for lift and tilt hydraulics of the loader unit locked with the lock? (➠ 50)

Complete the checklist below when parking the machine: ✔

No. Question When parking: 1

Attachments on the loader unit lowered to the ground? (➠ 57, 78)

2

Parking brake applied? (➠ 54)

3

Machine cab locked (especially if the machine cannot be supervised)? (➠ 68)

When parking on public roads: 4

Machine adequately secured? (➠ 57)

When parking on uphill and downhill gradients: 5

Machine additionally secured with chocks under the tires to prevent it from rolling away? (➠ 57)

Battery Disconnect Switch The battery master switch is located in the engine compartment next to the battery.

Interrupting power supply:

☞ Turn and remove the key of the battery master switch (notched position).

Switching on power supply:

☞ Insert the key in the battery master switch. ☞ Turn the key to the notched position.

Printed in U.S.A.

46

918296/BP1209

Operation

Operation Working with the Machine General safety instructions • Never drive up to the edge of a pit from the outside – risk of cave-in.

• Never undermine the foundations of walls – risk of collapse.

• When excavating, look out for high-voltage and underground cables, and gas and water pipes.

• When using lifting accessories such as pallet forks, comply with the load diagrams – see Picking up loads with the pallet forks on page 104.

• The hydraulic system of the machine is still pressurized even when the engine is not running. Depressurize the sections of the system and hydraulic lines that you want to open before starting setup or repair work (e.g., fitting/removing an attachment with hydraulic functions) – see Depressurizing the quick-couplers on the loader unit on page 80.

Printed in U.S.A.

77

918296/BP1209

Operation Control lever (joystick) Control lever for lift and tilt cylinder hydraulics

DANGER! Unintentional operation of control lever 9 when driving on public roads:

Accident risk. ☞ Lock the control lever 76/9 – see Control lever lock (joystick) on page 78.

D C

A

B E

9

Position Lever 9

Function

• A • B • C • D • E

➥ Tilts back attachment ➥ Dumps out attachment ➥ Lowers boom ➥ Lowers boom to float position ➥ Raises boom

☞ Left ☞ Right ☞ Forward ☞ Fully forward ☞ Rearward

IMPORTANT! The control valve is equipped with a float position. This helps when working with a rotary broom, snowplow, and grading in reverse.

Fig. 75: Control lever for loader unit

Complete the following procedures to turn on the float position:

☞ Push control lever 9 fully forward to final position D. Control lever lock (joystick) The lock lever for locking the control lever is located on the control lever base console.

9

Locking the control lever

☞ Put the control lever 9 into the neutral position and push it down vertically ➥ The control lever is locked in this position and cannot be moved. ➥ Follow these instructions:

.

– see Before driving the machine on page 50.

Unlocking the control lever

☞ Pull up on the control lever to unlock.

Fig. 76: Control lever lock

Printed in U.S.A.

78

918296/BP1209

Operation Operation of 3rd control circuit

WARNING! When working with attachments without a hydraulic function, operating the 3rd control circuit 10 unlocks the quickhitch –

Risk of personal injury. ☞ Lock control lever 10 (3rd control circuit) when working with an attachment.

– see Operation of 3rd control circuit on page 79.

☞ To unlock control lever 10: 10

• Pull lock sleeve A upward and rotate it counter-clockwise.

☞ To briefly unlock control lever 10

:

• Pull lock sleeve A upward and hold.

A

Unlocking the 3rd control circuit

☞ Push the control lever 10 forward: ➥ The attachment on the quickhitch is unlocked.

C

O

Fig. 77:

Attachments with hydraulic functions ➥ Pushing the control lever forward O operates hydraulic attachment functions, such as closing the multi-purpose bucket. ☞ Pull the control lever C to the rear.

➥ The attachment on the quickhitch is locked. ➥ Pulling the control lever to the rear C operates hydraulic attachment functions, such as

10

opening the multi-purpose bucket.

Fig. 78: Operation of 3rd control circuit

3rd control circuit continuous operation 10

C

A

IMPORTANT! 3rd control circuit continuous operation is useful when using attachments with additional hydraulic functions, or when operating hydraulic motors (e.g., rotary broom) or attachments with separate control valves.

3rd control circuit continuous operation is controlled with the control lever.

Fig. 79: Continuous operation of 3rd control circuit

☞ Pull control lever 10 to the rear C. ☞ Unscrew lock sleeve A clockwise until it is pulled down by spring action and engage control lever 10 in position C.

➥ The control lever is locked in this position and cannot be moved.

Printed in U.S.A.

79

918296/BP1209

Operation Lowering the loader unit with the engine turned off Lower the loader unit as follows: C

9

☞ Make sure no one is near the machine. ☞ Push and hold control lever 9 forward C. ➥ Until the loader unit is completely lowered. ☞ Return control lever 9 to neutral.

Fig. 80: Lowering the loader unit with the engine turned off

Depressurizing the quick-couplers on the loader unit IMPORTANT! The hydraulic system of the machine is still pressurized even when the engine is not running. The hydraulic quick-couplers can be released, but they cannot be re-attached because the hydraulic lines are pressurized. Therefore:

☞ Depressurize the sections of the system and hydraulic lines that you want to

open before starting setup or repair work (e.g., fitting/removing an attachment).

C

O

Depressurize as follows:

10

☞ Engage the parking brake. ➥ – see Parking brake on page 54. ☞ Unlock the 3rd control circuit. ➥ – see Operation of 3rd control circuit on page 79. ☞ Turn off the engine. ➥ Do not turn off the ignition. ☞ Move control lever 10 back and forth several times O/C.

Fig. 81: Depressurizing hydraulic lines

Printed in U.S.A.

80

918296/BP1209

Operation Installing attachments Installing the standard bucket is described below. If you are fitting or removing attachments with their own hydraulic functions, you must follow the information provided in the Operator’s Manual of the attachment.

Fitting attachments onto the quickhitch

WARNING! The attachment must always be locked onto the quickhitch –

Accident risk. ☞ Before working, be sure that the attachment is locked onto the quickhitch by using the lock cylinder. Be sure that you can see the lock pins on both sides of the mounting holes on the attachment.

Install as follows:

C

A D

☞ Drive the machine up to the attachment. ☞ Lower loader unit E by pushing control lever 10 forward C. ☞ Tilt the quickhitch forward by pushing control lever 10 to the right B. ☞ Adjust the height of pin shanks G of the quickhitch so that they are under catch hooks F of

10

B

the attachment.

☞ Drive the machine forward until pin shanks G of the quickhitch are directly beneath the catch hooks of attachment F.

E

F

G

Fig. 82: Driving up to the attachment

☞ Raise loader unit E until pin shanks G engage in pin shanks F of the attachment. To do this: Pull control lever 10 rearward D.

E

C

A D

☞ Fully tilt back the quickhitch. To do this: Push control lever 10

to the left A.

10

B

Fig. 83: Raising the attachment

Printed in U.S.A.

81

918296/BP1209

Operation Locking: attachments without hydraulic function

C

O

Secure the attachment with lock pins H of the quickhitch. To do this:

10

☞ Pull control lever 10 to the rear C. ➥ Lock pin H engages in the mounting holes of the attachment. ➥ Make sure the attachment is safely locked with lock pins H. ☞ Lock the 3rd control circuit. ➥ – see Operation of 3rd control circuit on page 79.

IMPORTANT! H

You must be able to see lock pins H on the left and right of the mounting holes on the attachment. The attachment is not safely locked unless you can see the lock pins.

Fig. 84: Locking the attachment

Locking: attachments with hydraulic function

☞ Turn off the engine. ➥ Do not turn off the ignition. ☞ Apply the parking brake. ☞ Unlock the 3rd control circuit. ➥ – see Operation of 3rd control circuit on page 79. ☞ Depressurize the 3rd control circuit. ➥ – see Depressurizing the quick-couplers on the loader unit on page 80. ☞ Attach the hydraulic and electrical connections (if used) for the attachment by following its Operator’s Manual.

Printed in U.S.A.

82

918296/BP1209

Operation Removing an attachment from the quickhitch

WARNING! The attachment must be placed on the ground so that it will not fall over when removed –

Risk of personal injury. ☞ Position the attachment so that after unlocking it will not tip over.

Take the attachment off the quickhitch as follows:

☞ Be sure that the attachment is empty and up. ☞ Tilt in the quickhitch by pushing control lever 9 to the left A. ☞ Lower the lift arms until the attachment is about 2–4 in. (5–10 cm) above the ground by

C

A

B

D

pushing control lever 9 forward C, and tilt forward the attachment by pushing control lever 9 to the right B.

9 Fig. 85: Lowering and tilting back the attachment

For attachments with hydraulic function

C

O

☞ Turn off the engine. ➥ Do not turn off the ignition. ☞ Engage the parking brake. ☞ Unlock control lever 10 for the 3rd control circuit:

10

– see Operation of 3rd control circuit on page 79.

☞ Depressurize the quick couplers – see Depressurizing the quick-couplers on the loader unit on page 80.

A

☞ Change over the quick couplers on the lock cylinder: • Connect flexible line A onto the right plug D of the quickhitch.

C

• Connect flexible line B onto the left plug C of the quickhitch.

D B

E

• Remove electrical connections (if necessary).

☞ Start the engine. ☞ Slightly tilt the quickhitch forward. To do this: ➥ Push control lever fig. 85/9 to the right B. ☞ Lower the loader unit. To do this: ➥ Push control lever 85/9 forward C. As soon as the pin shanks of quickhitch F are beneath the catch hooks of attachment E:

F

☞ Release the parking brake. ☞ Reverse the machine away from the attachment.

Fig. 86: Changing over hydraulic connections – setting down an attachment

Printed in U.S.A.

83

918296/BP1209

Operation Working with the Standard Bucket This section describes work operations for the machine equipped with the standard bucket.

The standard bucket is mainly used for digging, loosening, lifting, transporting and loading loose or solid materials.

Applications of the Standard Bucket The standard bucket is mainly used for digging earth, and for loosening, picking up, transporting and loading loose or solid materials.

Safety instructions for working with the bucket • • • •

Never drive up to the edge of a dropoff - risk of cave-in.

Never compromise wall foundations - risk of collapse.

Operation of the machine by unauthorized staff is prohibited.

When working with the machine, look out for high-voltage cables, underground cables, gas and water pipes.

• When using lifting gear such as pallet forks, follow the load diagram that apply to the machine.

• Follow all applicable local legal regulations, which may prohibit driving on public roads with a full bucket.

• Also, – see Fields of Application, Attachments on page 9.

Digging tips When completing digging work, the following is recommended:

• Exit the pit, as level as possible, from outside the digging line.

• Dig by removing adjacent strips.

• Drive forward when transporting a full bucket out of the digging area.

• Drive reverse when transporting a full bucket down a steep slope.

Loading trucks When loading trucks, the following is recommended:

• The truck and machine working direction should form an angle of 45°.

• Only raise a full bucket to the dump height when you are driving in a straight line toward the truck.

• Dump with the wind behind you to keep the dust away from your eyes, air filters and fans.

Fig. 87: Loading machines

Printed in U.S.A.

84

918296/BP1209

Operation Freeing the wheel loader from soft ground If the machine gets stuck in soft ground:

☞ Dump the bucket until the cutting edge is vertical above the ground. ☞ Completely lower the lift arm. ☞ Gradually tilt back the bucket. ➥ The machine is pushed rearward. ☞ Move slowly in reverse. ☞ Repeat this procedure until the wheels reach firm ground.

Practical hints for digging • Exits from pits must be outside the digging line and be as level as possible.

• If possible, dig by removing adjacent strips.

• Make sure you can drive forward with a fully loaded bucket when driving out of the digging area.

• Whenever possible, drive in Reverse when transporting a full bucket down a steep slope.

Checking the tilt position of the bucket

NOTE

A

Angle of mark A = angle of blade B. B

Fig. 88: Tilt position of the bucket

Checking the transport position of the bucket

NOTE A B Fig. 89: The transport position of the bucket

The bucket is in the transport position if: • Bucket is tilted back completely A. • Marks on the loader unit and the machine frame are lined up 90/C. The distance of the bucket (with standard tires) to the ground B is about 8” (250 mm).

IMPORTANT! In order to avoid damage to the machine or tires, do not move the machine with the bucket fully tilted forward.

☞ Lower the attachment to the transport position and tilt it back.

Printed in U.S.A.

85

918296/BP1209

Operation Transporting with a full bucket

WARNING!

C

Transporting full buckets in the raised position is an –

Accident risk.

Pay attention to this when cornering or driving on slopes. The lower the bucket and center of gravity, the less risk there is of tipping over.

To avoid accidents:

Fig. 90: Marks on loader unit and machine frame

☞ Tilt the bucket all the way back A. ☞ Raise the bucket to the transport position: ➥B and C.

A B Fig. 91: The transport position of the bucket

C

Fig. 92: Marks on loader unit and machine frame

Loading loose material

☞ Align the blade flush with the ground A. ☞ Lower the bucket to the ground B. To do this:

C

A

D

B

Push control lever forward C.

B A Fig. 93: Lowering the loader unit

Printed in U.S.A.

86

918296/BP1209

Operation ☞ Drive forward into the material A.

C

A

When the engine speeds decreases due to too much material: B

D

☞ Slightly raise the bucket B. To do this: Pull control lever rearward D.

B A

Fig. 94: Driving into the material

Loading if the material is hard to penetrate

C

A

B

D

☞ Proceed as for loading loose material. ☞ Tilt the bucket back and out slightly by moving control lever to the left and right A and B.

Fig. 95: Loading, if the material is hard to penetrate

D

A

Ending loading

C

A

B

☞ Tilt back the bucket C by pushing control lever to the left A. ☞ Reduce engine speed. ☞ Reverse out of the material A. ☞ Raise the bucket to the transport position B.

C B

Fig. 96: Tilting back the bucket

Printed in U.S.A.

87

918296/BP1209

Operation Removing material/digging in soft soil C

A

DANGER! B

D

If foundations or walls are undermined – risk of collapse.

Accident risk.

B

☞ Never undermine foundations or walls. ☞ Place the bucket horizontally on the ground B by pushing control lever forward C. Fig. 97: Lowering the bucket horizontal to the ground

☞ Set the digging angle α 1 by pushing control lever to the right B.

C

A

B

D

1

α

1 Fig. 98: Setting the digging angle

☞ Drive the machine forward 1.

C

A

After the bucket has penetrated the soil: B

D

☞ Set the digging angle α (slightly flatter) 2 by pushing control lever to the left A, so that the: • Layer being removed is as even as possible.

• Wheel spin is reduced.

☞ Proceed as for loading loose material.

1

2 Fig. 99: Removing an even layer

Printed in U.S.A.

88

918296/BP1209

Operation Removing material/digging in hard soil C

A

B

D

☞ Lower the bucket horizontally to the ground 1 by pushing control lever forward C. ☞ Set the digging angle α (downward) 2 by pushing control lever to the left A. ☞ Drive the machine forward 3. ☞ Press the bucket downward slightly by pushing control lever forward C.

3 1

2 Fig. 100: Removing hard soil

After the bucket has penetrated the soil: C

A

☞ Set the digging angle α (slightly flatter) 1 by pushing control lever to the left A, so that the: B

D

• Layer being removed is as even as possible.

• Wheel spin is reduced.

☞ Push control lever to the left A, or move it alternately to the left and right A and B to loosen the material.

☞ Proceed as for loading material hard to penetrate.

1 Fig. 101: Setting the digging angle flatter

Loading heaped material (non-compacted material)

WARNING! Digging under heaped material can cause it to collapse –

Accident risk. ☞ Never undermine heaped material. ☞ Set the cutting edge parallel to the ground by pushing control lever to the left or right A

C

A

D

and B.

B

☞ Lower the bucket horizontally to the ground by pushing control lever forward C. ☞ Drive forward.

After penetrating the heaped material:

☞ Smoothly raise the lift arm. ☞ Keep the bucket level.

Fig. 102: Penetrating heaped material

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Operation When the lift arms cannot be raised farther:

☞ Tilt the bucket 1 back. ☞ Raise the lift arms 2. ☞ Reverse out of the material 3. ☞ Lower the bucket into the transport position.

1

3 2

Fig. 103: Reversing away from heaped material

Loading heaped material (compacted material)

☞ Proceed as for non-compacted material. ☞ When raising the loader unit through the heaped material: tilt the bucket slightly back and

C

A

out 1.

