Mustang ML48T All Wheel Steer Loader Operator's Manual 918137 - PDF DOWNLOAD

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ML48T Beginning Serial Number: 342100001

ALL-WHEEL-STEER LOADER

OPERATOR’S MANUAL PART #918137 Revision C - 08/07

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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 Introduction General information .................................................................................................... 3 Designated uses and exemption from liability ............................................................ 5 Identification of warnings and hazards ....................................................................... 6 Machine overview ....................................................................................................... 7 Overview ..................................................................................................................... 8 Fields of application, attachments .............................................................................. 9 Serial number plate locations ................................................................................... 10 Safety decals ............................................................................................................ 12 Safety instructions General safety rules .................................................................................................. 17 Additional safety equipment ...................................................................................... 19 Safety reminders ....................................................................................................... 19 Transporting .............................................................................................................. 20 Moving the machine with a crane ............................................................................. 21 Loading and transporting the machine ..................................................................... 22 Maintenance safety ................................................................................................... 24 Operation Overview of controls ................................................................................................. 33 Cab overview ............................................................................................................ 34 Instrument panel, multifunctional and drive levers: overview ................................... 36 Indicators and warning lights: overview ................................................................... 38 Getting started .......................................................................................................... 40 Starting the engine .................................................................................................... 44 Before driving the machine ....................................................................................... 47 Load stabilizer ........................................................................................................... 53 Backup warning system ............................................................................................ 54 Differential lock ......................................................................................................... 54 Steering system ........................................................................................................ 55 Stopping/parking the machine .................................................................................. 56 Light system .............................................................................................................. 57 Signaling system ....................................................................................................... 59 Cab heating and ventilation ...................................................................................... 60 Windshield washer system ....................................................................................... 62 Operator's seat ......................................................................................................... 63 Doors ........................................................................................................................ 67 Engine cover ............................................................................................................. 68 Other controls ........................................................................................................... 69 Working with the machine ......................................................................................... 70 Load diagram ............................................................................................................ 71 Control valve of the telescopic unit: overview ........................................................... 73 Working with the telescopic unit ............................................................................... 76 Re-installing attachments ......................................................................................... 79 Hose burst valve safety feature ............................................................................... 83 Working with the standard bucket ............................................................................. 84 Working with the pallet forks ..................................................................................... 89 Fitting the pallet forks onto the quickhitch facility ...................................................... 94 Removing the pallet forks from the quickhitch facility ............................................... 94 Adjusting the fork arms ............................................................................................. 95 Troubleshooting Engine trouble .......................................................................................................... 96 Maintenance Introduction ............................................................................................................... 99 Fuel system .............................................................................................................. 99 Engine lubrication system ....................................................................................... 101

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Table of contents Engine and hydraulics cooling system .................................................................... 103 Air filter .................................................................................................................... 104 V-belt ....................................................................................................................... 106 Hydraulic system ..................................................................................................... 107 Checking hydraulic pressure lines .......................................................................... 110 Lubrication work ...................................................................................................... 111 Checking the wear pads ......................................................................................... 112 Maintenance of attachments ................................................................................... 113 Maintenance of the brake system ........................................................................... 113 Tires ........................................................................................................................ 114 Heating .................................................................................................................... 116 Electrical system ..................................................................................................... 117 General maintenance work ..................................................................................... 119 Fluids and lubricants .............................................................................................. 122 Maintenance schedule Model ML48T (overview) ................................................... 124 Maintenance log ...................................................................................................... 127 Maintenance decal .................................................................................................. 130 Specifications Frame ...................................................................................................................... 133 Engine ..................................................................................................................... 133 Power train .............................................................................................................. 134 Axles ....................................................................................................................... 135 Brakes ..................................................................................................................... 135 Steering ................................................................................................................... 136 Work hydraulics ...................................................................................................... 136 Pilot control ............................................................................................................. 137 Telescopic unit ........................................................................................................ 137 Electrical system ..................................................................................................... 138 Tires ........................................................................................................................ 140 Weights ................................................................................................................... 140 Sound levels .......................................................................................................... 140 Vibration ................................................................................................................. 140 Hardware torques ................................................................................................... 141 Dimensions model ML48T ...................................................................................... 142

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918137/CP0807

Introduction

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

Mustang Company 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 Company asks that you read and COMPLETELY understand the contents of this manual and become familiar with your new machine, BEFORE attempting to operate it.

This manual was developed specifically for the machine you have purchased. The information within is for your assistance in preparing, adjusting, maintaining and servicing your machine. More importantly, this manual provides an operating plan for safe and proper use of your machine. Major points of safe operation are detailed in the SAFETY chapter of this manual – see Safety instructions on page 16. 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 Company recommends that this manual be given to the new owner.

If this machine was purchased "used," or if the owner's address has changed, please provide your Mustang dealer or Mustang Company 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 the position of sitting in the operator’s seat, facing forward.

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

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

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

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

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

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

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Introduction

Serial number The serial number A is stamped on the front axle attachment (on the right in driving direction)

A

It is also located on the type decal.

Type decal information Example: Model 342-10 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.

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

Fig. 2:

Type decal

Machine model:

ML48T

Version:

342-10

Serial no.:

342 10 0001

Model year:

2005

Front gross axle weight rating:

8818 lbs. (4000 kg)

Rear gross axle weight rating:

8818 lbs. (4000 kg)

Gross weight rating:

14,330 lbs. (6500 kg)

Output:

59 hp (44 kW)

Other information– see Specifications on page 133.

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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918137/CP0807

Introduction Designated uses and exemption from liability • The machine is intended for: • Moving earth, gravel, coarse gravel or ballast and rubble as well as • Working with the attachments mentioned – see Fields of application, attachments on page 9.

• Every other use and attachment is not designated for this 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, 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 checked or released 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.

• Repair the machine (in accordance with the Operator’s Manual).

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

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

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918137/CP0807

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

1

Eye hook1 for cab

1

2

Rearview mirror

2

3

Handle

3

4

Headlight with turn indicator

5

Tilt ram inside telescopic unit

6

Telescopic unit

7

Front eye hook for tieing down the machine

8

Access

4 5

6

19

7

8

11

2

12 20

13

18

14

17

15

16

1.

Fig. 4:

9

10

9

Door handle

10

Rear eye hook for tieing down the machine

11

Rotating beacon (option)

12

Rear working light

13

Engine cover lock

14

Backup warning system

15

Reflector

16

Tow away facility

17

Brake, rear and turn indicator lights

18

Door arrester

19

Protective FOPS screen

20

Rear wiper

Eye hooks are for removing the cab only, and may not be used for crane-lifting the machine

Machine outside views

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918137/CP0807

Introduction Overview The Model ML48T is a versatile and powerful helper for moving earth, gravel and debris on construction sites and elsewhere. The wide range of attachments allows numerous uses for the machine: as a fork lift, a snow plow, a spreader for grit, salt etc., a sweeper or a tree replanter – see Fields of application, attachments on page 9 for further applications. Equip the machine with the respective safety devices when using it as a lifting gear – see Applications with lifting gear on page 18.

The main components of the machine are: • ROPS certified cab, enclosed version.

• Oil-cooled Deutz four-cylinder in-line diesel engine, 59 hp (44 kW) at 2400 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) (25 mph [40 km/h] option).

• Hydraulic four-wheel power steering with emergency steering feature. The emergency steering feature, located inside the hydraulic system, allows you to steer the machine if you lose hydraulic or motor power.

• 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, whose oil flow is sent to a hydraulic motor flanged on the gearbox. 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 speeds only.

When the machine is in operation, the entire diesel engine output can be transmitted to the gear pump for work hydraulics and steering. This is made possible by a so-called inching valve which 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 telescopic unit 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 constantly monitor the engine and hydraulic oil temperatures, and the coolant temperature and level.

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918137/CP0807

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

IMPORTANT! In order to avoid damage to the machine, only the attachments listed below have been certified for attachment to the machine.

☞ See Use: attachment.

Use: attachment

Possible attachments and material densities.

Description of attachment

Model

Stock number

Use

Standard bucket – normal material

343-10

810136

Loosening, picking up, transporting and loading loose or solid material (material density ≤ p=1.35 t/yd³ [≤ p=1.8 t/m³])

Standard bucket – lightweight material

343-10

810134

Picking up, transporting and loading lightweight material (material density ≤ p=0.98 t/yd³ [≤ p=1.3 t/m³])

Standard bucket – ultra lightweight material

343-10

810137

Picking up, transporting and loading very lightweight material (material density ≤ p=0.65 t/yd³ [≤ p=0.9 t/m³])

Pallet forks1

343-10

810135

Picking up and transporting pallets

1.

Only in connection with load diagram.

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918137/CP0807

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

A

Type decal information Example: Model 342-10

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.

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

Fig. 6:

Type decal

Machine model:

ML48T

Version:

342-10

Serial no.:

342 10 0001

Model year:

2005

Front gross axle weight rating:

8818 lbs. (4000 kg)

Rear gross axle weight rating:

8818 lbs. (4000 kg)

Gross weight rating:

14,330 (6500 kg)

Output:

59 hp (44 kW)

Other information – see Specifications on page 133.

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

Fig. 8:

Cab type decal

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

Example:

Fig. 9:

Deutz F4M 2011

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. 10: 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. 11: Hydraulic motor: type decal

Rear axle number The type decal (arrow) is located on the inside of the axle tube, on the left in driving direction (arrow).

Fig. 12: 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 in driving direction (arrow).

Fig. 13: Front axle: type decal

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918137/CP0807

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

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 21.

Location Cab roof (4x).

Fig. 14: Eye hook decal

Meaning Points for tieing down the machine.

The eye hooks are used for tieing down the machine during loading and transport – see Tieing down the machine on page 23.

Location Fig. 15: Decal for points used for tieing down the machine

On the left and right of the machine frame above the front axle attachment, and on the towing facility at the rear.

Meaning Sound levels produced by the machine.

XX Fig. 16: Decal: sound levels

Printed in U.S.A.

LWA = sound power level.

Other information – see Sound levels on page 140.

Location Rear window.

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918137/CP0807

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

Fig. 17: Danger decal

Meaning The CE mark means that the machine meets the requirements of the Machinery Directive and that the conformity procedure has been carried out. The machine meets all the health and safety requirements of the Machinery Directive.

Location

ce.ai

On the rear window.

Fig. 18: CE mark

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.

100 010 40 15

Fig. 19: Prohibitory decal

10 h

T glich Daily Tous les jours

Meaning Maintenance decal.

Location Inside the cab, on left side of rear window.

50 h I=> 342 10 0001

Fig. 20: Maintenance decal

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918137/CP0807

Introduction Meaning Tire pressure table.

List of authorized types of tires with prescribed tire inflation pressures.

Location

xxxxxx xxxxxx xxxxxx

xxx xxx xxx

xxx xxx xxx

Inside the cab, on left side of front window.

xxx-xx Fig. 21: Tire inflation pressure table

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918137/CP0807

Safety instructions

Safety instructions

Safety instructions Mandatory safety shutdown procedure

Before operating this equipment, read and study the following safety information. In addition, be sure that every individual who operates or works with this equipment is familiar with these safety precautions.

Before leaving the machine: • Lower the working equipment to the ground and support it securely.

• Reduce throttle and turn off the engine.

• Lock out controls by raising right-hand control console.

• Remove the ignition key and take it with you.

Unauthorized modifications

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.

Attachment precautions

Optional kits are available through your dealer. Because Mustang cannot anticipate, identify and test all of the attachments that owners may wish to install on their machines, please contact Mustang for information on approval of attachments, and their compatibility with optional kits.

Operational safety

Control the machine cautiously and gradually until you are fully familiar with all the controls and handling.

Avoid high-voltage lines. Serious injury or death can result from contact or proximity to high-voltage electric lines. The bucket or boom 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 line and atmospheric conditions, strong current shocks can occur if the boom or bucket is closer than 10’ (3 m) to the power line. Very high voltage and rainy weather can further increase the safe operating distance.

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

Before starting to dig, contact authorities. Contact Diggers Hotline One-Call Information at 1-888-258-0808.

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

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

Use care on loose ground. Carrying heavy loads over 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 temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground. Stay away from ditches, overhangs and other weak support surfaces.

Never rely on jacks or other inadequate supports when maintenance work is being done.

Use solid support blocking.

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918137/CP0807

Safety instructions Overhangs are hazardous. 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.

Sloping terrain requires caution. Dig evenly around the work site whenever possible, trying to gradually level any existing slope. If it is not possible to level the area or avoid working on a slope, reduce the cycling rate and size of the load.

On sloping surfaces, use caution when positioning the machine prior to starting a work cycle. Stay alert for instability situations. Lifting the bucket too high while the boom is turned uphill can also be hazardous.

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

Avoid loading over the cab of a truck, even if the driver is in a safe spot, because someone else could have gone inside.

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

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

Operate ONLY while seated at operator’s station. Never reach in through a window to work a control. Do not try to operate the machine unless you’re in the operator’s position, seated at the controls. Stay alert and focused on your work at all times.

Use a signal person if you cannot see the entire work area clearly.

Replace damaged safety decals and lost or damaged Operator’s Manuals.

Do not let anyone operate the machine unless they have been fully trained in safety and in operation of the machine.

DO NOT raise or lower a loaded bucket suddenly. Abrupt movements under load can cause serious instability.

Before starting the engine

Do a safety check: • Walk around the machine before getting in the cab. Look for leaking fluids, loose fasteners, misaligned assemblies and other possible equipment hazards.

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

• The lighting system must be checked for proper working condition before working in darkness.

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

• All equipment covers and safety guards must be in place while the machine is being operated, to protect against injury.

• Look around the work site area for potential hazards, and for people or property that could be at risk while operation is in progress.

• 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 controls in the cab.

• Check gauges and displays for normal operation prior to and after starting the engine.

Listen for unusual sounds and remain alert for other potentially hazardous conditions.

• Never use ether starting aids. Glow plugs are used for cold weather starting. Glow plugs can cause ether or other starting fluid to detonate, causing injury.

• Before starting or moving the machine, warn any personnel in the area.

Printed in U.S.A.

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918137/CP0807

Safety instructions General safety rules Only trained and authorized personnel, with a full awareness of safe procedures, may be allowed to operate or perform maintenance or service on the machine.

All personnel at the work site should be aware of assigned individual responsibilities. Communication and hand signals used should be understood by everyone.

Terrain and soil conditions at the job 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.

Unless necessary for servicing the engine, the engine hood must not be opened while the engine is running.

Engine exhaust gases can cause unconsciousness and fatalities. Ensure adequate ventilation before starting the engine in an enclosed area.

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

Use a signal person in high traffic areas and whenever the operator’s view is not clear, such as when traveling in reverse.

Make sure that no one comes inside the working area of the machine.

Anyone standing near the machine is at risk of being caught between moving parts of the machine.

Never allow anyone to ride on any part of the machine or attachment, including any part of the boom or operator’s cab.

Fire hazards

The machine has several components that operate at high temperature 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.

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, poses a fire hazard.

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

The machine must be parked with controls, lights and switches turned off. The engine must be turned off before refueling or service checks are performed.

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.

Make sure that the static line 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.

Jump-starting or charging battery

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

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

DANGER! Explosion Hazard – Electrical spark can cause battery to explode.

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.

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918137/CP0807

Safety instructions Disconnect the negative cable first when removing the jumper cables. For instructions refer – see Battery on page 117.

Travel precautions

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

IMPORTANT! Do not change selected travel mode (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 10º.

Operate carefully on snow and ice and in very cold temperatures.

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.

Parking the machine

When shutting down the machine for the day, plan ahead so that the machine will be on a firm, level surface away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff. If parking on an incline is unavoidable, block the wheels to prevent movement. Lower the bucket to the ground. There should be no possibility of unintended or accidental machine movement.

After the machine has been parked properly, shut down the engine and cycle all controls to release any remaining hydraulic system pressure. Be sure all switches and operating controls are in the OFF position and the right-hand console is raised, locking out the hydraulic functions.

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 boom 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 (e.g., slings, chains).

• Always wear protective gloves when working with lifting attachments.

Printed in U.S.A.

18

918137/CP0807

Safety instructions 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 relocating fasteners. Any serious impact or damage to the system requires a complete integrity re-evaluation, and the 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 – see Fire extinguisher (option) on page 13.

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.

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 (at least 1 in 100) 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, jewelry 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 boom 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.

Printed in U.S.A.

19

918137/CP0807

Safety instructions 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.

Towing the machine • The machine may only be towed using a tow bar or cable and towing facilities (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 diesel engine is off.

Remember this when towing the machine.

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

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

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

C

☞ Set the drive to neutral

B

– see Stopping/parking the machine on page 56.

☞ Apply the parking brake. ☞ Turn off the engine. ☞ Attach an adequately sized tow bar to the towing facilities. ☞ Switch over the HP pressure relief valves A on the hydraulic pump. To do this:

A

• Release hexagon lock nuts B on both HP valves A.

A

B C

Fig. 22: Hydraulic pump when towing away

• Screw in hexagon socket head screws C on both HP valves A until they are flush with lock nuts B. • Secure hexagon socket head screws C on both HP valves A with lock nuts B.

☞ Release the parking brake. ☞ Run the engine at idling speed when towing the machine.

Follow these procedures before taking the machine back into service:

☞ Change over the HP valves.

• Unscrew hexagon socket screws C. • Secure them with lock nuts B. Printed in U.S.A.

20

918137/CP0807

Safety instructions Moving the machine with a crane Safety instructions

• The crane and the lifting gear must have sufficient capacity – see Specifications on page 133.

