Operation

Transporting loads with the pallet forks

DANGER!

When transporting loads with the pallet forks raised, the load can fall down or the machine can tilt –

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. (ground clearance –see Checking the transport position of the bucket on page83).

☞ Always tilt the pallet forks slightly back (towards 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 tilting forward when braking.

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

Troubleshooting

Engine trouble

Use this section to determine

Maintenance Introduction

Operational readiness and the service life of the machine can be increased through proper maintenance.

Before carrying out service and maintenance work, always read, understand and follow the instructions given in:

• –see Safety instructions on page15.

• 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 Model ML48 (overview) on page124.

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.

Refueling

Filler inlet A of the fuel tank is located on the right side, in the front section of the cab.

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 naked flames or sparks.

Environment!

Collect and dispose of the fuel in a manner that is consistent with environmental laws.

Stationary fuel pumpsGeneral

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.

• No. 2-D according to DIN 51601. Min. 45 For normal outside temperatures.

• No. 1-D according to DIN 51601. For outside temperatures below 39°F (4°C) or for operation above 4’9” (1500 m) altitude.

Bleeding the fuel system

IMPORTANT!

The fuel system of the machine is bled automatically.

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 Model ML48 (overview) on page124.

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.

☞ Turn off the engine

–see Parking the machine on page61.

☞ 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.

•Pull it out and read the oil level.

☞ You must fill the oil tank when the oil level reads at the MIN mark on the oil dipstick A

–see Adding engine oil on page102.

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 111/A.

☞ Only use the engine oil specified –see Fluids and lubricants on page123.

Environment!

Use a container to collect the engine oil as it drains and dispose of it in a manner consistent with environmental laws.

Filling up the engine oil

☞ Proceed as follows:

• Clean the area around oil filler cap B by using a lint-free cloth

• 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.

• Check the oil level –see Checking the oil level on page101.

• Add oil if necessary and check the level again.

• Close filler cap B

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

• Completely clean any oil spilt on the engine.

Engine and hydraulics cooling system

The combined engine/hydraulic oil cooler is located in the engine compartment, on the right side, next to the engine. It cools the diesel engine, hydraulic oil of the drive and the 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 Model ML48 (overview) on page124.

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

• 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 Model ML48 (overview) on page124.

☞ If coolant must be added frequently, check the cooling system for leaking and/or contact your dealer.

Cleaning the oil cooler

DANGER!

You may come into contact with the engine at hot temperatures when cleaning the oil cooler –

Risk of burns.

☞ Wait at least 10 minutes after turning off the engine.

☞ Wear protective goggles, gloves, and clothing.

☞ Proceed as follows:

• Park the machine on level ground.

• Lower the loader unit.

• Apply the parking brake.

• Turn off the engine.

• Let the engine cool down.

• Remove the key.

• Open the engine cover.

• Clean the cooling fins by blowing compressed air from side A of the cooler.

Air filter

Weekly air filter contamination check

IMPORTANT!

The filter cartridge will be damaged if it is washed or brushed out. To avoid premature engine wear:

☞ DO NOT clean the filter cartridge.

☞ Replace the filter cartridge when the indicator comes on.

☞ Never reuse a damaged filter cartridge.

☞ Ensure cleanliness when replacing the filter cartridge.

Air filter restriction indicator display B on the filter housing monitors the filter cartridge.

☞ Filter cartridge D must be replaced:

• If you can see red mark C in the display maintenance window.

• After 1500 service hours (or yearly if you use the machine for less than 1500 service hours during one year).

–see Replacing the filter cartridge on page105.

IMPORTANT!

For dusty environments , the air filter is fitted with an extra safety cartridge F. DO NOT clean the safety cartridge. Replace the safety cartridge every third time maintenance work is performed.

IMPORTANT!

Filter cartridges degrade prematurely when you use 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 nonferrousmetal plants.

☞ Replace filter cartridge D and safety cartridge F after 500 service hours

–see Replacing the filter cartridge on page105.

Weekly dust valve functional check

☞ Proceed as follows:

• Squeeze the discharge slot of dust valve E.

• Remove hardened dust by compressing the upper area of the valve.

☞ Clean the discharge slot if necessary.

Replacing the filter cartridge

☞ Replace filter cartridge D as follows:

• Turn off the engine.

• Prevent the machine from rolling away and remove the ignition key –see Parking the machine on page61.

• Open the engine cover.

• Fold bow hooks G on lower housing section H to the outside.

• Remove lower housing section H

• Carefully remove filter cartridge D by using slight turning movements.

• Every third time you replace the filter, carefully remove safety cartridge 114/F by using slight turning movements.

• Make sure all contamination (such as dust) inside the upper and lower housing sections is removed.

• Carefully insert new safety cartridge 114/F into the upper housing section.

• Carefully insert new filter cartridge D into the upper housing section.

• Position lower housing section H (make sure it is properly seated).

• Close both bow hooks G.

☞ After replacing the filter:

• Press button A to reset red mark C (visible in the display maintenance window of indicator B).

V-belt

DANGER!

Only check, re-tension, or replace the V-belt after the engine is turned off –Risk of personal injury.

☞ Turn 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 you use the machine for less than 50 service hours in one day). Re-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:

• Turn off the engine.