B

D

☞ To do this: move control lever alternately to the left and right (A and B). ➥ Material is loosened.

1 Fig. 104: Heaped compacted material

Grading After having finished removing/loading the material:

☞ Lower the bucket horizontally to the ground 1. ☞ Reverse across the surface to be graded 2.

2

1

Fig. 105: Grading

Connecting a Multi-purpose Bucket (option) Connecting a multi-purpose bucket to the quickhitch ☞ Connect the multi-purpose bucket. ➥ – see Fitting attachments onto the quickhitch on page 81. ☞ Make sure both lock pins of the lock cylinder are safely locked in the attachment.

Fig. 106: Checking the lock pins

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Operation

DANGER! The attachment must always be safely locked onto the quickhitch -

Accident risk. ☞ Before using the machine, make sure the attachment is safely locked onto the quickhitch. You must be able to see the quickhitch lock pins on either side of the mounting holes on the attachment.

☞ Make sure the lock pins of the quickhitch are fully extended before connecting the 3rd control circuit hydraulic lines to the attachment.

Hydraulic connections on the multi-purpose bucket: overview

230 bar

D

Hydraulic connection

Function

C Pressurized

Opens the multi-purpose bucket

D Pressurized

Closes the multi-purpose bucket

C Hydr_plan.eps

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Operation Connecting hydraulic lines to the machine IMPORTANT! The hydraulic system is pressurised even when the engine is not running. When the hydraulic system is pressurized, the hydraulic quick-couplers cannot be connected.

Because of this, before connecting the hydraulic quick-couplers: • Release the pressure in the sections of the system and hydraulic lines that will be opened before starting setup or repair work, e.g., fitting/removing an attachment.

B A

☞ Shut off the engine. ☞ Engage the parking brake. ☞ Release the pressure in the hydraulic lines. ➥ – see Depressurizing the quick-couplers on the loader unit on page 80. ☞ Remove hydraulic lines A and B from the quickhitch.

Fig. 107: Removing hydraulic connections from the quickhitch

B

☞ Connect hydraulic lines A and B to the hydraulic connections C and D on the attachment.

A

NOTE Make sure the quick-couplers are properly connected – never connect the hydraulic lines crosswise, otherwise the attachment functions will be reversed.

☞ Functional check: C

D

• Make sure the hydraulic lines are not pinched throughout the entire range of motion of the attachment.

Fig. 108: Connecting hydraulic multi-purpose bucket lines

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Operation Removing the multi-purpose bucket from the quickhitch DANGER! The attachment must be placed on the ground so that it will not fall over when removed -

Accident risk. ☞ Position the attachment on the ground so it will stand safely and not tip over when unlocked from the quickhitch.

IMPORTANT! If the attachment is placed in direct sunlight after it is removed, the oil in the hydraulic cylinders will warm up. This leads to a pressure increase in the hydraulic cylinders, which can make it difficult to attach the hydraulic lines to the hydraulic connections.

To avoid this problem, remove the attachment as follows: B

☞ Tilt the multi-purpose bucket back as far as it will go. ☞ Close the multi-purpose bucket to a gap of about 8” (20 cm). ☞ Unlock the multi-purpose bucket. ➥ – see Hydraulic connections on the multi-purpose bucket: overview on page 91. ☞ Shut off the engine. ☞ Engage the parking brake. ☞ Release the pressure in the hydraulic lines. ➥ – see Depressurizing the quick-couplers on the loader unit on page 80. ➥ The multi-purpose bucket closes when the pressure is released. ☞ Disconnect hydraulic lines A and B from quick-couplers E and F on the multi-purpose

A

F E

bucket.

Fig. 109: Removing hydraulic multi-purpose bucket connections

☞ Connect hydraulic lines A and B onto quick couplers C and D on the quickhitch.

B A

NOTE Make sure the quick-couplers are properly connected – never connect the hydraulic lines crosswise, otherwise the quickhitch cylinder functions will be reversed.

D C Fig. 110: Connecting hydraulic quickhitch lines

Printed in U.S.A.

After making the hydraulic connections as described earlier:

☞ Slightly tilt the multi-purpose bucket to a horizontal position. ☞ Set the multi-purpose bucket onto the ground. ➥ – see Removing an attachment from the quickhitch on page 83.

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Operation Working with the Multi-purpose Bucket DANGER! The attachment must always be safely locked onto the quickhitch -

Accident risk. ☞ Before using the attachment, make certain it is safely locked onto the quickhitch. You must be able to see the lock pins on either side of the mounting holes on the attachment.

☞ – see Locking: attachments without hydraulic function on page 82.

IMPORTANT! To avoid damage to the machine or tires, do not move the machine with the bucket fully tilted forward.

☞ Lower the attachment to transport position and tilt it back.

Driving on public roads with the multi-purpose bucket ☞ Empty the multi-purpose bucket. ☞ Tilt the multi-purpose bucket back (base position). ☞ Shut off the engine. ☞ Engage the parking brake. ☞ Depressurize the quick-couplers. ➥ – see Depressurizing the quick-couplers on the loader unit on page 80. ☞ Disconnect the hydraulic lines from the multi-purpose bucket and connect them to the quickhitch.

➥ – see Removing the multi-purpose bucket from the quickhitch on page 93. ☞ Position the multi-purpose bucket into transport position. ☞ Lock the control lever (joystick). ➥ – see Control lever lock (joystick) on page 78.

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Operation Grading and scraping DANGER! Do not transport attachments in the raised position -

Accident risk.

Pay particular attention to this when cornering or driving on slopes. Keep the attachment as low as safely possible, because the lower the position of the attachment, the lower the center of gravity, which lessens the danger of tipping the machine.

☞ To avoid accidents: • Tilt the attachment back as far as it will go.

• Lower the attachment to the transport position.

Grading ☞ Open up the front half of the multi-purpose bucket.

☞ Use the lift to set the bucket depth for the layer you want to remove. ☞ Set the cutting edge angle.

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Drawing material rearward ☞ Tilt the multi-purpose bucket forward.

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☞ Use the lift to raise the bucket. ☞ Open up the front half of the bucket. ☞ Lower the bucket to the ground. ☞ Set the angle of the bucket. ☞ Surfaces are graded or scraped bydriving in reverse.

Stripping in thin layers (scraper) ☞ Set a flat digging angle. ☞ Open the front half of the bucket by about 4–6” (10–15 cm). ☞ Drive the machine forward. ➥ The material rolls into the bucket and is picked up at the same time.

NOTE This position allows stripping material, e.g., grass turf, down to a thickness of about 3” (8 cm).

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Operation Spreading material in thin layers ☞ Set the rear cutting edge parallel to the ground. ☞ Open the front half of the bucket until the required quantity of material is emptied onto the ground.

☞ Drive the machine forward. ☞ Lower the multi-purpose bucket to the ground. ➥ The rear cutting edge grades the material as it is emptied by opening the front half of the bucket.

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NOTE This position allows the spreading of material without driving on the lower layer with the machine (e.g., applying the first bituminous base onto sensitive antifrost layers, applying granulated material onto plastic coatings, etc.).

Pulling out material from slopes NOTE This position allows for pulling material out of slopes or roadside ditches with maximum safety and to spread it as required.

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Moving material with a longer reach NOTE This position allows moving material without damaging slopes or structures.

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Operation Picking up remaining material NOTE Both bucket halves must touch the ground or all the material may not be picked up.

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☞ Open up the front half of the multi-purpose bucket. ☞ Tilt the bucket forward. ☞ Lower the bucket to the ground. Make sure both bucket halves touch the ground. ☞ Close and tilt back the multi-purpose bucket at the same time ☞ Use the lift to raise the bucket.

Grabbing bulky material ➥ The multi-purpose bucket allows for safely grabbing, picking up and transporting building timber, reinforcement bars, packaging bands, wire, etc.

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Grabbing large objects ➥ The multi-purpose bucket allows for safely grabbing, picking up and transporting large objects.

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Pulling out and setting posts ☞ Open the multi-purpose bucket and lower it over the post. Close the bucket to grip the post firmly.

☞ Loosen the post with careful, up-and-down movements.

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Operation Precise unloading ➥ Precise regulation and placement of pourable material.

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Backfilling gravel into drainage ditches ➥ Bucket teeth move back from the wall as the bucket opens.

Ansicht_011.iso

Unloading from the bottom of the bucket for increased dump heights ➥ The multi-purpose bucket increases the dump height by at least 22” (55 cm) (depending on bucket size), as compared to dumping with a standard bucket.

NOTE Smaller dump reach can be compensated by pushing the material with the open multi-purpose bucket as shown.

Ansicht_010.iso

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Operation 0.1

Working with Pallet Forks a

• Read and follow all instructions in the operator’s manual provided with the pallet forks.

• Maintain a minimum distance of 20’ (6 m) between loader unit/load and overhead lines.

• Before working, be sure that the fork arms on the fork frame are safely locked.

• Always approach the material with the machine wheels in the straight-ahead position.

• Always tilt the forks slightly back (toward the machine) for transport.

• Always transport the load close to the ground. Observe minimum ground clearance.

• Only set loads onto designated areas, with a stable base, that have load-bearing capacity.

• Only load on firm and level ground with sufficient load-bearing capacity (for a fully loaded machine).

• Only stack loads up to the authorized maximum pallet height.

• Only place loads in designated areas within the construction site. Set down loads only in places where they will stand safely without tilting, falling down or sliding. Appropriately label loads that have been set down, especially in high-traffic areas.

• Do not set down loads in transit or escape routes, or in front of safety facilities or

b

equipment that must be accessible at all times.

• Move the fork arms all the way under the pallets so that the load is picked up as closely as possible to the fork frame.

• Do not carry passengers on the pallet forks.

• Move under the load with the straight fork arms as far apart as possible and at an equal distance to the left and right side of the load (figure b).

• Lock the adjustable fork arms with the locking lever before moving the machine (with loaded or unloaded pallet forks).

• Lower the forks as near as possible to the ground for transport. Follow minimum ground clearance.

• Drive slowly with a raised load, especially in off-road applications, to avoid swinging movements of the load.

• When driving or working across a slope, the load must be on the uphill side of the machine/attachment.

• On sloping terrain, drive the machine rearward to prevent the load from falling off and the machine from tilting forward when braking.

• When transporting large bulk loads, drive the machine rearward for improved visibility.

• Learn the loa- bearing capacity of bridges, basement ceilings, vaults and similar structures before moving the machine onto them.

• Learn the clearances of underpasses, tunnels, gates and similar structures before driving through or under them.

126801d0.ai

• Follow the load-bearing capacity of the set-down area (e.g., truck platforms, storage areas in high-bay warehouses).

• Position and distribute the load evenly on the front tires.

• Never raise a load with only one fork arm.

• Never operate the machine and loaded attachment at high speeds.

• Never leave the machine with the load raised.

• Never work or stand under raised or suspended loads (figure a).

• Never use the controls, movable lines or cables as handles.

Printed in U.S.A.

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Operation • Never use bent, cracked or damaged fork arms/pallet forks.

• DO NOT stack or set down loads that are not properly packaged, have shifted in higher places, or have damaged pallets/stacking containers.

• Load vehicles and trailers evenly, and distribute the load evenly on vehicle/trailers axles.

• DO NOT overload the attachment or the machine – follow the load diagram.

• DO NOT set down loads too near slopes, construction pits, fire escape routes, equipment that you need to access, etc.

Overview of fork arms • Only use fork arms according to their designated use.

• Only the manufacturer is authorized to complete repair work on the fork arms.

• Always keep fork arms clean.

• Load both fork arms evenly.

• Secure loads to avoid losing them.

• Follow the limits of application for the fork lift, and its Operator’s Manual.

• Complete frequent visual checks.

• Complete regular checks according to the Operator’s Manual.

• DO NOT exceed the load center and lifting capacity.

• DO NOT use standard fork arms as reverse forks.

• DO NOT push, pull or shove the fork arms, or move them in at a slanting angle (risk of damaging them due to lateral forces).

• DO NOT pull off loads, or allow them to fall onto the fork arms.

• DO NOT use the tilt cylinder to raise loads on the pallet forks.

• DO NOT modify the fork arms, or attach any additional device.

• DO NOT transport people on the fork arms.

• DO NOT transport molten material.

• DO NOT perform any cable-laying work.

• The operator must regularly check: • Lock: Functional check.

• Hooks: Visual check for cracks and deformations.

• Bend: Visual check for indents, nicks and cracks.

• Bend and blade: Do not use any longer if worn over 10%.

• Blade and tip: Check for deformations.

• Wear on fork arms: See service manual or manufacturer.

• In case of damage: Stop using the fork arms.

Printed in U.S.A.

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Operation Specific safety instructions for pallet fork use • Always lock the 3rd control circuit when working with the pallet forks – see Operation of 3rd control circuit on page 79.

• Always follow the – see Pallet forks load diagram on page 101. Approach the material as closely as possible.

• Always approach the material with the machine wheels in a straight-ahead position.

• Always load on firm and level ground with sufficient load-bearing capacity for a fully loaded machine.

• Never raise a load with only one fork arm.

• Maintain a distance of a minimum 20 ft. (6 m) between the machine/load and overhead power lines.

• Before starting work, make sure the fork arms on the fork frame are safely locked!

• Always use the slower machine speed range when using pallet forks.

• Never leave the machine with a raised load.

• Always transport the load close to the ground!

Pallet forks load diagram The load diagram is located in the cab (left window) of the machine – see Fields of Application, Attachments on page 9. Do not exceed the maximum loads stated, otherwise machine stability is no longer ensured.

Fig. 111: Load diagram

Printed in U.S.A.

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Operation Fitting the attachment onto the quickhitch ☞ Pick up the attachment

WARNING! ➥ – see Locking: attachments without hydraulic function on page 82.

The attachment must always be safely locked onto the quickhitch –

Accident risk. ☞ Before working, make sure that the attachment is safely locked onto the quickhitch by using the lock cylinder.

➥ You must be able to see the lock pins on both sides of the mounting holes on the attachment.

Checking the lock pins

Removing the pallet forks from the quickhitch

WARNING! The attachment must be placed on the ground so that it will not fall over when removed –

Risk of personal injury. ☞ Position the attachment so that after unlocking it will stand safely and not tip over.

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Operation Adjusting the fork arms WARNING! If the fork arms are not secured to avoid lateral sliding or slipping –

Accident risk. ☞ Before using the pallet forks, be sure that both locking levers on the fork arms are folded down. This locks the safety pins of the fork arms in the notches on the fork frame, and prevents the fork arms from slipping or sliding.

When you position the fork arms under the load, make sure that they have the greatest possible space between them.

Always evenly align the fork arms to the fork frame.

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If necessary, adjust the spacing of the fork arms as follows:

☞ Set the locking lever to vertical position a. ➥ The fork arms can be moved on the fork frame. ☞ Slide the fork arms to the required distance until the safety pin engages in a slot on the

a

fork frame.

☞ Fold down the locking lever, to position b. ➥ The upper edge of the locking lever must be flush with edge c.

IMPORTANT! The locking mechanism must be replaced immediately if it is damaged.

b c

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Operation Picking up loads with the pallet forks ☞ Move the wheel loader up to the load so that the forks are at a right angle to the load. ➥ The fork arms must be the farthest possible distance apart, and at an equal distance from the left and right side of the load.

Ansicht_021.iso

☞ Drive the wheel loader forward and position the fork arms as far as possible underneath the pallet.

➥ The load must fit closely to the fork frame.

Ansicht_022.iso

☞ Carefully raise the load.

IMPORTANT! Do not exceed the loader's capacity, otherwise the machine may become unstable.

Ansicht_023.iso

☞ Follow the load diagram.

– see Pallet forks load diagram on page 101.

☞ Tilt the load back slightly rearward.

Printed in U.S.A.

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Operation Transporting loads with the pallet forks DANGER! When transporting loads with the pallet forks raised, the load can fall off or the machine can tip –

Accident risk.

When turning or driving on slopes, the center of gravity must always be in the lowest possible position.

☞ To avoid accidents: • Tilt the pallet forks slightly rearward.

• Lower the pallet forks to the transport position, and only raise them (if necessary) just before setting down the load.

• Never raise the load over persons.

• Never park the machine with the load raised.

• Avoid any operation that might endanger machine stability.

☞ Only move the load after it is placed on the fork arms. ☞ Only move the machine after you have sufficient visibility. ☞ Lower/raise loads to the transport position before moving and transporting them. If necessary, increase ground clearance for off-road applications.