• 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 allow anyone to stay in the machine. ☞ The person giving the instructions to the crane operator must be within sight or sound of the crane operator.

☞ Make sure that the lifting capacity 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. ☞ Move the machine with a crane as follows: • Install and safely lock the standard bucket – see Re-installing attachments on page 79.

• Empty the standard bucket • Set the drive to neutral – see Select driving direction on page 51.

34101b330_01.iso

• Tilt in the standard bucket and lower it into the transport position – see Before driving the machine on page 47.

• Turn off the engine • Apply the parking brake – see Parking brake on page 50.

• Remove the ignition key.

• Do not allow anyone to stay in the cab.

• Close the doors and the engine cover.

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

Fig. 23: Crane handling

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

• Carefully raise the machine

Printed in U.S.A.

21

918137/CP0807

Safety instructions Loading and transporting the machine Safety instructions

• The transport vehicle must support the height and weight of the machine – see Specifications on page 133.

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

• Secure the machine to prevent unintentional movement.

Loading the machine DANGER! The machine must be loaded and transported properly –

Accident risk. ☞ – see Safety instructions on page 40. ☞ Follow these instructions to load the machine onto the transport vehicle: • Secure the transport vehicle with chocks to prevent it from rolling.

• Place the access ramps at the smallest possible angle.

IMPORTANT! 30˚ 30864brampe.eps

Do not exceed an angle of 30°.

Fig. 24: Access ramps

• Use access ramps with an antiskid surface only.

• Make sure that the loading area is clear and access to it is not obstructed.

• Make sure that the access ramps and the wheels of the machine are free of oil, grease and ice.

• Start the engine of the machine.

• Raise the bucket so that it does not touch the access ramps.

• Carefully drive the loader onto the middle of the transport vehicle.

• Set the drive to neutral – see Select driving direction on page 51.

• Lower the bucket onto the loading area.

• Turn off the engine.

• Apply the parking brake – see Parking brake on page 50.

• Remove the ignition key.

• DO NOT allow anyone to stay in the cab.

• Close the doors and engine cover.

Printed in U.S.A.

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918137/CP0807

Safety instructions Tieing down the machine DANGER! The machine must be loaded and transported properly –

Accident risk. ☞ – see Safety instructions on page 40.

34001b330_02.eps

• Be sure that the authorized maximum height is not exceeded – see Specifications on page 133.

• Secure all tires of the wheel loader with chocks in front of and behind each wheel.

• Firmly tie the machine onto the platform by using the eye hooks and belts or chains – see Machine overview on page 7.

34001b330_17.eps Fig. 25: Tieing down the loader

Attachments

• Before transporting the machine through heavy rain, seal the muffler with a cap or adhesive tape.

• Be sure that the operator of the transport vehicle knows the overall height, width and weight of the vehicle (including the machine) before leaving.

• Coupling attachments requires special care.

• Before fitting attachments to the telescopic unit, secure the control lever of the hydraulic valve against unintentional movement.

• Attachments and counterweights affect handling, steering, and brake capability of the machine.

• Fit the attachments with the required devices only.

• Before uncoupling or coupling hydraulic lines (hydraulic quick couplers): • Turn off the engine.

• Move the control lever(s) of the hydraulic valve back and forth two times to relieve the hydraulic oil pressure in the hydraulic system.

• Secure the attachments against unintentional movement.

• Only operate the machine if all brake, light, hydraulic connections, and protective accessories are installed and functional.

• If optional equipment is installed, all required lights, indicators, etc., must be installed and functional.

• Mount the attachments only after stopping the engine.

• When driving or working with machines that have a quickhitch facility, make sure that the attachment is safely locked in the quickhitch facility. The lock pin must be visible on both sides of the holes on the attachment. Check before starting work.

CAUTION! When mounting attachments to the machine, there is a risk of personal injury due to crushing and shearing. Make sure nobody is between the machine and attachment, after first securing the machine and attachment against movement.

Printed in U.S.A.

23

918137/CP0807

Safety instructions Maintenance safety ☞ Use proper tools • While working on the machine, never use inadequate 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.

☞ 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.

Printed in U.S.A.

24

918137/CP0807

Safety instructions • 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.

Printed in U.S.A.

25

918137/CP0807

Safety instructions Safety instructions for maintenance • Remove the ignition key before performing any service, maintenance, or repair work.

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

• 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.).

• Carry out service, maintenance and repair work only if the: • 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.

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

CAUTION! 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 up 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 afterward – 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 explosions.

Service and maintenance work on ROPS superstructures (ROPS bar)

Printed in U.S.A.

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

26

918137/CP0807

Safety instructions Safety instructions for specific hazards Electric energy

• Only use original 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 carried out 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 rectified immediately.

• Follow the operating voltage of the machine/attachments.

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

• 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.

• Carry out welding, flame-cutting and grinding work on the machine only if this has been authorized. Before carrying out welding, flame-cutting and grinding work, 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. Splashed oil may cause injury and fire.

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

• Hydraulic lines must be laid 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.

Sound

• Maintain the muffler and exhaust system in good condition.

• Wear ear protectors if necessary.

Oil, grease and other chemical substances

Printed in U.S.A.

• When handling oil, grease and other chemical substances (e.g., battery electrolyte – sulphuric acid), follow the product-related safety requirements (safety data sheet) carefully to prevent burning or scalding yourself or other persons.

27

918137/CP0807

Safety instructions 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.

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

Printed in U.S.A.

28

918137/CP0807

Safety instructions Notes:

Printed in U.S.A.

29

918137/CP0807

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

Pre-Delivery Checklist

_______________________________________________ Dealership Name

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: R

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

_______________________________________________

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

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:

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, and on page 3.

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

CHECK THAT:

R

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

R

The 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

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 the Mustang Company.

R

Drive controls and boom/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).

_______________________________________________

R

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

_______________________________________________

Date Delivered

RETAIN FOR CUSTOMER’S RECORDS

Printed in U.S.A.

30

918137/CP0807

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 Name ________________________________________________ Date Checklist Filled Out

CHECK THAT:

Remove dealer’s file copy at perforation.

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.

________________________________________________ Model & Serial Number

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.

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.

R

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

EXPLAIN:

R

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

R

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

R

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

R

R

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

The 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

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 the Mustang Company.

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

CHECK THAT: R

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

R

Drive controls are properly adjusted for correct neutral position.

R

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

R

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

Delivery Checklist

________________________________________________ Customer’s Signature ________________________________________________ Date Delivered

RETAIN FOR DEALER’S RECORDS

Printed in U.S.A.

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918137/CP0807

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

Printed in U.S.A.

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918137/CP0807

Operation

Operation

Operation Overview 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.

The identification of the control elements with a combination of digits, or a combination of digits and letters, e.g. 40/18 or 40/A, means: fig. no. 40/control element no. 18 or position A in fig. no. 40.

You can unfold pages (34 and/or 36) for a better overview.

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 carry out the activity described. ➥ Description of the effects or results of an activity. n. s. = not shown.

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

Printed in U.S.A.

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918137/CP0807

Cab overview: see overleaf

Operation 1

2

Cab overview

3

Pos. 5

34

4

5 3

Instrument panel

4 5

Steering electronics (25 mph [40 km/h] high speed option) ....................................................................................................................... 55 Air vent – front window

6 7

Fuse box (right side)................................................................................................................................................................................. 138 Air vent – side window

8

Accelerator pedal ....................................................................................................................................................................................... 48

9

Door locks .................................................................................................................................................................................................. 67

10

Control lever – telescopic unit .................................................................................................................................................................... 73

8

11 12

Arrester lock – cab door ............................................................................................................................................................................. 67 Control lever base

13

Parking Brake lever .................................................................................................................................................................................... 50

9

14 15

Preheating/start switch ............................................................................................................................................................................... 45 Switch panel in control lever base

16 17

Control lever lock 10 for road travel........................................................................................................................................................... 47 Air vent – rear window

18 19

Bracket – cab door arrester........................................................................................................................................................................ 67 Storage pocket for Operator’s Manual

20 21 22

Tank – washer system ............................................................................................................................................................................... 62 Side console Prepared installation for radio (option)

23

Lever – weight adjustment ......................................................................................................................................................................... 63

24

Seat belt ..................................................................................................................................................................................................... 65

25 26

Lever – horizontal adjustment .................................................................................................................................................................... 64 Fixture – first-aid kit

27 28

Operator's seat........................................................................................................................................................................................... 63 Air vent – leg room

29

Lever – backrest adjustment ...................................................................................................................................................................... 64

6 7 7

9 km/h

30 29

0 I

10 28 11

11 27

12

26 13 25 24

14

0

23

Interior light................................................................................................................................................................................................. 58 Sun visor

Cab

32

31

For more information see page

Roof console 1 2

33

Description

15

30

Hydrostatic steering.................................................................................................................................................................................... 55

31

Service brake pedal (hydrostatic)/inching .................................................................................................................................................. 49

32

Brake fluid tank......................................................................................................................................................................................... 113

33

Multifunctional lever....................................................................................................................................................................... 57, 59, 62

34

Fuse box (left) .......................................................................................................................................................................................... 138

22 16 21 17

17

34200b00_00.iso

18

20

19

18

Fig. 26: Cab: overview

Printed in U.S.A.

34

918137/CP0807

Operation

Cab overview: see overleaf

Printed in U.S.A.

Cab overview: see overleaf

35

918137/CP0807

Operation Instrument panel, multifunctional and drive levers: overview 35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

Pos.

53

55

56

57

58

59

60

61

62

63

64

65

66

67

Fig. 27: Instrument panel: overview

68

69

70

71

71

72

73

87 72

74

73

75

76 76

Fig. 28: Multifunctional lever

0

84 14 85

81

77 1.

78

82

For more information see page

Instrument panel

km/h

54

Description

35

Rocker switch – quickhitch lock ................................................................................................................................................................. 80

36

Rocker switch – rotating beacon (option)................................................................................................................................................... 59

37

Rocker switch – front working light (option) ............................................................................................................................................... 58

38

Indicator (green) – right/left turn indicator for rear attachments ................................................................................................................. 38

39 40

Indicator (red) – steering synchronization (25 mph [40 km/h] high speed option) ..................................................................................... 55 Switch – hazard warning system

41

Pressure indicator – hydraulic oil filter ....................................................................................................................................................... 39

42

Temperature indicator – hydraulic oil ......................................................................................................................................................... 39

43

Indicator (red) – alternator charge function ................................................................................................................................................ 38

44

Indicator (red) – parking brake ................................................................................................................................................................... 49

45

Indicator (red) – diesel engine temperature ............................................................................................................................................... 38

46 47

Indicator (red) – engine oil pressure .......................................................................................................................................................... 38 Socket/cigarette lighter

48

Indicator (green) – front-axle steering (25 mph [40 km/h] high speed option) ........................................................................................... 39

49

Indicator (green) – 4-wheel steering (25 mph [40 km/h] high speed option).............................................................................................. 39

50

Indicator (green) – forwards driving direction............................................................................................................................................. 39

51

Rocker switch – front socket for electrically operated attachments (option) .............................................................................................. 80

52

Tip switch – steering synchronization ........................................................................................................................................................ 55

53

Rocker switch with lock – four wheel/front axle steering (25 mph [40 km/h] high speed option) ............................................................... 55

54

Rocker switch with lock – 3rd control circuit............................................................................................................................................... 80

55

Rocker switch – lights ................................................................................................................................................................................ 57

56

Rocker switch – rear working light ............................................................................................................................................................. 58

57

Indicator (yellow) – hose burst valve 1 (option) .......................................................................................................................................... 83

58

Indicator (green) – right/left turn indicator .................................................................................................................................................. 59

59

Indicator (yellow) – cold starter .................................................................................................................................................................. 38

60 61

Indicator (blue) – high beam ...................................................................................................................................................................... 57 Fuel level indicator

62 63

Indicator (red) – 3rd control circuit, continuous operation .......................................................................................................................... 75 Speedometer – high speed (option)

64

Indicator (green) – reverse driving direction......................................................................................................................................... 39, 51

65

Rocker switch – load stabilizer................................................................................................................................................................... 53

66

Rocker switch – rear wiper with tip switch for wiper water ......................................................................................................................... 62

67

Rocker switch – high speed (25 mph [40 km/h] high speed option)........................................................................................................... 52

Hose burst valve is not functional with the load stabilizer turned on (indicator comes on)

79

86 83

80 16

Fig. 29: Switch panel for heating

Fig. 30: Control lever base

Printed in U.S.A.

36

918137/CP0807

Operation

Pos.

Operation

Description

For more information see page

Multifunctional lever 68 69 70

Tip switch – horn ...................................................................................................................................................................................... 59 Rotary switch and tip switch – front wiper, washer pump .......................................................................................................................... 62 Lever – turn indicator, high beam, horn ..................................................................................................................................................... 57 Control lever

71

Toggle switch – drive range selection 1 ..................................................................................................................................................... 51

72

Tip switch – unlock 3rd control circuit (electric operation).......................................................................................................................... 74

73

Tip switch – lock 3rd control circuit (electric operation).............................................................................................................................. 74

74

Tip switch – extend telescopic unit............................................................................................................................................................. 76

75

Tip switch – retract telescopic unit ............................................................................................................................................................. 77

76

Tip switch – neutral drive range 2............................................................................................................................................................... 51

Control lever console 77

Rocker switch – air conditioning (option)

78

Rocker switch – high flow control circuit (option) ....................................................................................................................................... 82

79 80 81 82

Rocker switch – 3rd control circuit for continuous operation (option)......................................................................................................... 74 Lock – tilt cylinder (option) Not assigned Not assigned

83

Rotary switch – auxiliary heating (option) .................................................................................................................................................. 61

Left side console

1.

2.

84

Rotary switch – heater fan ......................................................................................................................................................................... 60

85

Rotary switch – heater fan temperature regulation .................................................................................................................................... 60

86 87

Rotary switch – fresh air/recirculated air .................................................................................................................................................... 60

Not assigned

Joystick can also be equipped with switch for selection of driving direction Tip switch not fitted if joystick is equipped with switch (neutral position in switch) for selection of driving direction

Printed in U.S.A.

37

918137/CP0807

Operation

Operation

Indicators and warning lights: overview Unfold page 34 for a better overview.

48 Indicator (red) – engine oil pressure Comes on if the engine oil pressure is too low. In this case: 48

☞ Stop the machine. ☞ Turn off the engine immediately and check the oil level (➠ page 101).

The indicator comes on when the ignition is turned on and turns off as soon as the engine runs.

43 Temperature indicator – engine Indicates the engine oil temperature detected by a sensor.

NOTE:

43

The engine oil temperature must range from 80 – 248°F (80 – 120°C). The maximum permissible engine oil temperature is 266°F (130°C) (red section).

46 Indicator (red) – alternator charge function The indicator comes on when the ignition is turned on and turns off as soon as the engine runs.

46

The V-belt for the alternator, or the charging circuit of the alternator is faulty if the indicator comes on with the engine running. The battery is not charged anymore (➠ page 106).

45 Indicator (yellow) – air filter Indicates air filter contamination. In this case:

45

Have the air filter replaced by an authorized dealer 66 Indicator (green) – right/left turn indicator on rear attachment Flashes repeatedly when turn indicator 27/34 is used,

66

and if there is an electric connection to a front or rear attachment.

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

62

61 Indicator (yellow) – cold starter Comes on when the key in start switch 27/14 is in position 2 preheating.

61

A glow plug preheats the air in the combustion chamber of the engine when the key is in position 2.

47 Indicator (red) – parking brake

47

Printed in U.S.A.

P

Comes on when parking brake lever 28/13 is applied.

The electric interlock prevents moving the machine with the parking brake applied.

38

918137/CP0807

Operation 49 Hydraulic oil temperature indicator Comes on if hydraulic oil temperature exceeds 203°F (95°C).

49

IMPORTANT! Risk of hydraulic damage as soon as temperature indicator 49 comes on.

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

• Move control lever 27/10 of the telescopic unit to neutral.

• Select neutral by using tip switch 76.

• Run the engine at increased speeds until indicator 49 turns off.

44 Indicator (red) – hydraulic oil filter Indicates too high of pressure in the hydraulic reflux line to the tank. In this case: 44

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

60 Indicator (green) – right/left turn indicator Flashes repeatedly when turn indicator 27/34 is used.

60

59 Indicator (yellow) – hose burst valve (option) Indicates that the hose burst valve is turned on. This avoids lowering or dumping out the telescopic unit without any resistance

59

➥ – see Hose burst valve safety feature on page 83.

41 Indicator (red) – steering synchronization Indicates that the wheels on both axles are aligned

41

➥ – see Steering synchronization (with 25 mph [40 km/h] high speed) on page 55.

51 Indicator (green) – 4-wheel steering Indicates that four wheel steering is turned on

51

➥ – see Changing steering mode (with high speed option) on page 56.

69 Indicator (green) – front-axle steering (option) Indicates that front axle steering is turned on

69

➥ – see Changing steering mode (with high speed option) on page 56.

52 and 68 indicator (green) – driving direction

68

Printed in U.S.A.

52

Indicates forward/reverse driving direction

➥ – see Select drive range on page 51.

39

918137/CP0807

Operation Getting started Safety instructions

• Never use the controls or cables as handles.

• Never climb onto or jump off a moving machine.

• Refer to the load diagrams for the telescopic unit pallet forks.

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 Start-up checklist on page 41.

Running-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 high speeds for extended periods of time.

