Mustang Wheel Loader ML28 Service Manual(918133)- PDF DOWNLOAD

®

ML 28 ALL-WHEEL-STEER LOADER

SERVICE MANUAL PART #918133 Revision A - 04/05

®

Mustang Manufacturing Company, Inc.

Table of contents

Table of contents Specifications Type decals and component numbers ................................................................................................................TD-1 Machine overview ................................................................................................................................................TD-3 Cab overview .......................................................................................................................................................TD-4 Cab overview ..................................................................................................................................................TD-5 Instrument panel, multifunctional lever and drive lever .......................................................................................TD-6 Instrument panel, multifunctional lever and drive lever: overview ..................................................................TD-7 Machine specifications ........................................................................................................................................TD-8 Frame .............................................................................................................................................................TD-8 Engine ............................................................................................................................................................TD-8 Power train .....................................................................................................................................................TD-9 Axles .............................................................................................................................................................TD-10 Brakes ..........................................................................................................................................................TD-10 Steering ........................................................................................................................................................TD-11 Work hydraulics ............................................................................................................................................TD-11 Pilot control ...................................................................................................................................................TD-11 Additional control circuit + 4th control circuit (option) ...................................................................................TD-12 Loader unit ...................................................................................................................................................TD-12 Electrical system ..........................................................................................................................................TD-13 Fuse box in control lever base .....................................................................................................................TD-13 Main fuse box with relays in the engine compartment .................................................................................TD-13 Relays ..........................................................................................................................................................TD-14 Tires .............................................................................................................................................................TD-15 Weights ........................................................................................................................................................TD-15 Sound levels ................................................................................................................................................TD-15 Vibration ......................................................................................................................................................TD-16 Coolant compound table ..............................................................................................................................TD-16 General torques ............................................................................................................................................TD-16 Specific torques ...........................................................................................................................................TD-16 Dimensions ...................................................................................................................................................TD-17 Maintenance Fluids and lubricants ............................................................................................................................................00-1 Explanation of symbols for the maintenance decal ..............................................................................................00-2 Maintenance decal ..........................................................................................................................................00-3 Maintenance schedule (overview) ........................................................................................................................00-4 Maintenance items ...............................................................................................................................................00-7 Refueling ..............................................................................................................................................................00-8 Stationary fuel pumps ......................................................................................................................................00-8 Fuel prefilter (water separator) .............................................................................................................................00-9 Cleaning the fuel filter .........................................................................................................................................00-10 Bleeding the fuel system ....................................................................................................................................00-11 Engine lubrication system ...................................................................................................................................00-12 Checking the oil level ....................................................................................................................................00-12 Changing engine oil .......................................................................................................................................00-13 Changing the engine oil filter cartridge ..........................................................................................................00-14 Checking/filling up the coolant level ...................................................................................................................00-15 Air filter ...............................................................................................................................................................00-16 Replacing the filter cartridge ..........................................................................................................................00-17 V-belt ..................................................................................................................................................................00-18 918133/AP0405

Checking the V-belt tension ..........................................................................................................................00-18

Tightening the V-belt .....................................................................................................................................00-18 Hydraulic system ................................................................................................................................................00-19 Specific safety instructions ............................................................................................................................00-19 Checking the hydraulic oil level .....................................................................................................................00-20 Adding hydraulic oil .......................................................................................................................................00-20 Changing hydraulic oil ...................................................................................................................................00-21 Use of biodegradable oil ................................................................................................................................00-22 Replacing the hydraulic oil return filter ..........................................................................................................00-23 Replacing the filler and breather filter ............................................................................................................00-23 Checking hydraulic pressure lines .................................................................................................................00-24 Gearboxes and axles ..........................................................................................................................................00-25 Rear axle transfer gearbox ............................................................................................................................00-25 Front and rear axle differentials .....................................................................................................................00-27 Lubricating the rear axle oscillation-type bearing ..........................................................................................00-28 Front and rear axle planetary drives ..............................................................................................................00-28 Loader unit ..........................................................................................................................................................00-29 Lubricating the pivots on the loader unit ........................................................................................................00-29 Tire care .............................................................................................................................................................00-30 Tire check ......................................................................................................................................................00-31 Wheel change ...............................................................................................................................................00-31 Electrical system .................................................................................................................................................00-32 Specific safety instructions ............................................................................................................................00-32 Service and maintenance work at regular intervals .......................................................................................00-32 Instructions concerning specific components ................................................................................................00-33 Battery ...........................................................................................................................................................00-34 General maintenance work .................................................................................................................................00-35 Cleaning ........................................................................................................................................................00-35 Screw connections ........................................................................................................................................00-37 Pivots and hinges ..........................................................................................................................................00-37 Engine Specifications .......................................................................................................................................................01-1 Description of engine type decal ......................................................................................................................01-2 Engine overview (front driving direction) ..............................................................................................................01-3 Engine overview (rear driving direction) ...............................................................................................................01-4 Fuel injection system ............................................................................................................................................01-5 Fuel injection nozzle .............................................................................................................................................01-6 Engine valve tip clearance ....................................................................................................................................01-7 Engine cooling: overview ......................................................................................................................................01-8 Fuel system: overview ..........................................................................................................................................01-9 Engine trouble ....................................................................................................................................................01-10 Power train Description: Variable displacement pump A 10 VG 28 DA ...................................................................................22-1 Description: Hydraulic motor VM 45 EZ 6 ............................................................................................................22-2 Fuel system: overview ..........................................................................................................................................22-3 Measuring points: variable displacement pump ...................................................................................................22-4 Overview: hydraulic motor ....................................................................................................................................22-5 Diagram: hydraulic speed range ...........................................................................................................................22-6 918133/AP0405

Table of contents

Check and adjustment instructions .......................................................................................................................22-7 Towing .............................................................................................................................................................22-7 Test report model ............................................................................................................................................22-8 Adjusting boost pressure .................................................................................................................................22-9 Adjusting pilot pressure .................................................................................................................................22-10 Adjusting starting speeds ..............................................................................................................................22-11 Adjusting the hydraulic resistance curve on the transposition screw ............................................................22-12 Readjusting the hydraulic resistance curve ...................................................................................................22-13 Adjusting variable displacement pump output ...............................................................................................22-14 Adjusting high pressure/pressure cut-off .......................................................................................................22-15 Pressure cut-off: exploded view ....................................................................................................................22-16 Adjusting control piston pressure of hydraulic motor .....................................................................................22-17 Axles Type decal – axle .................................................................................................................................................23-1 Drain, fill and check plug ......................................................................................................................................23-2 Tightening values lb-ft (Nm) .................................................................................................................................23-3 Screw connections ...............................................................................................................................................23-4 Sealing work .........................................................................................................................................................23-5 Differential – front axle ....................................................................................................................................23-5 Overview: Planetary carrier – double drive shaft .............................................................................................23-6 Sealing: Planetary carrier ................................................................................................................................23-6 Overview: Planetary drive .............................................................................................................................23-11 Sealing: Planetary drive ................................................................................................................................23-11 Sealing: Axle carrier ......................................................................................................................................23-13 Sealing: Axle carrier – differential ..................................................................................................................23-15 Sealing: Gearbox – input flange ....................................................................................................................23-16 Overview: Self-locking differential ......................................................................................................................23-17 Brakes Overview: Brake system .......................................................................................................................................24-1 Readjustment: Parking brake ...............................................................................................................................24-2 Replacing brake linings ...................................................................................................................................24-3 Basic setting: Cables ............................................................................................................................................24-4 Cable for inching .............................................................................................................................................24-4 Cable – parking brake .....................................................................................................................................24-5 Cable for parking brake ...................................................................................................................................24-6 Steering Overview – steering circuit ...................................................................................................................................27-1 Steering diagram ..................................................................................................................................................27-2 Hydraulic circuit: Steered to the left ......................................................................................................................27-3 Hydraulic circuit: Steered to the right ....................................................................................................................27-4 Hydraulic ports on servostat .................................................................................................................................27-5 Adjustment: Pressure relief valve – servostat ......................................................................................................27-5 Sealing steering cylinders .....................................................................................................................................27-6 Adjustment: Pressure relief valve – servostat ......................................................................................................27-5 Sealing steering cylinders .....................................................................................................................................27-6

918133/AP0405

Electrical system

Ohm's Law (current, voltage, resistance); power .................................................................................................33-1 Measuring equipment, measuring methods .........................................................................................................33-1 Terminal description .............................................................................................................................................33-3 Cable color coding ................................................................................................................................................33-6 Relays ...................................................................................................................................................................33-7 Use, mode of function .....................................................................................................................................33-7 Terminal description on relay .........................................................................................................................33-7 Types of relays used .......................................................................................................................................33-8 Overview: Relays ............................................................................................................................................33-8 Three-phase alternator, starter .............................................................................................................................33-8 Battery ..................................................................................................................................................................33-8 Fuse box in control lever base ..............................................................................................................................33-9 Main fuse box with relays in the engine compartment ..........................................................................................33-9 Overview: Board .................................................................................................................................................33-10 Plug and socket connection: Wiring harness 209336 frame – cab .....................................................................33-11 Plug and socket connection: Wiring harness 209336 instrument panel .............................................................33-12 Plug and socket connection: wiring harness 207414 – working light/rotating beacon ...........................................................................................................................33-13 Wiring harness 207404 .......................................................................................................................................33-15 Cab – wiring harness 207412..............................................................................................................................33-16 Roof – wiring harness 209336 ...........................................................................................................................33-17 Roof – wiring harness 207414 ...........................................................................................................................33-17 Wiring diagram 207406 ......................................................................................................................................33-18 Cable colors: Steering-column control lever S2 and S3 to plugs 10.1, 10.2 and X9 ..........................................33-21 Cable routing from steering-column control lever S3 on left, starting plug X9 ....................................................33-23 Cable routing from steering-column control lever S2 on right, starting plug 10.1 ...............................................33-24 Cable routing from steering-column control lever S2 on right, starting plug 10.2 ...............................................33-25 Hydraulics Hydraulics diagram – pilot control ........................................................................................................................36-1 Hydraulics diagram – float position .......................................................................................................................36-2 Hydraulic circuit: Pump – control valve – tank ......................................................................................................36-3 Overview: Control valve ........................................................................................................................................36-4 Hydraulic ports on control valve ...........................................................................................................................36-5 Hydraulic circuit pilot control .................................................................................................................................36-6 Sealing the lift cylinder ..........................................................................................................................................36-7 Sealing the tilt cylinder ..........................................................................................................................................36-8 Sealing the quickhitch cylinder .............................................................................................................................36-9 Sealing: Quickhitch cylinder piston rod .........................................................................................................36-10 Assembly tools ..............................................................................................................................................36-10 Overview: Loader unit .........................................................................................................................................36-11 Hydraulic circuit 4th control circuit ......................................................................................................................36-12 Hydraulics diagram: 4th control circuit – solenoid valve no contact (neutral circulation) ....................................36-13 918133/AP0405

Table of contents Hydraulics diagram: 4th control circuit – solenoid valve with contact .................................................................36-14 Hydraulics diagram: 3rd + 4th control circuit – solenoid valve with contact .......................................................36-15 Test and setting instructions for work hydraulics ................................................................................................36-16 Test report .....................................................................................................................................................36-16 Legend for hydraulics diagram ...........................................................................................................................36-17 Hydraulics diagram ........................................................................................................................................37-18 Heating Heating circuit: overview .......................................................................................................................................41-1

918133/AP0405

NOTES

918133/AP0405

Specifications

Specifications

TD

Specifications TD

TD.1

Type decals and component numbers Serial number The serial number is stamped on the machine frame (fig. 1/A). It is also located on the type decal (fig. 2).

A

The type decal is located at the front right of the machine frame (on one side of the loader unit bulkhead).

Type decal information Example: ML28 Fig. 1:

Type decal: location

Machine model:

Fhzg-Typ Model ModËle Typ / Ausf.

Version Version Fg.-Nr. Serial no.

No. de sÈrie Baujahr Model year AnnÈe 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

Type decal

Version:

342-01

Serial no.:

342 01 xxxx

Model year:

2005

Front gross axle weight rating: 3527 lbs. (1600 kg) Rear gross axle weight rating: 3527 lbs. (1600 kg) 30300b0010.eps

Fig. 2:

ML28

Gross weight rating:

5071 lbs. (2300 kg)

Output:

38 hp (3.5 kW)

Other information – see section TD.5 Machine specifications on page TD-8.

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

Fig. 3:

Cab type decal

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

Example:

Fig. 4:

Yanmar 46557

Diesel engine number

918133/AP0405

TD-1

Specifications 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).

Example:

Fig. 5:

6204226

Hydraulic pump: type decal

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

Example:

Fig. 6:

7657648

Hydraulic motor: type decal

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

Fig. 7:

Rear axle and gearbox: type decal

Front axle number The type decal (arrow) is located on the differential housing, at the front.