Ansicht_024.iso

☞ Always tilt the pallet forks slightly back (toward the machine) for transport. ☞ Always drive slowly (especially in off-road applications) to avoid strong swinging movements.

☞ When driving or working across a slope, the load must be on the uphill side of the machine/attachment.

☞ Drive the machine rearward on sloping terrain to prevent the load from falling off and the machine from tipping forward when braking.

☞ Drive the machine rearward for improved visibility when transporting large bulk loads.

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Operation

NOTES

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Operation

Operation Starting the Engine Before starting the engine

0 ☞ Complete the Start-up checklist on page 45.

☞ Switch on the battery disconnect switch (if required). ☞ Adjust seat position and rearview mirror.

CAUTION! All controls must be within easy reach. The operator must be able to fully move the brake and accelerator pedals.

☞ Fasten the seat belt. ☞ Make sure that: • Parking brake (25/14) is engaged.

• Control lever (25/9) for the loader unit is in neutral.

IMPORTANT! General

You MUST apply parking brake (fig. 25/14) to start the engine.

Do NOT run the starter for more than 10 seconds continuously.

If the engine does not start, wait for about one minute to let the battery recover before trying again.

IMPORTANT! You cannot start the engine by towing the machine, because there is no driving connection between the engine and gearbox when the engine is off.

• You cannot actuate the starter if the engine is already running (start repeat interlock).

Printed in U.S.A.

47

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Operation Starting the engine

0

1

After completing the instructions – see Before starting the engine on page 47:

2

☞ Insert the ignition key in preheating/start switch 24/14. ☞ Turn the ignition key to position “1”. ☞ Check whether the following indicators come on:

3

• 25/45 for the engine oil pressure.

• 25/43 for the alternator charge function.

• 25/44 if the parking brake is applied.

14 Fig. 24: Preheating/start switch

43

44 45

IMPORTANT! If any of the above indicators do NOT come on, they may have failed and should be replaced immediately.

1

☞ Turn the ignition key to position “2” and hold it in this position for about 5 seconds. The oil pressure, alternator charge and parking brake indicators should be on.

Fig. 25: Indicators

➥ The intake air is preheated. ☞ Press accelerator pedal 25/6 down about 1/4 of full travel. ☞ Turn the ignition key to position “3” and hold it in this position until the engine starts. ☞ Release the ignition key.

Starting at low temperatures

☞ Press accelerator pedal 25/6 all the way down. ☞ Turn the ignition key to position “3” and hold it in this position until the engine starts. The starter may take a few seconds to engage as preheat is applied automatically.

☞ Release the ignition key.

When the engine runs smoothly (increased engine speed):

☞ Release accelerator pedal 25/6.

IMPORTANT! In general, a battery delivers less energy in cold conditions. Therefore, make sure the battery is always well charged.

After the engine has started

☞ Check that indicators 25/43 and 25/45 have gone out: ☞ Let the engine idle for about 2 minutes.

In cold (winter-type) weather

☞ Increase the engine speed slowly. ☞ Do NOT run the engine at full load until it has reached operating temperature.

Printed in U.S.A.

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Operation Jump-starting the engine

Safety instructions

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

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

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

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

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

Procedure

☞ Start the engine of the jump-starting machine. ☞ Connect one end of the red positive (+) jumper cable to the positive (+) terminal of the dead battery, then connect the other end to the positive (+) terminal of the starting battery.

Dead battery

12 V

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

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

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

12 V Starting battery

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

After the engine has started:

☞ While the engine is running, disconnect both jumper cables in exactly the reverse order Fig. 26: Starting aid with jumper cables 34001b710_05.eps

Printed in U.S.A.

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

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Operation Before driving the machine Special instructions for public roads

• Follow these instructions – see Use: Attachment on page 9. ☞ Carry out a functional check of: • Brakes • Steering • Lights

A

☞ Empty the bucket.

– see Control lever (joystick) on page 78.

B C

☞ Tilt back the bucket 27/B.

308b0350.eps

Fig. 27: Driving on public roads

☞ Raise the loader unit so that both red marks 28/D on the lift frame and the bulkhead are aligned.

D

IMPORTANT! Ground clearance for transport 27/C is about 10” (250 mm) with the standard bucket, standard tires, and marks 28/D aligned.

Fig. 28: Marks for the transport position

Control lever lock: loader unit and 3rd control circuit

DANGER! Secure control lever 29/8 (joystick) and control lever 29/9 (3rd control circuit) against unintentional actuation when driving on public roads. If the control levers are not secured –

8

Accident risk. ☞ Push control lever 29/8 down vertically in neutral position . ➥ The control lever is locked in this position and can no longer be moved. ☞ Unscrew lock sleeve A of control lever 29/9 clockwise until it is pulled down by spring action.

☞ Let control lever 29/9 engage in center position . ➥ The control lever is locked in this position and can no longer be moved.

9

A

Fig. Fig. 29: 29: Lock Lock for for control control levers levers

Printed in U.S.A.

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Operation Inspection and adjustment of important functional units

Steering

☞ Functional check: Move the steering wheel to the left and right.

IMPORTANT! The power steering system is only operational when the engine is running. But if the engine or hydraulic steering fails (e.g., failure of the pump drive), the machine can still be steered.

CAUTION! If the power steering fails, turning the steering wheel requires greater effort.

Take this into account especially when towing the machine.

☞ Adapt towing speed to the steering. ☞ Use a tow bar.

Wheel synchronization position

IMPORTANT! The machine has self-synchronizing axles. If you notice that the wheels on the axles do NOT run in the same track – see Synchronizing the steering system on page 56.

Service brake/inching pedal The rear brake lights do not come on when you: • Brake by applying the parking brake.

• Brake hydrostatically with the drive.

☞ Only pressing brake/inching pedal 25/31 causes the brake lights to come on.

WARNING! Dirt accumulating around the brake pedal can result in brake malfunctions–

Accident risk. ☞ Always keep brake/inching pedal 25/31 clean. ☞ Before driving the machine, press brake/inching pedal 25/31 down and check: • For resistance after pressing the pedal down to about 50% of its maximum travel.

• If the brake lights come on after you press the brake pedal down.

☞ For resistance after pressing the pedal down at a low speed.

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Operation WARNING! Pressing brake/inching pedal 25/31 down slightly causes the inching valve to respond; the inching valve does NOT effectively brake the machine –

Accident risk. ☞ Press brake/inching pedal 25/31 down to its maximum power.

Driving IMPORTANT! You can only move the machine after releasing parking brake 25/14.

After starting the engine:

☞ Release parking brake 25/14. ☞ Select the driving direction by using toggle switch 33/59 on the control lever. ➥ Indicator 30/59 or 30/61 comes on. ☞ Gradually press down accelerator pedal 25/6. ➥ Machine travels.

Preheating/start switch

0

1

2

IMPORTANT! 3

The engine will NOT start unless the parking brake is applied and the indicator is on.

14 Fig. 30: Preheating/start switch

Position

Function

Power application

0

Inserting or removing the ignition key

None

1

ON/drive position

➥ All functions are operational ➥ Indicator comes on if the parking brake is applied

Printed in U.S.A.

2

Preheating the engine (10 – 15 seconds)

➥ – see Starting the Engine on page 47

3

Starts the engine

➥ – see Starting the Engine on page 47

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Operation Accelerator pedal

Accelerator pedal 25/6 controls the drive speed as follows:

• Press accelerator pedal down.

• Release accelerator pedal slowly.

• Release accelerator pedal fully.

➥ Drive speed is increased. ➥ Drive speed is reduced. ➥ Hydrostatic braking.

Speed depends on the drive range selected with rocker switch 34/67.

Brake/inching pedal

WARNING! Dirt accumulation in the area of the brake can result in brake malfunctions –

Accident risk. ☞ Always keep brake/inching pedal 25/31 clean.

Use the brake/inching pedal to brake the machine regardless of the speed range setting and position of the accelerator pedal.

When you inch the brake pedal (pedal pressed in slightly), the pedal can be used like a car’s clutch. The drive system is no longer supplied with hydraulic oil, which means the entire engine output is available to the work hydraulics. This allows you to raise the loader unit rapidly.

☞ Before driving the machine, press brake/inching pedal 25/31 down and check for: • Resistance after pressing the brake pedal down to about 50% of its maximum travel • The brake lights come on after you press the pedal down • Traffic in the rearview mirror • For resistance after pressing the pedal down at a low speed

WARNING! Pressing the brake/inching pedal down slightly causes only the inching valve to respond; the inching valve does NOT effectively brake the machine -

Accident risk. ☞ Press brake/inching pedal down to its maximum travel until the braking effect is felt.

Braking

☞ Press brake/inching pedal 25/31 down with force.

Inching

☞ Press brake/inching pedal 25/31 down slightly.

Printed in U.S.A.

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Operation Parking brake

IMPORTANT! You cannot drive the machine unless parking brake 31/13 is released.

Function

• Prevents the machine from rolling away (use on sloped surfaces only).

• Emergency brake (only use if the service brake fails).

13

WARNING! Only use parking brake 31/13 instead of the service brake if the service brake fails. When you use parking brake 31/13, the brake lights do not light up, and the machine brakes abruptly –

Fig. 31: Parking brake

Accident risk.

Prevent rolling away 13

A

☞ Pull lever 32/13 up into the top notch. ➥ Indicator 23/41 comes on. ➥ Neutral is activated.

Release the parking brake

Fig. 32: Applying and releasing the parking brake

☞ Pull up lever 32/13 slightly. ☞ Press button A. ☞ Move lever 32/13 all the way down.

Changing direction

F

WARNING!

59

R

Changing direction at high speed and full throttle causes the machine to stop abruptly.

6

☞ Slow the machine to walking speed before changing direction. ☞ Reduce engine speed: remove your foot from the accelerator pedal. ☞ Slow the machine to walking speed. ☞ Select a new driving direction with switch 33/59: Function

Fig. 33: Selecting driving direction

Printed in U.S.A.

Reverse

Operation ☞ Press switch 59 forward F ☞ Press switch 59 rearward R

Neutral

☞ Press tip switch 61

Forward

54

Effect ➥ Indicator F comes on

➥ Indicator R comes on ➥ Indicator goes out

918296/BP1209

Operation Selecting a speed range The machine has two travel speed ranges.

☞ Set driving direction to neutral with tip switch 34/61 on the joystick. ☞ Press switch 34/52 to the required speed range. ➥ Indicator in switch comes on.

59 61

Symbol Meaning 52

A B Fig. 34: Switch for speed range selection

Work range A ➥ 0 – 4 mph (0 – 6 kph) 12 mph (20 kph)

Recommended Used for work involving short loading cycles, i.e., a rapid succession of loading and unloading operations, e.g., onto a truck, and for work requiring precise speed adjustment, e.g., rotary broom applications.

Speed range B = 0 – 12 mph (0 – For long-haul travel 20 kph)

IMPORTANT! You can only move the machine after releasing parking brake 31/13.

☞ Release the parking brake 31/13. ☞ Select the driving direction with switch 34/61 on the control lever. ☞ Gradually press accelerator pedal 25/6. ☞ Test the brakes at low speed.

Backup warning system The backup warning system consists of backup alarm A, fitted onto the inside of the towing device cover, and a switch and wiring. The backup alarm generates an acoustic signal when you shift into reverse. The acoustic level is about 103 dB(A) at a distance of 3’ (1 m) and at a frequency of 2800 Hz. A

WARNING! When backing up with the machine –

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

Fig. 35: Backup warning system

Printed in U.S.A.

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Operation Differential Lock Switching the differential lock on and off 73

IMPORTANT! To prevent damage, the differential lock can only be switched on using tip switch 73 when the brake/inching pedal is engaged.

72

IMPORTANT! Fig. 36: Tip switch for differential lock

The differential lock tip switch 73 may be located on either the right or the left on the joystick.

Switching on the differential lock ☞ Stop the machine.

☞ Press and hold tip switch 73 on the joystick. ☞ Press and hold the brake/inching pedal for 3 – 5 seconds. ➥ indicator 72 in the side console (next to the instrument panel) illuminates and the differential lock is switched on. ☞ Carefully release the brake/inching pedal with tip switch 73 pressed.

Switching off the differential lock

☞ Reduce engine speed. ☞ Release tip switch 73. ➥ Indicator 72 on the instrument panel goes out and the differential lock is switched off.

Steering System Synchronizing the steering system

WARNING! DO NOT synchronize the steering system as you drive on public roads –

Accident risk. ☞ Synchronize the steering system as described below before driving on public roads.

If the wheels on both axles are not running in the same track:

☞ Drive at a slow speed, turn the steering wheel slowly to the left and right as far as it will go. Repeat.

☞ Quickly turn the steering wheel back to the straight-ahead position. ☞ Contact your Mustang dealer if this does not synchronize the wheels.

Printed in U.S.A.

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Operation Stopping the Machine ☞ To stop the machine, follow the Mandatory Safety Shutdown Procedure – see Mandatory Safety Shutdown Procedure on page 18.

Parking the Machine WARNING! Machines parked on slopes may roll away. If you park on a slope, park across the slope if possible and:

☞ Apply the parking brake.

– see Parking brake on page 54.

☞ Place chocks under the downhill sides of the tires. ☞ Perform the Mandatory Safety Shutdown Procedure – see Mandatory Safety Shutdown Procedure on page 18.

After operation at full power

☞ Allow the engine to run until the temperature stabilizes. ☞ Turn off the engine. To do this: • Turn the ignition key to position “0.” Wait for all movement to stop.

• Remove the ignition key and take it with you.

On slopes:

☞ Park across the slope and block the tires.

Printed in U.S.A.

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Operation Light System The switch panel for the light system is located on the left on the instrument panel

1

43

62

Parking lights ☞ Press switch 62 to the ON 1st position B ☞ Press switch 62 down to OFF position A Low beam ☞ Press switch 62 to the 2nd position B ON

A B

OFF

☞ Move lever 28 to position II ☞ Press switch 62 down to position A

➥ Indicator in switch comes on ➥ Indicator in switch goes out

➥ Indicator in switch comes on ➥ Indicator in switch goes out

IMPORTANT! Turn off the parking light by turning the ignition switch 30/14 to position 0.

I

II High beam ☞ Press switch 62 to the 2nd position B ON

28

34200b0312.eps

Fig. 37: Light system

OFF

☞ Move lever 28 to position I ☞ Move lever 28 to position II

Headlight flasher ☞ Briefly pull lever 28 fully up ON (beyond position II)

Printed in U.S.A.

58

➥ Indicator (blue) 43 comes on ➥ Indicator (blue) 43 goes out ➥ Low beam comes on ➥ Indicator (blue) 43 comes on

918296/BP1209

Operation Work lights WARNING! The work lights may momentary blind motorists on public roads.

☞ Do not switch on the work lights when driving on public roads.

68

66

Front and/or rear working lights (option) ON ☞ Press switch 68 to position B OFF ☞ Press switch 68 to position A

➥ Indicator in switch comes on ➥ Indicator in switch goes out

2 front working lights (option) ON ☞ Press switch 68 to position B OFF ☞ Push switch 68 to position A

➥ Indicator in switch comes on ➥ Indicator in switch goes out

2 rear working lights (option) ON ☞ Press tip switch 66 briefly OFF ☞ Press tip switch 66 briefly

➥ Indicator in tip switch comes on ➥ Indicator in tip switch goes out

A B Fig. 38: Switch f

Interior light Interior light ON ☞ Press switch 2 to the left or right OFF ☞ Move switch 2 to center position

2 Fig. 39: Switch for interior light

Printed in U.S.A.

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918296/BP1209

Operation Signalling System 36

Turn indicator ☞ Push lever 28 forward R RIGHT

35

LEFT

1

☞ Pull lever 28 to the rear L

➥ Indicator 36 flashes ➥ Indicator 36 flashes

➥ Indicator 35 flashes during trailer operation.

R

34200b0313.eps

L

28

CAUTION! The turn indicator is not in working order if indicator 36 flashes about twice as fast as normal.

☞ Check the front and rear indicators immediately. ➥ Have the turn indicator system repaired if necessary.

Fig. 40: Turn indicator

55

Hazard warning system ☞ Press switch for hazard ➥ The Indicator in the switch and Indicator 36 warning system 55 to on the instrument panel flashes ON notched position ☞ Release switch for hazard ➥ The Indicator in the switch and Indicator 36 warning system 55 from on the instrument panel goes out OFF notched position by applying slight pressure

Fig. 41: Switch for hazard warning system

Printed in U.S.A.