• Increase the load gradually while varying the engine speed.

• Follow the maintenance schedule – see Maintenance schedule Model ML48T (overview) on page 124.

Printed in U.S.A.

40

918137/CP0807

Operation Start-up checklist

Use the checklists below to help you check and monitor the machine before, during and after operation.

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

No. Question 1

Enough fuel in the tank? (➠ 99)

2

Engine oil level OK? (➠ 102)

3

Oil level in hydraulic tank OK? (➠ 108)

4

Water level in washer tank OK? (➠ 62)

5

V-belt condition and tension checked? (➠ 106)

6

Telescopic unit lubricated? (➠ 112)

7

Brake system (including parking brake) OK? (➠ 49)

8

Tire condition and inflation pressure OK? (➠ 114, 140)

9

Wheel nuts safely tightened (especially after a wheel change)? (➠ 115, 141)

10

Lights, signals, indicators, warning lights and indicators OK? (➠ 57, 59, 38)

11 Windows, mirrors, lights and steps clean?

12 Is the attachment on the telescopic unit safely locked? (➠ 79) 13 Is the engine cover safely locked? (➠ 68) 14

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

15 Seat position and rearview mirror correctly adjusted? (➠ 44) 16 Seat belt fastened? (➠ 65)

Printed in U.S.A.

41

918137/CP0807

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? (➠ 38)

2

Braking effect sufficient? (➠ 49)

3

Temperature indicator for engine coolant in normal range? (➠ 38)

4

Steering system working properly? (➠ 48)

5

Is anyone hazardously close to the machine? (➠ 17, 47)

6

Safe load indicator tested and OK?

7

3rd control circuit locked? (➠ 74, 80)

When driving on public roads:

Parking checklist

8

Telescopic unit completely retracted?

9

Bucket and attachments in transport position? (➠ 47)

10

Control lever for lift and tilt hydraulics of the telescopic unit locked with the lock lever? (➠ 47)

Complete the checklist below when parking the machine: ✔

No. Question When parking: 1

Attachments on the telescopic unit lowered to the ground? (➠ 56, 73)

2

Parking brake applied? (➠ 50)

3

Machine cab locked, especially if the machine cannot be supervised? (➠ 67)

When parking on public roads: 4

Machine adequately secured? (➠ 56)

When parking on uphill and downhill gradients: 5

Printed in U.S.A.

Machine additionally secured with chocks under the wheels to prevent it from rolling away? (➠ 56)

42

918137/CP0807

Operation Notes:

Printed in U.S.A.

43

918137/CP0807

Operation

Operation

Starting the engine Before starting the engine

0 ☞ Complete the Start-up checklist

– see Start-up checklist on page 41.

☞ 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 (27/13) is applied.

– The right-hand control lever base is folded down.

– Control lever (27/10) for the telescopic unit is in neutral.

General

• The engine will not start unless the parking brake is applied to the last notch

➥ – see Parking brake on page 50.

• The starter cannot be operated if the engine is already running (start repeat interlock).

• Do not run the starter for more than 10 seconds.

• Wait for about one minute to let the battery recover before trying again.

NOTE: The engine cannot be started by towing the machine, because there is no driving connection between the engine and gearbox when the engine is off.

Printed in U.S.A.

44

918137/CP0807

Operation Starting the engine

0

1

After completing the instructions – see Starting the engine on page 44:

2

☞ Insert the ignition key in preheating/start switch 31/14. ☞ Turn the ignition key to position “1”. ☞ Check that the following indicators come on:

3

• • • •

14 Fig. 31: Preheating/start switch

43 59

44

46

Indicator 46 for engine oil pressure.

Indicator 43 for the alternator charge function.

Indicator 59 for the cold starter.

Indicator 44 if the parking brake is applied.

☞ Replace defective indicators immediately. ☞ Turn the ignition key to position “2” and hold it in this position for about 5 seconds. ➥ The intake air is preheated. ➥ Indicator 59 comes on. ☞ Press accelerator pedal 27/8 to about 25% of its maximum power. ☞ Turn the ignition key to position “3” and hold it in this position until the engine starts. ☞ Release the ignition key.

Starting the engine at low temperatures

Fig. 32: Indicators

☞ Turn the ignition key to position “2” hold it in this position for about 15 seconds. ☞ Press accelerator pedal 27/8 all the way down. ☞ Turn the ignition key to position “3” and hold it in this position until the engine starts. ☞ Release the ignition key.

After the engine has started

☞ Release accelerator pedal 27/8. ☞ Check that the following indicators have gone out: • Indicator 43.

• Indicator 46.

☞ Let the engine warm up. ☞ Increase the engine speed slowly. ☞ Do not run the engine at full load until it has reached its operating temperature.

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

Printed in U.S.A.

45

918137/CP0807

Operation Jump-starting the engine

Safety instructions DANGER! Never jump-start the engine if the battery of the machine is frozen, because there is a risk of explosion. The Model ML48T must not touch the jump-starting machine because when both machines are connected with jump leads, there is a risk of sparking.

• The external power source must deliver 12-V; higher supply voltages will damage the electrical systems of both machines.

• Use only 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

☞ Let the engine of the jump-starting machine run. ☞ First connect one end of the red jump lead (+) to the + terminal of the dead battery, then connect the other end to the + terminal of the starting battery.

Dead battery

12 V

☞ Connect one end of the black jump lead (–) to the – terminal of the starting battery.

Connect the other end of the black jump lead (–) 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.

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

12 V Starting battery

After the engine has started:

☞ With the engine running, disconnect both jump leads in exactly the reverse order (first

remove the – terminal, then the + terminal) – this prevents sparking near the battery.

Fig. 34: Starting aid with jump leads 34001b710_05.eps

Printed in U.S.A.

46

918137/CP0807

Operation Before driving the machine Special instructions for public roads

• Follow these instructions – see Use: attachment on page 9.

IMPORTANT!

A

When driving on public roads, hitch the bucket onto the inside transport hooks.

To do this:

☞ Lower the bucket to the ground. ☞ Use the inside transport hooks A to mount and safely lock the bucket onto the quickhitch facility

– see Re-installing attachments on page 79.

☞ Adjust the bucket to transport position. To do this:

B

• Fully retract the telescopic unit B. • Raise the telescopic unit until red marks C on the lift frame and the bulkhead are aligned.

IMPORTANT! DO NOT tilt in or dump out the bucket as you pick it up.

200 mm

☞ Align the bucket parallel to the ground in transport position.

C

IMPORTANT! With both marks C aligned, ground clearance for transport in connection with the standard bucket and standard tires is about 8” (200 mm).

Fig. 35: Transport position

Control lever lock (joystick) The lock lever for locking the control lever is located on the console of the control lever base.

Locking the lock lever:

☞ Push lock lever 16 forward A ➥ The control valve is cut off from the hydraulic oil circuit.

Opening the lock lever: A

10 B

16

☞ Push 16 rearward B. ☞ The control valve is connected with the hydraulic oil circuit. ☞ High speed (option): Press rocker switch 28/70 for the load stabilizer ➥ – see Load stabilizer on page 53.

Fig. 36: Control lever lock

Printed in U.S.A.

47

918137/CP0807

Operation Checking the steering system

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

The power steering system is only operational when the engine is running. The machine can still be steered if the diesel engine or the pump drive fails because of the emergency steering feature.

WARNING! 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

To synchronize the wheels – see Steering synchronization (with 25 mph [40 km/h] high speed) on page 55.

Accelerator pedal

Accelerator pedal 27/8 controls the drive speed as follows: • Press accelerator pedal 27/8 down • Release accelerator pedal 27/8 slowly

➥ Drive speed is increased ➥ Drive speed is reduced

• Release accelerator pedal 27/8 fully ➥ Hydrostatic braking NOTE: Speed depends on the drive range selected with rocker switch 41/72.

Printed in U.S.A.

48

918137/CP0807

Operation Service brake WARNING! The rear brake lights do not come on when you: • Brake by applying the parking brake.

• Braking hydrostatically with the drive.

☞ Only pressing brake/inching pedal 27/32 causes the brake lights to come on.

Dirt accumulation in the area of the brake pedal can result in brake malfunctions –

Accident risk. ☞ Always keep brake/inching pedal 27/32 clean. ☞ Before driving the machine, press brake/inching pedal 27/32 down and check: • For resistance after pressing the pedal down to about 50% of its maximum thrust.

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

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

WARNING! Pressing brake/inching pedal 27/32 down slightly causes the inching valve to respond; the inching valve does NOT effectively brake the machine –

Accident risk. ☞ Press brake/inching pedal 27/32 down to its maximum power.

Brake/inching pedal

Function • To brake the machine regardless of the setting of toggle switch 32/71 and accelerator pedal 27/8.

• 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 telescopic unit rapidly.

Braking

☞ Press brake/inching pedal 27/32 down with force.

Inching

☞ Press brake/inching pedal 27/32 down slightly.

Printed in U.S.A.

49

918137/CP0807

Operation Parking brake NOTE: A starting interlock prevents the machine from starting with the parking brake applied.

You cannot select the driving direction by using toggle switch 32/57 unless you completely release parking brake 13.

Applying the parking brake automatically cancels the selection of forward/ reverse driving direction and activates neutral.

Function • Prevents the machine from rolling away.

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

WARNING!

B

Use parking brake 37/B instead of the service brake in an emergency only, i.e. in case of service brake breakdown. The brake lights do not light up, and the machine brakes abruptly –

Accident risk. ☞ In normal operation only use brake/inching pedal 27/32 as a service brake.

Fig. 37: Parking Brake

Prevent rolling away A B

☞ Pull lever 38/B up into the top notch. ➥ Indicator 28/47 comes on. ➥ The engine can be started. ➥ Forward/reverse driving direction is automatically cancelled and neutral activated.

Release the parking brake

Fig. 38: Applying and releasing the parking brake

☞ Pull lever 38/B up slightly. ☞ Press button 38/A. ☞ Move lever 38/B all the way down. ➥ Indicator 28/47 turns off.

NOTE: The machine can be moved only after releasing parking brake 27/13 completely.

After starting the engine:

☞ Release parking brake 27/13. ☞ Select the driving direction with toggle switch 26/76 (32/84) in the control lever. ➥ Indicator 28/52 comes on. ☞ Gradually press down accelerator pedal 27/8. ➥ Machine moves off. ☞ Test the brakes at low speed.

Printed in U.S.A.

50

918137/CP0807

Operation Select driving direction CAUTION!

F

Changing direction at high speed and full throttle causes the machine to brake immediately.

71

☞ Slow the machine to walking pace before changing direction.

R

☞ Reduce engine speed: Remove your foot from accelerator pedal 27/8. ☞ Slow the machine to walking pace. ☞ Select the new driving direction by using toggle switch 71 as follows:

76

Function 52

68

Operation ☞ Press toggle switch 71 forward F. ☞ Press toggle switch 71 rearward R. ☞ Press tip switch 81 (if equipped with switch 71 without neutral position).

Forward Reverse Neutral

Fig. 39: Select driving direction

Effect ➥ Indicator 52 comes on.

➥ Indicator 68 comes on. ➥ Indicators 52/68 turn off.

Select drive range The machine has two (A/B) drive ranges.

☞ Set the driving direction to neutral by using tip switch 76. ☞ Select the required drive range by using rocker switch 67. To do this:

76

• Press rocker switch B.

➥2nd drive range selected.

• Press rocker switch A.

➥1st drive range selected.

Drive speed without high speed Symbol

A

67

B

Meaning

Recommended

Drive range A = 0 – 3.2 mph (0 – 5.1 km/h).

Specially 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).

Drive range B = 0 – 12.4 mph For long-haul travel.

(0 – 20 km/h).

Fig. 40: Select drive range

Drive speed with high speed (option) Symbol

Printed in U.S.A.

Meaning

Recommended

Drive range A = 0 – 3.2 mph (0 – 5.1 km/h).

Specially 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) however allowing for speeds above 3 mph (5 km/h).

Drive range B = 0 – 25 mph (0 – 40 km/h).

For long-haul travel.

51

918137/CP0807

Operation Selecting drive range, high speed (option)

IMPORTANT! Turning on front axle steering automatically selects high speed 12.4 – 25 mph (20 – 40 km/h).

71

69

51

☞ Press lock A of rocker switch 53 in the direction of the arrow and at the same time press rocker switch down (OFF).

OFF A

➥ Indicator 69 on the instrument panel comes on.

53

☞ Select the required drive range by using rocker switch 67. ☞ Select the required driving direction by using toggle switch 71 (on the joystick).

Turning off high speed

ON

CAUTION! 67

Changing over from front-axle to four-wheel steering at high speed and high engine speeds is hazardous –

Accident risk.

Fig. 41: Rocker switch – high speed (option)

☞ Slow down the machine to 12.4 mph (20 km/h). ☞ Press rocker switch 53 down (ON). ➥ Indicator 51 on the instrument panel comes on. ☞ Select the required drive range by using rocker switch 67. ☞ Select the required driving direction by using toggle switch 71 on the joystick.

Printed in U.S.A.

52

918137/CP0807

Operation Load stabilizer The load stabilizer protects the machine against unstable oscillating movements.

WARNING! When driving on public roads, the machine may become unstable if the load stabilizer is NOT turned on –

Accident risk. ☞ Always turn on the load stabilizer when driving on public roads. ☞ Follow the procedure described – see Before driving the machine on page 47, when setting transport position.

IMPORTANT! DO NOT use the load stabilizer during heavy duty work.

Refer to the following table to determine when to use the load stabilizer: Load stabilizer Turned off

Turned on

May be turned on

In general for heavy-duty work, e.g., picking up excavated material.

For driving on public roads.

For lighter work with the machine.

For light off-road transport.

Before working with the telescopic unit:

☞ Turn off the load stabilizer.

NOTE: The telescopic unit yields easily with the load stabilizer turned on, making it difficult to carry out any precise lifting movements. The lifting capacity of the telescopic unit is only about 60% of the rated capacity.

Turning on 65

☞ Press bottom of rocker switch 65, below A. ➥ Indicator in rocker switch comes on.

Turning off

A

☞ Press top of rocker switch 65, above B. ➥ Indicator in rocker switch turns off.

B Fig. 42: Rocker switch for load stabilizer (option)

Printed in U.S.A.

53

918137/CP0807

Operation Backup warning system The backup warning system consists of a backup alarm A fitted on the inside of the cover over the towing device, 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. WARNING! When backing up with the machine –

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

A

Fig. 43: Backup warning system

Differential lock

IMPORTANT! A differential lock distributes traction evenly to the front and rear wheels.

Both the front and rear axles of the machine are fitted with self-locking differentials. The lock value is 45% for each axle. The differential is locked automatically and cannot be turned on or off by the operator.

Printed in U.S.A.

54

918137/CP0807

Operation Steering system Steering synchronization 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.

☞ At low drive speed, slowly turn the steering wheel to the left and right maximum posi-

tions and try turning it even further in the end position for a few seconds (as if cornering).

☞ Turn the steering wheel back to the straight-ahead position. ☞ Contact your Mustang dealer if this does not synchronize the wheels.

Steering synchronization (with 25 mph [40 km/h] high speed) 52 41

A B A B Fig. 44: Tip switch for steering synchronization

Wheel synchronization is automatically set by turning the steering wheel to the left and right when starting the machine, indicator 41 flashes as you turn the wheel. When both steering rams have passed through the straight-ahead position from both directions, synchronization is completed and indicator 41 on the instrument panel turns off.

Only the first drive range is active during synchronization. Use rocker switch 67 to select the second range, but the shift to this range does not take place until synchronization is completed.

67 IMPORTANT! You must synchronize if the wheels no longer follow the same track when driving straight-ahead on level ground.

☞ Proceed as follows: • Machines with high speed (option): make sure high speed is turned off.

IMPORTANT! Make sure that the machine is at a standstill.

• Select low drive range 67 A – see Select drive range on page 51.

• Drive at walking pace on level ground and press tip switch 52/B. • Steer to the left and right while driving until indicator 41 turns off.

• Complete a functional check of the steering system.

Printed in U.S.A.

55

918137/CP0807

Operation Changing steering mode (with high speed option) Front wheel steering The machine actuates front-wheel steering when you shift to high speed (option).

A B

➥ – see Selecting drive range, high speed (option) on page 52 ➥ The machine shifts only after the rear axle is set to straight-ahead. Indicator 69

53

flashes as the machine shifts.

➥ Indicator 69 for four-wheel steering comes on 51 Fig. 45:

69

Steering mode selection (with high speed)

Four wheel steering

The machine actuates four-wheel steering when you disengage the high speed (option).

➥ – see Select drive range on page 51. ➥ The machine shifts after the front axle is set to straight ahead. Indicator 51 flashes as the machine shifts.

➥ Indicator 51 for four-wheel steering comes on

Stopping/parking the machine WARNING! Machines parked on slopes may roll away. If you park on a slope:

☞ Apply the parking brake – see Parking brake on page 50.

☞ Place chocks under the downhill sides of the tires. ☞ Reduce engine speeds: remove your foot from accelerator pedal 27/8. ☞ Stop the machine by using the service brakes 27/32 ☞ Set the machine to neutral by using tip switch 32/76 on the joystick ☞ Apply the parking brake – see Parking brake on page 50.

☞ Lower the telescopic unit. To do this: • Push control lever 27/10 forward out of neutral.

• Place the bucket on the ground so that the edge is flush with the ground. To do this: Push control lever 27/10 to the left or right – see Control valve of the telescopic unit: overview on page 73.