Fig. 8:

TD-2

Front axle: type decal

918133/AP0405

Specifications

TD.2

Machine overview

1

Eye hook for loading or tieing down the machine

1

2

Rearview mirror

2

3

Handle

4

Headlights

5

Warning decal

6

Turn indicator

7

Foothold

8

Door handle and lock

9

Speed decal

10

Door arrester

10

3 4

1

1 20

2

15 19

3 8

5

6

7

8

9

11

Reflectors

12

Turn indicator/brake/rear light

13

Socket for oil preheater (option)

14

Towing device/eye hook for loading/ tieing down the machine

16

Hydraulic ports (option)

17

Engine cover lock

18

Decal (Do not open engine cover)

19

Working light

20

Rotating beacon (option)

18 17 16

11 Fig. 9:

12

13

14

Machine outside views

918133/AP0405

TD-3

Specifications

TD.3

Cab overview

1

33

2

3

5

4

32

5

31

Fig. 10:

6

Cab: overview

30

7

7

8

9

9 F N

I 0

R

29

10

28

11

12

12

27

13

26

14

25

15

24

16

23

17

22

18

20

20 30401b0010.iso

21

TD-4

19

918133/AP0405

Specifications

TD.3.1

Cab overview

Ref No. Description Roof console 1

Sun visor

2

Switch – interior lighting

3

Interior light Operator compartment

4

Instrument panel

5

Air vent – front window

6

Accelerator pedal

7

Door locks

8

Multifunctional lever

9

Opener – side window

10

Air vent – leg room

11

Control lever – loader unit

12

Arrester – side window

13

Fixture – first-aid kit

14

Control lever base

15

Preheating start switch

16

Switch panel

17

Fuse box

18

Storage compartment/prepared radio installation (option)

19

Prepared installation for loudspeakers (option)

20

Arrester – side window lock

21

Storage pocket for Operator's Manual

22

Operator's seat

23

Lever – weight setting

24

Seat belt

25

Lever – horizontal seat adjustment

26

Parking brake lever

27

Backrest adjustment lever

28

Hydrostatic steering

29

Drive lever

30

Service brake pedal (hydrostatic)/inching

31

Tank – washer system

32

Lock for control lever 11 (driving on public roads)

33

Rotary switch – heating

918133/AP0405

TD-5

Specifications

TD.4

Instrument panel, multifunctional lever and drive lever

5

34

35

36

37

38

39

40

50

5

Instrument panel: overview

41

42

53

54

44

43

Drive lever

45

46

47

48

49

55

56

57

51

52

Multifunctional lever

15 58

59

60

64

65

61

62

Switch panel

66

67

68 Control lever base

TD-6

918133/AP0405

Specifications

TD.4.1

Instrument panel, multifunctional lever and drive lever: overview Ref No. Description Instrument panel 34

Indicator (red) – hydraulic oil filter

35

Indicator (red) – hydraulic oil temperature

36

Indicator (red) – alternator charge function

37

Indicator (red) – engine oil pressure

38

Indicator (red) – coolant temperature

39

Indicator (yellow) – cold starter

40

Fuel level indicator

41

Indicator (yellow) – hose burst valve (option)

42

Indicator (red) – 3rd control circuit continuous operation

43

Indicator (red) – parking brake

44

Hour meter

45

Indicator (green) – right/left turn indicator

46

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

47

Indicator (blue) – high beam

48

Switch – hazard warning system

49

Socket/cigarette lighter

50

Tip switch – unlock 3rd control circuit (electrical operation)

51

Not assigned

52

Tip switch – lock 3rd control circuit (electrical operation) Drive lever

53

Rotary switch – selection of drive range

54

Lever – selection of driving direction Multifunctional lever

55

Lever – turn indicators, high beam, headlight flasher

56

Rotary switch and tip switch – front/rear wipers, washer pump

57

Tip switch – horn Switch panel

918133/AP0405

58

Rocker switch – lights

59

Rocker switch with lock – 3rd control circuit

60

Rocker switch – 3rd control circuit (continuous operation)

61

Rocker switch – heater fan

62

Tip switch – rear window heating

64

Rocker switch – working light (option)

65

Rocker switch – rotating beacon (option)

66

Rocker switch – 4th control circuit (option)

67

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

68

Decal – fuse box assignment

TD-7

Specifications

Specifications

TD

TD.5

Machine specifications

TD.5.1

Frame Sturdy steel sheet frame, rubber-mounted engine

TD.5.2

Engine Engine Product Model

4TNV 88

Type

Water-cooled 4-cycle diesel engine

No. of cylinders

4

Displacement

134 in.³ (2190 cm.³)

Bore and stroke

3.5 x 3.5'' (88 x 90 mm)

Output

38 hp (28 kW) at 2400 rpm

Max. torque Max. engine speed without load Idle engine speed Specific fuel consumption

97 –105 lb.-ft. (132 –143 Nm) @ 1600 rpm 2590 +/- 50 rpm 1050 +/- 25 rpm 319 g/hph (238 g/kWh)

Fuel injection system

Direct injection

Firing order

1–3–4–2

Starting aid

Glow plug (preheating time 10 – 15 seconds)

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

TD-8

Yanmar diesel engine

25° in all directions (Machine tilting limit is 20° lateral).

97/68/EC

918133/AP0405

Specifications

TD.5.3

Power train Variable displacement pump Type

Infinitely adjustable axial pistons

Displacement

0 – 1.7 in.³/rev (0 – 28 cm.³/rev)

Max. service pressure

5076 psi (350 bar)

Starting RPMs

1250 +100 rpm

Droop

2250 +100 rpm

Boost pump (integrated in variable displacement pump) Type Displacement Charging/boost pressure Driving direction Inching

Gear 0.5 in.³/rev (8.4 cm.³/rev) 435 psi (30 bar) Electro-hydraulic control (F – R on drive lever) Mechanical via brake inching pedal

Hydraulic motor Type Displacement Drive speed Tractive effort

Axial piston motor 3.4 in.³/rev (55 cm.³/rev) 0 – 12.4 mph (0 – 20 km/h), forward and reverse 5395 lbf (24.0 kN)

Transfer gearbox Type Transmission ratio

918133/AP0405

Single-stage 1.8529

TD-9

Specifications

TD.5.4

Axles Front axle (with 45% self-locking differential) Rigid steering and drive axle

Type King-pin inclination

7°

Camber

1.5°

Steering angle

38° 0'' (0 mm)

Toe-in

47'' (1193 mm)1

Tread width Rear axle (with 45% self-locking differential)

Steering and drive axle, oscillating

Type King-pin inclination

7°

Oscillation angle

+/- 7°

Camber

-/ 1.5°

Steering angle

38° 0'' (0 mm)

Toe-in

47'' (1193 mm)1

Tread width 1.

TD.5.5

With 12.0-18 tires

Brakes Service brake Type

Hydrostatic

Location

Drive (rear axle transfer gearbox)

Effect

Foot-operated hydrostatic brake system, braking effect on all wheels via drive shaft

Parking Brake Design

TD-10

Manual, mechanical disc brake

Location

Front axle gearbox input

Effect

On both axles via drive shaft

918133/AP0405

Specifications

TD.5.6

Steering Steering Type Steering mode Assemblies Max. pressure of hydraulic lines Hydraulic Pump Steering angle

TD.5.7

Hydrostatic four-wheel steering with emergency steering feature Four-wheel steering Hydraulic pump, priority valve, servostat with safety valves, steering cylinder, self-synchronizing in final position 2538 psi (175 bar) Gear Pump Displacement 1.4 in.³/rev (22.5 cm.³/rev) 2 x 38°

Work hydraulics Work hydraulics Hydraulic pump displacement: Control valve Max. service pressure Port relief tilt cylinder Port relief lift cylinder Filter Hydraulic oil tank

TD.5.8

1.4 in.³/rev (22.5 cm.³/rev) ≡ 14 gal/min (52 L/min) @ 2400 rpm 3 sections 3480 ±73 psi (240 ±5 bar) Rod side: 4061 psi (280 bar) Base side: 1740 psi (120 bar) Rod side: Recirculation Base side: 4351 psi (300 bar) Reflux suction filter (7 psi [0.5 bar] initial stress) 17 gal. (65 L)

Pilot control Pilot control pump = boost pump of hydraulic pump Displacement

0.5 in.³/rev (8.4 cm.³/rev)

Charging/boost pressure

435 psi (30 bar) at 2400 rpm

Pilot control unit Joystick

Lock lever

918133/AP0405

Four-way lever – control of lift and tilt cylinders Electric control of lock cylinder or attachments via tip switches Lock against unintentional operation (for long-haul travel and transport)

TD-11

Specifications

TD.5.9

Additional control circuit + 4th control circuit (option) Additional high-flow control circuit

TD.5.10

Hydraulic pump Displacement: front and rear Max. service pressure

1.4 in³/rev (22.5 cm³/rev) 14 gal/min (52 L/min) at 2400 rpm 3481 psi (240 bar)

Hydraulic pump Displacement: front only Max. service pressure

2.0 in³/rev (32 cm³/rev) 20 gal/min (75 L/min) at 2400 rpm 2756 psi (190 bar)

Front Hydraulic connections Pressure line: Unpressurized return line:

1 x nw 16 (red) 1 x nw 20 (blue)

Rear Hydraulic connections Pressure line: Unpressurized return line:

1 x nw 12 (red) 1 x nw 16 (blue)

Loader unit Machine with bucket 1 Bucket capacity

0.71 yd³ (0.65 m³)

Tipping load

5181 lbs. (2350 kg)

Rated operating load (per SAE J818)

2590 lbs. (1175 kg)

Bucket width

65'' (1650 mm)

Dump height

91'' (2300 mm)

Pin height

119'' (3020 mm)

Dump reach

10'' (250 mm)

Scraping depth

2'' (49 mm)

Tilt-back angle

45°

Dump angle

40°

Breakout force (lift cylinder)

6295 lbf (28.0 kN)

Breakout force (tilt cylinder)

6144 lbf (27.3 kN)

Fork arms (payloads stated for 24'' [610 mm] load distance) Rated operating load, safety factor 2.00: (per SAE J1197)

2205 lbs. (1000 kg.)

Tipping load

4409 lbs. (2000 kg.)

Lift height

105'' (2670 mm)

1.

TD-12

Model ML28 with tires 10.5 – 18 and standard bucket.

918133/AP0405

Specifications

TD.5.11

Electrical system Electrical system Alternator Starter Battery Socket (e.g., cigarette lighter)

TD.5.12

12 V, 55 A 12 V, 1.4 kW 12 V, 72 Ah 15 A max.

Fuse box in control lever base Fuse no.

Rated current (A)

Protected circuit

F1

7.5 A

– High beam (left)

F2

7.5 A

– High beam (right)

F3

5A

– Parking light (left)

F4

5A

– Parking light (right)

F5

10 A

– Start

F6

25 A

– Additional lights

F7

25 A

– Lights

F8

7.5 A

– Low beam (left)

F9

7.5 A

– Low beam (right)

F10

5A

– Relays, indicators, cutoff solenoid

F11

15 A

– Wiper

F12

15 A

– Valves

F13

7.5 A

– Maneuvering

F8 F9 F10 F11 F12 F13 F14 F15 F16

F14

30 A

– Fan, rear window heating

34001b710_01.eps

F15

7.5 A

– Turn indicator

F16

5A

– Radio

F1 F2 F3 F4 F5 F6 F7

Fig. 11: Fuse box

TD.5.13

Main fuse box with relays in the engine compartment

K33 K17 K16

F17 F18

Fuse no.

Rated current (A)

Protected circuit

F17

80 A

– Main fuse

F18

40 A

– Preheating/start fuse (starter)

Relay no.

Protected circuit

K 16

– Preheating

K 17

– Start

K 33

– Cutoff solenoid

Fig. 12: Main fuse box in engine compartment

918133/AP0405

TD-13

Specifications

TD.5.14

Relays The relays are installed in the control lever base under the switch panel (as seen from below the fuse board).

K1

K7 K31

K5 K12

K4

K11

K3

Switching relay no.

Protected circuit

K1

– High current relay – terminal 15

K3

– Solenoid valve – reverse driving

K4

– Solenoid valve – forward driving

K5

– Front attachments

K6

– Turn indicator relay

K7

– Wipers

K 11

– Changeover (3rd control circuit)

K 12

– Changeover (3rd control circuit)

K 13

– Unlock (quickhitch facility)

K 14

– Lock (quickhitch facility)

K 31

– Time-lag relay 5 min (rear window heating)

K13

K6

K14

Fig. 13: Relays

TD-14

918133/AP0405

Specifications

TD.5.15

Tires Tire pressure

Tire size 12.0-18 /12 PR

TD.5.16

Front

Rear

Wheel rim

Wheel offset

29 psi (2.0 bar)

29 psi (2.0 bar)

9x18

1.2'' (30 mm) wheel offset

Weights

Operating weight

Standard Open cab cab 7275 lbs. (3300 kg) 7099 lbs. (3230 kg)

Front axle load

2358 lbs. (1070 kg) 2271 lbs. (1030 kg)

Rear axle load

4916 lbs. (2230 kg) 4828 lbs. (2190 kg)

Gross weight rating

8378 lbs. (3800 kg)

Weights

Front axle weight rating

6063 lbs. (2750 kg)

Rear axle weight rating

6063 lbs. (2750 kg)

Max. authorized load for towing facility

TD.5.17

Wheel rims

5512 lbs. (2500 kg)

Sound levels Sound power level Measured value

100.5 dB (A)

Guaranteed value

102 dB (A)

Sound level in the cab (standard cab) (open cab and ROPS bar)

76 dB (A) 82 dB (A)

IMPORTANT! Measurement of sound power level according to EC Directive 2000/14/EC. Noise level in the cab measured according to EC Directives 84/532/EEC, 89/514/EEC and 95/27/EEC. Measurements carried out on asphalted surface.

918133/AP0405

TD-15

Specifications

TD.5.18

Vibration Vibration Effective acceleration value for the upper extremities of the body Effective acceleration value for the body

TD.5.19

m < 2.5 ----2 s

m < 0.5 ----2 s

Coolant compound table Outside temperature

Up to °F (°C) 39 (4) 14 (-10) -4 (-20) -13 (-25) -22 (-30)

TD.5.20

Coolant Water % by volume 99 79 65 59 55

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 1.

TD-16

Antifreeze agent

cm³/ltr.

% by volume

2.6 (10)

1

% by volume – 20 34 40 44

General torques Cap screw dimensions

TD.5.21

Anticorrosion agent

Torques in lb-ft (Nm)1 Grade 7 (8.8) Grade 8 (10.9) Grade 10 (12.9) 2 (3) 3 (4) 4 (5) 4 (5.5) 6 (8) 7 (10) 7 (10) 10 (14) 12 (16) 17 (23) 25 (34) 30 (40) 34 (46) 49 (67) 58 (79) 58 (79) 85 (115) 100 (135) 92 (125) 136 (185) 162 (220) 144 (195) 214 (290) 251 (340) 207 (280) 295 (400) 347 (470) 291 (395) 413 (560) 487 (660) 398 (540) 561 (760) 656 (890) 502 (680) 715 (970) 848 (1150) 738 (1000) 1069 (1450) 1254 (1700) 996 (1350) 1438 (1950) 1696 (2300)

These values are valid for cap screws with untreated, non-lubricated surfaces.

Specific torques Description

Torque

Wheel nut

221 ±15 lb.-ft. (300 ±20 Nm)

Track-rod end (steering)

118 lb.-ft. (160 Nm)

Piston rod (steering cylinder/track rod)

184 lb.-ft. (250 Nm)

918133/AP0405

Specifications

TD.5.22

Dimensions

34001b710_03.iso

8” (200)

98” (2490)

70” (1790)

92” (2340)

91” (2300)

111” (2820)

119” (3020)

10” (250)

34001b710_04.iso

64” (1620)

69” (1750)

49” (1240)

182” (4610)

65” (1650)

Fig. 14: Machine dimensions

Dimensions Overall length1

181'' (4610 mm)

Overall height 2, 3 without cab

70'' (1790 mm)

Overall height2 with cab

92'' (2340 mm)

Overall height2 with cab and protective FOPS screen4

94'' (2400 mm)

Overall height2 with cab and rotating beacon (option)

98'' (2490 mm)

Overall height2 with ROPS bar (option)

94'' (2400 mm)

Overall height2, 5 with ROPS bar folded down (option)

78'' (1985 mm)

Overall width without bucket6

59'' (1500 mm)

Overall width1

65'' (1650 mm)

Ground clearance in the transport position of machine

8'' (200 mm)

Ground clearance2 below rear axle gearbox

13'' (320 mm)

Tread width, front/rear

47'' (1193 mm)

Wheelbase

69'' (1750 mm)

Turning radius7

96'' (2430 mm)

1.

2.

3.

4.

5.

6.

7.

918133/AP0405

With standard bucket.

With tires 10.5-18 (1'' [25 mm] less with 12-16.5 tires).

Top edge of inside trim panel (behind operator's seat).