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918296/BP1209

Operation Rotating beacon (option)

IMPORTANT! Local regulations may prohibit rotating beacon use on public roads except under certain conditions, such as, if the road is within the machine's working range and the machine represents an obstruction to the normal flow of traffic.

Rotating beacon (option)

36

☞ Press rocker switch 36(B). ☞ Press rocker switch 36(A).

ON OFF

➥ Indicator in rocker switch comes on ➥ Indicator in rocker switch turns off

A B Fig. 42: Switch for rotating beacon

Cab heating and ventilation IMPORTANT! The heater can be set to two operating conditions: • Ventilation, fresh air • Heating The air flow is directed to the front window via defroster vents, and to the floor area via the floor vents. The floor vents can be closed and adjusted separately.

The ventilation switch and the rotary switch for the heater are located on the right on the side console.

Ventilation (fresh air) 1st ☞ Press switch 65/A down one step speed 2nd ☞ Press switch 65/A down two steps speed OFF ☞ Press switch 65/A completely down

65

57

B A

➥ Fan runs in 1st speed ➥ Fan runs in 2nd speed ➥ Fan OFF

Heating Colder Warmer

☞ Turn rotary switch 57 to B ☞ Turn rotary switch 57 to A

Fig. 43: Ventilation/heating switch

Printed in U.S.A.

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Operation Air Conditioning Air conditioning operation In warm weather, the air conditioning system supplies cool and dehumidified air to the cab via the vent nozzles in the cab roof.

25

IMPORTANT! Close the door and the windows to achieve the best air conditioning results.

The rotary switch for the air conditioning system is located on the left next to the operator’s seat.

Fig. 44: Air conditioning rotary switch

Air conditioning operation

Cooling

Turn rotary switch 25 to range 1

Low

Turn rotary switch 25 to range 2

Medium

Turn rotary switch 25 to range 3

High

Turn rotary switch 25 to range 0

OFF

IMPORTANT! The heating and ventilation system can be used along with the air conditioning.

• – see Cab heating and ventilation on page 61.

CAUTION! To prevent malfunctioning of the air conditioning system and possible loss of coolant:

☞ Run the air conditioning system once a month.

• This prevents the seals in the compressor from drying and becoming brittle.

☞ Check V-belt tension and clean the condenser.

• – see Air Conditioning Maintenance on page 130.

☞ The air conditioning system must be repaired, serviced and filled with a refrigerating agent only by trained staff and an authorised workshop.

Printed in U.S.A.

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Operation Windshield washer system Front window wiper ☞ Turn rotary switch 49 on lever 28 to posi- ➥ Front wiper is on OFF tion O ☞ Turn rotary switch 49 on lever 28 to posi- ➥ Front wiper returns to base ON tion | position

34200b0313.eps

28

49 Fig. 45: Front wiper switch

28

A

Washer pump

for front and rear window

ON

☞ Press and hold tip switch 48 on lever 28(A)

OFF

☞ Release tip switch 48

34200b0313.eps

48

Fig. 46: Washer pump switch

A

Rear wiper ON ☞ Press switch A / | OFF ☞ Press switch A / O

➥ Rear wiper is on ➥ Rear wiper returns to base position

Fig. 47: Rear wiper switch

Tank for windshield washer system Tank filler inlet 31 is located at the front inside of the cab, on the left.

IMPORTANT! 31

Fill the windshield washer system with clean tap water only. Add a cleaning agent if required. In winter, add antifreeze to the water. For further information on concentrations – see Fluids and Lubricants on page 138.

Fig. 48: Tank for washer system

Printed in U.S.A.

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918296/BP1209

Operation Operator's Seat Seat adjustment

Always adjust the seat to your individual needs. This will help avoid or minimize physical disorders related to bad posture.

WARNING! Never change the seat position when driving or working –

Accident risk.

d

☞ Adjust the seat before moving the machine. ☞ Make sure the levers for seat adjustment are safely engaged.

The seat can be set to the following positions: c

e f

a

b

• b = weight adjustment a with weight indication.

• c = height adjustment.

• d = armrest inclination.

• e = backrest adjustment (depending on version).

• f = horizontal adjustment.

Fig. 49: Seat adjustment

Weight adjustment

IMPORTANT! Adjust the seat suspension correctly to ensure a high level of ride comfort, and to avoid or minimize physical disorders related to bad posture. Use lever a to adjust the seat suspension to the operator's weight. The weight indicator b shows the set operator weight in kilograms. a

b

☞ Sit in the seat.

To adjust for a heavier operator weight:

Fig. 50: Weight adjustment

☞ Turn lever a clockwise.

To adjust for a lighter operator weight:

☞ Turn lever a counter-clockwise.

Printed in U.S.A.

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Operation Height adjustment Up:

☞ Raise seat as required. The seat locks clicks at the detents as the seat is raised.

Down:

c

☞ Raise seat as far as possible and lower seat to the lowest position.

Fig. 51: Height adjustment

Backrest adjustment

☞ Sit in the seat. ☞ Pull lever e up and lean back to push the backrest into the required position. ☞ Release lever e to lock the backrest in position.

e

Fig. 52: Backrest adjustment

Horizontal adjustment

☞ Sit in the seat. ☞ Pull lever f up and move the seat forward or rearward as required. ☞ Release lever f to lock the seat in position.

f Fig. 53: Horizontal seat adjustment with control lever

Printed in U.S.A.

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918296/BP1209

Operation Armrest adjustment The armrest can be folded back as required. Adjust the armrest as follows: g

Up:

☞ Turn handwheel g clockwise as required.

Down:

☞ Turn handwheel g counter-clockwise as required.

Fig. 54: Armrest adjustment

Seat belt WARNING! Do not drive or work without the seat belt fastened –

Risk of personal injury. ☞ Buckle up before moving or working with the machine.

• Seat belt must not be twisted.

• Seat belt must run over the hips, not over the stomach, and must always be applied tightly.

• Do not place seat belt over hard-edged or fragile items (tools, metal ruler, glasses, pen) carried inside your clothes.

• Never buckle up two persons using one seat belt.

• Check seat belt regularly. Have damaged parts immediately replaced by an authorized dealer.

• Always keep seat belt clean.

• Make sure the seat belt buckle is not obstructed by anything, such as paper or clothing, which may prevent the latch from locking properly.

After an accident, the seat belt strap is stretched and is no longer serviceable. In another accident the same strap –

Will not provide adequate protection. ☞ Replace the seat belt strap after an accident. ☞ Have fastening points and seat fixture checked for bearing capacity.

Printed in U.S.A.

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918296/BP1209

Operation Seat belt 24 is designed for the operator's safety during work on construction sites and road travel.

Fastening the seat belt A

24

☞ Fasten seat belt 24 as follows before moving the machine: • Hold the belt at buckle latch A and run it slowly and steadily over the hips to buckle B. • Insert buckle latch A into buckle B until it engages audibly (pull test).

B

• Tighten seat belt by pulling at its end.

➥The seat belt must always be tightly in place over the hips.

0763b0007.eps Fig. 55: Fasten your seat belt

Unfastening the seat belt

☞ Unfasten seat belt 24 as follows: • Hold the seat belt.

24 A

• Press red button C on buckle B.

➥Latch A is released from buckle B by spring action.

• Slowly return the seat belt to the retractor.

C B 30763b0006.eps Fig. 56: Unfastening the seat belt

Lengthen/shorten seat belt setting

A

☞ Lengthen the seat belt as follows: • Hold buckle latch A at a right angle to the seat belt and pull the seat belt to the required length.

☞ Shorten the seat belt by pulling the free end D of the belt.

IMPORTANT! D

30763b0005.eps Fig. 57: Lengthen/shorten seat belt setting

Printed in U.S.A.

When pulled slowly, the automatic seat belt allows full freedom of movement.

However, it locks during abrupt braking and may also lock when driving over potholes or uneven terrain.

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Operation Doors WARNING! Close the doors when driving and working with the machine –

Accident risk. ☞ Close the doors before moving the machine.

Opening the door from the outside: A

☞ Press button A. Locking/Unlocking the door:

Fig. 58:

☞ Lock/unlock the door with the ignition key. Turn the key clockwise to lock; counter-clock-

Outside door opener and lock

wise to unlock.

Opening the door from the outside

☞ Press button A. Opening the door from the inside

☞ Pull handle B up.

IMPORTANT! Enter and exit the cab by using the left door. In case of an emergency the right side window may be used as emergency exit.

– see Emergency Exit – Side Window on page 70.

B Fig. 59: Inside door opener left/right

Securing an open door 11

18

☞ Press the door against the bracket of arrester 18 until it locks in the arrester with a click.

IMPORTANT! Lubricate latch 11 weekly.

Fig. 60: Securing an open door

Printed in U.S.A.

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918296/BP1209

Operation

Releasing an open door

☞ Press button B on the door arrester forward. ➥ The door is released from the arrester.

B Fig. 61: Unlocking the door arrester

Side Window WARNING! Lock the side window when driving the machine.

If the side window is not locked –

Crushing risk. ☞ Make sure the side window is locked in place when either opened or closed. ☞ Make sure the open side window is engaged in the arrester.

– see Locking the open side window on page 70.

Closing the side window

☞ Turn lever A down.

A

Opening the side window

☞ Turn lever A up.

Fig. 62: Locking/unlocking the side window

Opening the side window b

☞ Turn lever A up. ☞ Push lever A horizontally to the outside. ☞ To fasten the window in its final position: A

Press the end of lever a downward until it is firmly seated in guide b.

a Fig. 63: Opening the side window

Printed in U.S.A.

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918296/BP1209

Operation Fully opening the side window b

☞ Turn lever A up. ☞ Push lever A horizontally to the outside. ☞ In order to completely swing the window outward: A

Pull the end of lever a to the rear through and out of guide b.

a Fig. 64: Fully opening the side window

Locking the open side window

☞ Open the side window completely and press it against the arrester until it locks in place with a click.

➥ The side window locks into the open position.

IMPORTANT! Lubricate the arrester at regular intervals.

Fig. 65: Locking the side window

Unlocking the open side window The side window can be unlocked from the inside only.

☞ Press the push button (at the rear right in the cab). ➥ Side window is released by spring action. ☞ Close the side window.

Fig. 66: Unlocking the side window

Emergency Exit – Side Window In the case of an emergency, the side window can be used to exit from the cab if the door can no longer be used.

Printed in U.S.A.

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918296/BP1209

Operation

WARNING! The right side of the machine does not have foot or hand holds that ensure safe access/exit. In addition, with the side window unlocked –

Crushing risk. ☞ Do not use the side window as access or exit except for emergency situations.

☞ Before resuming normal service, lock the window lock lever back into place in the guide.

– see Closing the side window on page 69.

Engine cover Opening

A

☞ Press lock A. ☞ Pull the engine cover upward.

Closing

☞ Firmly press down the engine cover until A it locks with a click.

L R

Locking and unlocking Lock the engine cover with the ignition switch key.

Fig. 67: Engine cover lock

Printed in U.S.A.

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918296/BP1209

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

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

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

• Tow the machine slowly and cautiously.

DANGER! Careful when towing the wheel loader -

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

☞ Only tow with a tow bar. ➥ – see Specifications on page 149 for the machine's dimensions and weights.

☞ Eye hooks for towing the machine – see Machine Overview on page 7. ☞ If possible, run the engine at idling speed when towing the machine. ➥ Turning the steering wheel requires greater effort if the diesel engine and the brakes fail.

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

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

Printed in U.S.A.

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918296/BP1209

Operation Towing preparation C

Disabling the variable-displacement drive pump

B

WARNING!

A

Turning the steering wheel requires greater effort if the engine is off. Remember this when towing the machine.

☞ Use a tow bar if the engine breaks down.

A

B

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

C

☞ Turn off the engine. ☞ Short-circuit the hydraulic circuit before towing (see next page). ☞ Do not tow the machine for more than 328 ft. (100 m), and do not tow it faster

Fig. 68: Hydraulic pump

than 1 – 2 mph (3 – 4 km/h).

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

Variable-displacement drive pump ☞ Switch over the HP pressure relief valves A on the variable-displacement pump. To do this: • Loosen lock nuts B on both HP valves A. • Tighten screws C on both HP valves A until they are flush with lock nuts B. • Secure screws C on both HP valves A with lock nuts B.

After towing C

Enabling the variable-displacement drive pump ☞ Switch over the HP pressure relief valves A on the variable-displacement pump. To do this:

B

A

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

B C

Fig. 70: Hydraulic pump

Printed in U.S.A.

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918296/BP1209

Operation Crane Handling the Machine Safety instructions regarding crane handling • The crane and the lifting gear must be adjusted to the proper dimensions. ➥ – see Specifications on page 149.

• Crane handling requires lifting gear of four equal lengths.

• Secure the machine against unintentional movement!

DANGER! Incorrect crane handling of the machine -

Accident risk. ☞ Make sure nobody is in the machine. ☞ Have loads fastened and crane operators instructed by experienced persons only. The person giving the instructions to the crane operator must be within sight or sound of the crane operator.

☞ Make sure the crane and the lifting gear (cables, chains) have sufficient loadbearing capacity.

☞ Load the machine only with the standard bucket empty and in transport position.

☞ Keep clear of suspended loads. ☞ It is essential to read the safety instructions in this manual – see Safety on page 17.

Crane handling the machine ☞ Load the machine as follows: • Empty the standard bucket.

• Mount and safely lock the standard bucket – see Installing attachments on page 81.

• Set the drive to neutral – see Changing direction on page 54.

• Tilt the standard bucket back and lower it to the transport position.

• Engage the parking brake – see Parking brake on page 54.

34101b330_01.iso

• Turn off the engine and remove the ignition key.

• Do not allow anyone to stay in the cab.

• Close the doors and the engine cover.

• Fasten the loader to the crane at the four lifting points – see Machine Overview on page 7.

CAUTION! Fig. 72: Crane handling

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

• Carefully raise the machine.

Printed in U.S.A.

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Operation Loading and Transporting the Machine on a Transport Vehicle General safety instructions • The transport vehicle must be of adequate size - see “Weights” on page 156 for the dimensions and weights of the machine.

• Remove any mud, snow or ice from the tires so the machine can be safely driven onto the ramps.

• Secure the machine against unintentional movement.

• When positioning the machine on the transport platform, make sure the machine is at the lowest possible position and that the center of gravity of the load is on the center line of the transport vehicle, if possible.

• Do not exceed the transport vehicle’s gross weight rating and the gross axle weight rating when loading and transporting the machine.

• Make sure the load does not fall short of the minimum axle load of the steering axle, otherwise the transport vehicle’s steering could be seriously affected.

• Distribute partial loads to ensure even load on all axles.

• Secure the load properly so it cannot slip, slide, roll, tip over or fall, or cause the transport vehicle to tip over under usual transport conditions. Use anti-slip bases and linings, loadsecuring straps and chains, clamping beams, protective paddings, nets, edge protectors, etc. as required to properly secure the load.

• Transport conditions to be considered as possibilities are conditions where the brakes are slammed on, evasive maneuvers are performed with the transport vehicle, and transport on uneven roadways.

• Depending on the load, adjust transport speed to the road and traffic conditions and to the handling of the transport vehicle.

• Always use the proper tie-down points when using straps and chains – see Machine Overview on page 7.

Printed in U.S.A.

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Operation Loading and tying down the machine DANGER! The machine must be loaded and transported properly -

Accident risk. ☞ It is essential to read and follow the safety instructions in this manual – see Safety on page 17.

☞ Load as follows: • Secure the transport vehicle tires with chocks to prevent it from rolling.

• Place the access ramps at the smallest possible angle. Do not exceed an angle of 20°. Only use access ramps with an anti-skid surface.

• Make sure the loading area is clear and access to it is not obstructed.

20% 20 30864brampe.eps

Fig. 73: Access ramps

• Make sure the access ramps and the wheels of the machine are free of oil, grease, snow, ice, etc.

• Start the engine of the machine.

• Raise the bucket enough so that it will not touch the access ramps.

• Carefully drive the loader onto the middle of the transport vehicle.

• Set the drive to neutral – see Changing direction on page 54.

• Lower the bucket onto the loading area.

• Stop the engine.

• Apply the parking brake – see Parking brake on page 54.

• Remove the ignition key.

• Do not allow anyone to stay in the cab.

• Close the doors and the engine cover.