☞ Turn off the engine – see Starting the engine on page 45.

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”.

Printed in U.S.A.

56

918137/CP0807

Operation Light system The switch panel for the light system is located on the left side of the instrument panel.

Parking lights ☞ Press rocker switch 55/B into the ON 1st position.

OFF ☞ Press rocker switch 55/A down.

60

00000

00

➥ Indicator in rocker switch comes on. ➥ Indicator in rocker switch turns off.

h

55

Low beam ☞ Press rocker switch 55/B to the ON 2nd position.

OFF ☞ Press rocker switch 55/A down.

➥ Indicator in rocker switch comes on. ➥ Indicator in rocker switch turns off.

IMPORTANT! A

The parking light stays lit if the ignition is turned off. Turn off the parking light by turning the key in the preheating/start switch 14 to position 0.

B

Fig. 46: Indicator instrument

II I O

High beam 70

ON

OFF

☞ With low beam turned on, pull

➥ High beam turns on. lever 70 to position II (toward the ➥ Indicator 60 turns on. steering wheel) and release. ☞ Pull lever 70 to position II ➥ Low beam turns on. (toward the steering wheel) and ➥ Indicator 60 turns off. release.

Headlight flasher Fig. 47: Multifunctional lever

Printed in U.S.A.

ON

☞ Pull lever 70 upward to position I ➥ High beam and indicator 46/60 come and hold.

57

on.

918137/CP0807

Operation Working light WARNING! The working light may momentarily blind motorists on public roads.

☞ DO NOT turn on the working light when driving on public roads.

Front and/or rear working lights (option) ☞ Press rocker switch 37/B ON Rocker switch 58/B down. ☞ Press rocker switch 37/A OFF Rocker switch 56/A down.

➥ Indicator in rocker switch comes on. ➥ Indicator in rocker switch turns off.

37 56 A B Fig. 48: Switch for working light

Interior light Interior light ON ☞ Press switch 1 to the left or right OFF ☞ Move switch 1 to center position

1 Fig. 49: Switch for interior light

Printed in U.S.A.

58

918137/CP0807

Operation Rotating beacon (option) Rotating beacon (option) ON ☞ Press rocker switch 36/B. OFF ☞ Press rocker switch 36/A.

36

➥ Indicator in rocker switch comes on. ➥ Indicator in rocker switch turns off.

A B

Fig. 50: Switch for rotating beacon

Signaling system 58

Hazard warning system ☞ Press switch for hazard warning ➥ The indicator in the switch and ON system 40 to notched position. indicator 58 flashes. ☞ Release switch for hazard warning ➥ The indicator in the switch and system 40 from notched position indicator 58 turns off.

OFF by applying slight pressure.

40

km/h

Fig. 51: Switch for hazard warning system l

L

R 70 Fig. 52: Turn indicator

Printed in U.S.A.

Turn indicator LEFT ☞ Push lever 70 forward L. RIGHT ☞ Pull lever 70 rearward R.

➥ Indicator 58 flashes. ➥ Indicator 58 flashes.

IMPORTANT! If indicator 58 flashes about twice as fast as normally.

☞ Check the front and rear indicators immediately. ➥ Have the turn indicator system repaired if necessary.

59

918137/CP0807

Operation Cab heating and ventilation NOTE: The machine heater can be set to four operating modes: • Ventilation, fresh air.

• Heating, fresh air.

• Heating, mixed mode.

• Heating, recirculated air mode.

The air flow is directed to the front window via the two defroster vents 27/4, to the two leg room vents via 27/6 and to the rear window via the two defroster vents 27/18.

Each nozzle can be closed and positioned separately.

A 0

The side console with the rotary switches for the heating system is located on the left in driving direction, next to the operator’s seat.

B C

84

Ventilation, fresh air

☞ Rotary switch 84 in position A. ☞ Rotary switch 86 in position D. Heating, fresh air

85 C W 86

D

E Fig. 53: Heating adjustment

☞ Rotary switch 84 in position B or C. ☞ Set the required temperature by using rotary switch 85. ➥ C = cold / W = warm. ☞ Rotary switch 86 in position D. Heating, mixed mode

☞ Rotary switch 84 in position B or C. ☞ Set the required temperature by using rotary switch 85. ➥ C = cold / W = warm. ☞ Rotary switch 86 between positions D and E. Heating, recirculated air mode

☞ Rotary switch 84 in position B or C. ☞ Set the required temperature by using rotary switch 85. ➥ C = cold / W = warm. ☞ Rotary switch 86 in position E.

Printed in U.S.A.

60

918137/CP0807

Operation Auxiliary heating (option) DANGER! Turn off the heater immediately if you are working near a gas station and/or are in any other work environment where flammable vapors or dust may arise (e.g. fuel, coal, wood dust, cereal storage, etc.) –

Risk of explosion. ☞ Turn off heater first. ☞ Always switch off heater before refueling.

Exhaust gases contain toxic matter –

Risk of poisoning and suffocation. ☞ Turn off the heater before entering closed rooms. ☞ Turn cab heating on and off; set the temperature.

Rotary switch for auxiliary heating (option) ☞ Continuously turn rotary ➥ Indicator A in the switch comes on, green switch 83 to the right (MAX). or red, when the machine lights are ON on. ☞ Turn rotary switch 83 to the ➥ Indicator A in switch turns off.

OFF left (OFF).

IMPORTANT! 83

A

There is a delay between when you turn rotary switch 83 to when the changes take effect. After switching off the auxiliary heating, it will run until it has cooled off.

In the event of overheating, indicator A will flash steadily.

Correcting malfunctions: Proceed as follows:

Fig. 54: Dial for auxiliary heating

☞ Turn off and on again, a maximum of two times. ☞ Check the fuse ➥ – see Fuse box on left and right of steering column on page 138. ➥ Have repair work carried out by an authorized dealer only.

If the heater overheats:

☞ Clean blocked heater ducts and hoses. ☞ Turn off and on again.

Printed in U.S.A.

61

918137/CP0807

Operation Windshield washer system

69

70

Front window wiper ☞ Turn rotary switch 69 on lever 70 ON to the second position. ☞ Turn rotary switch 69 on lever 70 ON to the third position. ☞ Turn back rotary switch 69 on OFF lever 70 completely.

➥ Slow wipe. ➥ Fast wipe. ➥ Wipers return to base position.

Fig. 55: Switch for front and rear wipers

Front window washer pump

A

ON ☞ Press and hold rotary switch 69 on lever 70 to the right A. OFF ☞ Release rotary switch 69 on lever 70.

69

70

Fig. 56: Washer pump

66

A B

Rear wiper ON ☞ Press rocker switch 66/B down.

OFF ☞ Press rocker switch 66/A down.

➥ Rear wiper is on. ➥ Rear wiper returns to base position.

Rear window washer pump OFF ☞ Press rocker switch 66/B fully downward (tip switch function).

Fig. 57: Washer pump

Tank for windshield washer system The tank filler inlet 20 is located in the engine compartment below the battery.

IMPORTANT!

0

20

Fill with clean tap water only.

Add a suitable cleaning agent if required.

In winter, add antifreeze for washer systems to the water – see Fluids and lubricants on page 122.

34300b00_00.iso

Fig. 58: Tank for washer system

Printed in U.S.A.

62

918137/CP0807

Operation Operator's seat 21

22

26 307b0370.ai 307b0380.ai

24

Fig. 59: Seat adjustment

WARNING! Never change the seat position when driving or working –

Accident risk. ☞ Adjust the seat before moving the machine.

Weight setting IMPORTANT! Adjust the seat suspension correctly to ensure a high level of ride comfort. The seat suspension can be adjusted to the operator’s weight in nine levels 110 – 287 lbs. (50 – 130 kg) by using lever 23.

307b0360.ai

☞ Sit down on the operator’s seat.

To adjust to a higher operator weight:

☞ Press lever 28 down (22 lbs. [10 kg] per notch), or turn handwheel 28 to the right.

28

To adjust to a lower operator weight:

☞ Press lever 28 down against the lower limit. ➥ Weight setting automatically returns to the upper 110 lbs. (50 kg.) position. ☞ Press lever 28 down to the required position, or turn handwheel 28 to the left.

Fig. 60: Weight setting

Printed in U.S.A.

63

918137/CP0807

Operation Horizontal adjustment

☞ Sit down on the operator’s seat. ☞ Pull lever 25 upward A and at the same time. ☞ Move the operator’s seat forward or rearward B.

B

A 307b0330.ai

25

B

A

Fig. 61: Horizontal seat adjustment

Backrest adjustment E D

☞ Sit down on the operator’s seat. ☞ Pull handle 29 up C – and at the same time. ☞ Move the seat forward or rearward D. The backrest reclines as follows E: • Seat moved forward

➥ Flatter backrest inclination.

307b0350.ai

C

• Seat moved rearward

➥ Steeper backrest inclination.

E 29

C

Fig. 62: Backrest adjustment

Printed in U.S.A.

64

918137/CP0807

Operation Seat belt WARNING! Do not drive or work with the seat belt unbuckled –

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 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 with one seat belt.

• Check seat belts regularly. Have damaged parts immediately replaced by an authorized dealer.

• Always keep the seat belt clean.

• Seat belt buckle must not be obstructed by other objects (paper or similar); otherwise the buckle latch cannot lock into place.

After an accident, the seat belt strap is stretched and must be replaced. 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.

The seat belt is for the operator's safety during work at construction sites and during road travel.

Fastening the seat belt Fasten seat belt 24 as follows before moving the machine:

A 24 B

☞ 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). ☞ Tighten the seat belt by pulling at its end. ➥ The seat belt must always be tightly in place over the hips.

0763b0007.eps Fig. 63: Fasten your seat belt

Printed in U.S.A.

65

918137/CP0807

Operation Unfastening the seat belt Unfasten seat belt 24 as follows: A A

☞ Hold the seat belt. ☞ 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. 64: Unfastening the seat belt

Lengthen/shorten lap belt setting

A

☞ Lengthen the lap belt as follows: • Hold buckle latch A at a right angle to the seat belt and pull the seat belt to the required length.

☞ To shorten the lap belt, pull the free end D of the belt.

IMPORTANT! D

30763b0005.eps Fig. 65: Longer/shorter seat belt setting

Printed in U.S.A.

When pulled slowly, the automatic seat belt offers full freedom of movement. However, it locks during abrupt braking and may also lock when driving over potholes or uneven terrain.

66

918137/CP0807

Operation Doors WARNING! Close the doors when driving on public roads –

Accident risk. ☞ Close the doors before moving the machine.

Opening the door from the outside:

☞ Pull door handle A to the outside.

A Fig. 66:

Outside door opener and lock

Opening the door from the inside:

☞ Pull lever (button) B.

NOTE: Normally, enter and exit the cab by using the left door.

B Fig. 67: Inside door opener left/right

Securing an open door: 11

19

☞ Press the door against the bracket of arrester 19 until it engages with an audible click.

NOTE: Lubricate arrester 11 at regular intervals.

Fig. 68: Securing an open door

Locking the door:

☞ Press button B of arrester 11. ➥ The door is released from the lock by spring action. ☞ Close the door.

B

Fig. 69: Unlocking the door arrester

Printed in U.S.A.

67

918137/CP0807

Operation Opening the left door to a gap The door can be opened to a gap and secured with the arrester to improve cab ventilation.

☞ Safely engage lever C in door lock D.

D

C Fig. 70: Door arrester

Engine cover Opening:

A

☞ Press lock A. ☞ Pull the engine cover upward.

Closing:

☞ Firmly press down the engine cover until lock A engages with an audible click.

L R

Locking and unlocking: Lock the engine cover with the ignition key of the ignition switch.

Fig. 71: Engine cover lock

Printed in U.S.A.

68

918137/CP0807

Operation Other controls Exit on right side of cab

The cab door on the right can be used as entry and exit.

☞ Do the following before entering or exiting the cab: • Stop and secure the machine – see Stopping/parking the machine on page 56.

• Lower the telescopic unit.

10 12

• Apply the parking brake.

• Turn off the engine.

• Remove the ignition key.

• Move control lever 10 (joystick) back and forth several times – see Lowering the telescopic unit with the engine turned off on page 77.

• Secure control lever 10 (joystick) – see Control lever lock (joystick) on page 47.

☞ Raise control lever base 12 by raising handle D to position A. ➥ The gas strut keeps the control lever base in the top position.

CAUTION! DO NOT use handle D on the control lever base as a support for your entrance or exit:

D

☞ Use the entrance handles in the cab.

12

A

B

C

☞ Fold control lever base 12 downward to position B after you are in the cab. ➥ The gas strut keeps the control lever base in the lower position.

NOTE: The height of the control lever base can be set by using stop bolt C.

Fig. 72: Control lever base

Printed in U.S.A.

69

918137/CP0807

Operation

Operation Working with the machine

3

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 gear such as pallet forks, comply with the load diagrams – see Load diagram on page 71.

• 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 telescopic unit on page 78.

• If your machine is equipped with a load stabilizer: IMPORTANT! Turn off the load stabilizer before working with the telescopic unit. If you leave the load stabilizer on, the lifting capacity of the telescopic unit is only about 60% of the rated force, and it is difficult to complete precise lifting movements.

Printed in U.S.A.

70

918137/CP0807

Operation Load diagram D C B A

Fig. 73: Load diagram

Follow the load diagram when using pallet forks with fork arms on the telescopic unit. The telescopic unit with fork arms moves within the shaded range. The load diagram states the rated operating load on the fork arms. The maximum load varies according to the horizontal distance of the load center to the front edge of the tires.

The diagram is divided into four shaded sections to show the movement of the telescopic unit. The distance between the center of the load and the rear side of the fork arms is 24” (610 mm).

Rated operating load, standard bucket (SAE) - lbs (kg) 3373 (1530)

Rated operating load, pallet forks (SAE) - lbs (kg)

Extended - lbs (kg)

2491 (1130)

1517 (688) Maximum load

Range – distance from load center to front edge of tires

Off-road applications (S=2.0)

A Over 9’7” (2.95 m)

1470 lbs. (665 kg)

B 8’5” to 9’7” (2.6 to 2.95 m)

1695 lbs. (770 kg)

C 7’2” to 8’5” (2.2 to 2.6 m)

1970 lbs. (895 kg)

D Below 7’2” (2.2 m)

2325 lbs. (1050 kg)

Example: • Off-road applications ➝ safety factor S=2.0

➥ Load distance to rear side of fork arms = 24” (610 mm).

• Height of fork arm above tire contact area = 4’9” (1.50 m).

• Distance to front edge of tires = 9’2” (2.80 m) (range B).

• Maximum load is 1997 lbs. (906 kg).

Printed in U.S.A.

71

918137/CP0807

Operation IMPORTANT! The load diagram in the cab is valid only for use with the pallet forks with fork arms as specified – see Fields of application, attachments on page 9. Follow the specific load diagrams of other attachments used.

Safe load indicator DANGER! The safe load indicator has been set for industrial applications (S=1.25). Do not rely on the safe load indicator when working off-road –

Accident risk. ☞ Adapt your drive speed and loads to the terrain. Refer to the load diagram for the maximum authorized loads.

A defective safe load indicator or working at more than 100% of the safe work load may cause the machine to tilt –

Accident risk. ☞ Check the safe load indicator daily. ☞ A flashing indicator and acoustic signal warn of loads exceeding 100%.

Reduce the load to below 100% by retracting the telescopic unit.

The telescopic loader is equipped with an electronic load indicator that continuously monitors weight changes on the rear axle during operation. c

Visible and acoustic signals warn the operator of critical loads on the telescopic unit that may cause the machine to tilt forward.

b a

IMPORTANT!

d

Critical side loads are not monitored, i.e., the operator is not warned of critical side loads.

e

f

The LEDS a, b and c indicate the percent of the load on the telescopic unit that is the safe work load: a Six green LEDS – indicates loads between 35 and 100% of the safe work load. b Two yellow LEDS – indicates loads over 100% of the safe work load.

Fig. 74: Safe load indicator

c Two red LEDs – indicates loads up to 122% of the safe work load. d Green LED to signal readiness. e Tip switch for checking the system. f Mute switch for adjusting the volume of the acoustic signal.

Printed in U.S.A.

72

918137/CP0807

Operation Control valve of the telescopic unit: overview Control lever for lift, tilt and telescopic cylinders

WARNING! Unintentional operation of the control lever (joystick) when driving on public roads –

Accident risk. ☞ Lock the lock lever 39/16 – see Control lever lock (joystick) on page 47.

E C

10 B

A D

Position Lever 10 A ☞ To the left B ☞ To the right C ☞ Forward D ☞ Rearward E ☞ Fully forward

Function ➥ Tilts in attachment ➥ Dumps out attachment ➥ Lowers telescopic unit ➥ Raises telescopic unit ➥ Lowers telescopic unit to float position

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

Fig. 75: Control lever for telescopic unit

Complete the following procedures to turn on the float position:

☞ Push control lever 10 fully forward to final position E. ➥ Control lever stays in final position E.

Printed in U.S.A.

73

918137/CP0807

Operation Locking the 3rd control circuit WARNING! 72

When working with attachments without a hydraulic function, press tip switch 72 on control lever 10 to unlock the quickhitch facility –

73

Risk of personal injury. ☞ Turn on rocker switch 54.

10

73

☞ The 3rd control circuit is locked via rocker switch 54 (on the right on the instrument

10

panel) as follows:

Locking the 3rd control circuit ☞ Push lock C down.

C

OFF ☞ At the same time press rocker switch 54 down to position B. A

54

☞ Press rocker switch 54 down to

B

position A.