According to ISO 3449 category I. Measured at upper edge of pivot.

With outside mirrors folded in.

Measured at outer edge of tires.

TD-17

Specifications Notes

TD-18

918133/AP0405

Maintenance

Maintenance 00

00

Maintenance

00.1

Fluids and lubricants

Component/ application

Diesel engine

Engine/machine fluid

Engine oil2

SAE grade Specification

Season/ temperature

SAE 10W; EO103

Below 23°F (-5°C)

SAE 20W20; EO23

14° to 50°F (-10° to 10°C)

SAE 30; EO303

41° to 86°F (5° to 30°C)

HD-C 10W/40; EO1040B3 HD-C 15W/40; EO1540B3

9.0 qt. (8.6 L)

Year-round

Rear axle transfer gearbox Planetary drives – left and right, front and rear axle

Capacities1

0.31 qt. (0.3 L) Gearbox oil4

Differential – front and rear axle

80W/90 API GL5 or SAE 90 LS (hypoid gear oil)

Year-round

0.52 qt. (0.5 L) each 2.64 qt. (2.5 L) each

SAE 5W/30

Engine oil2 Hydraulic oil tank Hydraulic oil5 Biodegradable oil

Up to -13°F (-25°C)

SAE 5W/40; EO 0540B3 SAE 10W/40; EO 0540B3

Up to 5°F (-15°C)

SAE 15W/40; EO 1540B3

Up to 14°F (-10°C)

About 17 gal. (65 L)

HVLPD 46 (HYD05303) (ATF 46) AVILUB Syntofluid 46 (bio-oil)

Year-round

PANOLIN HLP Synth 46 (bio-oil)

Grease zerks

Multipurpose grease

Lithium-based brand-name grease MPG-A3

Year-round

As required

Battery terminals

Acid-proof grease

SP-B3

Year-round

As required

Mounting of pins, shafts, etc.

Special grease

Optimoly paste “TA”6 White paste

Year-round

As required

Grade no. 2-D Fuel tank

Diesel fuel7

Over 39°F (4°C)

Grade no. 1-D

Below 39°F (4°C)

About 16 gal. (62 L)

Engine and hydraulic oil cooler

Coolant

Water + antifreeze; SP-C3

Year-round

About 5.6 qt. (5.3 L)

Washer system

Cleaning agent

Water + antifreeze

Year-round

About 1.6 qt. (1.5 L)

1. The capacities indicated are approximate values; only the oil level check is accurate for the correct oil level.

2. MIL-L-2104C; API CD/CE/CF4; CCMC-D4.

3. Abbreviation for lubricants.

4. MIL-L-2105B; API-GL5.

5. DIN 51 521 T3.

6. 250 gr tube, order no.: 0 00 441 32 10.

7. DIN 51 601, min 45 cetane.

918133/AP0405

00-1

Maintenance

00.2

Explanation of symbols on maintenance decal Symbol

Explanation Before starting maintenance work, follow the safety instructions in the operator’s manual!

Before starting maintenance work, follow the “Maintenance” section in the operator’s manual!

Perform a functional check of the light system!

Check tires for damage, pressure and tread depth!

Perform a functional check and synchronize the steering system!

Perform a functional check of the brake system!

Check hydraulic oil level. Fill up if necessary!

Check engine oil level. Fill up if necessary!

Check coolant level. Fill up if necessary!

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!

Check for leaks: Check for tightness, leaks and chafing: Pipes, flexible lines and screw connections. Correct if necessary!

Lubrication service: Lubricate the assemblies concerned!

00-2

918133/AP0405

Maintenance

00.2.1

Maintenance decal Location

0 00 435 30 89

Inside the cab on the rear window.

10 h

Daily

50 h 340 02 0001 0004353089.eps

918133/AP0405

00-3

Maintenance schedule/service hours “B” every 500 service hoursb 2nd Inspection

“C” every 1500 service hours (yearly)

1st Inspectiona at 100 hours

Oil and filter changes (

“A” every 50 service hours (weekly)

For service and maintenance work on the attachment, please refer to the Operator’s and Maintenance Manual of the attachment manufacturer as well.

Delivery inspection

Work description

Maintenance work (daily)

00.3 Maintenance schedule (overview)

● ● ● ●

● ● ● ● ● ● ● ● ●

):

Perform the following oil and filter changes (check oil levels after test run): • Engine oil • Engine oil filter • Fuel filter • Air filter insert c, d, replace safety cartridge every 3rd time the air filter insert is replaced • Gearbox oil in front and rear axle differentials and in rear axle gearbox • Gearbox oil in front and rear axle planetary drives, left and right side • Hydraulic oile • Hydraulic oil filter insert • Breather filter – hydraulic oil tank d Inspection work ( ): Check the following material. Refill if necessary: • Engine oil • Engine coolant f (also check antifreeze in autumn/winter and at temperatures below 39° F (4° C.) • 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

● ● ● ● ● ●

● ● ●

● ● ● ● ●

Check cooler for engine and hydraulic oil for contamination. Clean if necessaryg

● ● ●

● ●

● ● ● ●

● ● ● ●

●

●

●

●

●

●

When using biodegradable oil: Drain the condensation water in the hydraulic oil tank e Clean dust valve on air filter housing c

●

V-belt: Check condition and pretension. Tighten or replace if necessary Check the fuel/water separator. Drain water if necessary Check valve tip clearance (engine timing). Set if necessary Battery: Check charge condition 918133/AP0405

Heating: Clean dust filter, replace every 1500 service hours if necessaryh Check and set service and parking brake pads. Replace if necessary Tire check (damage, air pressure, tread depth)

●

●

●

●

●

●

● ●

● ●

● ● ● ●

● ● ● ● ●

●

●

●

●

●

●

●

●

●

Maintenance

00-4

00

“C” every 1500 service hours (yearly)

Lubrication service ( ):i Lubricate the following assemblies/components: • Rear axle oscillation-type bearing • Front and rear axle planetary drive bearings, left and right • Loader unit • Lift frame bearing • Tilt rod bearing • Tilt lever bearing • Lift cylinder bearing • Tilt cylinder bearing • Quickhitch facility: Bearing on lift frame • Hinges, joints and fittings (e.g., door arrester)

● ●

“B” every 500 service hoursb 2nd Inspection

Check screws and nuts or screw connections for tightness on the following assemblies/components. Tighten if necessary - see section 00.18.2, “Screw connections” on page 00-37 • Engine and engine bearing • Steering system • Hydraulic system • Loader unit (pin locking) • Axle mounting, axle suspension • Counterweight (attachment) • Fastening screws of propshafts • Fastening screws of cab • Wheel nuts Electrical system: Wire and ground connections, chafe marks on wiring harness, battery terminals

1st Inspectiona at 100 hours

For service and maintenance work on the attachment, please refer to the Operator’s and Maintenance Manual of the attachment manufacturer as well.

Delivery inspection

Work description

“A” every 50 service hours (weekly)

00.3 Maintenance schedule (overview)

Maintenance work (daily)

918133/AP0405

Maintenance schedule/service hours

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ●

● ●

● ●

● ●

● ●

● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

Maintenance

00-5

1st Inspectiona at 100 hours

“B” every 500 service hoursb 2nd Inspection

“C” every 1500 service hours (yearly)

Functional check ( ): Check the function of the following assemblies/components. Service if necessary: • Service and parking brake • Steering system • Lights and electrical system

“A” every 50 service hours (weekly)

For service and maintenance work on the attachment, please refer to the Operator’s and Maintenance Manual of the attachment manufacturer as well.

Delivery inspection

Work description

Maintenance work (daily)

00.3 Maintenance schedule (overview)

● ● ●

● ● ●

● ● ●

● ● ●

● ● ●

● ● ●

Leakage check ( ): Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Service if necessary: • Air intake line (air filter – engine) ● ● ● • Engine lubrication (engine – filter) ● ● ● • Fuel lines ● ● ● • Cooling system (coolant and hydraulic oil) ● ● ● • Steering system (flexible lines and cylinders) ● ● ● • Hydraulic system/loader unit (flexible lines and cylinders) j ● ● ●

● ● ● ● ● ●

● ● ● ● ● ●

● ● ● ● ● ●

a. Work to be carried out once after the first 100 service hours. This work must be carried out by an authorized workshop for warranty claims to be acknowledged. b. Work after the first 500 service hours (2nd Inspection) must be carried out by an authorized workshop for warranty claims to be acknowledged c. Replace filter insert as indicated on the filter housing, however at least once a year or every 1500 service hours. d. When working in an acidic environment, replace the filter every 300 service hours! e. When using biodegradable oil: Drain the condensation water in the hydraulic oil tank every 500 service hours, in any case before the cold season. f. Replace the engine coolant every 2 years. g. Depending on operation and dust conditions, it may be necessary to clean the cooler more frequently h. Depending on operation and dust conditions, it may be necessary to replace the dust filter more frequently i. Lubricate attachment according to manufacturer's instructions! j. Replace flexible lines every 6 years (UVV, DIN 20066 T5)

Maintenance

00-6

Maintenance schedule/service hours

918133/AP0405

Maintenance

Maintenance

00

00.4 Maintenance items

Part No.

Description

137499

Fuel filter

1

207465

Engine oil filter

1

209574

Hydraulic filter

1

208873

Seal kit

1

7593641029

Seal kit

1

209454

Air filter - outer

1

209455

Air filter - inner

1

177729

Valve cover seal

1

918133/AP0405

00-7

Maintenance

00.5 Refueling Filler inlet A for the fuel tank is located under the engine cover, on the left in driving direction WARNING! All work involving fuel carries an increased

A

Fig. 1:

Risk of fire and poisoning! ☞ Do not refuel in closed rooms ☞ Never perform work on the fuel system in the vicinity of open flames

Fuel filler inlet

or sparks Environment!

Use a container to collect the fuel as it drains and dispose of it in a manner consistent with environmental laws!

IMPORTANT! Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel system. This requires bleeding the fuel system - see section 00.8, “Bleeding the fuel system” on page 00-11.

00.5.1

Stationary fuel pumps General Only refuel from stationary fuel pumps. Fuel from barrels or canisters is usually contaminated.

Even the smallest particles of dirt can cause

• Increased engine wear • Malfunctions in the fuel system • Reduced effectiveness of the fuel filters

00-8

918133/AP0405

Maintenance

Maintenance

00

00.6

Fuel prefilter (water separator)

Housing (sight glass)

Lock lever

O-ring

Input

“C” => closed O C

“O” => open

Maintenance indicator (red ring)

Spring

Filter insert

Output

Clean the fuel prefilter if the maintenance indicator (red ring) rises in the sight glass with the engine running.

Environment!

Use a container to collect the fuel as it drains and dispose of it in a manner consistent with environmental laws!

☞ Close the lock lever to position “C” ☞ Remove and clean the housing (sight glass) ☞ Remove and clean the filter insert ☞ Mount the filter insert ☞ Mount the housing (sight glass) with the maintenance indicator (red ring) and the spring ☞ Open the lock lever to position “O”

918133/AP0405

00-9

Maintenance

00.7

Cleaning the fuel filter Environment!

Use a container to collect the fuel as it drains and dispose of it in a manner consistent with environmental laws!

Removing the fuel filter

☞ Close fuel cock 1. To do this: Turn the cock from A to B

☞ Unscrew union nut 2.

Caution! The filter housing is filled with fuel

B 2

☞ Remove filter housing 3 ☞ Clean filter housing 3 and filter element 4 with diesel fuel Mounting the fuel filter

A

☞ Mount all elements in the reverse order (fig. 2)

1

IMPORTANT!

3

Fig. 1:

To bleed the fuel system more quickly: Fill filter housing 3 with fuel before mounting it.

☞ Tighten union nut 2 by hand ☞ Open fuel cock 1. To do this:

Fuel filter

Turn the cock from B to A

☞ Bleed the fuel system – see Bleeding the fuel system on page 00-11 ☞ Make a test run – and check for tightness!

1 5

6 4

3 2

Fig. 2:

00-10

6 Fuel filter: assembly drawing

918133/AP0405

Maintenance

00.8

Bleeding the fuel system WARNING! If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased

Risk of burns! ☞ Never bleed the fuel system if the engine is hot!

Bleed the fuel system in the following cases:

• After removing and fitting the fuel filter, prefilter, or the fuel lines back on again • After running the fuel tank empty • After running the engine again, after it has been out of service for a long period of time ☞ Bleed the fuel system as follows: • Fill the fuel tank

A B

1

• Open fuel cock 1 on the fuel filter. To do this: Turn lever from A to B • Slacken bleed screw 2 on the injection pump by a few turns

2

• Actuate the lever on fuel pump 3 manually until the fuel comes out free of air from the slackened bleed screw • Tighten bleed screw 2 on the fuel injection pump • Start the engine

3

If the engine runs smoothly for a while, and then stops; or if it does not run smoothly: • Switch off the engine

Fig. 3:

Bleeding the fuel system

• Check once again if there is any air in the fuel system • Bleed the fuel system again as described above • Have this checked by authorized staff if necessary

918133/AP0405

00-11

Maintenance

00.9

Engine lubrication system CAUTION! 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 oil changed by an authorized dealer – see Maintenance Schedule in Sec. 00.3, Page 00-4.

00.9.1

Checking the oil level IMPORTANT! Check the oil level every 10 service hours or daily.

We recommend to check it before starting the engine. After turning off a warm engine, wait at least 5 minutes before checking.

Checking the oil level

☞ Proceed as follows: • Park the machine on level ground

A max min

• Turn off the engine!

• 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

☞ Fill the oil tank when the oil level reaches the MIN mark on oil dipstick A. DO NOT let Fig. 4:

00-12

Checking the oil level

the oil fall below the MIN mark.

918133/AP0405

Maintenance

00.9.2

Changing engine oil WARNING! Caution when draining hot oil:

Risk of burns! ☞ Wear protective gloves! ☞ Use suitable tools, e.g., for unscrewing the oil drain plug! + 80 °C

☞ Change the oil as follows: • Park the machine on level ground • Let the engine run until it reaches service temperature (oil temperature about 176° F (80° C)

OIL

• Turn off the engine

Fig. Fig.5:5: Checking Checkingthe theoiloillevel level

• Environment!

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

B C

• Place container E for collecting the oil under the engine

➥ minimum capacity: 13 qts. (12 L).

A

• Unscrew cap A of drain valve B. • Screw drain coupling C onto the drain valve with a sufficiently long hose D

➥ Make sure the end of the hose is in container E used for collecting the oil.

A

• Completely drain the oil.

• Unscrew drain coupling C. • Screw cap A onto drain valve B • Add engine oil 38b02

Fig. 6:

Oil drain plug

• Start the engine and run it at low speed for a short time.

• Turn off the engine.

➥ Wait a moment until all the oil has run into the oil sump

B

• Check the oil level again.

C

• Fill up if necessary and check again • Completely remove all oil spills from the engine

D E Fig. 7:

Drain coupling with hose

918133/AP0405

00-13

Maintenance

00.9.3

Changing the engine oil filter cartridge OIL

WARNING!