☞ Tie down the machine as follows: • Make sure the authorized maximum height is not exceeded.

• Secure all tires of the wheel loader with chocks in front of and behind each wheel.

• Securely strap the machine down at the eye hooks – see Machine Overview on page 7 – with sufficiently dimensioned belts or chains onto the platform.

• Before transporting the machine through heavy rain, close the outlet of the muffler with a cap or suitable adhesive tape.

34001b330_02.eps

• Make sure the driver of the transport vehicle knows the overall height, width and weight of the vehicle, including the loaded machine, before starting transport.

• Know and follow the legal transport regulations for the area in which the transport will occur.

34001b330_17.eps Fig. 74: Tying down the loader

Printed in U.S.A.

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Troubleshooting

Troubleshooting

Troubleshooting Use this section to determine malfunctions and repair solutions.

Engine trouble Problem

Possible causes Parking brake is not applied

See page 54

Driver direction control is not in neutral Engine starting temperature is too low

Engine does not start or is not easy to start

Wrong SAE grade of engine lubrication oil

138

Fuel quality does not comply with specifications

138

Battery defective or dead

134

Loose or oxidized cable connections in starter circuit Starter defective, or pinion does not engage Wrong valve clearance Fuel injector defective Fuel quality does not comply with specifications

138

Fuel system needs to be bled Engine starts, but does not run smoothly

Wrong valve clearance Injection line leaks Fuel injector defective

Engine overheats. Temperature warning system responds

Oil level is too low

112

Oil level is too high

112

Air filter not working

117

Air filter maintenance switch or gauge defective Oil cooler fins not working Fan defective, V-belt torn or loose

119

Cooling air heats up Resistance in cooling system too high, flow capacity too low Fuel injector defective Oil level too high

112

Fuel quality does not comply with specifications

138

Fuel system needs to be bled Insufficient engine output

Air filter not working

117

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

Engine does not run on all cylinders

Fuel system needs to be bled Fuel injector defective

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Troubleshooting

Problem

Possible causes Oil level is too low

Insufficient or no engine oil pressure

See page 112

Engine inclination is too high

Engine oil consumption too high

Wrong SAE grade of engine lubrication oil

138

Oil level is too high

112

Engine inclination is too high Blue

Oil level is too high

112

Engine inclination is too high Engine starting temperature is too low

White Engine smoke

Fuel quality does not comply with specifications

138

Wrong valve clearance Fuel injector defective Air filter not working

Black

117

Air filter maintenance switch or gauge defective Wrong valve clearance Fuel injector defective

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Maintenance

Maintenance Air Filter IMPORTANT! Maintenance display B on the filter housing monitors the filter element. The dust is removed by squeezing discharge slot E of the dust valve. The filter element will be damaged if it is washed or brushed out.

To avoid premature engine wear:

☞ DO NOT clean the filter element. ☞ Replace the filter element when the indicator comes on. ☞ Never reuse a damaged filter element. ☞ Ensure cleanliness when replacing the filter element.

Weekly air filter contamination check

☞ Checking the dust valve E. • Shut off the engine.

G

• Prevent the machine from rolling away and remove the ignition key – see Mandatory Safety Shutdown Procedure on page 18.

• Remove cover G. • Squeeze the discharge slot of dust valve E.

B

• Remove hardened dust by compressing the upper area of the valve.

• Clean the discharge slot if necessary.

Air filter restriction indicator display A on the filter housing monitors the filter elements.

☞ Primary filter element D must be replaced: • If you can see red mark C in the display maintenance window.

• After 1500 service hours (or annually if the machine is used for less than 1500 hours per year).

– see Replacing the filter element on page 118.

IMPORTANT!

E A

C

B

For dusty environments, the air filter is fitted with an extra safety element F. DO NOT clean the safety element. Replace the safety element every third time the primary element is replaced.

IMPORTANT! Filter elements degrade prematurely when using the machine in acidic air for long periods of time. Acidic air is present, for example, in acid production facilities, steel and aluminium mills, chemical plants and other nonferrous-metal plants.

☞ Replace filter element D and safety element F after 500 service hours – see Replacing the filter element on page 118.

Fig. 119: Air filter with safety cartridge

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Maintenance Replacing the filter element ☞ Replace primary filter element D as follows: • Shut off the engine.

G

• Prevent the machine from rolling away and remove the ignition key – see Parking the Machine on page 57.

• Open the engine cover.

• Remove cover G.

B

• Fold bow hooks X on lower housing section H to the outside.

• Remove lower housing section H.

H

• Carefully remove filter element D by using slight turning movements.

• Every third time you replace the primary filter, carefully remove safety element F by using slight turning movements.

X

• Make sure all contamination (such as dust) inside the upper and lower housing sections is removed.

K

• Carefully insert new safety element F into the upper housing section.

• Carefully insert new primary filter element D into the upper housing section.

307b0700.ai

Fig. 120: Removing the lower housing section

• Position lower housing section H (make sure it is properly seated).

• Close both bow hooks X. D

H

☞ After replacing the filter: • Press button A to reset red mark C (visible in the display maintenance window of indicator B).

307b0710.ai

Fig. 121: Removing the filter element

D

E

F A

34001b520_02.iso

C

B

Fig. 120: Air filter maintenance display

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Maintenance V-belt DANGER! Only check, tension, or replace the V-belt after the engine is shut off –

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

IMPORTANT! Cracked and stretched V-belts cause engine damage.

☞ Have the V-belt replaced by an authorized dealer.

Check the V-belt after 50 service hours (or weekly if the machine is used for less than 50 hours per week). Tension the V-belt if necessary.

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

Checking V-belt tension ☞ Check the V-belt tension as follows: • Shut off the engine.

• Prevent the machine from rolling away and remove the ignition key – see Parking the Machine on page 57.

• Open the engine cover.

approx. 0.39” (10 mm)

1

• Carefully inspect V-belt 1 for damage.

• If the V-belt is damaged: • Have the V-belt replaced by authorized staff.

• Press with your thumb to be sure that the V-belt cannot be deflected between the pulleys by more than about 0.39” (10 mm).

Fig. 121: Checking V-belt tension

• Re-tension the V-belt if necessary. See below.

Tensioning the V-belt

☞ Tension the V-belt as follows:

4

• Shut off the engine.

• Prevent the machine from rolling away and remove the ignition key.

– see Parking the Machine on page 57.

A

• Open the engine cover.

• Slacken attachment screws 3 of alternator 4.

3

• Use a suitable tool to push the alternator in the direction of arrow A until the correct Vbelt tension is obtained (fig. 121).

• Keep the alternator in this position, and at the same time tighten attachment screws 3.

Fig. 122: Re-tensioning the V-belt

• Run the engine for 15 minutes.

• Repeat the V-belt tension (fig. 121) procedure.

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Maintenance Hydraulic System Safety instructions • You must depressurize all lines carrying hydraulic oil before performing any maintenance or repair work. To do this: • Lower all hydraulically controlled attachments to the ground.

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

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

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

IMPORTANT! If the hydraulic oil in the level glass is cloudy, this indicates that water or air has entered the hydraulic system. This may damage the hydraulic pump.

☞ Contact your Mustang dealer immediately.

IMPORTANT! Insufficient, incorrect, or contaminated hydraulic oil –

Risk of severe damage to the hydraulic system. ☞ Always add hydraulic oil by using the filling screen. ☞ Only use the same type of authorized oils – see Fluids and Lubricants on page 138.

☞ Always add the hydraulic oil before the level gets too low. ☞ If the hydraulic system is filled with biodegradable oil, only use the same type of biodegradable oil, following the label on the hydraulic oil reservoir.

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

Environment!

Collect hydraulic oil, including biodegradable oil, into a container. Dispose of drained oil and used filters according to environmental laws.

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

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Maintenance Monitoring the hydraulic oil return filter 42

Refer to the instrument panel, red indicator 41 monitors return pressure and filter. Indicator 42 monitors hydraulic oil temperature.

41

The filter must be replaced by an authorized dealer if: 1

• The hydraulic oil return pressure in the filter is too high and indicator 41 comes on.

• The hydraulic oil operating temperature is too high and indicator 42 comes on.

• After 1500 service hours (or yearly if the machine is used less than 1500 hours per year).

In cold weather, indicator 41 may come on when the engine is started because of increased oil viscosity. In this case:

☞ Run the engine until indicator 41 turns off.

Fig. 123: Return filter indicator

– see Starting the Engine on page 47.

Important information about the use of biodegradable oil • Only use biodegradable hydraulic that have been approved by Mustang – see Fluids and

Lubricants on page 138. Always contact your dealer before using other products that have not been recommended. In addition, ask the oil supplier for a written guarantee. This guarantee is applicable to damage occurring to the hydraulic components that can be proved to be due to the hydraulic fluid.

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

IMPORTANT! Replace missing decals.

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

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

• If running the machine with biodegradable oil, the same oil and filter replacement intervals used for mineral oil are valid – see Maintenance Schedule on page 139.

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

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

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

IMPORTANT! A change from mineral to biodegradable oil must be performed by an authorized dealer.

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

• Retract all hydraulic cylinders.

✓ A

• Shut off the engine.

• Apply the parking brake.

• Open the engine cover.

• Check the hydraulic oil level in sight gauge A. If the oil level is lower than it is in fig. 124/A: • Add hydraulic oil.

Fig. 124: Oil level sight gauge on the hydraulic oil tank

CAUTION! Excess hydraulic oil will escape via the breather as soon as the temperature rises! If the oil level is no longer visible in the upper half of the oil level sight gauge:

☞ Drain hydraulic oil.

Adding hydraulic oil IMPORTANT! Only add hydraulic oil to the hydraulic oil reservoir if the engine is turned off.

B

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

• Retract all hydraulic cylinders.

• Shut off the engine.

• Apply the parking brake.

• Open the engine cover.

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

• Open breather filter B.

☞ With the filter insert in place: • Add hydraulic oil until the reservoir is full.

Fig. 125: Hydraulic oil reservoir

• Check the hydraulic oil level by using the oil level sight gauge (124/A).

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

• Firmly close breather filter B.

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Maintenance Checking Hydraulic Pressure Lines Safety instructions

WARNING! Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries.

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

☞ Always follow these instructions: • Only tighten leaking threaded fittings and hose connections after having released the pressure.

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

• Only authorized dealers should replace damaged flexible lines.

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

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

• An authorized dealer should immediately repair or replace any leaking or damaged pressure lines.

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

1 Q/08

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

Example: The indication “1 Q/08” means manufactured in the 1st quarter of 2008.

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Maintenance Lubrication Points Lubricate all points listed below with lithium-based brand-name grease – see Fluids and Lubricants on page 138.

Lubricating the rear axle oscillation-type bearing IMPORTANT! The machine has an oscillation-type rear axle. The bearing must be greased after every 50 service hours (or weekly if the machine is used less than 50 hours per week).

The grease nipple is located above the axle tube, on the left side.

A

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

Fig. 126: Grease nipples for oscillation-type bearing

Lubricating the planetary drive bearing ☞ Lubricate grease nipples B on each planetary drive bearing every 50 service hours (or weekly if the machine is used less than 50 hours per week).

B

Fig. 127: Grease nipples on planetary drive bearings

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Maintenance

Maintenance

Maintenance Introduction Operational readiness and the service life of the machine can be increased through proper maintenance.

Before performing service and maintenance work, always read, understand and follow the instructions starting on:

• – see Safety on page 17.

• The operator’s manuals of the attachments.

Daily service and maintenance work, and maintenance according to maintenance plan “A” must be completed – see Maintenance Schedule on page 139.

DANGER! Do not perform assembly or maintenance work if the loader unit is raised and not secured -

Danger of crushing and injury! ☞ Secure the loader unit with an appropriate prop or support to prevent it from being lowered unintentionally.

☞ Also follow the instructions in the “Safety” chapter of this operator's manual. ☞ Also follow the instructions in the operator's manuals of the attachments.

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Maintenance Fuel System Safety instructions DANGER! • When handling fuel, there is a high risk of fire.

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

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

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

• Do not refuel in closed rooms.

• Wipe up fuel spills immediately.

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

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner. Keep the machine clean to reduce the risk of fire and wipe away fuel spills immediately.

Refueling Fuel tank filler inlet A is located on the left side of the machine.

A

DANGER! All work involving fuel carries an increased

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

Fig. 112: Fuel filler inlet

Environment!

Collect and dispose of the fuel in a manner that is consistent with environmental laws.

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Maintenance Stationary fuel pumps

General

IMPORTANT! Only refuel from stationary fuel pumps. Fuel from barrels or canisters is usually contaminated.

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

Diesel fuel specification

Only use high-grade fuels.

Cetane number

Grade

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

Use For normal outside temperatures

Min. 45

For outside temperatures below 39°F (4°C) or for operation above 5000 ft.(1500 m) altitude

Bleeding the fuel system DANGER! If draining fuel comes into contact with hot engine parts or the exhaust system, there is an increased

Risk of fire.

A

☞ Never bleed the fuel system if the engine is hot.

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in a manner consistent with environmental laws.

B

Bleed the fuel system in the following cases: • After removing/replacing the fuel filter, prefilter or fuel lines, • After running the fuel tank empty, and • After running the engine after it has been out of service for more than a few months.

☞ Bleed the fuel system as follows: • Place a suitable container under the engine.

• Fill the fuel tank.

Fig. 113: Bleeding the fuel system

• Loosen bleed screw A on the injection pump by a few turns.

• Press button B on the fuel pump until the fuel comes out free of air from the loosened bleed screw.

• Tighten bleed screw A. • Start the engine.

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Maintenance If the engine runs smoothly for a while, and then stops; or if it does not run smoothly: • Stop the engine, and repeat the fuel system bleeding procedure.

• See your dealer for service.

Engine Lubrication System IMPORTANT! If the engine oil level is too low or if an oil change is overdue, this may cause: Engine damage or loss of output.

☞ Have the oil changed by an authorized dealer.

– see Maintenance Schedule on page 139.

Checking the oil level IMPORTANT! Check the oil level before starting the engine and after every 10 service hours or daily (if you use the machine less than 10 service hours in one day). After turning off a warm engine, wait at least 5 minutes before checking the oil level.

Checking the oil level Proceed as follows:

☞ Park the machine on level ground. ☞ Shut off the engine – see Parking the Machine on page 57.

max min

A

☞ Remove the key. ☞ Apply the parking brake. ☞ Open the engine cover. ☞ Pull out oil dipstick A. • Wipe it with a lint-free cloth.

• Push it back in as far as possible.

Fig. 114: Checking the oil level

• Pull it out and read the oil level.

☞ You must add oil to the reservoir when the oil level reads at the MIN mark on the oil dipstick A.

– see Adding engine oil on page 113.

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Maintenance Adding engine oil IMPORTANT! Excessive or incorrect engine oil may result in engine damage. For this reason:

☞ Do NOT add engine oil above the MAX mark of oil dipstick 114/A. ☞ Only use the engine oil specified – see Fluids and Lubricants on page 138.

Environment!

Use a suitable container to collect the engine oil as it drains and dispose of it in a manner consistent with environmental laws.

Adding engine oil

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

OIL

B

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

• Add engine oil.

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

A

• Check the oil level – see Checking the oil level on page 112.

• Add oil if necessary and check the level again.

• Close filler cap B.

Fig. 115: Oil dipstick and oil filler cap

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

• Completely clean any oil spills from the engine.

Engine and Hydraulics Cooling System The combined engine/hydraulic oil cooler cools the engine and the hydraulic oil for the drive and work hydraulics.

Specific safety instructions • Dirt on the cooling fins reduces the cooler’s heat dissipation capacity. To avoid this: ☞ Clean the outside of the cooler at regular intervals – see Maintenance Schedule on page 139.

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

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Maintenance • An insufficient coolant level (engine/hydraulic oil) reduces the heat dissipation capacity and can lead to engine damage.

☞ Check the oil level at regular intervals – see Maintenance Schedule on page 139. ☞ If coolant must be added frequently, check the cooling system for leaking and/or contact your dealer.

☞ Never add coolant if the engine is hot. ☞ Run the engine after filling the expansion tank. Stop the engine and check the coolant level again.

• Using the wrong coolant can damage the engine and radiator. ☞ Add the proper amount of antifreeze to the coolant – see Fluids and Lubricants on page 138.

☞ Use quality antifreeze compounds containing anti-corrosion additives. ☞ Do not use radiator cleaning compounds if antifreeze has been added to the coolant.