• Prevent the machine from rolling away and remove the ignition key –see Parking the machine on page61.

• Open the engine cover.

• 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).

• Re-tension the V-belt if necessary. See below.

Re-tensioning the V-belt

☞ Re-tension the V-belt as follows:

• Turn off the engine.

• Prevent the machine from rolling away and remove the ignition key –see Parking the machine on page61.

• Open the engine cover.

• Slacken attachment screws 3 of alternator 4

• Use a suitable tool to push the alternator in the direction of arrow A until the correct V-belt tension is obtained (fig. 119).

• Keep the alternator in this position, and at the same time tighten attachment screws 3

• Check the V-belt tension (fig. 119) again.

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 set in.

IMPORTANT!

If the hydraulic oil in the level glass is cloudy, this indicates that water or air has penetrated 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 page123.

☞ 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 tank.

☞ 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, with a container. Dispose of drained oil and used filters in accordance with environmental laws. Always contact the authorities or establishments in charge of oil disposal before disposing of biodegradable oil.

Checking the hydraulic oil level

☞ Proceed as follows:

• Park the machine on level ground.

• Retract all hydraulic cylinders.

• Turn off the engine.

• Apply the parking brake.

• Open the engine cover.

• Check the hydraulic oil level in sight glass A. If the oil level is lower than it is in fig. 121/A:

• Fill up the hydraulic oil.

Adding hydraulic oil

IMPORTANT!

Only add hydraulic oil to the hydraulic oil tank if the engine is turned off.

☞ Add oil as follows:

• Park the machine on level ground.

• Retract all hydraulic cylinders.

• Turn off the engine.

• Apply the parking brake.

• Open the engine cover.

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

• Open breather filter B With the filter insert in place:

• Add hydraulic oil until the tank is full.

• Check the hydraulic oil level by using the oil level sight glass (121/A).

• Fill up if necessary and check again.

• Firmly close breather filter B

Monitoring the hydraulic oil reflux filter

Refer to the instrument panel, red indicator 41 monitors reflux pressure and filter, indicator 42 monitors oil temperature.

The filter must be replaced by an authorized dealer:

• The hydraulic oil reflux pressure in the filter is too high and indicator 42 comes on.

• The hydraulic oil operating temperature is too high and indicator 41 comes on.

• After 1500 service hours (or yearly if you use the machine less than 1500 service hours per year).

In cold weather, indicator 41 may come on when you start the engine because of increased oil viscosity. In this case:

☞ Set the engine speed so that indicator 41 turns off.

–see Starting the engine on page45.

Important information about th e use of biodegradable oil

• Only use biodegradable hydraulic fluids that have been approved by Mustang –see Fluids and lubricants on page123. Always contact your Mustang dealer for the use of other products that have not been recommended. In addition, ask the oil supplier for a written guarantee. This guarantee is applicable to damage occurring on the hydraulic components, which can be proved to be due to the hydraulic fluid.

• Only use the same type of biodegradable oil when filling up. A decal stating the oil used is located on the hydraulic oil tank (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 you are running the machine with biodegradable oil, the same oil and filter replacement intervals used for mineral oil are valid –see Maintenance schedule Model ML48 (overview) on page124.

• 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 tank after every 500 service hours (or before the cold season if you have not yet used your machine for 500 service hours). The water content must NOT exceed 0.1% by weight.

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

IMPORTANT!

Achangefrommineraltobiodegradableoilmustbecarriedoutbyan authorizeddealer.

Checking hydraulic pressure lines

Safety instructions

DANGER!

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

Risk of personal injury.

☞ Always consult a doctor immediately, even if the wound appears insignificant, to be sure that serious infections do not set in.

☞ Always follow these instructions:

•Only tighten leaking screwed fittings and hose connections after you have 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 or after-sales staff should immediately repair or replace any leaking or damaged pressure lines.

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

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

Example:

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

Lubrication points

Lubricate all points listed below with lithium-based brand-name grease –see Fluids and lubricants on page123.

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 you use the machine for less than 50 service hours during one week).

The grease nipple is located above the axle tube, on the left side.

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

Lubricating the planetary drive bearing

☞ Lubricate grease nipples B on each planetary drive bearing every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week).

Maintenance

Lubricating the loader unit

Lubricate the following points on the loader unit

☞ Lubricate grease nipple C on the tilt cylinder bearing on the frame with grease every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple D on the loader unit bearing every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple E on the lift cylinder bearing on the frame every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple F on the tilt rod bearing every 10 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple G on the tilt cylinder bearing every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple H on the lift cylinder bearing every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipple I on the tilt lever bearing every 10 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipples K on the quickhitch bearing every 10 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipples L on the tilt lever bearing every 10 service hours (or weekly if you use the machine for less than 50 service hours during one 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.

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 necessary 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/filling up the brake fluid level

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

DANGER!

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

Accident risk.

☞ Check the brake fluid in the tank regularly.

☞ Fill the brake fluid up to the upper edge of the sight glass.

☞ The brake fluid must comply with the SAE specification

–see Fluids and lubricants on page123

☞ Replace brake fluid every two years.

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

• Open tank cover A.

☞ Fill the brake fluid up to the upper edge of the sight glass.