A

B

C

Hot engine oil –

Risk of burns! ☞ Wear protective gloves

Environment!

Fig. 8:

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

Oil dipstick, oil filter, filler cap

☞ Change the oil filter as follows: • Turn off the engine • Place a suitable container under the oil filter • Unscrew oil filter cartridge B using a commercially available tool

B

Fig. 9:

Unscrewing the engine oil filter

• Clean the inside of the filter head • Apply a thin coat of engine oil to seal D of the new oil filter cartridge

D

• Screw oil filter cartridge B until the filter contacts the sealing surface of the filter head

Fig. 10: Cleaning the filter head

• Tighten oil filter cartridge B by hand by about a further half revolution • Check engine oil level (oil dipstick fig. 8/A) • Run the engine for a short time

B

• Turn off the engine • Check oil filter cartridge B for leaks and tighten by hand if necessary • Check the engine oil level, and refill engine oil if necessary (fig. 8/C) • Completely remove all oil spills from the engine

Fig. 11: Tightening the engine oil filter

00-14

• Dispose of used oil filter cartridges in a manner consistent with environmental laws

918133/AP0405

Maintenance

00.10

Checking/filling up the coolant level IMPORTANT! Check the coolant level every 10 service hours or daily.

We recommend checking it before starting the engine.

Checking the coolant level

A

☞ Proceed as follows: • Park the machine on level ground

B

• Turn off the engine!

• Apply the parking brake • Open the engine cover • Check the coolant level in the transparent expansion tank A

➥If the coolant level is below the LOW mark of the expansion tank: Fig. 12: Expansion tank for coolant

• Fill up the coolant level Filling up the coolant level WARNING! The cooling system is under high pressure – never open the coolant tank and never drain coolant if the engine is warm, because of

Risk of burns! ☞ Wait at least 10 minutes after turning off the engine! ☞ Wear protective gloves and clothing ☞ Open filler cap B to the first notch and allow pressure to escape After the engine has cooled down:

☞ Reduce the pressure in the radiator. To do this: Press filler cap B down

☞ Open the cap to the first notch and allow the pressure to escape ☞ Open filler cap B ☞ Add coolant to the lower edge of the radiator ☞ Close filler cap B ☞ Start the engine and let it warm up for about 5 – 10 minutes ☞ Turn off the engine and check the coolant level again ➥ The coolant level must be between the LOW and FULL marks of the tank ☞ If necessary, add coolant and repeat the procedure until the coolant level remains constant

918133/AP0405

00-15

Maintenance

00.11

Air filter CAUTION! The filter cartridge will be damaged if it is washed or brushed out!

To avoid premature engine wear:

☞ Do not clean the filter cartridge ☞ Replace the filter cartridge when the indicator comes on ☞ Never reuse a damaged filter cartridge ☞ Ensure cleanliness when replacing the filter cartridge!

Weekly check of air filter contamination The filter cartridge is monitored by maintenance display B on the filter housing.

☞ Filter cartridge D must be replaced:

A

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

B

• At the latest after 1200 service hours (yearly)

C IMPORTANT! For dusty environments, the air filter is fitted with an extra safety cartridge F. Do not clean the safety cartridge. Replace the safety cartridge every third time maintenance work is performed!

D

CAUTION!

34001b520_02.iso

Filter cartridges degrade prematurely when in service in acidic air for longer periods of time. This risk is present for example in acid production facilities, steel and aluminium mills, chemical plants and other nonferrous-metal plants.

☞ Replace filter cartridge D and safety cartridge F at the latest after 300 service hours!

E

F

Fig. 13: Air filter with maintenance display

Weekly functional check of the dust valve

☞ Proceed as follows: • Squeeze the discharge slot of dust valve E • Remove hardened dust by compressing the upper area of the valve

☞ Clean the discharge slot if necessary

E Fig. 14: Air filter – dust valve

00-16

918133/AP0405

Maintenance

00.11.1

Replacing the filter cartridge ☞ Replace filter cartridge D as follows:

G

• Turn off the engine • Prevent the machine from rolling away and remove the ignition key • Open the engine cover • Fold both bow clips G on lower housing section H to the outside

H

• Remove lower housing section H • Carefully remove filter cartridge D with slight turning movements • Every 3rd time you replace the filter:

307b0700.ai

Fig. 15: Removing the lower housing section

• Carefully remove safety cartridge fig.16/F with slight turning movements • Make sure all contamination (dust) inside the upper and lower housing sections has been removed

D

• Carefully insert a new safety cartridge fig.16/F in the upper housing section • Carefully insert new filter cartridge D into the upper housing section • Position lower housing section H (make sure it is properly seated) • Close both bow clips G

307b0710.ai

Fig. 16: Removing the filter element

☞ After replacing the filter:

A

• Press reset button A to reset red mark C in maintenance display B

B C

Fig. 17: Air filter with maintenance display

918133/AP0405

00-17

Maintenance

00.12

V-belt WARNING! Only check or tighten/replace the V-belt when the engine is turned off –

Risk of personal injury! ☞ Turn off the engine before performing inspection work in the engine compartment!

IMPORTANT! Cracked and stretched V-belts cause engine damage

☞ Have the V-belt replaced by an authorized dealer Check the V-belt daily or every 10 service hours, and tighten if necessary!

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

00.12.1

Checking the V-belt tension ☞ Check as follows:

2

• Turn off the engine

1

• Prevent the machine from rolling away and remove the ignition key • Open the engine cover • Carefully inspect V-belt 1 for damage

approx. 10 mm

• If the V-belt is damaged: • Have the V-belt replaced by an authorized dealer • Press with your thumb to check whether the V-belt can be deflected between the pulleys by no more than about 0.39” (10 mm) 2 • Tighten the V-belt if necessary Fig. 18: Checking the V-belt tension

00.12.2

Tightening the V-belt ☞ Tighten as follows: • Turn off the engine

3

• Prevent the machine from rolling away and remove the ignition key • Open the engine cover • Slacken fastening 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. 18)

A

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

4 Fig. 19: Re-tensioning the V-belt

00-18

918133/AP0405

Maintenance

00.13

Hydraulic system

00.13.1

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 • Actuate all the control levers of the hydraulic control valves several times

• Apply the parking brake to prevent the machine from rolling away before you perform service and maintenance work WARNING! Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries. Always consult a doctor immediately, even if the wound seems 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 entered the hydraulic system. This may damage 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 fill in hydraulic oil using the filling screen! ☞ Only use authorized oils of the same type - see section 00.1, “Fluids and lubricants” on page 00-1

☞ Always fill up the hydraulic oil before the level gets too low ☞ If the hydraulic system is filled with biodegradable oil, only use the same type of biodegradable oil – follow instructions on the decal on the hydraulic oil tank!

☞ Contact your MUSTANG dealer if the hydraulic system filter is contaminated with metal chippings. Otherwise, damage may result!

Environment!

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

918133/AP0405

00-19

Maintenance

00.13.2

Checking the hydraulic oil level ☞ Proceed as follows: • Park the machine on level ground

A

• Retract all the hydraulic rams • 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 figure A, add hydraulic oil

Fig. 20: Oil level sight glass on the hydraulic oil tank

00.13.3

Adding hydraulic oil IMPORTANT! Only add hydraulic oil to the hydraulic oil tank if 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 the hydraulic cylinders • Turn off the engine • Apply the parking brake • Open the engine cover

B

• Clean the area around the filler and breather filter B with a cloth • Open breather filter B by hand With the filter insert in place: • Add hydraulic oil until the tank is full • Check the hydraulic oil level on oil level sight glass A • Add more oil if necessary and check again

A

• Firmly close breather filter B by hand

✓

Fig. 21: Hydraulic oil tank

00-20

918133/AP0405

Maintenance

00.13.4

Changing hydraulic oil WARNING! Draining hot hydraulic oil and removing the filter element is hazardous –

Risk of burns! ☞ Wear protective gloves ☞ Fit a sufficiently long hose to the drain coupling ☞ Proceed as follows: • Park the machine on level ground • Lower the loader unit completely. To do this: Push the lever forward

C D

• Tilt in the bucket completely. To do this: Push the lever to the left • Turn off the engine • Open the engine cover

Fig. 22: Drain valve with cap

• Unscrew filler and breather filter fig. 21/B • Place a suitable container to collect the oil as it drains, with a minimum capacity of 42 qts. (40L) • Remove cap C of the drain valve • Screw drain coupling D with a sufficiently long hose onto the drain valve

➥ Make sure the end of the hose is in the container used for collecting the oil. ➥ The drain valve opens and the oil drains into the container • Remove the filter insert of the filler and breather filter (fig. 21/B) • Reinsert the clean filter insert • Flush out the hydraulic oil tank with a little hydraulic oil • Unscrew the drain coupling from the drain valve • Screw on cap C of the drain valve • Replace the hydraulic oil reflux filter • Fill the system with fresh hydraulic oil up to the middle of oil level sight glass 20/A • Screw on a new filler and breather filter (fig. 21/B) • Start the engine With the engine running at low speed: • Fully extend the lift and tilt cylinders on the loader unit • Turn the steering wheel to the left and right several times, from lock to lock • Retract all the hydraulic cylinders again • Turn off the engine • Check the hydraulic oil level and fill up if necessary

918133/AP0405

00-21

Maintenance

00.13.5

Use of biodegradable oil

Important information

• Use only the biodegradable hydraulic fluids which have been tested and approved by Mustang – see Fluids and lubricants on page 00-1. Always contact your Mustang dealer for the use of other, not recommended products. In addition, ask the oil supplier for a written declaration of 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 schedules on pages 00-4 through 00-6.

• Have the condensation water in the hydraulic oil tank drained by an authorized dealer every 500 service hours; in any case before the cold season. The water content should 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.

A subsequent change from mineral to biodegradable oil must be performed by an authorized dealer or by your MUSTANG dealer.

00-22

918133/AP0405

Maintenance

00.13.6

Replacing the hydraulic oil return filter A red indicator 34 in the instrument panel monitors the filter. Replace the filter:

34

• If indicator 34 comes on when the hydraulic oil is at operating temperature • At the latest after 1500 service hours (yearly) In cold weather indicator 34 may come on immediately after starting the engine. This is caused by increased oil viscosity. In this case:

☞ Let the engine run at idling speed for about two minutes Fig. 23: Hydraulic oil reflux filter: telltale

Changing the filter insert

☞ Proceed as follows:

E

• Turn off the engine

B

• Open breather filter/cap B • Unscrew cap E by about two turns and wait for the oil level in the filter housing to drop to the level in the hydraulic oil tank

2

• Remove cap E completely • Pull out filler pipe F with filter element G, turning them slightly • Pull filter element G off filler pipe F and dispose of the filter element • Check that flat gasket H on the filter cap and O-ring I on the filler pipe are in perfect condition

307b0770.ai

• Fit new O-rings if the old ones are damaged

Fig. 24: Reflux filter – breather filter

• Slide filler pipe F onto a new filter element G and insert the assembly into the filter • Tighten cap E by hand (tightening torque 15 lb.-ft. [20 Nm])

E F

• Tighten cap/breather filter B by hand

H I

• Perform a test run of the hydraulic system With the engine turned off:

2

G

• Check the hydraulic oil filter for leaks

307b0760.ai

Fig. 25: Reflux suction filter

00.13.7

Replacing the filler and breather filter Replace breather filter B for the hydraulic oil tank every 1500 service hours (yearly)

B

☞ Proceed as follows: • Unscrew breather filter B • Remove retaining chain J on lower section K of the filter

K

• Attach retaining chain J on lower section K of the new breather filter B 307b0780.ai

J

• Screw in the new breather filter B

L

Fig. 26: Securing the filler and breather filter

918133/AP0405

00-23

Maintenance

00.13.8

Checking hydraulic pressure lines

Specific safety instructions WARNING! Caution when checking hydraulic lines, especially when searching for leaks.

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 seems insignificant – otherwise serious infections could set in!

☞ Always follow these instructions: • Tighten leaking screwed fittings and hose connections only when the system is not under pressure; i.e., release the pressure before working on pressurized lines!

• Never weld or solder faulty or leaking pressure lines and connections.

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!

• Have damaged flexible lines replaced by authorized dealers only!

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

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

• Replace hydraulic hoses every six years from the date of manufacture, even if they do not appear to be damaged In this respect, we recommend that you follow all the relevant safety regulations for hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country. Also follow DIN 20066, part 5.

1 Q/00

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

Example: The indication “1 Q/00” means manufactured in the 1st quarter of 2000.

00-24

918133/AP0405

Maintenance

00.14

Gearboxes and axles Maintenance of these components is limited to checking the oil levels and changing the oil at prescribed intervals – see maintenance schedules on pages 00-4 through 00-6. See Section 00.1, “Fluids and lubricants” for authorized oil types.

IMPORTANT! Only use new sealing rings for oil filler and drain plugs. Drain oil only after running the machine for a longer period of time!

00.14.1

Rear axle transfer gearbox A

B

Fig. 27: Rear axle transfer gearbox

Checking the oil level

C

☞ Proceed as follows: • Park the machine on level ground when the gearbox is at operating temperature • Clean and unscrew plug B on transfer gearbox A If the oil level is below the opening or if the oil level cannot be seen at all, add oil If the oil level is correct: • Tighten plug B with a new sealing ring to make an oil-tight seal

Filling up the oil level

☞ Proceed as follows: • Park the machine on level ground when the gearbox is at operating temperature • Clean and unscrew plug B on transfer gearbox A • Fill in oil until it runs out of the filler opening If the oil level in the gearbox remains constant: • Tighten plug B with a new sealing ring to make an oil-tight seal

918133/AP0405

00-25

Maintenance

Changing the oil WARNING! Draining hot gearbox oil is hazardous –

Risk of burns! ☞ Wear protective gloves ☞ Use suitable tools, e.g., for unscrewing the oil drain plug ☞ Proceed as follows: • Park the machine on level ground when the gearbox is at operating temperature • Place a sufficiently large container under the transfer gearbox to collect the oil • Clean and unscrew plug B on transfer gearbox A • Unscrew plug C on transfer gearbox A

A

• Completely drain the old gearbox oil

B

• Tighten plug C with a new sealing ring to make an oil-tight seal • Add oil until it runs out of the filler opening If the oil level in the gearbox remains constant: • Tighten plug B with a new sealing ring to make an oil-tight seal After carrying out a test run: • Check the oil level again after about 5 minutes, and add if necessary

C Fig. 28: Rear axle transfer gearbox

00-26

918133/AP0405

Maintenance

00.14.2

Front and rear axle differentials

Environment!

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

IMPORTANT! Only use new sealing rings for oil filler and drain plugs. Drain oil only after running the machine for a longer period of time! Authorized oil types – see section 00.1, Fluids and lubricants on page 00-1.