This causes sludge to form, which can damage the engine.

Environment!

Use a suitable container to collect the coolant as it drains and dispose of it in a manner consistent with environmental laws.

Cleaning the oil/water radiator cooling fins DANGER! Use care when working on a hot engine and radiator -

Risk of burns. ☞ Wait at least 10 minutes after turning off the engine before starting work. ☞ Wear protective gloves and clothing during maintenance work.

IMPORTANT! Dirt on the radiator fins reduces the radiator's heat dissipation capacity and can cause damage to the engine and the hydraulic system.

In order to ensure the radiator's optimal cooling capacity, do not damage the radiator fins as you clean them with a compressed-air gun.

☞ Check the radiator once a day for dirt and clean it if necessary. ☞ Clean the radiator more frequently in dusty or dirty work conditions.

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Maintenance ☞ Park the machine on level ground. ☞ Lower the loader unit to the ground. ☞ Engage the parking brake. ☞ Shut off the engine and let it cool. ☞ Remove the ignition key. ☞ Open the engine cover. ☞ Clean the radiator fins by blowing compressed air through the radiator from the engine side.

Fig. 116: Cleaning the oil cooler

Checking the coolant level DANGER! Never open the coolant tank filler cap or drain coolant when the engine is hot.

The cooling system is under high pressure -

Risk of burns. ☞ Wait at least 10 minutes after shutting off the engine. ☞ Wear protective gloves and clothing. ☞ When opening the coolant filler cap, always loosen the cap to the first notch to release the pressure in the cooling system.

IMPORTANT! Check the coolant level every 10 service hours or once a day.

Check before starting the engine.

☞ Check the coolant level as follows:

A B MAX MIN

Fig. 117: Expansion tank for coolant

Printed in U.S.A.

• Park the machine on level ground.

• Lower the loader unit to the ground.

• Apply the parking brake.

• Shut off the engine.

• Remove the ignition key.

• Open the engine cover.

• Check the coolant level in the expansion tank A. If the coolant level is below the MIN mark B on the expansion tank: • Add coolant to the MAX mark B. ☞ Check the coolant quality (antifreeze) with suitable testing equipment (antifreeze tester) – see Fluids and Lubricants on page 138.

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Maintenance Adding coolant DANGER! Never open the coolant tank and never drain coolant if the engine is running because the cooling system is under high pressure -

Risk of burns! ☞ Wait at least 10 minutes after shutting off the engine. ☞ Wear protective gloves and clothing. ☞ Before removing the filler cap, always loosen the cap to the first notch to release the pressure in the coolant system.

☞ Add coolant as follows

A B MAX MIN

Fig. 118: Filling up coolant in the expansion tank

Printed in U.S.A.

• Park the machine on level ground.

• Lower the loader unit to the ground.

• Engage the parking brake.

• Shut off the engine and remove the key.

• Allow the engine/cooling system to cool. ☞ Release the pressure in the cooling system pressure. To do this: • Loosen cap A to the first notch. Allow the pressure to release.

• Remove filler cap A. • Add coolant to the MAX mark B. • Use quality antifreeze compounds with anti-corrosion additives – see Fluids and Lubricants on page 138.

• Replace and tighten filler cap A. • Start and warm up the engine. Fully open the heating circuit as the engine warms.

• Shut off the engine.

• Check the cooling system and the heating circuit for leaks. Repair any leaks.

• Check the coolant level again. ☞ If necessary, add coolant and repeat the procedure until reaching the correct coolant level.

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Maintenance

Maintenance Lubricating the loader unit Lubricate the following points on the loader unit

C

☞ Lubricate grease nipple C on the tilt cylinder bearing on the frame with grease every 50 service hours (or weekly if the machine is used for less than 50 hours per week).

Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple D on the loader unit bearing every 50 service hours (or weekly if

D

the machine is used for less than 50 hours per week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple E on the lift cylinder bearing on the frame every 50 service

E

hours (or weekly if the machine is used for less than 50 hours per week). Lubricate daily during heavy-duty operation.

Fig. 128: Lubrication points on frame

☞ Lubricate grease nipple F on the tilt rod bearing every 10 service hours (or weekly if the F G

L

machine is used for less than 50 hours per week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple G on the tilt cylinder bearing every 50 service hours (or weekly

if the machine is used for less than 50 hours per week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple H on the lift cylinder bearing every 50 service hours (or weekly if the machine is used for less than 50 hours per week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple I on the tilt lever bearing every 10 service hours (or weekly if the

machine is used for less than 50 hours per week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipples K on the quickhitch bearing every 10 service hours (or weekly

if the machine is used for less than 50 hours per week). Lubricate daily during heavy-duty operation.

K

I

H

Fig. 129: Lubrication points for lift and tilt cylinder bearings

☞ Lubricate grease nipples L on the tilt lever bearing every 10 service hours (or weekly if the machine is used for less than 50 hours per week). Lubricate daily during heavy-duty operation.

Maintenance of Attachments IMPORTANT! Correct maintenance and service improves operation and increases the service life of attachments. Follow the lubrication and maintenance instructions in the attachments' operator’s manuals.

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Maintenance Maintenance of the Brake System Environment!

Use a container to collect brake fluid as it drains and dispose of it in accordance with environmental laws.

Safety instructions

WARNING! Brakes are critical for safety. Incorrect maintenance or repair may cause brake failure.

• All maintenance and repair work on the brakes must be completed by trained staff.

• The machine operator must complete a daily check of the brake fluid level in the tank.

• An authorized dealer must immediately replace damaged brake lines or hoses – risk of accidents.

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

A

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

Accident risk.

MAX MIN

Fig. 130: Checking the brake fluid level in the tank

☞ Check the brake fluid in the tank regularly. ☞ Fill the brake fluid up to the upper edge of the sight gauge (MAX). ☞ The brake fluid must comply with the SAE specification.

– see Fluids and Lubricants on page 138.

☞ Replace brake fluid every two years. ☞ If the brake system loses a significant amount of fluid continuously, have the system checked and repaired by your dealer.

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

☞ Clean the area around the brake fluid filler cap with a clean cloth. ☞ Open tank cover A. ☞ Fill the brake fluid up to upper edge of the sight gauge (MAX). ☞ Close tank cover A.

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Maintenance Tire Care WARNING! Improper tire repairs present an –

Accident risk. ☞ All tire and rim repairs must only be completed by authorized personnel. ☞ All repair work on tires and rims may only be completed by authorized spe-

IMPORTANT! cialist dealers.

Regular inspection of the tires: • Improves operating safety, • Increases the service life, and • Can reduce machine downtime.

– see Specifications on page 149 for the authorized tire types and the correct tire pressures. Machines are also delivered with a tire table decal on the front window or on the loader unit bulkhead.

Tire check Daily check

☞ Complete the following maintenance daily: • Check tire pressure.

• Check the inside and outside of tires and rims for damage (cracks, aging, etc.).

• Remove objects from the tire tread.

• Remove oil and grease.

Weekly check

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

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Maintenance Wheel Change DANGER! Using the wrong tires or wheels –

Accident risk. ☞ Only use authorized wheels and tires.

– see Tires on page 156.

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

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

☞ Use the correct assembly tools, such as covering sleeves for the studs, a jack, etc.

Removing the wheels

☞ Proceed as follows: • Park the machine on level and firm ground; prevent it from rolling away – see Parking the Machine on page 57.

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

• Place a jack under the axle beam; and make sure that it is secure and properly positioned.

• Raise the axle on the side from where you want to remove the wheel.

• Be sure that the machine is firmly positioned.

• Remove the wheel nuts.

• Remove the wheel.

Fitting the wheels

☞ Proceed as follows: • Place the wheel onto the wheel studs.

• Partially tighten all wheel nuts.

• Lower the raised axle.

• Tighten the wheel nuts to the correct torque – see Hardware Torques on page 157.

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Maintenance Heating The machine’s heating system is equipped with a dust filter that must be cleaned regularly and replaced yearly.

The filter is located in the cab behind the maintenance cover on the right outside of the cab.

Cleaning the dust filter of the heating system A dust filter cleans the air taken in by the heater. Clean the filter with compressed air as required, but at least yearly. The air that flows from the vents decreases as dust on the filter increases.

☞ Clean the filter as follows: • Open cover A. • Remove dust filter B.

A

• Clean dust filter D; replace it if necessary.

☞ Replace the filter every 500 hours.

• Close cover A.

B

Fig. 131:

Replacing the heating system dust filter

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Maintenance Air Conditioning Maintenance General instructions regarding the air conditioning system For your own safety, please observe the following instructions: • Air conditioning maintenance and repair work must only be carried out by trained staff or by an authorized workshop.

• Use care when performing maintenance and repair work – sharp-edged fins on the condenser and the heat exchanger can cause injury.

• Wear protective equipment (protective gloves and goggles) during maintenance and repair work.

• Do not perform maintenance work unless the heating and air conditioning systems are turned off.

• Observe all regulations relevant to accident prevention, and other generally acknowledged regulations regarding safety.

DANGER! Lines and hoses containing refrigerants and cooling fluids are under pressure and can be hot –

Risk of burns. ☞ Avoid touching components containing refrigerants. ☞ Turn off the air conditioning during checks and when performing maintenance.

Soldering and welding on the closed system presents a -

Risk of explosions. ☞ Maintenance and repair must only be performed in an authorized workshop by properly training persons.

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Maintenance Daily functional and visual checks of the air conditioning The machine operator must perform daily visual checks.

DANGER! Use care when performing maintenance on a hot engine and radiator –

Risk of burns. ☞ Wait at least 10 minutes after shutting off the engine. ☞ Wear protective gloves and clothing during maintenance.

B

A

C

☞ Shut off the engine. ☞ Engage the parking brake. ☞ Remove the ignition key. ☞ Check the refrigerating and heating lines for damage. ☞ Check the hoses for tightness, leaks and chafing. ☞ Check the electric connections for condition and tightness. ☞ Clean the dirty condenser A: • Remove screws B. • Tilt condenser A. ☞ Clean the condenser with compressed air or with a water jet (do not use high-pressure cleaners).

IMPORTANT! Use care not damage the fins while cleaning the condenser.

☞ Replace condenser A after cleaning. ☞ Check V-belt tension C and/if necessary, tighten the V-belt. ➥ Press with your thumb to check whether the V-belt can be deflected between the pulleys by no more than about 3/8” (10 mm). ➥ Have the V-belt replaced or tightened by an authorized workshop only.

IMPORTANT!

D

The air conditioning system must be checked and serviced twice a year in an authorized workshop by properly training persons. Replace the dehumidifier D every two years.

Fig. 132: Air conditioning: evaporator, dehumidifier

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Maintenance Electrical System Safety instructions The battery contains sulphuric acid. Sulphuric acid must not come into contact with skin, eyes, clothing, or the machine.

DANGER! Battery acid is highly caustic –

Risk of acid burn.

When recharging and/or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves.

If acid is spilled:

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

During charging and normal battery operation, an oxygen-hydrogen mixture is formed in the battery cells – risk of explosion.

☞ Avoid open flames and sparks in the vicinity of the battery and do not smoke. ☞ Never jump-start the machine if the battery is frozen or if the acid level is low.

The battery may rupture or explode.

IMPORTANT! Always disconnect the negative terminal (–) from the battery before starting repair work on the electrical system. Only use 12-V power sources; higher voltages damage the electrical components.

When connecting the battery leads, make sure that the terminal (+/–) are not reversed. Reversing the terminals damages sensitive electrical components.

Never disconnect voltage-carrying circuits at the battery terminals. The disconnection creates a risk of sparking.

Never place tools or other conductive articles on the battery, because this presents a risk of a short circuit.

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Maintenance Service and maintenance work at regular intervals Before driving the machine

☞ Check every time before using the machine: • Light system • Signalling and warning system Weekly

☞ Check weekly: • Electrical fuses – see Switching relays for differential lock, warning sensor, air conditioning on page 153.

• Battery terminals, battery cables, cable and ground connections.

• Charge condition of battery – see Battery on page 134.

• Battery terminal connections.

Instructions for cables, fuses, bulbs, alternator Cables, bulbs and fuses

Follow these instructions:

• Failed electrical system components must always be replaced by an authorized technician. The operator or other persons may change bulbs and fuses.

• Ensure good contact in leads and fuses.

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

• Only use fuses with the specified amperage – see Switching relays for differential lock, warning sensor, air conditioning on page 153.

Alternator

Follow these instructions:

• Only test the engine with the battery connected.

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

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

• Replace failed charge indicators immediately.

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Maintenance Battery

DANGER! Battery acid is highly caustic –

Risk of acid burn.

When recharging and/or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves.

If acid is spilled:

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

During charging and normal battery operation, an oxygen-hydrogen mixture is formed in the battery cells –

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

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

-

+

Battery A is located on the left side of the engine compartment, next to the hydraulic oil reservoir. The original equipment battery does not need any fluid to be refilled under normal operating conditions. However, have the battery checked at regular intervals.

A

Fig. 133: Battery Fig 133: Battery

Printed in U.S.A.

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Maintenance General Maintenance Cleaning Cleaning the machine consists of three separate cleaning areas:

• Machine interior • Machine exterior • Engine compartment The wrong cleaning equipment and agents can affect machine safety and offset the health of the persons cleaning the machine.

Follow these instructions: General instructions for all areas of the machine

When using washing solvents

• Ensure adequate room ventilation.

• Wear suitable protective clothing.

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

When using compressed air

• Wear goggles and protective clothing.

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

• DO NOT use compressed air for cleaning your clothing.

When using a high-pressure or steam jet cleaner

• Cover electrical components and insulating materials.

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

• Protect the following components from moisture: • Engine • Electrical components (such as the alternator, etc.)

• Control devices and seals • Air intake filters, etc.

When using volatile and flammable anti-corrosion agents and sprays

• Ensure adequate room ventilation.

• DO NOT use unprotected lights or open flames.

• DO NOT smoke.

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Maintenance Cleaning inside the cab

CAUTION! Never use high-pressure cleaners, steam jets, or high-pressure water to clean the inside of the cab. Water under high-pressure may: • Penetrate into the electrical systems and cause short circuits • Damage the seals and disable controls Use any of the following to clean the cab:

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

• Only clean the seat belt (DO NOT disconnect the seat belt from the machine) by using a mild soap solution; DO NOT use chemical agents because they may destroy the fabric.

WARNING! Debris or water on retracting seat belts may affect rewinding –

Risk of personal injury. ☞ Only rewind the seat belt if it is both clean and dry.

Exterior of the machine

Use either or both of the following to clean the outside of the cab:

• High-pressure cleaner • Steam jet Engine compartment

WARNING! Only clean the engine after it is shut off and stopped –

Risk of personal injury. ☞ Shut off the engine before cleaning.

IMPORTANT! When cleaning the engine with a steam or water jet:

☞ The engine must be cold. ☞ DO NOT point the jet directly at electrical sensors, such as the oil pressure sender.

Any humidity penetrating these sensors causes them to fail and can lead to engine damage.

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Maintenance Checking bolted connections

IMPORTANT! All bolted connections must be checked regularly, even if they are not listed in the maintenance schedules. Tighten loose connections immediately – see Specifications on page 149 for the tightening torques.

Checking pivots and hinges

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

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Maintenance Fluids and Lubricants Component/ application

Diesel engine

Fluid

Engine oil2 with filter

SAE grade Specification

Season/ temperature

SAE 10W; EO103

Below 23° F (-5° C)

SAE 20W/20; EO203

14° to 50° F (-10° to 10° C)

SAE 30; EO303

41° F to 86° F (5° C to 30° C)

HD-C 10W/40; EO1040B3 HD-C 15W/40; EO1540B3 Gearbox Differential – front and rear axle Planetary drives – left and right, front and rear axle

Gearbox oil4

80W/90 API GL5 or SAE 90 LS (hypoid gear oil) SAE 5W/30 SAE 5W/40; EO 0540B3

Engine oil2 Hydraulic oil tank Hydraulic oil5 Biodegradable oil

Capacities1

11.2 qts. (10.5 L)

Year-round 0.85 qts. (0.80 L) Year-round

4.2 qts. (4.0 L) 0.95 qts. (0.90 L) each

Up to -13° F (-25° C)

SAE 10W/40; EO 0540B3

Up to 5°F (-15°C)

SAE 15W/40; EO 1540B3

Up to 14°F (-10°C)

About 13 gal.