Function ➥ Indicator 62 on the instrument panel comes on.

➥ Tip switches 72 and 73 are opera-

tional. ➥ Indicator 62 on the instrument panel turns off.

➥ Rocker switch 54 is locked. ➥ Tip switches 72 and 73 are not opera-

ON 62

tional.

00000

00

h

Fig. 76: Locking 3rd control circuit

Locking/unlocking the quickhitch facility

35

Fig. 77: Toggle switch – unlocking the quickhitch facility

NOTE: The attachment on the quickhitch facility is locked by using toggle switch 35 “Quickhitch lock” on the instrument panel. The lock cylinder can only be locked if: • You press tip switch 72 on control lever 10 (joystick) and toggle switch 35 on the instrument panel at the same time.

You only have to press tip switch 73 on control lever 10 (joystick) to lock the lock cylinder.

Printed in U.S.A.

74

918137/CP0807

Operation Operation of 3rd control circuit

☞ The 3rd control circuit is activated by pressing tip switches 72 and 73 on the control lever 10 (rocker switch 54 turned off):

72 73

Operation

Function

Unlocking attachments without hydraulic function: ➥ Quickhitch facility is unlocked

.

☞ Press tip switch 72 and toggle

73

switch 35 at the same time.

10

Unlocking attachments with hydraulic function:

☞ Press tip switch 72.

➥ Pressurizes the right-hand side blue hydraulic line.

➥ Attachment without hydraulic function: • Locks the quickhitch facility.

Locking: 79

☞ Press tip switch 73.

Continuous setting:

☞ Press rocker switch 79 down.

➥ Attachment with hydraulic function: • Pressurizes the left-hand side red hydraulic line. ➥ With an attachment fitted, hydraulic movements/procedures over a longer period of time or operation of hydraulic motors (e.g., rotary broom) or

➥ Operation of hydraulic equipment with a

control valve adjusted to maximum oil flow, with an unpressurized reflux.

• Indicator in rocker switch 79 comes on.

Fig. 78: Operation of 3rd control circuit

Printed in U.S.A.

• Indicator (fig. 76/62) on the instrument panel comes on.

75

918137/CP0807

Operation Working with the telescopic unit Raising/extending the telescopic unit

☞ Raise the retracted telescopic unit to the required height. To do this: ☞ Pull control lever 10/D rearward.

10 D

1 Fig. 79: Raising the telescopic unit

☞ Extend telescopic unit. To do this: ☞ Press tip switch 74 until the telescopic unit is extended to the required length.

74

2

Fig. 80: Extending the telescopic unit

Printed in U.S.A.

76

918137/CP0807

Operation Retracting/lowering the telescopic unit

WARNING! The safe work load can be exceeded if the telescopic unit is lowered while it is extended. This can cause the machine to tilt –

Accident risk. ☞ Always retract the telescopic unit before you lower it. ☞ Retract the telescopic unit. To do this: ☞ Press tip switch 75 until the telescopic unit is completely retracted.

75

1

Fig. 81: Retracting the telescopic unit

☞ Lower the retracted telescopic unit. To do this: ☞ Push lever 10/C forward.

C

10

2 Fig. 82: Lowering the telescopic unit

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

10

☞ Make sure no one is near the work area of the machine. ☞ Push and hold control lever 10 forward C. ➥ Until the telescopic unit is completely lowered. ☞ Return control lever 10 to neutral.

Fig. 83: Lowering the telescopic unit

Printed in U.S.A.

77

918137/CP0807

Operation Depressurizing the quick couplers on the telescopic 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, however they cannot be re-attached because the hydraulic lines are not depressurized. Therefore:

☞ Depressurize sections of the system and hydraulic lines that you plan to open before starting setup or repair work, e.g., fitting/removing an attachment.

Depressurize as follows:

72

73

☞ Apply the parking brake ➥ – see Parking brake on page 50. ☞ Unlock the 3rd control circuit ➥ – see Locking the 3rd control circuit on page 74. ☞ Turn off the engine ➥ Do not turn off the ignition. ☞ Press tip switches 72 and 73 on the control lever between 5 – 8 seconds. ➥ Hydraulic lines are depressurized. ☞ Turn off the ignition and remove the ignition key.

Fig. 84: Depressurizing hydraulic lines

Printed in U.S.A.

78

918137/CP0807

Operation Re-installing attachments Re-installing attachments is described below for the standard bucket. If you are fitting or removing attachments with their own hydraulic functions (e.g. high-tilt or side dump bucket), you must follow the information provided in the Operator’s Manual of the attachment.

Fitting attachments onto the quickhitch facility

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

Accident risk. ☞ Before working, be sure that the attachment is safely 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.

Re-install as follows: C

☞ Drive the machine up to the attachment. ☞ Lower telescopic unit E. To do this:

10

Push control lever 10 forward C.

☞ Tilt the quickhitch facility forward. To do this: Push control lever 10 to the right B.

B

☞ Adjust the height of pin shanks G of the quickhitch facility so that they are under catch

D

hooks F of the attachment.

E

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

F G Fig. 85: Driving up to the attachment

E

☞ Raise telescopic unit E until pin shanks G engage in catch hooks F. To do this: Pull control lever 10

rearward D.

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

to the left A.

C

A

10

H D Fig. 86: Raising the attachment

Printed in U.S.A.

79

918137/CP0807

Operation Locking: Attachments without hydraulic function Secure the attachment with lock pin H of the quickhitch facility. To do this:

☞ Press tip switch 73 on the control lever. ➥ 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 with rocker switch (fig. 76/54) ➥ – see Locking the 3rd control circuit on page 74. ☞ Lock the quickhitch facility (fig. 77/35) ➥ – see Locking/unlocking the quickhitch facility on page 74.

H

73

WARNING! You must be able to see lock pins G 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.

H Fig. 87: 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 Locking the 3rd control circuit on page 74. ☞ Depressurize the 3rd control circuit. ➥ – see Depressurizing the quick couplers on the telescopic unit on page 78. ☞ Attach the hydraulic, and if used, electrical connections for the attachment in accordance with its Operator’s Manual.

Connection of electrically operated attachments (option) A

The machine can be equipped with a 4-pole front socket. Rocker switch 51 on the left side of the instrument panel switches electric power supply on or off for electrically operated attachments such as a spray water pump for a rotary broom.

B 51

Fig. 88: Switch for attachments (option)

Printed in U.S.A.

Power supply for front attachments (option) ☞ Press rocker switch 51 down ➥ Power supply at the front socket is to position B. turned on.

ON OFF

➥ Indicator in switch comes on. ☞ Press rocker switch 51 down ➥ Power supply is interrupted. to position A. ➥ Indicator turns off.

80

918137/CP0807

Operation Removing an attachment from the quickhitch facility

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 facility as follows:

☞ Drive the machine, with the attachment empty and up, to the drop-off position. ☞ Tilt in the quickhitch facility by pushing control lever 10 to the left A. ☞ Lower the telescopic unit until the attachment is about 2–4” (5–10 cm) above the

C 10 A

ground by pushing control lever 10 forward C.

☞ Unlock the 3rd control circuit with rocker switch (fig. 30/54):

H D

– see Locking the 3rd control circuit on page 74.

Fig. 89: Lowering and tilting in the attachment

For attachments with hydraulic function

72

C

☞ Turn off the engine. ➥ Do not turn off the ignition. ☞ Apply the parking brake. ☞ Unlock the 3rd control circuit with the rocker switch:

B

– see Locking the 3rd control circuit on page 74.

☞ Depressurize the quick couplers:

10

– see Depressurizing the quick couplers on the telescopic unit on page 78.

☞ Hydraulic connection for the quick couplers on the lock cylinder: A

• Connect flexible line A onto plug D of the quickhitch facility.

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

C

• Remove electrical connections if necessary.

D B

E

F Fig. 90: Changing over hydraulic connections – setting down an attachment

Printed in U.S.A.

☞ Start the engine. ☞ Release the quickhitch facility lock on the toggle switch (fig. 76/35). ➥ – see Locking/unlocking the quickhitch facility on page 74. ☞ Press tip switch 72 on control lever 10. ☞ Slightly tilt the quickhitch facility forward by pushing control lever 10 to the right B. ☞ Lower the telescopic unit. To do this: ➥ Push control lever 10 forward C. As soon as the pin shanks of quickhitch facility F are beneath the catch hooks of attachment E:

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

81

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Operation High-flow control circuit (option) WARNING! When working with attachments: Pressing tip switch 72 on the control lever (joystick) unlocks the quickhitch facility –

Risk of personal injury. ☞ Lock the 3rd control circuit with rocker switch 54 on the instrument panel – see Locking the 3rd control circuit on page 74.

The machine can be fitted with a high-flow control circuit (option) for operation of hydraulically operated front attachments.

Operation: 78 A B

Rocker switch 78 on the control lever base console electrically locks and unlocks the highflow control circuit via a solenoid valve.

Operation of high flow control circuit (option) ☞ Press rocker switch 78 down ➥ High-flow control circuit is turned on.

ON to position B. ➥ Indicator comes on.

OFF

☞ Press rocker switch 78 down ➥ High-flow control circuit is turned off. to position A. ➥ Indicator turns off.

Fig. 91: Operation of high-flow control circuit (option)

Printed in U.S.A.

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Operation Hose burst valve safety feature IMPORTANT! If a hose or line bursts, the hose burst valve prevents the boom from being lowered or dumped out without being braked – see Applications with lifting gear on page 18.

WARNING! Hose burst valve activates when a hose or a line bursts –

Accident risk. ☞ Have any hydraulic system or hose burst valve damage repaired and checked immediately by technical staff with training.

If there is damage, follow these instructions:

☞ Stop the machine. ☞ If possible: ☞ Carefully lower the telescopic unit into the transport position. ☞ Drive the machine out of the area of danger with the telescopic unit lowered. ☞ Apply the parking brake. ☞ Turn off the engine. ☞ Remove the ignition key and lock the cab. ☞ Secure both the machine and the attachment.

Environment! ☞ Collect and dispose of drained hydraulic oil in accordance with environmental laws.

☞ Have the hose burst valve repaired immediately by an authorized dealer.

Printed in U.S.A.

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Operation Working with the standard bucket The following section describes work operations with the machine equipped with the standard bucket.

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

Checking the tilt position of the bucket A

IMPORTANT! Angle of mark A = angle of blade B. B

Fig. 92: Tilt position of the bucket

Checking the transport position of the bucket IMPORTANT!

A

The bucket is in transport position if: • Bucket is tilted back completely A.

B Fig. 93: Transport position of the bucket

• Marks on the telescopic unit and the machine frame are lined up 94/C. The distance of the bucket to the ground B is about 8” (200 mm) with standard tires.

Transporting with a full bucket

C

WARNING! Transporting full buckets in the raised position is hazardous –

Accident risk.

Fig. 94: Marks on telescopic unit and machine frame

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:

☞ Tilt the bucket fully back. ☞ Raise the telescopic unit to transport position.

Printed in U.S.A.

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Operation Loading loose material

☞ Align the blade parallel with the ground A C

10

– see Checking the tilt position of the bucket on page 84.

☞ Lower the telescopic unit to the ground B by pushing control lever 10 forward C. B A Fig. 95: Lowering the telescopic unit

☞ Drive forward into the material A.

10

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

☞ Slightly raise the telescopic unit B. To do this: Pull control lever 10 rearward D.

B A

Fig. 96: Driving into the material

Loading if the material is hard to penetrate A

B

☞ Proceed as for loading loose material, but in addition: ☞ Tilt the bucket in and out slightly. To do this: Move control lever 10 to the left and right (A and B).

10

Fig. 97: Loading if the material is hard to penetrate

A 10

A

C

Ending loading:

☞ Tilt in the bucket C. To do this:

Push control lever 10 to the left A.

☞ Reduce engine speed. ☞ Reverse out of the material A. ☞ Raise the bucket to transport position B.

B Fig. 98: Tilting back the bucket

Printed in U.S.A.

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Operation Removing material/digging in soft soil C

10

WARNING! If foundations or walls are undermined – risk of collapse.

Accident risk.

B

☞ Never undermine foundations or walls.

Fig. 99: Lowering the telescopic unit horizontal to the ground

Push control lever 10 forward C.

☞ Set the digging angle α 1. To do this:

10

α

☞ Place the bucket horizontally on the ground B. To do this:

B

Push control lever 10 to the right B.

1 1

Fig. 100: Setting the digging angle

10

A

☞ Drive the machine forward 1.

After the bucket has penetrated the soil:

☞ Set the digging angle α slightly flatter 2. To do this: Push control lever 10 to the left A, so that:

1

• Layer being removed is as even as possible.

• Wheel spin is reduced.

2 Fig. 101: Removing an even layer

Printed in U.S.A.

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Operation Removing material/digging in hard soil C 10

A

☞ Lower the bucket horizontally to the ground 1. To do this: Push control lever 10 forward C.

☞ Set the digging angle α flatter 2 than for digging in soft soil. To do this: Push control lever 10 to the left A.

☞ Drive the machine forward 3. ☞ Press the bucket down slightly. To do this: Slightly push control lever 10 forward C.

3 1

2 Fig. 102: Removing hard soil

A

B

10

After the bucket has penetrated the soil:

☞ Set the digging angle α slightly flatter 1. To do this: Push control lever 10 to the left A, so that:

• Layer being removed is as even as possible.

• Wheel spin is reduced.

☞ Push control lever 10 to the left A, or move it alternately to the left and right A and B to loosen the material.

1 Fig. 103: 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 bucket blade parallel to the ground. To do this: Push control lever 10 to the left or right A and B.

C A 10

B

☞ Lower the telescopic unit horizontally to the ground. To do this: Push control lever 10 forward C.

☞ Drive forward.

After penetrating the heaped material:

☞ Smoothly raise the telescopic unit. ☞ Keep the bucket level.

Fig. 104: Penetrating heaped material

When the telescopic unit cannot be raised further:

1

3

☞ Tilt in the bucket 1. ☞ Raise the telescopic unit 2. ☞ Reverse out of the material 3. ☞ Lower the telescopic unit to transport position.

2 Fig. 105: Reversing away from heaped material

Printed in U.S.A.

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Operation Loading heaped material (compacted material) A

B

☞ Proceed as for non-compacted material, however when raising the telescopic unit

10

☞ Tilt the bucket slightly in and out (1). To do this:

through the heaped material:

Move control lever 10 alternately to the left and right (A and B).

➥ Material is loosened.

1 Fig. 106: Heaped compacted material

Grading After having finished removing/loading the material:

2

1

☞ Lower the telescopic unit horizontally to the ground (1). ☞ Reverse across the surface to be graded (2).

Fig. 107: Grading

Digging tips

When planning and carrying out digging work, we recommend the following: • Exits from pits should be outside the digging line and should be as level as possible.

• Dig by removing adjacent strips if possible.

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

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

Loading trucks When loading trucks, we recommend taking the following into account: • If possible, the truck and the working direction of the machine should form an angle of 45°.

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

Fig. 108: Loading machines

Freeing the wheel loader

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

If your machine gets stuck in soft ground:

☞ Dump out the bucket until the blade is vertical above the ground. ☞ Lower the telescopic unit all the way. ☞ Gradually tilt back the bucket. ➥ The machine is pushed rearward. ☞ Reverse slowly. ☞ Repeat this procedure until the wheels reach firm ground. ☞ Reverse the machine away.

Printed in U.S.A.

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918137/CP0807

Operation Working with the pallet forks Safety instructions N

a

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

• Maintain a minimum distance of 19’7” (6 m) between the telescopic unit/load and overhead lines.

• Always lock the control lever for the 3rd control circuit when working with the pallet forks – see Locking the 3rd control circuit on page 74.

• Always follow these instructions – see Load diagram on page 71. Never exceed maximum load.

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

• Always approach the material as closely as possible.

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

• Always transport the load close to the ground.

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

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

b

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

• Only place loads in designated areas within the construction site.

• Move the fork arms all the way under a pallet, as far as they will go, so that the load is picked up as closely as possible to the fork frame.

• 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 closely 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 load 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.

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

• Load the vehicles or trailers evenly.

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

• Never raise a load with only one fork arm.

• Never operate the telescopic unit and loaded attachments at high speeds.

• Never leave the machine with the load raised.

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

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

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

Printed in U.S.A.

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Operation • DO NOT transport people in the attachment.

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

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

• DO NOT exceed the authorized maximum pallet height.

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

• DO NOT lower the extended telescopic unit from a high fork arm position, always retract the telescopic unit first.

Overview of fork arms

These instructions are based on the “Guidelines for testing and repairing fork arms” (© by VETTER Umformtechnik GmbH): • Only use fork arms according to their designed use.

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

• Always keep fork arms clean.

• Load both fork arms evenly.

• Tie down loads to avoid losing them.

• 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 raise by using the tilt cylinder (tilt device).

• 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 dents, 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 Approaching the material

☞ Proceed as follows: • Stop the machine immediately in front of the material.

• Apply the parking brake.

• Set the fork arms parallel to the ground.

Fig. 109: Position of machine and tines toward the material

• Check the distance of the fork arms to the center line (dashed line in fig. 110).

➥The fork arms must be: • At the same distance to the center line.

Fig. 110: Check fork spacing

Printed in U.S.A.

• As far apart as possible.

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Operation Loading the material Proceed as follows: • Adjust the height of the fork arms so that the pallet can be correctly loaded.

• Move carefully forward until the fork frame is in contact with the material.