Checking the oil level

☞ Proceed as follows:

B

• Park the machine on level ground • Clean and unscrew plug B If the oil level is below the opening or if the oil level cannot be seen at all, add oil If the oil level is correct: • Tighten plug B with a new sealing ring to make an oil-tight seal

C Fig. 29: Checking the oil level on the rear axle

B

Adding the oil level

☞ Proceed as follows: • Park the machine on level ground • Clean and unscrew plug B • Add oil until it runs out of the filler opening • Tighten plug B with a new sealing ring to make an oil-tight seal

C Fig. 30: Checking the oil level on the front axle

Changing the oil

☞ Proceed as follows: • Park the machine on level ground when it is at operating temperature • Place a container under plug C to collect the oil • Clean and unscrew plug B • Clean and unscrew plug C • Completely drain the old oil • Tighten plug C with a new sealing ring to make an oil-tight seal • Add oil until it runs out of the filler opening • Tighten plug B with a new sealing ring to make an oil-tight seal

918133/AP0405

00-27

Maintenance

00.14.3

Lubricating the rear axle oscillation-type bearing IMPORTANT! The machine has an oscillation-type rear axle. The bearing must be greased at the latest after every 50 service hours (weekly).

☞ Grease the oscillation-type bearing on grease zerk D with lithium-based multipurpose

D

grease – see section 00.1, Fluids and lubricants on page 00-1

Fig. 31: Grease zerks for oscillation-type bearing

00.14.4

Front and rear axle planetary drives Checking the oil level

☞ Proceed as follows: • Park the machine on level ground

H

G

F

2

• Turn plug E and oil level mark F to a horizontal position • Clean and unscrew plug E If the oil level is below opening G or if the oil level cannot be seen at all:

E Fig. 32: Checking the oil level in the planetary drive

• Add to the oil level • Tighten plug E with a new sealing ring H to make an oil-tight seal Adding the oil level

☞ Proceed as follows: • Park the machine on level ground • Turn plug E and oil level mark F to a horizontal position • Clean and unscrew plug E • Add fresh oil up to oil level mark F (overflow) • Tighten plug E with a new sealing ring H to make an oil-tight seal Changing the oil

☞ Proceed as follows: • Park the machine on level ground when it is at operating temperature • Place a container under the axle to collect the oil • Turn plug E to the topmost position • Clean and unscrew plug E • Turn plug E to the lowest position • Completely drain the old oil • Turn plug E and oil level mark F to a horizontal position • Add fresh oil up to oil level mark F (overflow) Tighten plug E with a new sealing ring H to make an oil-tight seal

00-28

918133/AP0405

Maintenance

00.15

Loader unit

00.15.1

Lubricating the pivots on the loader unit Lubricate the following lubrication points on the loader unit of the machine:

☞ Lubricate grease zerks C on the loader unit bearing every 50 service hours (weekly).

Lubricate daily during heavy-duty operation.

C

Fig. 33: Upper lubrication points on loader unit

☞ Lubricate grease zerks D on the lift cylinder bearing every 50 service hours (or once a week). Lubricate daily during heavy-duty operation.

☞ Lubricate grease zerks E on the tilt cylinder bearing with grease every 50 service hours (weekly). Lubricate daily during heavy-duty operation.

D

E

Fig. 34: Lubrication points for lift and tilt cylinder bearings

☞ Lubricate grease zerks F (2 x) on the tilt rod bearing with grease every 50 service hours (weekly). Lubricate daily during heavy-duty operation.

F

Fig. 35: Lubrication points on tilt rod bearing

918133/AP0405

00-29

Maintenance

☞ Lubricate grease zerk G on the tilt lever bearing every 50 service hours (weekly).

G

Lubricate daily during heavy-duty operation.

Fig. 36: Lubrication points on tilt lever bearing

☞ Lubricate grease zerks H (2 x) on the quickhitch bearing every 50 service hours (weekly). Lubricate daily during heavy-duty operation.

H

Fig. 37: Lubrication points on quickhitch facility

00.16

Tire care WARNING! Improper tire repairs constitute an

Accident risk! ☞ All repair work on tires and rims may only be performed by authorized dealers.

IMPORTANT! Regular inspection of the tires • Improves operating safety • Increases the service life of the tires • Reduces machine downtimes Refer to the table in “Specifications” section on page TD-15 for the authorized tire types and the correct tire pressures. Machines are also delivered from the supplier with a tire table decal on the front window or on the loader unit bulkhead.

00-30

918133/AP0405

Maintenance

00.16.1

Tire check

Daily checks

☞ Perform the following maintenance work daily: • Check tire pressure • Check tires and rims for damage (cracks, aging, etc.) – also on the inside • Remove foreign bodies from the tire tread • Remove traces of oil and grease from the tires Weekly checks

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

00.16.2

Wheel change WARNING! Use of wrong tires or wheels –

Accident risk! ☞ Use only wheels and tires authorized for your machine – see section TD.5.15, Tires on page TD-15

☞ Check the wheel nuts for tightness after every wheel or tire change

IMPORTANT! The wheels are heavy and can damage the threads on the wheel studs if they are handled incorrectly!

☞ 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 and prevent it from rolling away • Slightly loosen the wheel nuts of the tire you want to remove • Place a jack under the axle beam, making sure it is standing firmly • Raise the side of the axle from which you want to remove the tire • Check that the machine is standing firmly • Completely remove the wheel nuts • Remove the wheel

Fitting the wheels

☞ Proceed as follows: • Place the wheel onto the wheel studs • Tighten all the wheel nuts part-way • Lower the raised axle • Tighten the wheel nuts to the prescribed tightening torque – see section TD.5.20, General torques on page TD-16

918133/AP0405

00-31

Maintenance

00.17

Electrical system

00.17.1

Specific safety instructions • The battery contains sulphuric acid! This acid must not be allowed to come into contact with the skin, the eyes, clothing or the machine.

Therefore when recharging 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 part of the body 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 oxygenhydrogen mixture is formed in the battery cells – risk of explosion!

• Do not attempt to jump-start the machine if the battery is frozen or if the acid level is low. The battery may rupture or explode!

• Avoid open flames and sparks and do not smoke in the vicinity of open battery cells – otherwise the gas produced during normal battery operation may ignite!

• Use only 12 V power sources. Higher voltages will damage the electrical components • When connecting the battery leads, make sure the poles +/– are not reversed; otherwise sensitive electrical components will be damaged

• Do not interrupt voltage-carrying circuits at the battery terminals, because of the risk of sparking!

• Never place tools or other conductive articles on the battery – risk of short circuit!

• Disconnect the negative (–) battery terminal from the battery before starting repair work on the electrical system

• Dispose of used batteries properly 00.17.2

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 signalling and warning system OK? Weekly

☞ Check weekly: • Electric fuses – see section TD.5.12, Fuse box in control lever base on page TD-13 • Cable and ground connections • Charge condition of battery – See Battery on page 00-34.

• Condition of battery terminals

00-32

918133/AP0405

Maintenance

00.17.3

Instructions concerning specific components

Cables, bulbs and fuses

Always follow these instructions:

• Defective components of the electrical system must always be replaced by an authorized expert. Bulbs and fuses may be changed by unqualified persons

• When performing maintenance work on the electrical system, pay particular attention to ensure good contact in leads and fuses

• Blown fuses indicate overloading or short circuits. The electrical system should therefore be checked before installing the new fuse

• Only use fuses with the specified load capacity (amperage) – see section TD.5.12, Fuse box in control lever base on page TD-13 Alternator

Always follow these instructions:

• Only test run the engine with the battery connected • When connecting the battery, make sure the poles (+/–) are not reversed • Always disconnect the battery before performing welding work or connecting a quick battery charger

• Replace defective charge indicators immediately

918133/AP0405

00-33

Maintenance

00.17.4

Battery WARNING! Battery acid is highly caustic!

Risk of acid burn!

Therefore 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 part of the body 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 attempt to 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 electrical system!

-

Battery A is located in the engine compartment, on the right in driving direction. The battery is low in maintenance and no fluid needs to be refilled under normal operating conditions. However have the battery checked at regular intervals to make sure the fluid level is between the MIN and MAX marks.

+ A

Checking the battery requires it to be removed and must be carried out by an authorized dealer.

Always follow the specific safety instructions for the battery!

Fig. 38: Battery

IMPORTANT! As an option, the machine can be fitted with a battery master switch.

00-34

918133/AP0405

Maintenance

00.18

General maintenance work

00.18.1

Cleaning Cleaning the machine is divided into three separate areas:

• Inside the cab • Exterior of the machine • Engine compartment The wrong choice of cleaning equipment and agents may impair the operating safety of the machine on the one hand, and on the other undermine the health of the persons in charge of cleaning the machine. It is therefore essential to follow these instructions.

General instructions for all areas of the machine

When using washing solvents

• Ensure adequate room ventilation • Wear suitable protective clothing • Do not use flammable liquids, such as petrol or diesel When using compressed air

• Work carefully • Wear goggles and protective clothing • Do not aim the compressed air at the skin or 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 should 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 • Electrical 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!

918133/AP0405

00-35

Maintenance 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 and • 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

• Clean the seat belt (which remains fitted in the machine) only with a mild soap solution; do not use chemical agents as they may destroy the fabric!

WARNING! In the case of automatic seat belts (option), soiled belts may affect and impair winding –

Risk of personal injury! ☞ Only wind in the seat belt when it is dry!

Exterior of the machine

The following articles are generally suitable:

• High-pressure cleaner • Steam jet Engine compartment WARNING! Clean the engine at engine standstill only –

Risk of personal injury! ☞ Turn off the engine before cleaning

IMPORTANT! When cleaning the engine with a water or steam jet

☞ The engine must be cold, ☞ and do not point the jet directly at electrical sensors such as the oil pressure switch.

The humidity penetrating any such sensors causes them to fail and leads to engine damage!

00-36

918133/AP0405

Maintenance

00.18.2

Screw connections All screw connections must be checked regularly, even if they are not listed in the maintenance schedules.

Tighten loose connections immediately. Refer to section “Specifications” for the tightening torques.

00.18.3

Pivots and hinges All mechanical pivot points on the machine (e.g., door hinges, joints) and fittings (e.g. door arresters) should be lubricated regularly, even if they are not listed in the lubrication schedule.

Notes

918133/AP0405

00-37

Maintenance Notes

00-38

918133/AP0405

Engine

Engine

01 Engine 01.1

01

Specifications Engine Product

Yanmar diesel engine

Model

4TNV 88

Design

Water-cooled 4-cycle diesel engine

No. of cylinders1

4

Displacement

134 in.³ (2190 cm.³)

Displacement, compression

406 - 508 psi (28 - 35 bar)

Nominal Bore and stroke

3.5 x 3.5'' (88 x 90 mm)

Output

38 hp (28 kW) at 2400 rpm

Max. torque Max. engine speed without load

97 – 105 lb.-ft. (132 – 143 Nm) @ 1600 rpm 2590 +/- 50 rpm

Idle engine speed

1050 +/- 25 rpm

Oil Temperature

248° F (120° C) max. (at 104° F (40° C) outside temperature

Engine oil pressure at max. speeds

58 psi +/- 7.25 psi (4.0 bar +/- 0.5 bar)

Engine oil consumption

0.13 - 0.80 g/hph (0.1 - 0.6 g/kWh)

Valve tip clearance (intake-exhaust)

.008'' (0.2 mm)

Max. inclined position (engine no longer supplied with oil):

25° in all directions (Machine tilting limit is 20° lateral).

Specific fuel consumption

319 g/hph (238 g/kWh)

Fuel injection system

Direct injection

Firing order

1-3-4-2

Injection pressure (fuel nozzles)2 Starting aid Cooling-water temperature

3190 - 3335 psi (220 - 230 bar) Glow plug (preheating time 10 – 15 seconds) max. 221° F (105° C)

Radiator cap

13 psi (0.9 bar) pretension

Coolant thermostat3

162° - 181° F (72° - 83° C)

Exhaust values according to

97/68/EC

1. 1st cylinder on flywheel side 2. Nozzles set with spacers (0.1 mm = about 20 bar) 3. Do not run the engine without thermostat

918133/AP0405

01-1

Engine

01.1.1

Description of engine type decal The type decal is located on the cylinder-head cover of the engine

O TNE OO (A) (T) OO

Shipment code Turbocharger Model version Cylinder bore Model code Number of cylinders

Example: Mustang Model ML28

3 TNE 88 E N KR

Model

EPA standard Cylinder bore ø 3.5'' (88 mm) Model TNE 3 cylinders

01-2

918133/AP0405

Engine

01.2

Engine overview (forward driving direction)

Fuel filter with lock lever

Air intake

Fuel injection pump Oil pressure switch (engine oil)

Oil filler neck

Direction of rotation (“left”)

Fuel pump (maintenance-free)

Engine ventilation Engine oil filter

Elastic clutch with flywheel mass

34001s0100.iso

Oil dipstick Oil drain valve (plug)

918133/AP0405

01-3

Engine

01.3

Engine overview (reverse driving direction)

Thermostat housing

Temperature sensor S 21 (coolant)

Muffler

Alternator (12 V/55 A)

Starter (12 V/1.2 kW) 34001e0101.iso

01-4

918133/AP0405

Engine

01.4

Fuel injection system

Injection nozzles

Injection line

Fuel injection pump

Return line to tank Bleed screw

Water separator from fuel tank

Fuel filter

918133/AP0405

Fuel pump

01-5

Engine

01.5

Fuel injection nozzle

Reflux tube

Nozzle holder

Spacer injection pressure 3190 psi (220 bar) 0.039'' (0.1 mm) = 290 psi (20 bar)

Nozzle spring

Seat for nozzle spring Spacer washer Parallel pin

Nozzle needle Nozzle Nozzle body

Union nut

01-6

918133/AP0405

Engine

01.6

Fuel valve tip clearance

Tilt lever Valve tip clearance 0.005'' – 0.008'' (0.15 – 0.20 mm)

Adjusting screw Locknut

Firing order 1 – 3 – 4 – 2 – 1

918133/AP0405

01-7

Engine

01.7

Engine cooling: overview

Expansion tank (coolant)

Thermostat – opens at 162° F (72° C) – opens fully at 181° F (83° C)

Coolant

Oil

Radiator cap 13 psi (0.9 bar)

Fresh air aspirated through the radiator, from outside to inside

34001e1500.iso

Temperature sensor S21

01-8

Water pump

918133/AP0405

Engine

01.8

Fuel system: overview

Tank sensor (fuel level indication)

Filter insert

Fuel tank

Fuel filter with lock lever

Water separator (mounted in lower section of frame)

Fe e

Lock lever C = closed O = open

918133/AP0405

Re

d

tur

n

Filter insert with maintenance indicator

Fuel pump (maintenance-free) 34001s0800.iso

01-9

Engine

01.9 Engine trouble Problem

Possible causes Steering-column control lever not in neutral Engine starting temperature too low Wrong SAE grade of engine lubrication oil Fuel quality does not comply with specifications

Engine does not start or is not easy to start

Battery defective or dead Loose or oxidized cable connections in starter circuit Starter defective, or pinion does not engage Wrong valve tip clearance Fuel injector defective Fuel quality does not comply with specifications

Engine starts, but does not run smoothly or faultless

Wrong valve tip clearance Injection line leaks Fuel injector defective Oil level too low Oil level too high Air filter not working

Engine overheats. Temperature warning system responds

Air filter maintenance switch or gauge defective Oil cooler fins not working Fan defective, V-belt torn or loose Cooling air heats up Resistance in cooling system too high, flow capacity too low Fuel injector defective Oil level too high Fuel quality does not comply with specifications Air filter not working

Insufficient engine output

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

Engine does not run on all cylinders

Injection line leaks Fuel injector defective Oil level too low

Insufficient or no engine oil pressure

Engine inclination too high Wrong SAE grade of engine lubrication oil

Engine oil consumption too high

01-10

Oil level too high Engine inclination too high

918133/AP0405

Engine

Problem

Possible causes Blue

Oil level too high Engine inclination too high Engine starting temperature too low

White Engine smoke

Fuel quality does not comply with specifications Wrong valve tip clearance Fuel injector defective Air filter not working

Black

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

Notes:

918133/AP0405

01-11

Engine Notes:

01-12

918133/AP0405

Power train

Power train

22

Power train

22.1

Description: Variable displacement pump A 10 VG 28 DA

22

Example: Variable displacement pump with electric-hydraulic adjustment, speed-sensitive control and integrated auxiliary pump

Description:

• A 10 VG ➥ Axial-piston machine, adjustable swash plate design, closed circuit

• 28 ➥ Max. displacement volume Vg in cm³

• DA ➥ Hydraulic adjustment, speed-sensitive The A10VG pump is a variable displacement pump of axial-piston swash plate design.