(50 L)

HVLPD 46 (HYD05303) (ATF 46) AVILUB Syntofluid 46 (bio-oil)

Year-round

PANOLIN HLP Synth 46 (bio-oil)

Grease nipples, telescopic unit pad tracks

multi-purpose grease

Lithium-based brand-name grease MPG-A3

Year-round

As required

Battery terminals

Acid-proof grease

SP-B3

Year-round

As required

Year-round

As required

Mounting of pins, shafts, etc.

Special grease

Fuel tank

Diesel fuel7

Brake system

Brake fluid8

Engine coolant

Antifreeze

6

Optimoly paste “TA” White paste Grade no. 2-D

Over 39° F (4° C)

Grade no. 1-D

Below 39° F (4° C)

About 16 gal. (60 L)

Agip LHM Super / Shell LHM

Year-round

–

Havoline extended-life XLC9, 10, 11

– see Coolant Compound Table on page 157

Washer system

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Cleaning agent

Water + antifreeze

Year-round

Water/Antifreeze 10 qts. (9.5 L) Water 1.4 qts. (1.3 L) 67% Antifreeze 0.7 qts. (0.7 L) 33%)

The capacities indicated are approximate values; only the oil level check is accurate for the correct oil level.

MIL-L-2104C; API CD/CE/CF4; CCMC-D4.

Abbreviation for lubricants.

MIL-L-2105B; API-GL5.

DIN 51 521 T3.

250 gr tube.

DIN 51 601, min 45 Cetane.

Standard: B 71 2710.

See coolant compound table on page 157.

See manufacturer’s instructions.

Replace coolant every 2 years.

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● ● ● ●

“C” every 1500 service hours (yearly)

● ● ●

):

139

Carry out the following oil and filter changes (check oil levels after test run): • Engine oil • Engine oil filter • Fuel filter, Fuel pre-filter • Air filter3, 4 replace safety element every third time the primary air filter element is replaced • Gearbox oil in front and rear axle differentials and in rear axle gearbox • Gearbox oil in front and rear axle planetary drives, left and right • Hydraulic oil5 • Hydraulic oil filter • Breather filter – hydraulic oil reservoir 4 • Heater: fine-dust filter 6 Inspections (

“B” every 500 hours2 2nd Inspection

Oil and filter changes (

“A” every 50 hours (weekly)

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

Delivery inspection

Work description

1st Inspection1 at 100 hours

Maintenance Schedule

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

●

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● ● ● ●

● ● ●

):

Check the following items. Refill if necessary.

• Engine oil • Hydraulic oil • Gearbox oil in front and rear axle differentials and in rear axle gearbox • Gearbox oil in front and rear axle planetary drives, left and right side • Brake fluid7

● ●

●

● ● ● ● ●

8

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

● ●

●

●

●

● ● ● ●

●

●

●

●

●

●

●

Clean dust valve on air filter housing 3

●

●

●

●

●

●

V-belt: Check condition and pre-tension. Tighten or replace if necessary9

●

●

●

●

●

●

●

●

●

●

●

●

●

Check the fuel/water separator. Drain water if necessary 10

Engine coolant (also check antifreeze in autumn/winter and temperatures below 40º F [4º C])

●

Maintenance

918296/BP1209

When using biodegradable oil: Drain the condensation water in the hydraulic oil reservoir 5

“C” every 1500 service hours (yearly)

●

●

●

●

Check valve clearance (engine timing), set if necessary

●

●

Battery: Check charge condition

●

●

Other inspections (

):

●

Heating: Clean dust filter, replace every 1500 service hours if necessary11 Check and set service and parking brake pads, replace if necessary Tire check (damage, air pressure, tread depth) 140

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

• Engine and engine mounts • Steering system • Hydraulic system • Loader unit (pin locking) • Axle mounting, axle suspension • Counterweight (attachment) • Attachment capscrews of driveshafts • Cab attachment fasteners • Wheel nuts Electric system: Check electrical and ground connections, chafing on wiring harness, battery terminals Lubrication service (

):12

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● ● ● ● ● ● ● ● ● ●

Maintenance

“B” every 500 hours2 2nd Inspection

Clean filter insert on fuel pump, replace if necessary

1st Inspection1 at 100 hours

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

Delivery inspection

Work description

“A” every 50 hours (weekly)

Maintenance Schedule

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

918296/BP1209

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):

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

• Air intake line (air filter – engine) ● ● ● • Engine lubrication (engine – filter) ● ● ● • Fuel lines13 ● ● ● • Cooling system (engine – hydraulic oil) ● ● ● • Steering system (hoses and cylinders) ● ● ● ● ● ● • Hydraulic system/loader unit (hoses and cylinders) 14 • Brake system (hoses and cylinders) ● ● ● 1.

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

Maintenance

918296/BP1209

● ●

):

Check the function of the following assemblies/components. Repair if necessary.

• Service and parking brakes • Steering system • Lights and electrical system Leakage check (

“C” every 1500 service hours (yearly)

Functional check (

“B” every 500 hours2 2nd Inspection

141

Lubricate the following assemblies/components: • Rear axle oscillating bearings • Front and rear axle planetary drive bearings, left and right • Loader unit– see Lubricating the loader unit on page 125 • Lift arm bearings • Tilt rod bearings • Tilt lever bearings • Lift cylinder bearings • Tilt cylinder bearings • Quickhitch: Bearing on lift frame • Hinges, joints and fittings (e.g., door arrester)

1st Inspection1 at 100 hours

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

“A” every 50 hours (weekly)

Work description

Delivery inspection

Maintenance Schedule

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

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

Replace filter as indicated by the indicator on the instrument panel, however at least every 12 months or 1500 service hours.

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

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

More frequent dust filter replacement may be required, depending upon conditions.

Replace every two years.

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

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

Replace engine coolant every 2 years.

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

Lubricate attachment according to manufacturer's instructions.

Replace fuel leak oil lines every two years.

Replace hoses every six years (UVV, DIN 20066 part 5).

Maintenance

Printed in U.S.A.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

142 918296/BP1209

Maintenance

Maintenance

Maintenance Log Use the following table to record the maintenance and service work that is completed after a certain amount of service hours – see Maintenance Schedule on page 139.

Check off the columns in the boxes below after the work is completed.

The 1st and 2nd inspections must be completed by an authorized dealer for warranty claims to be approved. For information on maintenance material, consumables and lubricants – see Fluids and Lubricants on page 138.

A

100

1st Inspection

750

A

150

A

800

A

200

A

850

A

250

A

900

A

300

A

950

A

350

A

1000

B

400

A

1050

A

450

A

1100

A

500

B 2nd Inspection

1150

A

550

A

1200

A

600

A

1250

A

Printed in U.S.A.

143

Company/ signature

700

Service hours

Maintenance schedule

A

Company/ signature

After service hours

Service hours

50

Date

A

Maintenance schedule

650

After service hours

Delivery

Date

Maintenance log

Maintenance log

918296/BP1209

Maintenance

1350

A

2150

A

1400

A

2200

A

1450

A

2250

A

1500

C yearly

2300

A

1550

A

2350

A

1600

A

2400

A

1650

A

2450

A

1700

A

2500

B

1750

A

2550

A

1800

C

2600

A

1850

A

2650

A

1900

A

2700

A

1950

A

2750

A

2000

B

2800

A

2050

A

2850

A

Printed in U.S.A.

144

Company/ signature

A

Service hours

Maintenance schedule

2100

Date

After service hours

A

Company/ signature

1300

Date

Maintenance schedule

Maintenance log

After service hours

Service hours

Maintenance log

918296/BP1209

Maintenance

2950

A

3700

A

3000

C

3750

A

3050

A

3800

A

3100

A

3850

A

3150

A

3900

A

3200

A

3950

A

3250

A

4000

B

3300

A

4050

A

3350

A

4100

A

3400

A

4150

A

3450

A

4200

A

3500

B

4250

A

3550

A

4300

A

3600

A

4350

A

Printed in U.S.A.

145

Company/ signature

A

Service hours

Maintenance schedule

3650

Date

After service hours

A

Company/ signature

2900

Date

Maintenance schedule

Maintenance log

After service hours

Service hours

Maintenance log

918296/BP1209

Maintenance

4450

A

5200

A

4500

C

5250

A

4550

A

5300

A

4600

A

5350

A

4650

A

5400

A

4700

A

5450

A

4750

A

5500

B

4800

A

5600

A

4850

A

5650

A

4900

A

5700

A

4950

A

5750

A

5000

B

5800

A

5000

A

5850

A

5050

A

5900

A

5100

A

5950

A

Printed in U.S.A.

146

Company/ signature

A

Service hours

Maintenance schedule

5150

Date

After service hours

A

Company/ signature

4400

Date

Maintenance schedule

Maintenance log

After service hours

Service hours

Maintenance log

918296/BP1209

Maintenance

Maintenance Maintenance Decal Location: Inside the cab on the rear window.

Explanation of symbols on maintenance decals Symbol

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

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

Check that the light system functions correctly.

Check tires for damage, pressure and tread depth.

Complete a functional check and synchronize the steering system.

Complete a functional check of the brake system.

Check hydraulic oil level. Add oil if necessary.

Check engine oil level. Add oil if necessary.

Check coolant level. Add coolant if necessary.

Compress the dust valve.

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

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

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

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

Lubrication service: Lubricate the assemblies.

Printed in U.S.A.

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100 010 40 14

Maintenance

10 h

Täglich Daily Tous les jours

50 h |=> 347 04 0001

Printed in U.S.A.

148

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Specifications

Specifications

Specifications Frame Sturdy steel frame, rubber-mounted engine.

Engine Engine Product

Deutz diesel engine

Model

D 2011 L04 W - Tier III

Type

In-line

No. of cylinders

4

Displacement

221 in.³ (3620 cm³)

Bore and stroke

3.7 x 4.92” (92 x 125 mm)

Compression ratio

18:1 78 DIN hp (58 kW) at 2300 rpm 199 lb.-ft. (270 Nm) at 1600 rpm

Output (per ISO 9249) Max. torque Min. idling speed Specific minimum fuel consumption Fuel injection system

315 g/hph (235 g/kWh) Direct fuel injection

Firing order

1–3–4–2

Starting aid

Glow plug Max. lateral left/right inclination: 30°/57% Max. uphill/downhill inclination: 30°/57% Follow tilting limit of the machine.

44 – 65 psi (3.0 – 4.5 bar) at 2300 rpm Intake valve 0.01” (0.3 mm) Exhaust valve 0.02” (0.5 mm)

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

Printed in U.S.A.

900 rpm

149

918296/BP1209

Specifications Power Train Variable-displacement pump Automotive, infinitely variable hydrostatic axial-piston gearbox 0 – 3.4 in.³/rev (0 – 56 cm³/rev)

Type

Displacement

6962 psi (480 bar) 1150 – 1250 rpm at 725 psi (50 bar) HP 2200 – 2300 rpm, 3625 psi (250 bar) HP

Max. operating pressure Dp Starting RPMs Droop Boost pump:

Internal gear pump

Type

0.7 in.³/rev (11.6 cm³/rev)

Displacement

435 psi (30 bar) at 1500 rpm Speed-sensitive, hydraulic displacement adjustment with pressure cut-off Electro-hydraulic control

Charging/boost pressure Control

Driving direction

Inching valve

Inching Variable-displacement motor Type Displacement 12.5 mph (20 km/h) Drive speed

Tractive effort

Printed in U.S.A.

150

Axial-piston motor (swash-plate design) 1.8 to 6.5 in.³/rev (29.4 to 107 cm³/rev) 1st speed range: 0 – 3.7 mph (0 – 6 km/h), forward and reverse 2nd speed range: 0 – 12.5 mph (0 – 20 km/h), forward and reverse 12,138 lbf (54 kN)

918296/BP1209

Specifications Axles Front axle

Differential lock

Planetary drive steering axle, rigid connection with frame 100% differential

King-pin inclination

0°

Type

Camber

0°

Steering angle

40° 0” (0 mm)

Toe-in

60” (1530 mm)

Tread width Rear axle

Oscillating planetary-drive steering axle

Type King-pin inclination

0°

Camber

0°

Oscillation angle

+/- 11°

Steering angle

40° 0” (0 mm)

Toe-in

60” (1530 mm)

Tread width

Brakes Service brake Type

Foot-operated, hydraulic multi-disc brake + hydrostatic

Location

Front axle input

Effect

On both axles via driveshaft

Brake fluid

– see Fluids and Lubricants on page 138

Parking brake

Printed in U.S.A.

Type

Manual, mechanical disc brake

Location

Front axle input

151

918296/BP1209

Specifications Steering Steering Type Steering mode Assemblies

Max. pressure of hydraulic lines Hydraulic pump (gear pump) Maximum steering angle

Hydrostatic four-wheel steering with emergency steering feature Four-wheel steering Hydraulic pump, steering unit with flanged priority valve, steering cylinder, self-synchronizing in left and right final position 2538 – 2611 psi (175 – 180 bar) Displacement 2.3 in.³/rev (38 cm³/rev) ±40°

Work Hydraulics Hydraulic pump Displacement Control valve

Gear pump 2.3 in.³/rev (38 cm³/rev) 22.2 gpm (84 L/min) at 2300 rpm 3 sections (control circuits) 3481 psi (240 bar)

Max. service pressure Secondary pressure limiting

Tilt cylinder

Lift cylinder Filter

Rod side 4061 psi (280 bar) Bottom side 1740 psi (120 bar) Bottom side 4061 psi (280 bar) Suction return filter

Pilot Control Pilot control pump Joystick

3rd control circuit control lever

Printed in U.S.A.

152

Four-way lever – control of lift and tilt cylinders With mechanical lock preventing unintended actuation and electric control switch for driving direction and neutral Lock against unintentional operation (for long-haul travel and transport)

918296/BP1209

Specifications Payloads Loader unit with bucket 1, 2

Tipping load (ISO 14397)

41 ft.³ (1.15 m³) according to ISO 9127 lbs. (4140 kg)

Rated operating capacity (ISO 14397)

4564 lbs. (2070 kg)

Pin height

136 in. (3450 mm)

Dump reach

26 in. (660 mm)

Tilt-back angle

50°

Dump angle

45°

Bucket capacity

Breakout force (lift cylinder)

10881 lbf (48 kN)

Breakout force (tilt cylinder)

9892 lbf (44 kN)

Scraping depth

2.0 in.(50 mm)

Fork arms (payloads stated for 24” [610 mm) load center) Payload

3790 lbs. (1720 kg)

Lift height

129 in. (3280 mm)

1.

2.

With 405/70-24 tires With standard bucket

Electrical System Electrical system Alternator

14-V, 95 A

Starter

12-V, 3.0 hp (2.3 kW)

Battery

12-V, 88 Ah; Group size 48 (opt. 91) CCA 570

Switching relays for differential lock, warning sensor, air conditioning K21

The switching relays are located on the control valve bracket.

K11

B18

(accessed via the maintenance cover on the right on the outside of the cab).

Switching relay no.

Protected circuit

K21

Differential lock switching relay

K11

Air conditioning switching relay

B18

Diesel engine temperature warning buzzer

Fig. 134: Differential lock switching relay

Printed in U.S.A.

153

918296/BP1209

Specifications Fuse box on left and right of steering column

F7

F6

F5 F4

F3 F2

F16 F15 F14 F13 F12 F11 F10 F9

F

F1

F8

No.

Rated current

F1

7.5

High beam (left)

F2

7.5

High beam (right)

F3

5

Left side marker and rear lights, front socket

F4

5

Switch assignment: front/rear working lights, front attachments (option), rotating beacon (option) Switch lights: lights, heating S5, load stabilizer S8, 3rd control circuit Right side marker and rear lights, front socket (option)

F5

7.5

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

F6

25

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

F7

25

All lights

F8

7.5

Low beam (left)

F9

7.5

Low beam (right)

F10

5

Switching relay - front attachment (option), instrument panel, cutoff solenoid, sensor (coolant level indicator)

F11

15

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

F12

7.5

Solenoid valve 1st/2nd speed range

F13

7.5

Relays - forward/reverse, solenoid valve - forward/reverse, backup warning system

F14

20

Front attachment (option), heating fan

F15

7.5

Relay - turn indicators, brake lights, solenoid valve (exhaust gas recirculation)

F16

5

Radio (option)

F

20

Air conditioning (accessed via the maintenance cover on the right on the outside of the cab)

Protected circuit

Fig. 135: Fuses

Printed in U.S.A.