• Make sure that the pallet is safely loaded onto the fork arms.

• Apply the parking brake – see Parking brake on page 50.

Fig. 111: Loading the material

• Raise the telescopic unit slowly.

IMPORTANT! Be sure that the load diagram is not exceeded.

Fig. 112: Raising the telescopic unit

1

2

4

• Tilt the fork frame slightly rearward (1).

• Retract the telescopic unit completely (2).

• Be sure that the area behind the machine is clear.

3

• Release the parking brake.

• Select reverse driving direction.

Fig. 113: Moving the material to transport position

• Reverse carefully (4) until the telescopic unit can be lowered into the transport position.

• In the transport position, lower the telescopic unit as far as possible (3).

• Reverse slowly from the stack (4).

• Only transport the material in transport position.

Printed in U.S.A.

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Operation Setting down the material Proceed as follows: • With the material in transport position, approach the stack from the front so that the material is in the middle of the stack (fig. 114).

Fig. 114: Aligning the material with the stack

3 2

• Apply the parking brake – see Parking brake on page 50.

• Raise the telescopic unit (1).

• Extend the telescopic unit (2) with caution until the load is positioned precisely above the stack.

• Be sure that the fork arms are level (3).

4

1

• Lower the telescopic unit slowly (4).

IMPORTANT!

Fig. 115: Setting down the material

Be sure that the load diagram is not exceeded. If there is a safety risk, stop stacking immediately.

To stop stacking: • Retract the telescopic unit.

• Lower the telescopic unit.

• Align the load with the stack by retracting/extending the telescopic unit with caution.

• Lower the load.

• Make sure that the fork arms are no longer under the load:

☞ Retract the telescopic unit. ☞ Make sure that the area behind the machine is clear. ☞ Release the parking brake. ☞ Carefully reverse from the stack until the telescopic unit can be lowered into the transport position.

☞ Tilt the fork frame rearward.

Transport position of pallet forks

☞ In transport position: • The material must be slightly tilted rearward.

• The telescopic unit must be fully retracted.

Fig. 116: Transport position – pallet forks

Printed in U.S.A.

• The telescopic unit must be lowered as far as possible (about 8“ [200 mm] above the ground).

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Operation Fitting the pallet forks onto the quickhitch facility Fitting the attachment onto the quickhitch facility

☞ Pick up the attachment ➥ – see Locking: Attachments without hydraulic function on page 80. ☞ Make sure both pins of the lock ram are safely locked into place in the attachment.

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

Accident risk. ☞ Before working, make sure that the attachment is safely locked onto the

quickhitch facility 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 facility 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.

Printed in U.S.A.

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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 with or without load, check whether 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 sideways.

When the fork arms are moved under the load, they must have the greatest possible spacing between them, and must always be evenly aligned with the fork frame.

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To achieve this, the spacing of the fork arms can be adjusted as follows:

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

IMPORTANT! Locking mechanism must be replaced immediately if damaged.

b c

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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

See page

Parking brake not applied

50

Drive lever not in neutral

51

Engine starting temperature too low

Engine does not start or is not easy to start

Wrong SAE grade of engine lubrication oil

122

Fuel quality does not comply with specifications

122

Battery defective or dead

118

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 Engine starts, but does not run smoothly or faultless

122

Wrong valve clearance Injection line leaks Fuel injector defective

Engine overheats. Temperature warning system responds

Oil level too low

101

Oil level too high

101

Air filter fouled

105

Air filter maintenance switch or gauge defective

104

Oil cooler fins fouled Fan defective, V-belt torn or loose

106

Resistance in cooling system too high, flow capacity too low Fuel injector defective

Insufficient engine output

Oil level too high

101

Fuel quality does not comply with specifications

122

Air filter fouled

105

Air filter maintenance switch or gauge defective

105

Wrong valve clearance Injection line leaks Fuel injector defective

Printed in U.S.A.

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918137/CP0807

Troubleshooting Problem

Possible causes

See page

Injection line leaks

Engine does not run on all cylinders

Fuel injector defective Oil level too low

Insufficient or no engine oil pressure

101

Engine inclination too high

Engine oil consumption too high

Wrong SAE grade of engine lubrication oil

122

Oil level too high

101

Engine inclination too high Blue

Oil level too high

101

Engine inclination too high Engine starting temperature too low

White Engine smoke

Fuel quality does not comply with specifications

122

Wrong valve clearance Fuel injector defective

Black

Air filter fouled

105

Air filter maintenance switch or gauge defective

105

Wrong valve clearance Fuel injector defective

Printed in U.S.A.

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918137/CP0807

Troubleshooting Notes:

Printed in U.S.A.

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Maintenance

Maintenance

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 page 15.

• The Operator’s Manuals of the attachments.

Daily service and maintenance work, and maintenance according to maintenance schedule “A” must be completed – see Maintenance schedule Model ML48T (overview) on page 124.

Fuel system Specific safety instructions DANGER! • Extreme caution is essential when handling fuel – high risk of fire.

• Never work on the fuel system in the vicinity of open flames or sparks.

• Do not smoke when working on the fuel system or when refueling.

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

• Do not refuel in closed rooms.

• Wipe away fuel spills immediately.

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

Printed in U.S.A.

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

WARNING! 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.

A

Environment!

Fig. 117: Fuel filler inlet

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner.

Stationary fuel pumps

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

Even the smallest particles of dirt can cause: • Increased engine wear.

• Malfunctions in the fuel system.

• Reduced effectiveness of the fuel filters.

Diesel fuel specification

Use only high-grade fuels.

Cetane number

Grade No. 2-D according to DIN 51601.

No. 1-D according to DIN 51601.

Bleeding the fuel system

Printed in U.S.A.

Use For normal outside temperatures.

Min. 45

For outside temperatures below 39°F (4°C) or for operation above 4921’ (1500 m) altitude.

The fuel system of the machine is bled automatically.

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918137/CP0807

Maintenance 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 ML48T (overview) on page 124.

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 for less than 10 service hours during one day.

After turning off a warm engine, wait at least 5 minutes before checking the oil level.

max min

A Fig. 118: Checking the oil level

☞ Park the machine on level ground. ☞ Turn off the engine. ☞ Remove the key ➥ – see Stopping/parking the machine on page 56. ☞ Apply the parking brake. ☞ Open the engine cover. ☞ Oil dipstick A: ➥ Pull it out. ➥ Wipe it with a lint-free cloth. ➥ Push it back in as far as possible. ➥ Withdraw it and read off the oil level. ☞ If necessary, fill the oil tank when the oil reaches the MIN mark on oil dipstick A – see Adding engine oil on page 102.

Printed in U.S.A.

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918137/CP0807

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 the oil dipstick A. ☞ Only use the engine oil specified – see Fluids and lubricants on page 122.

Environment!

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

OIL

B A Fig. 119: Oil dipstick and oil filler cap

Printed in U.S.A.

☞ Clean the area around oil filler cap B with a lint-free cloth. ☞ Open filler cap B. ☞ Raise oil dipstick A slightly to allow any trapped air to escape. ☞ Filling in engine oil. ➥ Wait a moment until all the oil has run into the oil sump. ☞ Check the oil level ➥ – see Checking the oil level on page 101. ☞ If necessary, add oil and then check the oil level again. ☞ Close the filler cap B. ☞ Push oil dipstick A back in as far as possible. ☞ Completely clean any oil spilt on the engine.

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918137/CP0807

Maintenance Engine and hydraulics cooling system The combined engine/hydraulic oil cooler is located in the engine compartment, on the right side of the engine. It cools the diesel engine, and the hydraulic oil of 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 Model ML48T (overview) on page 124.

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

• An insufficient coolant level reduces the heat dissipation capacity as well, and can lead to engine damage. Therefore:

☞ Check the oil level at regular intervals – see Maintenance schedule Model ML48T (overview) on page 124.

Cleaning the oil cooler WARNING! Hot engine –

Risk of burns. ☞ Wait at least 10 minutes after turning off the engine. ☞ Wear protective goggles, gloves and clothing.

A

☞ Park the machine on level ground. ☞ Lower the telescopic unit. ☞ Apply the parking brake. ☞ Turn off the engine and let it cool down. ☞ Remove the key. ☞ Open the engine cover. ☞ Clean the cooling fins by blowing compressed air from side A of the cooler.

Fig. 120: Cleaning the oil cooler

Printed in U.S.A.

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918137/CP0807

Maintenance

Maintenance Air filter The air filter is located in the engine compartment, on the right side of the machine.

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. ☞ Make sure the work area is clean when you replace the filter cartridge.

Weekly filter contamination check

Air filter restriction indicator 45 on the instrument panel monitors the filter cartridge.

☞ Filter cartridge D must be replaced:

A

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

B

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

C

– see Replacing the filter cartridge on page 105.

IMPORTANT! If you are working in especially 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 carried out.

D

IMPORTANT! 34001b520_02.iso

E

F

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.

Fig. 121: Air filter with safety cartridge

Printed in U.S.A.

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918137/CP0807

Maintenance Weekly functional check of the dust valve

☞ Proceed as follows: • Turn off the engine.

• Apply the parking brake.

E

• 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.

Fig. 122: Air filter – dust valve

Replacing the filter cartridge

☞ Change the filter cartridge as follows:

G

• Turn off the engine.

• Prevent the machine from rolling away and remove the ignition key – see Stopping/parking the machine on page 56.

• Open the engine cover.

H

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

• Remove lower housing section H. • Carefully remove filter cartridge D by using slight turning movements.

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• Every 3rd time the filter is replaced:

Fig. 123: Removing the lower housing section

• Carefully remove safety cartridge 121/F by using slight turning movements.

D

• Be sure that all contamination (dust) inside the upper and lower housing sections has been removed.

• Carefully insert a new safety cartridge 121/F into the upper housing section.

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

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

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• Close both bow clips G.

Fig. 124: Removing the filter element

Printed in U.S.A.

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918137/CP0807

Maintenance V-belt DANGER! DO NOT check, tighten, or replace the V-belt when the engine is turned on –

Risk of personal injury. ☞ Turn off the engine before working in the engine compartment.

IMPORTANT! Cracked and stretched V-belts cause engine damage.

☞ Have the V-belt replaced by an authorized dealer.

Check and tighten (if necessary) the V-belt weekly or after every 50 service hours.

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

Checking the V-belt tension Check the V-belt tension as follows:

About 10 mm

1

Fig. 125: Checking V-belt tension

☞ Turn off the engine. ☞ Prevent the machine from rolling away and remove the ignition key ➥ – see Stopping/parking the machine on page 56. ☞ 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 check if the V-belt can be deflected between the pulleys by no more than about 0.39” (10 mm).

☞ Tighten the V-belt if necessary.

Tightening the V-belt Tighten as follows:

4 A

3

☞ Turn off the engine. ☞ Prevent the machine from rolling away and remove the ignition key. ➥ – see Stopping/parking the machine on page 56. ☞ 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. 126).

Fig. 126: Tightening the V-belt

Printed in U.S.A.

☞ Keep the alternator in this position, and at the same time tighten attachment screws 3. ☞ Check V-belt tension (fig. 125) again.

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Maintenance Hydraulic system Specific safety instructions • All lines carrying hydraulic oil must be depressurized prior to any maintenance and repair work. To do this: • Lower all hydraulically controlled attachments to the ground.

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

• Apply the parking brake to prevent the machine from rolling away.

WARNING! Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries. Always consult a doctor immediately even if the wound appears insignificant – otherwise serious infections could 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 cause damage to the hydraulic pump.

IMPORTANT! Insufficient, incorrect or contaminated hydraulic oil –

Risk of severe damage to the hydraulic system. ☞ Take care to avoid contamination when working. ☞ Always add hydraulic oil using the filling screen. ☞ Only use authorized oils of the same type – see Fluids and lubricants on page 122.

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

gradable oil of the same type for filling up, following the label on the hydraulic oil tank.

IMPORTANT! Contact customer service if the hydraulic system filter is contaminated with metal chippings. Otherwise, damage may result.

Environment!

Collect hydraulic oil, including biodegradable oil, with a suitable container.

Dispose of drained oil according to environmental regulations.

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Maintenance Checking the hydraulic oil level

☞ Proceed as follows:

A

• 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 in fig. 127/A, add hydraulic oil.

Fig. 127: Oil level sight glass on hydraulic oil tank

Adding hydraulic oil IMPORTANT! Do not fill up the hydraulic oil unless the engine is turned off. If the engine is turned on, hydraulic oil will run out of the filler opening and onto the hydraulic tank.

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

• Retract all hydraulic cylinders.

• Turn off the engine.

B

• 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 by hand.

Fig. 128: Hydraulic oil tank

With the filter insert in place: • Filling up the hydraulic oil.

• Check hydraulic oil level on the oil level sight glass (127/A).

• Add more oil if necessary and check again.

• Firmly close breather filter B by hand.

Printed in U.S.A.

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Maintenance Monitoring the hydraulic oil reflux filter The red indicator 41 on the instrument panel monitors the reflux filter.

41

The filter element must be replaced by an authorized dealer during either of the following conditions: • If indicator 41 on the instrument panel comes on when the hydraulic oil is at operating temperature.

• At the latest, after 1500 service hours (or yearly if you use the machine less than 1500 service hours per year).

Indicator 41 on the instrument panel may come on during cold weather immediately after starting the engine. This is caused by increased oil viscosity. In this case:

Fig. 129: Indicator for reflux filter

☞ Set engine speeds so that indicator 41 on the instrument panel turns off. ☞ Follow these instructions – see Starting the engine on page 44.

Important information about the use of biodegradable oil

• Only use the biodegradable hydraulic fluids that have been approved by Mustang – see Fluids and lubricants on page 122. Always contact Mustang 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.

• Use only biodegradable oil of the same type for filling up. In order to avoid misunderstandings, a decal providing clear information is located on the hydraulic oil tank (next to the filler inlet) regarding the type of oil currently used. Replace missing decals.

The joint use of two different biodegradable oils can affect the quality of one of the oil types. Therefore, make sure the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8% when changing biodegradable oil (manufacturer indications).

• Do not fill up with mineral oil – the content of mineral oil should not exceed 2% in order to avoid foaming problems and to ensure biological degradability.

• When running the machine with biodegradable oil, the same oil and filter replacement intervals are valid as for mineral oil – see Maintenance schedule Model ML48T (overview) on page 124.

• Have the condensation water in the hydraulic oil tank drained by an authorized dealer every 500 service hours, and in any case before the cold season. The water content must not exceed 0.1% by weight.

• The instructions in this Operator’s Manual concerning environmental protection are also valid for the use of biodegradable oil.

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

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

Printed in U.S.A.

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Maintenance Checking hydraulic pressure lines Specific safety instructions DANGER! Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries.

Risk of personal injury. ☞ Always consult a doctor immediately, even if the wound appears insignificant – otherwise serious infections could set in.

☞ Always follow these instructions: • Tighten leaking screwed fittings and hose connections only after releasing the pressure.

• Never repair malfunctioning or leaking pressure lines and connections.

Always replace damaged parts with new ones.

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

• Use paper or wood to check for minor leaks, never use an unprotected light or open flame.

• Leaks and damaged pressure lines must be immediately repaired or replaced by an authorized dealer or after-sales staff.

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

1 Q/05

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

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

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Maintenance

Maintenance Lubrication work Lubricate all points with lithium-based brand-name grease – see Fluids and lubricants on page 122.

Lubricating the rear axle oscillation-type bearing IMPORTANT! The machine has an oscillation-type rear axle. The bearing must be greased weekly or after every 50 service hours if you use your machine for less than 50 service hours during one week.

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

A

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

Fig. 130: Grease nipples for oscillation-type bearing

Lubricating the planetary drive bearing

☞ Lubricate grease nipples B (2x) on each planetary drive bearing after every 50 service hours or weekly if you use your machine for less than 50 service hours during one week.

B

Fig. 131: Grease nipples on planetary drive bearings

Printed in U.S.A.

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918137/CP0807

Maintenance Lubricating the pivots on the telescopic unit

C

D A A B

B

Fig. 132: Lubrication points of telescopic unit

If the machine is in continual use

☞ Apply grease to grease nipples (circles in fig. 132) daily.

If the machine is in occasional use

☞ Apply grease to grease nipples (circles in fig. 132) after every 50 service hours or weekly if you use your machine for less than 50 service hours during one week.

Lubricating the telescopic unit

Lubricate the pad tracks at regular intervals.

Recommended lubricant – see Fluids and lubricants on page 122.

☞ Before lubricating: fully extend the telescopic unit. ☞ If the machine is in continual use: ➥ Grease the pad tracks every 10 service hours, or daily if you use your machine for less than 10 service hours during one day.

Fig. 133: Pad tracks of the telescopic unit

☞ If the machine is in occasional use: ➥ Grease the pad tracks every 50 service hours, or weekly if you use your machine for less than 50 service hours during one week.

Checking the wear pads The (green) wear pads are located between the inner 132/C and outer 132/D boom section.

The wear pads can be readjusted as they wear down to a minimum thickness of 0.2” (6 mm) by adjusting set screws 132/A and 132/B. Replace the wear pads if they are below the minimum thickness.

Only an authorized dealer may adjust and replace wear pads.

Printed in U.S.A.

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Maintenance Maintenance of attachments Correct maintenance and service is necessary for smooth and continuous operation, and and for the increased service life of the attachments. Please follow the lubrication and maintenance instructions in the attachments' Operator’s Manuals.

Maintenance of the brake system Environment!

Use a suitable container to collect brake fluid as it drains and dispose of it in accordance with environmental laws.