Volume flow can be proportionally and continuously adjusted to drive speeds and to displacement volume. As deflection increases, so does volume flow from 0 to maximum value. Feed flow changes as the swash plate moves through the zero position, i.e., flow direction changes.

The pump is equipped with two pressure relief valves, pressure cut-off, control cartridge with integrated inching valve, feed pressure valve and forward/reverse solenoid.

918133/AP0405

22-1

Power train

22.2

Description: Hydraulic motor VM 45 EZ 6

Description:

• A10 VM ➥ Axial-piston machine, swash plate design, adjustable motor

• 45 ➥ Series code

• EZ ➥ Two-point adjustment, electrical with switching magnet The A10VM hydraulic motor is an axial-piston motor of swash plate design. Output speeds are proportional to the inflowing volume of liquid. Capacity changes as the tilting angle is changed. The changeover valve supplies the control piston with setting pressure in order to switch capacity from “Q max to Q min”.

22-2

918133/AP0405

Power train

22.3

Fuel system: overview

X1/setting pressure X2/setting pressure

X2/solenoid forward

Magnet – reverse

Mechanical zero position

Pressure cut-off 4931 - 5076 psi (340 – 350 bar)

Pilot pressure

HP – forward [about 5656 psi (390 bar)]

Transposition plug HP measuring point – forward Starting speeds setting Control cartridge with orifice

Measuring point – boost pressure

Lever for inching, actuated via Bowden cable Boost pressure valve

918133/AP0405

HP measuring point – reverse

HP – reverse [about 5656 psi (390 bar)]

22-3

Power train

22.4

Measuring points: variable displacement pump

HP measuring point – forward

Boost pressure

Pilot pressure

HP measuring point – reverse Transposition plug

22-4

918133/AP0405

Power train

22.5

Overview: hydraulic motor

qmin speed qmax tractive power

Measuring point control piston pressure

Scouring slide valve

Control line (variable displacement pump)

Y4

Solenoid valve 1st – 2nd speed range

918133/AP0405

Y13

Solenoid valve driving direction recognition

Electrical contact 1st – 2nd speed range:1st speed range => (+) 2nd speed range => (-) Driving direction recognition: forward => (+) reverse => (-)

22-5

Power train

22.6

Diagram: hydraulic speed range

Solenoid valve Y 2 => forwards Y 3 => reverse

HP valve about 5656 psi (390 bar)

Control cartridge

Control cylinder

Solenoid valve Y 4 => 1st – 2nd speed range

Control line

Pressure controller

Reflux: T 1 => variable displacement pump T 2 => hydraulic T2

Y2

Y3

b

a

T

X1

G

U

X3

PS

MB X

>

X

Shuttle throttle

B

X

L T2

X

X

B

>

Y 13 => driving direction recognition

X V= 1.70 cin/U (28 ccm/U) Q= 17.1 g/min (65 l/min) X2

G

S

P= 30 hp (22,3kw)

A

M1

X

X1

V= 0.37 cin/U (6,1 ccm/U) Q= 3.7 g/min (14 l/min) A MA

Measuring point (control piston pressure)

X

Flush valve

Scouring slide valve

Servo cylinder

A

Boost pump

P

P1

B1 )

)

Feed pressure valve 435 – 508 psi (30 – 35 bar)

36.2 psi (2,5 bar)

B2

Pressure cut-off 4931 – 5076 psi (340 – 350 bar)

7.2 psi 0,5 bar

Bypass 36 psi (2.5 bar) Return line (suction filter)

S4

3.0 psi (0,2 bar)

T

T X 34101s22_08.iso

Pilot control pressure to pressure accumulator 435 – 508 psi (30 – 35 bar)

22-6

S 20 => Temperature switch 203° F(95° C)

Hydraulic oil tank ventilation 2.9 psi (0.2 bar)

918133/AP0405

Power train

Power train

22

22.7

Check and adjustment instructions CAUTION! Run the machine warm to operating temperature (about 122° - 140° F (50 – 60° C)) before taking any measures or making any settings.

☞ Adjust valves only with the engine at a standstill

22.7.1

Towing Tow away the machine as follows:

☞ Open the two HP limiting valves on the hydraulic pump. To do this:

HP valve forward

• Unscrew locknut A • Screw in hexagon socket screw B until it is flush with the locknut IMPORTANT! Do not tow the machine over longer distances. The variable displacement pump and the hydraulic motor may be damaged.

☞ Tow the machine out of the hazard zone, e.g., on a low-platform semitrailer ☞ If possible, run the engine at idling speed when towing the machine ☞ Reverse the changeover of the HP valves before taking the machine back into service!

HP valve reverse

• Unscrew hexagon socket screw B to the limit • Tighten locknut A

307s2210.ai

A B

918133/AP0405

22-7

Power train

22.7.2

Test report model

Model: ____________________

Prod. no. variable displacement pump ____________________

Prod. no. variable displacement motor ____________________

Test conditions:

Rated oil temperature: Rated driving direction:

See page:

Notes:

22-9 22-10 22-11

Test features:

22-14 22-17

22-8

___________________

122° – 140° F (50° – 60° C) forward

Rated value: (rpm)

Min. idling speed

1025 – 1075

Max. idling speed

2565 – 2615

Boost pressure

Max. engine speeds

435 – 508 psi (30 – 35 bar)

Pilot pressure

Max. engine speeds

406 – 464 psi (28 – 32 bar)

Starting speeds

2nd range

1200 – 1300

High pressure

2nd speed range braked max. engine speeds

5366 – 5511 psi (370 – 380 bar)

Hydraulic resistance curve

2nd speed range braked at 2000 rpm

Over 4061 psi (280 bar)

Engine droop

1st speed range braked max. engine speeds

2250 – 2350

Control piston pressure

2nd speed range after braking

Wheel speed

Max. engine speeds 19 sec over 100 m

22-15

22-12

Serial no.

Nominal value: (rpm)

✔

3481 psi (240 bar) 18 km/h = 140 – 150

918133/AP0405

Power train

22.7.3

Adjusting boost pressure Tools required:

• Pressure gauge up to 870 psi (60 bar) Measuring point: boost pressure at max. engine speeds 2780 – 2840 rpm

Boost pressure valve

☞ Check/adjust boost pressure as follows: • Move the drive lever to neutral • Apply the parking brake • Connect the pressure gauge 870 psi (60 bar) to the measuring point • Start the diesel engine

➥ Boost pressure at idling speed: 435 psi (30 bar) ➥ At full load about 508 psi (35 bar) ☞ If boost pressure is too low: • Unscrew the boost pressure valve

➥ Set boost pressure with spacers

918133/AP0405

22-9

Power train

22.7.4

Adjusting pilot pressure Tools required:

• Pressure gauge up to 870 psi (60 bar)

Measuring point: pilot pressure Control cartridge with orifice ø 0.17'' (4.4 mm)

Set screw: (starting speeds)

Orifice 0.17'' (4.4 mm)

307s2230.ai

☞ Check/adjust pilot pressure as follows: • Move the drive lever to neutral • Apply the parking brake • Connect the pressure gauge 870 psi (60 bar) to the measuring point • Start the diesel engine and set max. speeds

➥ Rated pilot pressure: 406 – 435 psi (28 – 30 bar) ☞ Pilot pressure is achieved by: • The orifice ø 0.17'' (4.4 mm) in the control cartridge • Setting the starting speeds with the set screw

☞ If pilot pressure is not reached in spite of existing boost pressure, check the following: • Control cartridge

➥ Sleeve easily movable • Orifice • Inching facility • Pressure cut-off • Servo cylinder

22-10

918133/AP0405

Power train

22.7.5

Adjusting starting speeds Tools required:

• Tachometer HP valve forward

Control cartridge with orifice ø 0.17'' (4.4 mm)

HP valve reverse

w/f 10 Orifice 0.17'' (4.4 mm) Set screw starting speeds (hexagon socket 0.09'' (2.5 mm) 307s2230.ai

☞ Check/adjust the starting speeds as follows: • Move the drive lever to neutral • Apply the parking brake • Connect the tachometer • Start the diesel engine and engage 2nd speed range (forward)

➥ Machine must move off at engine speeds of 1250 – 1350 rpm ☞ Machine moves off too early (at lower speed): • Adjust the set screw on the control cartridge

☞ To do this, slacken the locknut w/f 10 and screw in the hexagon socket screw 0.09'' (2.5 mm)

☞ Tighten locknut w/f 10 ☞ Machine moves off too late (at higher speed): • Adjust the set screw on the control cartridge

☞ To do this, slacken the locknut w/f 10 and unscrew the hexagon socket screw 0.09'' (2.5 mm)

☞ Tighten locknut w/f 10

918133/AP0405

22-11

Power train

22.7.6

Adjusting the hydraulic resistance curve on the transposition screw Tools required:

• Tachometer (3000 rpm) • Pressure gauge up to 8702 psi (600 bar)

Transposition screw w/f 17 and allen key 5

Transposition screw is set from the supplier

Leaded transposition screw

HP measuring point forward

IMPORTANT! Please contact Mustang customer service before making any changes on the hydraulic resistance curve.

☞ After contacting Mustang customer service, check/adjust the hydraulic resistance curve as follows: • Safely jack up the machine at the front and rear • Turn off the engine • Unhitch the cable on the inching pedal • Connect a pressure gauge max. 8702 psi (600 bar) to the measuring point • Connect a tachometer to the diesel engine • Start the engine • Move the drive lever to 2nd speed range (forward) • Set the diesel engine to maximum speeds (2780 – 2850 rpm) • Slowly brake the machine with the service brake

➥ With the engine speeds at 2000 rpm, high pressure must be 4061 psi (280 bar) as a minimum

22-12

918133/AP0405

Power train

22.7.7

Readjusting the hydraulic resistance curve

IMPORTANT! In order to avoid damage to the variable displacement pump:

☞ Adjust the transposition screw only in the 0 – 6 o'clock range (see figure)

Hydraulic resistance curve (bar)

0 o'clock

Hydraulic resistance curve is set from the supplier

500 450 400

3 o'clock

300

6 o'clock

200 100

Pilot pressure 1000

Transposition plug

1500

2000

2500

Engine speed (rpm)

☞ Readjust the hydraulic resistance curve as follows: ➥ 0 o'clock => 4061 psi (280 bar) high pressure is easily reached ➥ 3 o'clock => adjustment from the supplier ➥ 6 o'clock => 4061 psi (280 bar) high pressure is not reached as easily

918133/AP0405

22-13

Power train

22.7.8

Adjusting variable displacement pump output Tools required:

• Tachometer (3000 rpm) • Pressure gauge 8702 psi (600 bar)

HP measuring point – forward Control cartridge with orifice ø 0.17'' (4.4 mm)

Pilot pressure measuring point [406 – 464 psi (28 – 32 bar) at full engine speeds]

☞ Check engine droop as follows: • Safely jack up the machine at the front and rear • Turn off the engine • Unhitch the cable pull on the inching pedal • Connect the pressure gauge 8702 psi (600 bar) to the HP measuring point (forward) • Connect a tachometer to the diesel engine • Start the engine • Move the drive lever to 1st speed range (forward) • Set the diesel engine to maximum speeds (2780 – 2850 rpm) • Brake the drive with the service brake to 2175 – 2321 psi (150 – 160 bar) pump pressure

➥ Engine droop must set in at an engine speed of 2450 – 2550 rpm ☞ If engine speeds are over 2550 rpm at an identical brake-pedal pressure: • Check the orifice of the control cartridge, and check pilot pressure

☞ If engine speeds are below 2450 rpm at an identical brake-pedal pressure: • Check diesel engine output • Check the air filter (increased dust pile-up on filter cartridge) • Check the fuel system (filter, dirt, etc.)

22-14

918133/AP0405

Power train

22.7.9

Adjusting high pressure/pressure cut-off Tools required:

• Pressure gauge 8702 psi (600 bar) Pressure cut-off

HP valve forward

Loosen hexagon socket screw Apply tension to spring cap

HP measuring point forward

Set w/f 8 here 1 revolution equals about 580 psi (40 bar) Measuring point HP valve reverse HP valve reverse

302S2214.ai

Remove valve completely (w/f 32)

☞ Check high pressure as follows: • Connect the pressure gauge.

• Start the diesel engine and move the drive lever to 1st speed range (forward).

• Drive the machine against hydraulic resistance and read off the pressure on the gauge.

➥ High pressure must be 4931 – 5076 psi (340 – 350 bar) Adjust the pressure on the pressure cut-off

☞ Pressure increase: • Screw in the pressure cut-off

☞ Pressure reduction: • Unscrew the pressure cut-off Pressure setting of the HP valves exceeds the pressure cut-off setting by about 10%.

☞ Check/adjust the HP valves as follows: • Set pressure cut-off to “hydraulic resistance” • Connect both pressure gauges to measurement ports HP forward and HP reverse • Start the diesel engine and move the drive lever to 1st speed range (forward).

• Drive the machine against hydraulic resistance and read off the pressure on the gauge.

➥ Do not allow the wheels to spin ➥ High pressure must be about 5656 psi (390 bar) ☞ Pressure increase: • Remove the respective pressure valve completely • Remove the spring pile • Clamp the spring cap in a vise • Loosen hexagon socket screw • Adjust with w/f 8

➥ Once adjustment/measurement is finished, set the pressure back to 4931 – 5076 psi (340 – 350 bar).