154

918296/BP1209

Specifications Main fuse box with relays K6

F17

F18

K5 K7 K29

F19

F20

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

Fuse no.

Rated current (A)

Protected circuit

F17

80 A

Main fuse (machine)

F18

40 A

Preheating (air-intake preheating), starter fuse

F19

10 A

Minus compensation

F20

50 A

Preheating (2nd glow plug, intake-air preheating

Relay no.

Protected circuit

K5

Preheating: power relay

K6

Preheating time control unit

K7

Start: starter relay

K29

Minus compensation

Fig. 136: Main fuse box

Relays The relays are located underneath the switch panel on the right in the side console (accessed via the maintenance cover on the right on the outside of the cab).

K10

K3 K4 K16

Switching relay no.

Protected circuit

K1

High current relay

K3

Reverse driving switching relay

K4

Forward driving switching relay

K10

Switching relay - turn indicators

K16

Switching relay - front socket (option)

K23

Wiper switching relay

K23

K1

Fig. 137: Relays

Printed in U.S.A.

155

918296/BP1209

Specifications Tires Tire pressure1

Tire size

Wheel rims

Front

Rear

37 psi (2.5 bar)

29 psi (2.0 bar)

405/70 R24 14PR MPT-04T

13 x 24

1. Increase front tire pressure by 7 psi (0.5 bar) during pallet forks operation!

Weights Weight Operating weight1

13,007 lbs. (5900 kg)

Gross weight rating

15,432 lbs. (7000 kg)

Front axle weight rating Rear axle weight rating

9,921 lbs. (4500 kg) None

Max. authorized load for towing apparatus 1.

With standard bucket, operator and full fuel tank

Sound Levels Sound levels Measured sound power

100.1 dB (A)

Guaranteed sound power

101 dB (A)

Sound pressure level in the cab

78 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 an asphalt surface.

Vibration Vibration

Printed in U.S.A.

Effective acceleration value for the upper extremities of the body

m < 2.5 ----2

Effective acceleration value for the body

m < 0.5 ----2

156

s

s

918296/BP1209

Specifications Coolant Compound Table Outside temperature Up to °F (°C) 39 (4) 14 (- 10) -4 (- 20) -13 (- 25) -22 (- 30) -44 (-42) 1.

2.

Water1

Antifreeze2

% by volume

% by volume

99 79 65 59 55 50

– 20 34 40 45 50

Water quality at 68°F (20°C) = 6.5 - 8.5 ph/overall hardness 3 - 20 dGH

See Fluids and Lubricants on page 138

Hardware Torques General torques Capscrew dimensions

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

Grade 8 (10.9)

Grade 10 (12.9)

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

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

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

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

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

Specific torques

Printed in U.S.A.

Description

Torque

Wheel nut

288 ±7 lb.-ft. (390 ±10 Nm)

Track-rod end (steering cylinder)

207 ±7 lb.-ft. (280 ±10 Nm)

Piston rod (steering cylinder/track rod)

192 ±7 lb.-ft. (260 ±10 Nm)

157

918296/BP1209

Specifications Dimensions

8” (200 mm)

114” (2900 mm)

106” (2700 mm)

26” (660 mm

107” (2720 mm)

138” (3500 mm)

130” (3285 mm)

45°

50°

15” (375 mm)

85” (2170 mm)

58” (1480 mm)

85” (2150 mm)

59” (1490 mm) 85” (2150 mm)

228” (5800 mm)

Fig. 138:

Machine dimensions

Dimensions Overall length1

228” (5800 mm)

Overall height 2

106” (2700 mm)

Overall height with rotating beacon2

114” (2900 mm)

Overall width without bucket3

74” (1890 mm)

Overall width1

85” (2150 mm)

Ground clearance in transport position of loader unit

8” (200 mm)

Ground clearance 2 below rear axle gearbox

15” (375 mm)

Pin height

138” (3500 mm)

Load-over height

129” (3285 mm)

Dump height

107” (2720 mm)

Dump reach

26” (660 mm)

Rollback angle

50°

Dump angle

45°

Track width, front/rear

59” (1490 mm)

Wheelbase (front/rear axles)

60” (1530 mm)

Turning radius4

112” (2850 mm)

1.

2.

3.

4.

Printed in U.S.A.

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

158

918296/BP1209

Index I

A Abbreviations ............................................................................................ 5 Accelerator pedal .................................................................................... 53 Air conditioning (option) ..................................................................62, 130 Air filter ................................................................................................. 117 Cleaning the dust valve ............................................................... 117 Applications ..............................................................................................9 Applications with lifting gear ................................................................... 24 B Biodegradable oil .................................................................................. 121 Brake system ........................................................................................ 126 Brake fluid .................................................................................... 126 Safety instructions ....................................................................... 126 Brake/inching pedal ................................................................................ 53 C Cab Side window ................................................................................... 69 Side window emergency exit ......................................................... 70 Checklists .........................................................................................34, 45 Pre-delivery and Delivery ............................................................... 35 D Designated uses and exemption from liability ..........................................5 Differential lock ....................................................................................... 56 Dimensions ........................................................................................... 158 Driving on public roads ........................................................................... 50 With the multi-purpose bucket ....................................................... 94 Dust filter .............................................................................................. 129 F Fire extinguisher ..................................................................................... 16 Fluids and lubricants ............................................................................. 138 Fork arms Adjusting distance ........................................................................ 103 Overview ...................................................................................... 100 Functional check Dust valve .................................................................................... 117 G General information ..................................................................................3 General maintenance ........................................................................... 135 H Hazard warning system .......................................................................... 60 Heating ................................................................................................... 61 Hydraulic connections ............................................................................ 92 I Indicators ................................................................................................ 42 Interior light ............................................................................................. 59 J Jump-starting the engine ........................................................................ 49 L Light system ........................................................................................... 58 Load diagram ........................................................................................ 101 Loader unit Checking the tilt position of the bucket .......................................... 85 Checking the transport position of the bucket ................................ 85 Depressurizing quick-couplers ....................................................... 80 Lowering with the engine turned off ............................................... 80 Lubrication ................................................................................... 125 Re-installing ................................................................................... 81 Loading tie-bar ........................................................................................ 74 Lock cylinder ......................................................................................... 102 Locking lever ........................................................................................ 103 Lowering the loader unit with the engine turned off ................................ 80 M Machine Loading and transporting ......................................................... 28, 75 Overview ...................................................................................... 7, 8 Maintenance Adding engine oil ......................................................................... 113 Adding hydraulic oil ...................................................................... 122 Biodegradable oil ......................................................................... 121 Bolted connections ...................................................................... 137 Brake system ............................................................................... 126 Checking the engine oil level ....................................................... 112 Checking the hydraulic oil level ................................................... 122 Cleaning ....................................................................................... 135 Cleaning the oil cooler .........................................................114, 115

Printed in U.S.A.

159

Index Electrical system ..........................................................................132 Engine and hydraulics cooling system .........................................113 Engine lubrication system ............................................................112 Fluids and lubricants ....................................................................138 Fuel system ..................................................................................110 Heating .........................................................................................129 Hydraulic pressure lines ...............................................................123 Hydraulic system ..........................................................................120 Instructions for cables, fuses, bulbs, alternator ............................133 Maintenance log ...........................................................................143 Maintenance of attachments ........................................................125 Maintenance plan .........................................................................139 Pivots and hinges .........................................................................137 Service and maintenance work at regular intervals .....................133 Tire care .......................................................................................127 V-belt ............................................................................................119 Wheel change ..............................................................................128 Multifunctional lever ................................................................................57 O Operation ................................................................................................37 Cab (overview) ...............................................................................39 Driving ............................................................................................52 Driving the machine .......................................................................50 Instrument panel, multifunctional lever and drive lever (overview) .41 Parking the machine ......................................................................57 Seat belt height setting ...................................................................67 Selecting a speed range ................................................................55 Selecting the drive range ...............................................................55 Stopping the machine ....................................................................57 P Pallet forks Specific safety instructions ...........................................................101 Parking brake ..........................................................................................54 Preheating start switch ............................................................................52 Putting into service ..................................................................................44 Q Quickhitch .............................................................................................102 Quickhitch facility Fitting an attachment ....................................................................102 Removing an attachment .............................................................102 R Refueling ...............................................................................................110 Removing multi-purpose bucket from quickhitch ....................................93 Rotating beacon ......................................................................................61 Run-in period ..........................................................................................44 S Safety ......................................................................................................17 Safety decals ..........................................................................................13 Safety instructions Applications with lifting gear ...........................................................24 Maintenance ...................................................................................29 Specific hazards .............................................................................31 Seat Armrest adjustment ........................................................................66 Backrest adjustment .......................................................................65 Height adjustment ..........................................................................65 Horizontal adjustment ....................................................................65 Seat adjustment .............................................................................64 Weight adjustment .........................................................................64 Seat adjustment ......................................................................................64 Seat belt ............................................................................................66, 67 Service brake ..........................................................................................51 Signalling system ....................................................................................60 Sound levels ...................................................................................13, 156 Specifications ........................................................................................149 Axles ............................................................................................151 Brakes ..........................................................................................151 Coolant compounds .....................................................................157 Electrical system ..........................................................................153 Engine ..........................................................................................149 Frame ...........................................................................................149 Hardware torques .........................................................................157 Payloads ......................................................................................153 Pilot control ..................................................................................152 Power train ...................................................................................150 Sound levels .................................................................................156 Steering ........................................................................................152

918296/BP1209

Index Vibration ...................................................................................... 156 Weights ........................................................................................ 156 Work hydraulics ........................................................................... 152 Stability ........................................................................................... 93, 102 Switching the differential lock on and off ................................................ 56 T Taking into service Checklists ...................................................................................... 45 Safety instructions ......................................................................... 44 Tire care ............................................................................................... 127 Towing and transporting the machine .............................................. 26, 72 Transport ................................................................................................ 86 Transporting loads ................................................................................ 105 Turn indicators ........................................................................................ 60 U Unlocking .............................................................................................. 102 V Ventilation ............................................................................................... 61 Ventilation, fresh air ....................................................................... 61 W Washer system Tank ............................................................................................... 63 Wheel change ...................................................................................... 128 Wheel synchronization position .............................................................. 51 Windshield washer system ..................................................................... 63 Wipers .................................................................................................... 63 Working Freeing the machine ...................................................................... 85 Grading .......................................................................................... 90 Loading heaped material ............................................................... 89 Loading loose material .................................................................. 86 Removing material/digging in hard soil .......................................... 89 Removing material/digging in soft soil ........................................... 88 With a load hook (option) ............................................................. 105 With multi-purpose bucket ............................................................. 94 With pallet forks ............................................................................. 99 Working light ........................................................................................... 59

Printed in U.S.A.

160

918296/BP1209

TORQUE SPECIFICATIONS 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

41 (55)

52 (70)

33 (45)

52 (70)

0.7 in. (18 mm)

M22X1.5

48 (65)

92 (125)

44 (60)

92 (125)

0.9 in. (22 mm)

M27X2.0

66 (90)

133 (180)

74 (100)

107 (145)

1.0 in. (27 mm)

M33X2.0

111 (150)

229 (310)

118 (160)

155 (210)

1.3 in. (33 mm)

M42X2.0

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (42 mm)

M48X2.0

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (48 mm)

G1/8A

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (9.73 mm)

G1/4A

26 (35)

26 (35)

22 (30)

26 (35)

0.5 in. (13.16 mm)

G3/8A

33 (45)

52 (70)

33 (45)

37 (50)

0.7 in. (16.66 mm)

G1/2A

48 (65)

66 (90)

41 (55)

48 (65)

0.8 in. (20.96 mm)

G3/4A

66 (90)

133 (180)

74 (100)

103 (140)

1.0 in. (26.44 mm)

G1A

111 (150)

229 (310)

118 (160)

140 (190)

1.3 in. (33.25 mm)

G1 1/4A

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (41.91 mm)

G1 1/2A

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (47.80 mm)

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) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Identification aid outside Ø

M12X1.5

15 (20)

26 (35)

26 (35)

26 (35)

0.5 in. (12 mm)

M14X1.5

26 (35)

41 (55)

33 (45)

33 (45)

0.6 in. (14 mm)

Thread

M16X1.5

33 (45)

52 (70)

41 (55)

41 (55)

0.6 in. (16 mm)

M18X1.5

41 (55)

66 (90)

52 (70)

52 (70)

0.7 in. (18 mm)

M20X1.5

41 (55)

92 (125)

59 (80)

74 (100)

0.8 in. (20 mm)

M22X1.5

48 (65)

100 (135)

74 (100)

92 (125)

0.9 in. (22 mm)

M27X2.0

66 (90)

133 (180)

125 (170)

100 (135)

1.0 in. (27 mm)

M33X2.0

111 (150)

229 (310)

229 (310)

155 (210)

1.3 in. (33 mm)

M42X2.0

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (42 mm)

M48X2.0

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (48 mm)

G1/8A

26 (35)

41 (55)

33 (45)

33 (45)

0.5 in. (13.16 mm)

G1/4A

33 (45)

59 (80)

44 (60)

44 (60)

0.7 in. (16.66 mm)

G3/8A

48 (65)

85 (115)

55 (75)

74 (100)

0.8 in. (20.96 mm)

G1/2A

66 (90)

133 (180)

125 (170)

107 (145)

1.0 in. (26.44 mm)

G3/4A

111 (150)

229 (310)

229 (310)

192 (260)

1.3 in. (33.25 mm)

G1A

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (41.91 mm)

G1 1/4A

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (47.80 mm)

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

Thread

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

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M5

4.1 (5.5)

6 (8)

7 (10)

4 (5)

5 (7)

M6

7 (10)

10 (14)

13 (17)

6.3 (8.5)

9 (12)

M8

18 (25)

26 (35)

31 (42)

15 (20)

22 (30)

M10

33 (45)

48 (65)

59 (80)

30 (40)

44 (59)

M12

64 (87)

81 (110)

108 (147)

51 (69)

74 (100)

M14

100 (135)

133 (180)

170 (230)

81 (110)

118 (160)

M16

155 (210)

203 (275)

258 (350)

125 (170)

184 (250)

M18

207 (280)

302 (410)

354 (480)

181 (245)

254 (345)

M20

302 (410)

420 (570)

509 (690)

251 (340)

361 (490)

M22

406 (550)

575 (780)

686 (930)

339 (460)

487 (660)

M24

524 (710)

738 (1000)

878 (1190)

435 (590)

620 (840)

M27

767 (1040)

1092 (1480)

1305 (1770)

642 (870)

922 (1250)

M30

1047 (1420)

1482 (2010)

1770 (2400)

885 (1200)

1254 (1700)

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

Thread

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

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M8X1.0

18 (25)

27 (37)

32 (43)

16 (22)

24 (32)

M10X1.0

37 (50)

55 (75)

65 (88)

32 (43)

48 (65)

M10X1.25

36 (49)

52 (71)

61 (83)

31 (42)

46 (62)

M12X1.25

64 (87)

96 (130)

111 (150)

55 (75)

81 (110)

M12X1.5

61 (83)

92 (125)

107 (145)

53 (72)

77 (105)

M14X1.5

100 (135)

148 (200)

173 (235)

89 (120)

129 (175)

M16X1.5

155 (210)

229 (310)

266 (360)

133 (180)

195 (265)

M18X1.5

232 (315)

332 (450)

391 (530)

199 (270)

284 (385)

M20X1.5

325 (440)

465 (630)

538 (730)

277 (375)

391 (530)

M22X1.5

435 (590)

620 (840)

723 (980)

369 (500)

524 (710)

M24X2.0

546 (740)

789 (1070)

922 (1250)

465 (630)

664 (900)

M27X2.0

811 (1100)

1143 (1550)

1328 (1800)

679 (920)

959 (1300)

M30X2.0

1106 (1500)

1586 (2150)

1844 (2500)

959 (1300)

1364 (1850)

NOTES

WARNING THIS OPERATOR’S MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THIS MACHINE Do not start, operate or work on the machine until you carefully read and thoroughly understand the contents of this Operator’s Manual.

Failure to follow safety, operating and maintenance instructions can result in serious injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of the machine, contact your dealer or the Mustang Manufacturing Company Service Department before starting or continuing operation.

California Proposition 65 Warnings: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and birth defects and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects and other reproductive harm. Wash hands after handling battery.

918296/BP1209

©2009 MUSTANG MANUFACTURING COMPANY, INC. All rights reserved.

Printed in U.S.A.