Specific safety instructions

IMPORTANT! All maintenance and repair work on the brakes must be carried out by technicians. Damaged brake lines or hoses must be replaced immediately by an authorized dealer.

• The operator or other persons may perform the following: • Daily check of the brake fluid tank level.

Checking/adding brake fluid

The brake fluid tank is located at the front left area of the cab, next to the brake/inching pedal.

DANGER!

A

An incorrect brake fluid grade or an insufficient brake fluid level may prevent the brake from functioning correctly –

Accident risk.

MAX MIN Fig. 134: Checking the brake fluid level in the tank

☞ Check the brake fluid in the tank at regular intervals. ☞ Add brake fluid until it reaches the upper edge of the sight glass. ☞ The brake fluid must comply with the SAE specification – see Fluids and lubricants on page 122.

☞ Replace brake fluid every two years.

If the level is below the upper edge of the sight glass: • Open tank cover A.

☞ Add brake fluid until it reaches the upper edge of the sight glass.

Printed in U.S.A.

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Maintenance Tires WARNING! Improper tire repairs constitute an:

Accident risk. ☞ All repair work on tires and rims may only be carried out by authorized personnel.

IMPORTANT! Regular inspection of the tires: • Improves operating safety.

• Increases the service life of the tires.

• Reduces machine downtimes – see Specifications on page 133 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 telescopic unit bulkhead.

Daily tire checks

☞ Carry out the following maintenance work daily: • Check tire pressure.

• Check the inside and outside of tires and rims for damage (cracks, aging, etc.).

• Remove foreign bodies from the tire tread.

• Remove traces of oil and grease from the tires.

Weekly tire checks

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

Printed in U.S.A.

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Maintenance Wheel change DANGER! Use of wrong tires or wheels –

Accident risk. ☞ Only use authorized wheels and tires – see Tires on page 140.

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

IMPORTANT! The wheels are heavy and can damage the threads on the wheel studs if they are not handled correctly.

☞ Use suitable 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 Stopping/parking the machine on page 56.

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

• Place a jack under the axle beam and make sure that it is secure.

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

• Check that the machine is secure.

• Completely remove the wheel nuts.

• Remove the wheel.

Fitting the wheels

☞ Proceed as follows: • Place the wheel onto the wheel studs.

• Tighten all wheel nuts partially.

• Lower the raised axle.

• Tighten the wheel nuts to the prescribed tightening torque – see Specific torques on page 141.

Printed in U.S.A.

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918137/CP0807

Maintenance Heating The heating system of the machine is equipped with a dust filter which must be cleaned at regular intervals and replaced yearly, as necessary.

It is located in the cab behind the operator’s seat.

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 volume of warm air flowing out of the air vents decreases as filter contamination increases.

A

Clean the filter as follows: B

☞ Remove cover A at the rear left beside the operator’s seat by removing screws B. ☞ Remove dust filter C by removing the screws. ☞ Clean dust filter C, replace it if necessary. ☞ Install cover A.

C

Fig. 135: Replacing the dust filter of the heating system

Printed in U.S.A.

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918137/CP0807

Maintenance Electrical system DANGER!

Specific safety instructions

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 spilt:

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

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

Risk of explosion. ☞ Avoid open flame and sparks in the vicinity of the battery, and do not smoke.

☞ Do not jump-start the machine if the battery is frozen or if the acid level is low. The battery may rupture or explode.

IMPORTANT! Always disconnect the negative pole (–) from the battery before starting repair work on the electrical system.

Only use 12-V power sources. Higher voltages will damage the electrical components.

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

Never place tools or other conductive items on the battery – danger of short circuit.

When connecting the battery leads, make sure the poles +/– are not reversed, reversing the poles will damage the electrical components.

Environment!

Dispose of used batteries properly.

Service and maintenance work at regular intervals

Before driving the machine

☞ Check every time before driving the machine: • Is the light system OK? • Is the signaling and warning system OK? Weekly

☞ Check weekly: • Electrical fuses – see Fuse box on left and right of steering column on page 138.

• Cable and ground connections.

• Charge condition of battery – see Battery on page 118.

• Condition of battery terminals.

Printed in U.S.A.

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918137/CP0807

Maintenance Cables, bulbs and fuses

Follow these instructions: • Defective 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 Fuse box on left and right of steering column on page 138.

Alternator

Follow these instructions: • Only test run the engine with the battery connected.

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

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

• Replace defective charge indicators immediately.

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 spilt:

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

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

Risk of explosion. ☞ Avoid open flame and sparks in the vicinity of the battery, and do not smoke.

☞ Do not jump-start the machine if the battery is frozen or if the acid level is low. The battery may rupture or explode.

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

Battery A is located in the engine compartment, on the left side. The original equipment manufacturer battery does not need to be refilled under normal operating conditions. Have the original equipment manufacturer battery checked at regular intervals to make sure that the electrolyte level is between the MIN and MAX levels.

A

Always follow the specific battery safety instructions.

+

Fig. 136: Battery

Printed in U.S.A.

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Maintenance General maintenance work Specific safety instructions

Cleaning the machine is divided into three separate areas: • Interior of the cab.

• Exterior of the machine.

• Engine compartment.

The wrong choice of cleaning equipment and agents may impair the operating safety of the machine, and undermine the health of the persons in charge of cleaning the machine.

Follow these instructions.

When using washing solvents • Ensure adequate room ventilation.

• Wear suitable protective clothing.

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

When using compressed air • Work carefully • Wear goggles and protective clothing.

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

• DO NOT use compressed air for cleaning your clothing.

When using a high-pressure cleaner or steam jet • Electrical components and damping materials must be covered and not directly exposed to the jet.

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

• Protect the following components from moisture: • Engine.

• Electric components such as the alternator, etc.

• Control devices and seals.

• Air intake filters, etc.

When using volatile and easily flammable anticorrosion 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 seals and disable the controls.

For cleaning the cab, we recommend using the following aids: • 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! Dry or dirty seat belts may impair winding –

Risk of personal injury. ☞ Only rewind the seat belt when it is dry.

Cleaning the exterior of the machine

Use any of the following to clean the outside of the cab: • High-pressure cleaner • Steam jet

Printed in U.S.A.

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918137/CP0807

Maintenance Cleaning the engine compartment WARNING! Only clean the engine after it is turned off and stopped –

Risk of personal injury. ☞ Turn off the engine before cleaning.

CAUTION! When cleaning the engine with a water or steam jet:

☞ The engine must be cold. ☞ DO NOT point the jet directly at electric sensors, such as the oil pressure sender.

Any humidity penetrating these sensors causes them to fail and leads to engine damage.

Screw connections

IMPORTANT! Check all bolted connections regularly, even if they are not listed in the maintenance schedules. Tighten all loose connections immediately – see Hardware torques on page 141 for the tightening torques.

Pivots and hinges

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

Printed in U.S.A.

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Maintenance Fluids and lubricants Component/ application

Diesel engine

Engine/machine SAE grade fluid Specification

Season/ temperature

SAE 10W; EO103

Below 23°F (-5°C)

SAE 20W20; EO203

14° to 50°F (-10° to 10°C)

SAE 30; EO303

41° to 86°F (5° to 30°C)

Engine oil2 with filter

HD-C 10W/40; EO1040B3 HD-C 15W/40; EO1540B3

Capacities1

2.8 gal. (10.5 L)

Year-round

12 mph(20 km/h) gearbox

0.3 gal. (1.25 L)

25 mph (40 km/h) gearbox (option)

1.0 gal. (4.0 L)

Planetary drives – left and right, front axle

Gearbox oil4

Planetary drives – left and right, rear axle

80W/90 API GL5 or SAE 90 LS (hypoid gear oil)

Year-round

0.4 gal. (1.5 L) each 0.2 gal. (0.7 L) each

Differential – front and rear axle

1.2 gal. (4.5 L) each SAE 5W/30

Up to -13°F (-25°C)

SAE 5W/40; EO 0540B3 2

Engine oil Hydraulic oil tank

Hydraulic oil5 Biodegradable oil

SAE 10W/40; EO 0540B3

Up to 5°F (-15°C)

SAE 15W/40; EO 1540B3

Up to 14°F (-10°C)

17 gal. (65 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

Multipurpose 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 Washer system 1.

2.

3.

4.

5.

6.

7.

8.

Optimoly paste “TA” White paste

6

Grade no. 2-D

Over 39°F (4°C)

Grade no. 1-D

Below 39°F (4°C)

Brake fluid8

Agip LHM Super/Shell LHM

Year-round

About 0.1 gal.

(0.5 L)

Cleaning agent

Water + antifreeze

Year-round

About 0.4 gal.

(1.5 L)

About 21 gal. (80 L)

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, order no.: 0 00 441 32 10.

DIN 51 601, min 45 cetane.

Standard: B 71 2710.

Printed in U.S.A.

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Maintenance Notes:

Printed in U.S.A.

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918137/CP0807

“C” every 1500 hours (yearly)

● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

● ● ●

● ● ●

):

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

124

• • • • • • • • • •

● ● ●

Engine oil Engine oil filter Fuel filter Air filter3, 4 replace safety cartridge every third time the air filter is replaced Gearbox oil in front and rear axle differentials and in rear axle gearbox Gearbox oil in 25 mph (40 km/h) gearbox (option) Gearbox oil in front and rear axle planetary drives (left and right) Hydraulic oil5 Hydraulic oil filter Breather filter – hydraulic oil tank 4

Inspection work (

● ● ● ●

):

Check the following material. Refill if necessary:

918137/CP0807

• • • • • • • • • • • • •

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 fluid6 Check cooler for engine and hydraulic oil for contamination. Clean if necessary7 When using biodegradable oil: Drain the condensation water in the hydraulic oil tank 5 Clean dust valve on air filter housing 3 V-belt: Check condition and pre-tension. Tighten or replace if necessary Replace the toothed belt every 3000 s/h or after a max. 5 years8 Check the fuel/water separator. Drain water if necessary Clean filter insert on fuel pump, replace if necessary Check valve tip clearance (engine timing). Set if necessary

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●

●

● ● ● ● ●

● ●

● ●

●

● ●

● ●

● ●

● ●

● ●

● ●

Maintenance

“B” every 500 hours2 2nd Inspection

1st Inspection1

Oil and filter changes (

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 Model ML48T (overview)

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

● ●

“C” every 1500 hours (yearly)

● ●

“B” every 500 hours2 2nd Inspection

● ●

● ● ● ●

● ● ●

● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

1st Inspection1

Other inspection work ( ): • Battery: Check charge condition • Heating: Clean dust filter, replace every 1500 s/h if necessary9 • Check and set service and parking brake pads. Replace if necessary • Tire check (damage, air pressure, tread depth) • Check and readjust wear pads on telescopic unit. Replace if necessary 10

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 Model ML48T (overview)

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

Check screws and nuts or screw connections for tightness on the following assemblies/components. Tighten if necessary 125

• • • • • • • • • •

Engine and engine bearing Steering system Hydraulic system Telescopic unit (pin locking) Axle mounting, axle suspension Counterweight (attachment) Attachment cap screws of propshafts Attachment cap screws of cab Wheel nuts Electric system: Check electric and ground connections, chafing on wiring harness, battery terminals

Lubrication service (

● ●

):11

Lubricate the following assemblies/components:

●12 ●12 ●12

● ●

● ●

● ●

● ●

● ●

● ● ● ● ●

● ● ● ● ●

● ● ● ● ●

● ● ● ● ●

● ● ● ● ●

Maintenance

918137/CP0807

• Rear axle oscillating bearing • Front and rear axle planetary drive bearings (left and right) • Telescopic unit – see Lubrication work on page 111.

• Pad tracks of the telescopic unit • Compensating ram bearing • Telescopic ram bearing (push-out ram) • Lift frame bearing • Tilt rod bearing

“C” every 1500 hours (yearly)

● ● ● ● ●

● ● ● ● ●

● ● ● ● ●

● ● ● ● ●

● ● ●

● ● ●

● ● ●

● ● ●

● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

):

Check the function of the following assemblies/components. Correct if necessary:

126

• Service and parking brake • Steering system • Lights and electrical system Leakage check (

● ● ●

):

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

918137/CP0807

• • • • • • •

Air intake line (air filter – engine) Engine lubrication (engine – filter) Fuel lines13 Cooling system (engine – hydraulic oil) Steering system (flexible lines and rams) Hydraulic system/telescopic unit (flexible lines and rams) 14 Brake system (flexible lines and rams)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Work to be carried out after the first 100 service hours. This work must be carried out by an authorized dealer for warranty claims to be acknowledged.

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

Replace filter insert as indicated by the indicator, 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 tank every 500 service hours, in any case before the cold season.

Replace every two years.

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

Toothed belt may be replaced by authorized staff only.

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

Minimum wear pad thickness (0.2” [6 mm]).

Lubricate attachment according to manufacturer's instructions.

Applications with increased dust development and contamination.

Replace flexible fuel leak oil lines every two years.

Replace flexible lines every six years (UVV, DIN 20066 part 5).

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

Maintenance

“B” every 500 hours2 2nd Inspection

Functional check (

● ● ● ●

1st Inspection1

• Tilt lever bearing • Lift cylinder bearing • Tilt cylinder bearing • Quickhitch facility: Bearing on lift frame • Hinges, joints and fittings (e.g., door arrester)

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 Model ML48T (overview)

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

Maintenance

Maintenance

Maintenance log Use the following table to record the maintenance and service work that you complete after a certain amount of service hours – see Maintenance schedule Model ML48T (overview) on page 124.

Company/ signature

Date

Service hours

The 1st and 2nd Inspections must be carried out by an authorized dealer for warranty claims to be acknowledged. For information on maintenance material, consumables, and lubricants – see Fluids and lubricants on page 122.

Maintenance schedule

Check off the columns in the boxes below after the work is completed.

After service hours

Maintenance log

600 A 650 A

Maintenance log Company/ signature

Service hours

Date

Maintenance schedule

After service hours

700 A 750 A 800 A

Delivery 50

850 A

A

900 A

100 1st Inspection

950 A

150 A

1000 B

200 A

1050 A

250 A

1100 A

300 A

1150 A

350 A

1200 A

400 A

1250 A

450 A 500

1300 A

B 2nd Inspection

1350 A

550 A

Printed in U.S.A.

127

918137/CP0807

Maintenance

1400 A

2250 A

1450 A

2300 A

1500 C yearly

2350 A

1550 A

2400 A

1600 A

2450 A

1650 A

2500 B

1700 A

2550 A

1750 A

2600 A

1800 C

2650 A

1850 A

2700 A

1900 A

2750 A

1950 A

2800 A

2000 B

2850 A

2050 A

2900 A

2100 A

2950 A

2150 A

3000 C

2200 A

3050 A

Printed in U.S.A.

128

Company/ signature

Service hours

Date

Maintenance schedule

After service hours

Maintenance log Company/ signature

Service hours

Date

Maintenance schedule

After service hours

Maintenance log

918137/CP0807

Maintenance

3100 A

3950 A

3150 A

4000 B

3200 A

4050 A

3250 A

4100 A

3300 A

4150 A

3350 A

4200 A

3400 A

4250 A

3450 A

4300 A

3500 B

4350 A

3550 A

4400 A

3600 A

4450 A

3650 A

4500 B

3700 A

4550 A

3750 A

4600 A

3800 A

4650 A

3850 A

4700 A

3900 A

4750 A

Printed in U.S.A.

129

Company/ signature

Service hours

Date

Maintenance schedule

After service hours

Maintenance log Company/ signature

Service hours

Date

Maintenance schedule

After service hours

Maintenance log

918137/CP0807

Maintenance Maintenance decal Location Inside the cab on the rear window.

Explanation of symbols on maintenance decal Symbol

Description 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.

Carry out a functional check of the light system.

Check tires for damage, pressure and tread depth.

Carry out a functional check and synchronize the steering system.

Carry out a functional check of the brake system.

Check hydraulic oil level. Fill up if necessary.

Check engine oil level. Fill up 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.

130

918137/CP0807

100 010 40 15

Maintenance

10 h

T glich Daily Tous les jours

50 h I=> 342 10 0001

Printed in U.S.A.

131

918137/CP0807

Maintenance Notes:

Printed in U.S.A.

132

918137/CP0807

Specifications

Specifications

Specifications Frame Sturdy steel frame, rubber-mounted engine

Engine Engine Product

Deutz diesel engine

Model

F4M2011

Design

In-line

No. of cylinders

4

Displacement

190 in.³ (3109 cm³)

Bore and stroke

3.7 x 4.4” (94 x 112 mm)

Compression ratio

19:1

Output (as per ISO 9249) Max. torque

144 lb.-ft. (195 Nm) at 1700 rpm

Specific minimum fuel consumption Fuel injection system Firing order

(222 g/kWh) Direct fuel injection 1-3-4-2

Starting aid

Glow plug

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

Max. lateral left/right inclination: 30°/57% Max. uphill/downhill inclination: 30°/57% Follow the tilting limit of the machine.

Oil pressure

44 – 65 psi (3.0 – 4.5 bar) at 2300 rpm

Valve clearance (engine at cold temperature)

Printed in U.S.A.