918133/AP0405

22-15

Power train

22.7.10

Pressure cut-off: exploded view

34001s22_10.eps

22-16

918133/AP0405

Power train

22.7.11

Adjusting control piston pressure of hydraulic motor Tools required:

• Two pressure gauges 8702 psi (600 bar)

HP measuring point – forward

Set screw for control piston pressure

Measuring point control piston pressure

☞ Check engine droop as follows: • Safely jack up the machine at the front and rear • Turn off the engine • Unhitch the cable pull on the inching pedal • Connect the pressure gauge 8702 psi (600 bar) to the HP measuring point forward • Connect the pressure gauge 8702 psi (600 bar) to the measuring point for control piston pressure • Connect a tachometer to the diesel engine • Start the engine • Move the drive lever to 2nd speed range (forward) • Set the diesel engine to maximum speeds (2560 – 2650 rpm)

➥ Both pressure gauges show approximately the same value • Slowly brake the drive with the service brake

➥ Identical pressure increase in both pressure gauges ➥ The pressure gauge at the measuring point for control piston pressure must drop at 3481 psi (240 bar)

☞ Adjusting the control piston pressure • Screw in the set screw => pressure increases • Unscrew the set screw => pressure drops

918133/AP0405

22-17

Power train Notes:

22-18

918133/AP0405

Axles

Axles

23 Axles 23.1

23

Type decal – axle

All axle data are located on the type decal

Type decal– axle Axle type

Carraro no.

Input shaft speed

Carraro serial no.

Customer no.

Total ratio

Differential type

Oil specification

Oil quantity in differential housing and transfer gearbox

918133/AP0405

23-1

Axles

23.2

Drain, fill and check plug

Pos

Description

1. Fill and check plug – axle tube 2. Drain plug – differential 3. Check plug – planetary drive 4. Fill plug – planetary drive 5. Drain plug – planetary drive 6. Breather 7. Lubrication points (grease zerks)

23-2

918133/AP0405

Axles

23.3

918133/AP0405

Tightening values lb-ft (Nm)

23-3

Axles

23.4

Screw connections

Loctite 270 or Superbond 331 Wheel bolts glued in wheel hub

Loctite 542 or Superbond 321

23-4

918133/AP0405

Axles

23.5

Sealing work

23.5.1

Differential – front axle

2

1

3 4 5

Replacing the rotary shaft seal

☞ Proceed as follows: • Remove the drive shaft • Remove brake caliper 2 • Remove brake disc 1 • Remove circlip 5 with appropriate tools • Remove flange 4 from the input shaft with an extractor • Replace rotary shaft seal 3 with a new one • Assemble in reverse order

918133/AP0405

23-5

Axles

23.5.2

Overview: Planetary carrier – double drive shaft

23.5.3

Sealing: Planetary carrier ☞ Drain the oil • Open check plug 13 • Remove drain plug 9 and drain the oil

Environment!

Collect the drained oil in a container and dispose of it in a manner consistent with environmental laws.

Fig. 1:

23-6

918133/AP0405

Axles

☞ Remove fastening screws 3 ☞ Remove cover 4 ☞ Remove O-ring 5 from the wheel hub

WARNING! Be careful when removing the planetary drive – Fig. 2:

Risk of personal injury! ☞ Use a strap or cable to secure the planetary drive onto a lifting tackle or other lifting gear to avoid damage or personal injury

☞ Mount the eyebolt for lifting the planetary drive ☞ Remove screws 10/15

Fig. 3:

☞ Extract bearing pins 14 (upper) and 11 (lower)

Fig. 4:

☞ Carefully remove the planetary drive with the double drive shaft from the axle carrier

Fig. 5:

918133/AP0405

23-7

Axles

☞ Remove circlip 6 with an appropriate tool from double drive shaft 21 ☞ Remove spacer washer 7

Fig. 6:

☞ Extract double drive shaft 21 from planetary drive 8 8

21 Fig. 7:

☞ Dismantle the planetary drive – see Sealing: Planetary drive on page 23-11

Fig. 8:

☞ Place the planetary carrier on firm and level ground

IMPORTANT! Do not damage the seat of the rotary shaft seal in the planetary carrier as you remove it

☞ Carefully remove rotary shaft seal 20 with a mounting lever Fig. 9:

☞ Turn the planetary carrier and drive out bushing 19 with a suitable adapter

23-8

918133/AP0405

Axles

19

20

☞ Thoroughly clean all parts removed ☞ Mount bushing 19 with an adapter ☞ Insert rotary shaft seal 20 into the planetary carrier housing with an adapter

Fig. 10:

20

IMPORTANT! The rotary shaft seal can be damaged when fitting the double drive shaft.

☞ Wrap thin protective tape around the profile of the double drive shaft, so that the tape can be removed after assembly.

☞ Fill the sealing ring grease chamber of rotary shaft seal 20 ¾ full with grease Fig. 11:

☞ Fit double drive shaft 21 into the planetary carrier ☞ Remove the protective cover from the double drive shaft

Fig. 12:

☞ Fit washer 7 and circlip 6 onto the end of the shaft

Fig. 13:

918133/AP0405

23-9

Axles

☞ Insert the planetary carrier with the double drive shaft into the axle carrier

Fig. 14:

Do not use the existing wave spring washers as spacers Follow these instructions during assembly:

☞ Fit the thick wave spring washer above ☞ Fit the thin wave spring washer below ☞ Mount king pins 11/14 and secure them with screws 10 / 15 (follow the torque – see Tightening values lb-ft (Nm) on page 23-3)

☞ Remove the protective tape from the double drive shaft Fig. 15:

☞ Place a new O-ring 5 onto the flange housing Mount cover 4 with screws 3 (follow the torque – see Tightening values lb-ft (Nm) on page 23-3)

Fig. 16:

☞ Fit the drain plug ☞ Fill in oil ☞ Check the oil level

Fig. 17:

23-10

918133/AP0405

Axles

23.5.4

Overview: Planetary drive

23.5.5

Sealing: Planetary drive ☞ Remove screws 1 on flange 2 ☞ Remove the flange

Fig. 18:

☞ Remove flange 2 and bearing 3

3 2

Fig. 19:

918133/AP0405

23-11

Axles

☞ Remove hub 4 with two mounting levers

Fig. 20:

☞ Press cassette-type sealing ring 6 out of housing 12 with a mounting lever

Fig. 21:

☞ Insert cassette-type sealing ring 6 into housing 12 with an adapter

Fig. 22:

☞ Mount wheel hub 4, bearing 3 and flange 2

3 2

4 Fig. 23:

23-12

918133/AP0405

Axles

☞ Mount flange 2 with screws 1

1

(follow the torque – see Tightening values lb-ft (Nm) on page 23-3) 2

Fig. 24:

23.5.6

Sealing: Axle carrier ☞ Mount the eyebolt for lifting the planetary drive ☞ Remove screws 10/15 15

10 Fig. 25:

☞ Extract bearing pins 14 (upper) and 11 (lower) 14

11 Fig. 26:

☞ Carefully remove the planetary drive with the double drive shaft from the axle carrier

Fig. 27:

918133/AP0405

23-13

Axles

☞ Remove rotary shaft seal 1 in the axle carrier

Fig. 28:

☞ Fill the sealing ring grease chamber of rotary shaft seal 1¾ full with grease ☞ Fit rotary shaft seal 1 with an adapter

Fig. 29:

IMPORTANT! The rotary shaft seal can be damaged when fitting the planetary carrier.

☞ Wrap thin protective tape around the profile of the double drive shaft, so that the tape can be removed after assembly.

☞ Insert the planetary carrier with the double drive shaft into the axle carrier Fig. 30:

Do not use the existing wave spring washers as spacers Follow the instructions during assembly:

15

☞ Fit the thick wave spring washer above ☞ Fit the thin wave spring washer below ☞ Mount king pins 11/14 and secure them with screws 10 / 15 (follow the torque – see Tightening values lb-ft (Nm) on page 23-3) 10

☞ Remove the protective tape from the double drive shaft

Fig. 31:

23-14

918133/AP0405

Axles

23.5.7

Sealing: Axle carrier – differential

Axle carrier housing (right) O-ring

Drain plug

Axle carrier housing (left)

Differential housing

O-ring

34001e2301.eps

WARNING! Be careful when removing the axle carrier housing –

Risk of personal injury! ☞ Place the axle on a suitable support to safely prop the differential and axle carrier after separating them.

☞ Drain the oil ☞ Remove the screws (axle carrier) ☞ Remove the axle carrier from the differential housing ☞ Check the O-ring and replace it if necessary ☞ Assemble in reverse order

918133/AP0405

23-15

Axles

23.5.8

Sealing: Gearbox – input flange

3

34001s23_27.eps

5

4

2 1 6

☞ Proceed as follows: • Remove the HP flexible hoses from the hydraulic motor • Remove the hydraulic motor from the gearbox housing • Drain the oil from the gearbox housing • Remove fastening screw 4 • Remove the complete gearbox from the gearbox housing • Remove circlip 6 with suitable tools • Extract input shaft 1 from the gearbox with suitable tools • Remove rotary shaft seals 2 and 5 • Fit rotary shaft seals 2 and 5 with an adapter • Mount the gearbox in the reverse order

➥ Torques – see Tightening values lb-ft (Nm) on page 23-3

23-16

918133/AP0405

Axles

23.6

Overview: Self-locking differential

34001e2305.eps

• The self-locking differentials are fitted in the front and rear axles • 10 outside discs • 8 inner discs • Efficiency 45%

918133/AP0405

23-17

Axles Notes:

23-18

918133/AP0405

Brakes

24 Brakes 24

24.1

Overview: Brake system

CAUTION! Do not readjust the parking brake on the cable

☞ – see Readjustment: Parking brake on page 24-2 Cable (parking brake)

Cable (parking brake)

Cable (inching)

• S 16 => check switch (parking brake) ➥ Actuating the parking brake interrupts the drive ➥ Installed: In the cab behind the parking brake lever 34001e2402.iso

918133/AP0405

24-1

Brakes

24.2

Readjustment: Parking brake

0.12'' (3 mm)

0.12'' (3 mm)

Lever for cables

A

B 1

Set screw (hexagon socket ø 0.24'' (6 mm)

2

Set screw (w/f 19)

• Readjust with set screws (1) and (2) ➥ Distance between lever (A/B) and brake caliper must be 0.12'' (3 mm) for each IMPORTANT! Do not readjust the parking brake with the cable in order to avoid damage to the brake system.

24-2

918133/AP0405

Brakes

24.2.1

Replacing brake linings

Mounting bore in brake disc Brake caliper

Fastening screw [hexagon socket ø 0.31'' (8 mm)] Loctite 243

☞ Proceed as follows: • Remove the cable (parking brake) on the brake caliper • Turn the mounting bore in the brake disc above the attachment of the brake caliper • Remove the fastening screws [hexagon socket ø 0.31'' (8 mm)] and the brake caliper • Replace the brake pads with new ones • Mount the brake caliper with the fastening screws

➥ Secure the screws with Loctite 243 ➥ Tightening torque 46 Nm • Mount the cable pulls (parking brake) on the brake caliper

➥ Setting – see Basic setting: Cables on page 24-4

918133/AP0405

24-3

Brakes

24.3

Basic setting: Cables

24.3.1

Cable for inching

Brake/inching pedal Set screw 3 Cable for inching Fork head 1

Angle joint 2

Inching lever

34001e2201.iso

☞ Proceed as follows: • Set the inching lever on the variable displacement pump to maximum deflection • Set the threaded bore in the fork head (1) flush with the threaded pin of the cable and secure it • Mount angle joint (2) onto the cable and secure it • Mount the cable for inching (bracket, inching lever and brake/inching pedal) IMPORTANT! Adjust the brake/inching pedal without applying any pressure in order to avoid damage to the inching valve

☞ Slightly press the brake/inching pedal down to the limit ☞ Adjust set screw (3) to the limit and secure it

24-4

918133/AP0405

Brakes

24.3.2

Cable – parking brake

Parking brake lever Cable (parking brake)

Fork head 1

Lever A

Lever B Fork head 2

Check switch (parking brake)

☞ Proceed as follows: • Set the threaded bore in the fork head (1 + 2) flush with the threaded pin of the cable and secure it 34001e2402.iso

• Mount the cable (parking brake) (lever A + B) • Secure fork head (1) • Pull the parking brake lever with force 5 – 6 times and release it • Adjust the cable (parking brake) on fork head (2)

➥ Setting: 4 – 5 notches on the parking brake lever • Secure fork head (2)

918133/AP0405

24-5

Brakes

24.3.3

Cable for parking brake

Pull the parking brake lever up 3 notches Lever A

Fork head 1

Fork head 2

Lever B

0.59 – 0.62'' (15 – 16 mm)

Fork head 1

☞ Proceed as follows: 34001e2402.iso

• Pull the parking brake lever up 3 notches • Set the threaded bore in fork head (1) flush with the threaded pin of the cable • Mount the cable on lever (B) and secure it • Fasten the brake/inching pedal 0.59 – 0.62'' (15 – 16 mm) before the stop bolt • Adjust fork head (2) on the cable and mount it onto lever (A) without any tolerance • Secure fork head (2)

➥ Hydraulic drive is interrupted, parking brake is actuated

24-6

918133/AP0405

918133/AP0405

27

27

Steering

27.1

Overview – steering circuit

Test port for service work and troubleshooting (steering system) Test port for service work and troubleshooting (work hydraulics)

Pressure relief valve 2538 psi (175 bar) Return line pilot control

Priority valve

Hydraulic return line suction filter Suction line

Return line

34001e2700.iso

Pressure line (to priority valve) Steering cylinder (rear axle)

Hydraulic pump (steering system/loader unit)

27-1

Steering

Steering cylinder (front axle)

Steering diagram

Steering

27-2

27.2

Hydrostatic steering Pressure line (control valve) Pressure relief valve 2538 psi (175 bar)

Test port (troubleshooting)

)(

Pressure line (hydraulic pump)

P

T LS

R X

L

CF

A2

P

7.2 psi (0,5 bar)

(

Return (tank) ( (

Pilot pressure line (work hydraulics) (

(

918133/AP0405

cylinder (inside), which compensates the pressure in both chambers (rod side/base side)

Test port (service work)

145 psi B2 (10 bar)

(

➥An oblong slot is milled into the end of the

145 psi (10 bar) B1

(

• Steer to the limit and hold with the engine running (left or right)

7.2 psi (0,5 bar)

(

synchronized as follows:

X

☞ The front/rear axle steering cylinders are

X

A1

)(

LS

)(

)(

Check block

Priority valve

EF

34101s27_01.iso

918133/AP0405

27.3

Hydraulic circuit: Steered to the left

Hydraulic return line suction filter

T P L R

Suction line

LD

34001e2700.iso

Front axle

Rear axle

Pressure line (priority valve)

27-3

Steering

Hydraulic pump (steering system/loader unit)

Hydraulic circuit: Steered to the right

Steering

27-4

27.4

T P

Hydraulic return line suction filter

L R Suction line

LD

34001e2700.iso

Pressure line (priority valve)

Front axle Rear axle 918133/AP0405

Hydraulic pump (steering system/loader unit)

Steering 27

27.5

Steering

Hydraulic ports on servostat 17 lb-ft (23 Nm)

L

29 lb-ft (40 Nm)

L

13 lb-ft (18 Nm)

T LD

17 lb-ft (23 Nm) 29 lb-ft (40 Nm)

R

R

P T

P

T

• LD • L • R • P • R

27.6

17 lb-ft (23 Nm)

LD

= load sensing Priority valve – servostat = left

Servostat – rear axle steering cylinder

= right

Servostat – front axle steering cylinder

= pressure

Hydraulic pump – priority valve – servostat

= return

Servostat – hydraulic tank

Adjustment: pressure relief valve – servostat ☞ Proceed as follows: • Remove the plug • Set pressure to 2538 psi (175 bar) with allen key (ø 6) • Mount the plug

Fig. 1:

918133/AP0405

27-5

Steering

27.7

Sealing steering cylinders 9 5 4

3 34001e2303,eps

7 8

2

6

1

9 Fig. 2:

☞ Proceed as follows: • Remove lock nut 1 on track rod joint 2 • Remove track rod joint 2 from the planetary carrier • Determine the setting value between the end of the piston rod and the track rod joint

➥e.g., determine the revolutions as you remove track rod joint 2 • Remove track rod joint 2 from piston rod 3 • Remove threaded pipe fitting 4 • Remove the complete steering cylinder from the axle carrier

➥3 screws 5 • Fasten the steering cylinder in a vise with aluminum clamps • Remove circlip 6 • Slide guide bushing 7 to the inside • Remove circlip 8 • Pull piston rod 3 with guide bushing 7 • Replace the seals and cuffs 9 • Reassemble in the reverse order.