44 kW/60 hp at 2400 rpm

133

Intake valve.01” (0.3 mm) Exhaust valve.02” (0.5 mm)

918137/CP0807

Specifications Power train Variable displacement pump Type

Automotive, infinitely variable hydrostatic axial-piston gearbox

Displacement

0 – 2.7 in.³/rev (0 – 45 cm.³/rev)

Max. operating pressure Δp

4931 psi (340 bar)

Starting RPMs

1250 – 1300 rpm at 725 psi (50 bar) HP

Droop

2100 ±150 rpm, 3771 psi (260 bar) HP

Boost pump Type

Internal gear pump

Displacement

0.7 in.³/rev (11.6 cm³/rev)

Charging/boost pressure

435 psi (30 bar) at 1500 rpm

Control

Speed-sensitive, hydraulic displacement adjustment with pressure cut-off

Driving direction

Electro-hydraulic control

Inching

Inching valve

Variable displacement motor Axial piston motor (swash plate design)

Type Standard Displacement High speed (option)

Standard

Drive speed

High speed (option)

8093 lbf (36.0 kN)

Tractive effort

Printed in U.S.A.

1.3 to 4.9 in.³/rev (20.6 to 80.7 cm.³/rev) 1.8 to 14.2 in.³/rev (30.1 to 233 cm.³/rev) 1st drive range: 0 – 5.8 mph (0 – 9.3 km/h), forward and reverse 2nd drive range: 0 – 12.4 mph (0 – 20 km/h), forward and reverse 1st drive range: 0 – 5.8 mph (0 – 9.3 km/h), forward and reverse 2nd drive range: 0 – 25.0 mph (0 – 40 km/h), forward and reverse

134

918137/CP0807

Specifications Axles Front axle Planetary steering and drive axle, rigid screw connection with frame

Type Differential lock

Self-locking differential 45%

King-pin inclination

7°

Camber

1.5°

Steering angle

40°

Toe-in

0” (0 mm)

Tread width

53” (1355 mm)

Rear axle Type

Oscillating planetary steering and drive axle

Differential lock

Self-locking differential 45%

King-pin inclination

7°

Camber

1.5°

Total oscillation angle

+/- 9°

Steering angle

40°

Toe-in

0” (0 mm)

Tread width

53” (1355 mm)

Brakes Service brake Type

Foot-operated, hydraulic multi-disc brake + hydrostatic

Location

Front axle, power train (rear axle)

Effect

On both axles via cardan shaft

Brake fluid

Special hydraulic fluid based on basic mineral oil – see Fluids and lubricants on page 122

Parking brake

Printed in U.S.A.

Type

Manual, mechanical disc brake

Location

Front axle input

135

918137/CP0807

Specifications Steering Steering Hydrostatic four-wheel steering with emergency steering feature

Design Steering mode 12 mph (20 km/h) version Steering mode 25 mph [40 km/h] high speed option)

Assemblies

Four-wheel steering 1st drive range: four-wheel steering 2nd drive range: front-axle steering High-speed version: 2nd speed allows for front axle steering only.

Hydraulic pump, servostat with priority valve, one steering cylinder per axle, self-synchronizing in left and right final position (25 mph [40 km/h] high speed: electronic synchronization)

Max. pressure of hydraulic lines

2538 psi (175 bar) Gear pump

Hydraulic pump displacement

2.0 in.³/rev (32 cm³/rev)

Maximum steering angle

±40°

Work hydraulics

Hydraulic pump

Gear pump

Displacement

2.0 in.³/rev (32 cm³/rev) 20 gal./min (74 L/min) at 2300 rpm

Control valve

3-fold pilot control

Max. service pressure

3046 psi (210 bar) Tilt cylinder

Rod side 3481 psi (240 bar) Bottom side 1740 psi (120 bar)

Lift cylinder

Bottom side 4351 psi (300 bar)

Secondary pressure limiting

Filter

Printed in U.S.A.

Suction reflux filter

136

918137/CP0807

Specifications Pilot control Pilot control pump = boost pump of hydraulic pump 0.7 in. ³/rev Displacement (11.6 cm. ³/rev)

0.8 in. ³/rev (13 cm. ³/rev)

435 psi (30 bar) at 2300 rpm

Charging/boost pressure Pilot control unit Joystick

Four-way lever – control of lift and tilt cylinders Electrical control of lock cylinder or attachments via tip switches

Locked via lock lever with fourway lever and rocker switch (electrical system)

Lock against unintentional operation (for long-haul travel and transport)

Telescopic unit Telescopic unit with bucket 1, 2 Bucket capacity

Retracted

Extended

30 ft. (0.85 m) according to ISO

Tipping capacity (SAE)

6746 lbs. (3060 kg)

Rated operating load (SAE)

3373 lbs. (1530 kg)

Length of telescopic extension

45” (1150 mm)

Dump height

118” (3000 mm)

157” (4000 mm)

Pin height

142” (3615 mm)

185” (4690 mm)

Dump reach

30” (760 mm)

48” (1230 mm)

Tilt-back angle

40 °

Dump angle

40 °

Breakout force (lift cylinder)

6744 lbf (30 kN)

Breakout force (tilt cylinder)

11,016 lbf (49 kN)

Fork arms (payloads stated for 24” [610 mm] load distance) Tipping load (ISO 14397)

4160 lbs. (1887 kg.)

–

Payload, safety factor 2.0:

2476 lbs. (1123 kg.)

1510 lbs. (685 kg.)

133” (3378 mm)

176” (4470 mm)

Lift height Movable payload in transport position (safety factor 2.0) 1.

2.

Printed in U.S.A.

3029 lbs. (1374 kg.)

With tires 12.5-20 With standard bucket 73” (1850 mm)

137

918137/CP0807

Specifications Electrical system Electrical system Alternator

12-V, 95 A

Starter

12-V, 3.0 hp (2.3 kW)

Battery

12-V, 72 Ah

Socket (e.g., for a cigarette lighter)

15 A

Fuse box on left and right of steering column F17 F18 F19 F20 F21 F22 F23 F24

F9 F10 F11 F12 F13 F14 F15 F16

F1 F2 F3 F4 F5 F6 F7 F8 Fig. 138: Fuse box model 342-10

Printed in U.S.A.

F1

Rated current 25

F2

10

Forwards/reverse solenoid valve, driving direction, 1st/2nd speed, front wiper motor, washer pump

F4

5

Rear wiper motor, washer pump

F5

10

Air-suspension seat (option)

F6

3

Cutoff solenoid

F7

5

Turn indicator unit

F8

3

Alternator charge function, hydraulic oil temperature, hydraulic oil filter, engine oil pressure, 3rd control circuit, coolant temperature, parking brake, preheating, high beam, hour meter, fuel gauge, drive lever, forwards/reverse relay

F9

7.5

Unlock/lock solenoid valve, front socket solenoid valve

F10

5

Brake lights

F11

10

Load stabilizer solenoid valve, load stabilizer relay, hose burst valve solenoid valve (option)

F12

7.5

Extend/retract telescopic unit relay, extend/retract solenoid valve, indicator, quickhitch lock, safe load indicator sensor, safe load indicator

F13

7.5

Steering electronics, 4 wheel steering solenoid valve, front axle steering, high speed, synchronism indicator, 4 wheel steering, front axle steering

F14

5

Steering sensor, radio

F15

15

Cigarette lighter, rotating beacon (option)

F16

10

Interior light, terminal 15 relay, preheating relay, starting relay

F17

25

Rear lights, parking lights, low beam, high beam, horn, relay: high, low beam

F19

7.5

High beam (right)

F20

7.5

High beam (left)

F21

7.5

Low beam (right)

F22

7.5

Low beam (left)

F23

7.5

Front right parking light, rear right light, front socket, instrument lights, switch lights, cigarette lighter

F24

7.5

Front left parking light, rear left light, front socket

No.

138

Protected circuit Heating, air conditioning (option)

918137/CP0807

Specifications Main fuse box with relays The main fuse box is located in the engine compartment, on the left in driving direction F25

F26 K20

K21

Fig. 139: Main fuse box model 342-10

Fuse no.

Rated current (A)

Protected circuit

F25

80 A

– Main fuse

F26

40 A

– Preheating/start fuse (starter)

Relay no.

Protected circuit

K 20

– Preheating

K 21

– Start

Relays The relays are installed on the left and right next to the fuse box

K3

K4

K7

K13

K6

K15

K11

K10

K1

K12

Switching relay no.

Protected circuit

K1

High-current relay

K3

Switching relay – RV

K4

Switching relay – FW

K6

Turn indicator relay

K7

Switching relay – wiper (1st speed)

K10

Switching relay (lock)

K11

Switching relay (unlock)

K12

Switching relay – retract telescopic unit

K13

Switching relay – extend telescopic unit

K15

Switching relay – load stabilizer

Fig. 140: Relays

Printed in U.S.A.

139

918137/CP0807

Specifications Tires Tire pressure

Tire size

Front

Rear

12.5-20 MPT 10PR

2.5 bar (36 psi)

2.0 bar (29 psi)

335/80 R 20 132 B

2.5 bar (36 psi)

2.0 bar (29 psi)

365/70 R 18 SPT9

2.5 bar (36 psi)

2.0 bar (29 psi)

Wheel rims Wheel rim

Wheel offset

11 x 20 0” (0 mm) 11 x 18

Weights Weight Operating weight1

11,684 lbs. (5300 kg)

Gross weight rating

14,330 lbs. (6500 kg)

Front axle weight rating

8818 lbs. (4000 kg)

Rear axle weight rating

8818 lbs. (4000 kg)

Max. authorized load for towing facility 1.

None

With standard bucket, operator and full fuel tank

Sound levels Sound power level Measured value

102 dB (A)

Guaranteed value

104 dB (A)

Sound 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 carried out 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

140

s

s

918137/CP0807

Specifications Hardware torques General torques Cap screw dimensions M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 1.

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)

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

Specific torques

Printed in U.S.A.

Description

Torque

Wheel nut

295 ±15 lb.-ft. (400 ±20 Nm)

Track-rod end (steering cylinder)

148 lb.-ft. (200 Nm)

Piston rod (steering cylinder/track rod)

184 lb.-ft. (250 Nm)

141

918137/CP0807

Specifications

30” (760)

118” (3000)

48” (1230) 103” (2610) 107” (2710) 8” (200)

136” (3465)

142” (3615)

157” (4000)

179” (4540)

185” (4690)

Dimensions model ML48T

88” (2230)

76” (1920)

54” (1360)

217” (5510)

53” (1355) 73” (1850)

Fig. 141: Machine dimensions

Dimensions Overall length1

217” (5510 mm)

Overall height 2, 3

99” (2510 mm)

Overall height2 with rotating beacon

107” (2710 mm)

Overall width without bucket4

69” (1750 mm)

Overall width1

73” (1850 mm)

Ground clearance in transport position of telescopic unit

8” (200 mm)

Ground clearance2 below rear axle gearbox

12” (300 mm)

Track width, front/rear

53” (1355 mm)

Wheelbase

76” (1920 mm)

Turning radius5

100” (2550 mm)

1.

2.

3.

4.

5.

Printed in U.S.A.

With standard bucket.

With tires 12.5-20.

Overall height with protective FOPS screen (option) 103” (2610 mm).

With outside mirrors folded in.

Measured at outer edge of tires.

142

918137/CP0807

Index

A Abbreviations ............................................................................................5 Adjusting fork arms distance ..................................................................95 Air filter .................................................................................................104 Dust valve ......................................................................................105 Applications with lifting gear ...................................................................18

B

Biodegradable oil ..................................................................................109 Brake system ........................................................................................113 Brake fluid .....................................................................................113 Safety instructions .........................................................................113 Brake/inching pedal ................................................................................49

C

Checklists ...............................................................................................30 Pre-delivery and Delivery ................................................................31

D

Designated use and exemption from liability ............................................5 Differential lock .......................................................................................54 Driving on public roads ...........................................................................47 Dust filter ..............................................................................................116

E

Electrical system ..................................................................................138 Electrically operated attachments (option) .............................................80

F

Fitting an attachment to the pallet forks .................................................94 Fluids and lubricants ............................................................................122 Fork arms Overview .........................................................................................90

G

General information ..................................................................................3

H

Hazard warning system ..........................................................................59 Heating ...................................................................................................60 Heating, fresh air .............................................................................60 Heating, mixed mode ......................................................................60 Heating, recirculated air mode ........................................................60 Hose burst valve .....................................................................................83 Hose burst valve safety feature ..............................................................83

I

Indicators ................................................................................................38 Interior light .............................................................................................58

L

Light system ...........................................................................................57 Load stabilizer ........................................................................................53 Lock cylinder ..........................................................................................94 Locking lever ..........................................................................................95 Lowering the telescopic unit with the engine turned off ..........................77

M

Machine Fields of application ...........................................................................9 Overview ......................................................................................7, 8 Maintenance Adding engine oil ...........................................................................102 Adding hydraulic oil .......................................................................108 Air filter cartridge ...........................................................................105 Biodegradable oil ...........................................................................109 Brake system .................................................................................113 Checking the engine oil level .........................................................101 Checking the hydraulic oil level .....................................................108 Cleaning ........................................................................................119 Cleaning the oil cooler ...................................................................103 Electrical system ...........................................................................117 Engine and hydraulics cooling system ..........................................103 Engine lubrication system .............................................................101 Fluids and lubricants .....................................................................122 Fuel system .....................................................................................99 General maintenance work ...........................................................119 Heating ..........................................................................................116 Hydraulic pressure lines ................................................................110 Hydraulic system ...........................................................................107 Maintenance log ............................................................................127 Maintenance of attachments .........................................................113

Printed in U.S.A.

143

Index Maintenance schedule .................................................................. 124 Pivots and hinges .......................................................................... 121 Screw connections ........................................................................ 121 Service and maintenance work at regular intervals ...................... 117 Tire care ........................................................................................ 114 Tire change ................................................................................... 115 V-belt ............................................................................................. 106 Moving the machine with a crane .......................................................... 21

O

Operation ............................................................................................... 33 Before driving the machine ............................................................. 47 Before starting the engine ............................................................... 44 Cab ................................................................................................. 34 Drive range selection ...................................................................... 51 Hose burst valve on tilt cylinder ...................................................... 83 Instrument panel ............................................................................. 36 Load stabilizer ................................................................................. 53 Parking the machine ....................................................................... 56 Seat belt height setting ................................................................... 65 Starting the engine .......................................................................... 44 Operational safety .................................................................................. 15

P

Pallet forks ............................................................................................. 89 Approaching the material ................................................................ 91 Loading the material ....................................................................... 92 Safety instructions ........................................................................... 89 Setting down the material ............................................................... 93 Parking brake ......................................................................................... 50

Q

Quickhitch facility ................................................................................... 79

R

Refueling .............................................................................................. 100 Removing an attachment from the pallet forks ...................................... 94 Rotating beacon ..................................................................................... 59 Running-in period .................................................................................. 40

S

Safety decals ......................................................................................... 12 Safety instructions ................................................................................. 15 Applications with lifting gear ............................................................ 18 Attachments .................................................................................... 23 Identification ...................................................................................... 6 Maintenance ................................................................................... 26 Specific hazards .............................................................................. 27 Trailers and attachments ................................................................ 23 Seat adjustment Backrest adjustment ....................................................................... 64 Horizontal adjustment ..................................................................... 64 Weight setting ................................................................................. 63 Seat belt ................................................................................................. 65 Seat belt height setting .......................................................................... 65 Service brake ......................................................................................... 49 Signaling system .................................................................................... 59 Sound levels ................................................................................. 12, 140 Specifications ....................................................................................... 133 Axles ............................................................................................. 135 Brakes ........................................................................................... 135 Dimensions ................................................................................... 142 Electrical system ........................................................................... 138 Engine ........................................................................................... 133 Frame ............................................................................................ 133 Hardware torques ......................................................................... 141 Pilot control ................................................................................... 137 Power train .................................................................................... 134 Sound levels ................................................................................. 140 Telescopic unit .............................................................................. 137 Tires .............................................................................................. 140 Vibration ........................................................................................ 140 Weights ......................................................................................... 140 Work hydraulics ............................................................................ 136 Stability .................................................................................................. 94 Starting aid ............................................................................................. 46 Synchronous wheel position .................................................................. 48

T

Taking into service

918137/CP0807

Index Safety instructions ...........................................................................40 Taking the machine into service for the first time ............................40 Telescopic unit Checking the tilt position of the bucket ............................................84 Checking the transport position of the bucket .................................84 Depressurizing quick couplers ........................................................78 Extending/raising .............................................................................76 Lowering with the engine turned off ................................................77 Lubricating .....................................................................................112 Retracting/lowering ..........................................................................77 Tire care ...............................................................................................114 Tire change ..........................................................................................115 Tire pressure table .................................................................................14 Towing and transporting the vehicle .......................................................20 Transport ................................................................................................84 Turn indicator .........................................................................................59

U

Unlocking ...............................................................................................94

V

Vehicle Loading and transporting .................................................................22 Ventilation ..............................................................................................60 Ventilation, fresh air .........................................................................60

W

Washer pump .........................................................................................62 Washer system Tank ................................................................................................62 Windshield washer system .....................................................................62 Wipers ....................................................................................................62 Working Approaching the material ................................................................91 Digging tips ......................................................................................88 Freeing the wheel loader .................................................................88 Grading ............................................................................................88 Loading heaped material .................................................................87 Loading loose material ....................................................................85 Loading the material ........................................................................92 Removing material/digging in hard soil ...........................................87 Removing material/digging in soft soil .............................................86 Setting down the material ................................................................93 With pallet forks ...............................................................................89 Working light ...........................................................................................58

Printed in U.S.A.

144

918137/CP0807

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)

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.

918137/CP0807

© 2007 MUSTANG MANUFACTURING COMPANY, INC. All rights reserved.

Printed in U.S.A.