➥Follow the torques – see section 23.3, Tightening values lb-ft (Nm) on page 23-3

27-6

918133/AP0405

Electrical system

Electrical system

33

33 Electrical system

33.1

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

Current “I” – Ampere (A) Voltage “U” – Volt (V) Resistance “R” – Ohm (Ω)

Mnemonic:

U R

I

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

33.2

Measuring equipment, measuring methods Multi-function measuring device

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

Follow AC/DC basic setting.

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

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

918133/AP0405

33-1

Electrical system Measuring methods – multifunction measuring device

• Measuring current (ignition turned on):

Black cable in COM socket (ground), red cable in A socket or mA socket; connect in series to consumer.

• Measuring voltage (ignition turned on):

Black cable in COM socket (ground), red cable in V socket; connect in parallel to consumer.

• Measuring resistance (ignition turned off): Black cable in COM socket (ground), red cable in Ω-socket; connect in parallel to consumer (see measuring voltage).

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

• Line test (testing voltage): Connect test lamp between test point (live cable) and machine ground or between test point (ground line) and a live cable.

• Functional check (testing current): Connect test lamp between a connection on the consumer to be tested and the connection line.

33-2

918133/AP0405

Electrical system

33.3

Terminal description (extract from DIN 72 552) Terminal descriptions and cable descriptions are not identical because equipment with different terminal descriptions can be connected to both ends of a cable. If there are not enough terminal descriptions (multiple plug and socket connections), the terminals are marked with continuous number or letter codes without any standardized function assignment.

Terminal

Significance

1

Ignition coil, distributor (low voltage)

1a 1b

Ignition distributor with two separate electrical circuits to ignition contact breaker I to ignition contact breaker II

2

Short-circuit terminal (magneto ignition)

4

Ignition coil, ignition distributor High voltage

4a 4b

Ignition distributor with two separate electrical circuits from ignition coil I, terminal 4 from ignition coil II, terminal 4

15

Switched plus behind battery (output ignition [drive] switch)

15a

Output at dropping resistor to ignition coil and starter

17 19

Preheating start switch Start Preheating

30

Battery Input from + battery terminal, direct

30a

12/24 V battery changeover relay Input from + terminal of battery II

31

Return line to battery Minus terminal or ground, direct

31b

Return line to battery Minus terminal or ground, via switch or relay (switched negative)

31a 31c

12/24 V battery changeover relay Return line to – minus terminal of battery II Return line to – minus terminal of battery I

32 33 33a 33b 33f 33g 33h 33L 33R

Electric motors Return line1) Main terminal connection1) Self-parking switch-off Shunt field For second lower speed range For third lower speed range For fourth lower speed range Counterclockwise rotation Clockwise rotation

45

Starter Separate starter relay, output; Starter, input (main current)

45a 45b

Two-starter parallel operation Starting relay for engagement current Output starter I, Input starters I and II Output starter II

48

Terminal on starter and on start-repeating relay (to monitor starting)

49 49a 49b 49c

Turn indicator unit (pulse generator) Input Output Output, 2nd turn indicator circuit Output, 3rd turn indicator circuit

50

Starter Starter control (direct)

50a

Battery changeover relay Output for starter control

918133/AP0405

33-3

Electrical system

Terminal

Significance

50b

Starter control with parallel operation of 2 starters with sequential control

50c 50d

Starting relay for sequential control of the engagement current during parallel operation of 2 starters Input at starting relay for starter I Input at starting relay for starter II

50e 50f

Start locking relay Input Output

50g 50 h

Start repeat relay Input Output

51 51e

AC alternator Direct current voltage at rectifier Direct current voltage at rectifier with choke coil for daytime driving

52

Trailer signal Signals from trailer to towing machine

53 53a 53b 53c 53e 53i

Wiper motor, input (+) Wiper (+), self-parking switch-off Wiper (shunt winding) Electric window washer pump Wiper (brake winding) Wiper motor with permanent magnet and third brush (for higher speed)

54g

Trailer signal For lamp combinations and trailer plug connections Brake lights Pneumatic valve for additional retarding brake, electromagnetically actuated

55

Fog lights

56 56a 56b 56d

Headlight High beam and high beam indicator Low beam Headlight flasher contact

57 57a 57L 57R

Side marker light for motorcycles (also for cars, trucks etc. in other countries) Parking light Parking light, left Parking light, right

58 58b 58c 58d 58L 58R

Side marker, rear, numberplate and instrument panel lights Rear light changeover for single-axle tractors Trailer plug-and-receptacle assembly for single-conductor rear light cable with fuse in trailer Variable-intensity instrument panel lights, side marker and rear light left right, numberplate light

59 59a 59b 59c

AC alternator (magneto alternator) Alternating voltage, output, rectifier, input Charging armature, output Rear light armature, output Brake light armature, output

61

Alternator charge indicator

71 71a 71b

Tone sequence control device Input Output to horns 1 + 2 low Output to horns 1 + 2 high

54

72

Alarm switch (rotating beacon)

75

Radio, cigarette lighter

76

Loudspeaker

77

Door valve control

33-4

918133/AP0405

Electrical system

Terminal

Significance

83 83a 83b 83L 83R

Switches Break-contact and change-over switches Input 1st output, break side 2nd output, break side Make-contact switch Input 1st output 2nd output 1st input 2nd input Multiple position switch Input Output, position 1 Output, position 2 Output, left-hand position Output, right-hand position

84 84a 84b

Current relay Input, actuator and relay contact Output, actuator Output, relay contact

81 81a 81b 82 82a 82b 82z 82y

85 86 86a 86b

84a

84b

84

Switching relay – output, actuator (end of winding negative or ground) Input, actuator Start of winding Start of winding or 1st winding Winding tap or 2nd winding 86

87a 88a 87a 88a 87a 88a 88b

85

87

88

87

87

87 87a 87b 87c 87z 87y 87x

Relay contact for break and changeover contacts Input 1st output (break side) 2nd output 3rd output 1st input 2nd input 3rd input

88

Relay contact for make-contact Input

88a 88b 88c

Relay point for make-contact and changeover contacts (make side) 1st output 2nd output 3rd output

88z 88y 88x

Relay contact for make-contact 1st input 2nd input 3rd input

Alternator and governor B+ BD+ DDF DF 1 DF 2

Battery positive Battery negative Dynamo positive Dynamo negative Dynamo field Dynamo field 1 Dynamo field 2

U, V, W

Three-phase alternator – three-phase terminals

Turn indicator (turn indicator unit) C C0 C2 C3 L R

918133/AP0405

First indicator Main terminal connection for separate indicator circuits actuated by the turn indicator switch Second indicator Third telltale (e.g. when towing two trailers) Indicator light, left Indicator light, right

33-5

Electrical system

33.4

Cable color coding The cables are color-coded based on DIN 72551 Part 4. However, this standard has been withdrawn and is not currently in use. Refer to the 21 pin cab/frame interface or the explanation in the wiring harness drawings for other colors not listed in this DIN standard

Extract from DIN 72551, sheet 4 Line From

to

Basic color

Identification color

Ignition coil I

Ignition distributor (low-voltage ignition lead)

Green

-

Ignition coil II

Ignition distributor (low-voltage ignition lead)

Green

Red

Battery

Starter

Black

-

Battery

Ground (if bare ground lead is not used)

Black

-

Starter

Alternator

Red

-

Starter

Control panel (30)

Red

-

Light switch (30)

Ignition switch (30)

Red

-

Control panel (30) or light switch (30)

Fuse

Red

-

Fuse

Hand lamp, radio, clock etc.

Red

-

Control panel (15/54)

Heater plug and starter switch; heater-plug indicator

Black

-

Heater plug and starter switch; heater-plug indicator

Glow plugs

Black

-

Ignition switch (15/54)

Ignition coil

Black

-

Ignition switch or control panel (54/15/61a)

Indicators

Black

-

Control panel or ignition switch (15/54)

Fuse

Black

-

Fuse box

Brake light

Black

Red White-green

Fuse box

Turn indicator switch

Black

Turn indicator switch

Turn indicator, left

Black

White

Turn indicator switch

Turn indicator, right

Black

Green

Indicator

Turn indicator

Light blue

-

Fuse

Cigarette lighter

Black

Yellow-red

Fuse

Heated window

Black

Fuse

1st horn

Black

Yellow

Fuse

2nd and 3rd horn

Black

Yellow-light blue

Horns

1 pole horn pushbutton (ground)

Brown

-

Fuse

Wipers

Black

Purple

Battery charge indicator

Terminal 61 of alternator or reverse current cutout

Light blue

-

Fuse

Main beam indicator

Light blue

White

Oil pressure gauge (indicator)

Oil pressure switch

Light blue

Green

Fuel level indicator

Fuel tank

Light blue

Black

Tire-pressure warning device

Tire-pressure drop indicator

Light blue

Yellow

Control panel and/or light switch

Low beam switch

White

Black

Low beam switch (a)

Fuse

White

-

Fuse

Main headlight, left

White

-

Fuse

Main headlight, right

White

-

Low beam switch (b)

Fuse

Yellow

-

Fuse

Low beam, left

Yellow

-

Fuse

Low beam, right

Yellow

-

Control panel or light switch (58)

Fuse

Grey

-

Fuse

Rear light, side light and parking light left

Grey

Black

Fuse

Numberplate light (combined with left rear light)

Grey

Black

Fuse

Rear light, side light and parking light right

Grey

Red

Fuse

Numberplate light (combined with right rear light)

Grey

Red

Fuse

Numberplate light (only if special line is laid)

Grey

-

Fuse

Dome light

Red

-

Control panel (57)

Fuse

Grey

Green

Control panel and/or light switch

Instrument panel light

Grey

Red

All consumers except the battery ground lead if the use of bare lineS Ground is not possible

Brown

-

Battery change-over switch (50)/starter pushbutton or heater plug Starter and starter switch

Black

-

33-6

918133/AP0405

Electrical system Extract from IEC 757, edition 1983 Electrical engineering Color coding Identical with IEC 757

edition 1983

Color

Abbreviation

Abbreviation

old

new

Black

sw

BK

Brown

br

BN

Red

rt

RD

Orange

or

OG

Yellow

ge

YE

Green

gn

GN BU

Blue

bl

Violet

vi

VT

Grey

gr

GY

White

ws

WH

Pink

rs

PK

Gold

-

GD

Turquoise

tk

TQ

Silver

-

SR

33.5

Relays

33.5.1

Use, mode of function Relays are used for switching electrical loads (high currents) whereby the control power of the relay coil is relatively low. Relays can therefore be controlled by micro electronics or micro switches (e.g., touchpad keyboards, sensors). The switch contacts can be makecontact, break-contact or changeover switches. These undertake the actual switching function.

33.5.2

Terminal description on relay

Zero-center relay 86 = Start of coil

(control line)

85 = End of coil

(ground)

30 = Input

(load line)

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

918133/AP0405

33-7

Electrical system

33.5.3

Types of relays used • Relay 12V, 10/15 A • Relay 12V, 70 A • Relay 12V, 40/60 A • Relay 12V, 10/20 A • Turn indicator relay 12 V

33.5.4

order no.

209193

order no.

0003322917

order no.

0003323317

order no.

209061

order no.

209194

Overview: Relays The relays are installed in the control lever base under the switch panel (as seen from below the fuse board)

K1

K7

K31

K5

K12

K4

K11

Switching relay no.

Protected circuit

K1

– High current relay – terminal 15

K3

– Solenoid valve – reverse driving

K4

– Solenoid valve – forward driving

K5

– Front attachments

K6

– Turn indicator relay

K7

– Wipers

K 11

– Changeover (3rd control circuit)

K 12

– Changeover (3rd control circuit)

K 13

– Unlock (quickhitch facility)

K 14

– Lock (quickhitch facility)

K 31

– Time-lag relay 5 min (rear window heating)

K3

K13 K6 Fig. 1:

33.6

33.7

33-8

K14

Relays

Three-phase alternator, starter Alternator

12 V, 55 A

Starter

12 V, 1.4 kW

Battery

12 V, 72 Ah

Battery

918133/AP0405

Electrical system

33.8

Fuse box in control lever base

F1

F8

F2

F3

F4

F5

F6

F7

F9 F10 F11 F12 F13 F14 F15 F16

34001b710_01.eps

Fig. 2:

Fuse box

33.9

Rated current (A)

Protected circuit

F1

7.5 A

– High beam (left)

F2

7.5 A

– High beam (right)

F3

5A

– Parking light (left)

F4

5A

– Parking light (right)

F5

10 A

– Start

F6

25 A

– Additional lights

F7

25 A

– Lights

F8

7.5 A

– Low beam (left)

F9

7.5 A

– Low beam (right)

F10

5A

– Relays, indicators, cutoff solenoid

F11

15 A

– Wiper

F12

15 A

– Valves

F13

7.5 A

– Driving

F14

30 A

– Fan, rear window heating

F15

7.5 A

– Turn indicator

F16

5A

– Radio

Main fuse box with relays in the engine compartment

K33

K17

K16

K32

F17

Fig. 3:

Fuse no.

F18

Main fuse box in the engine compartment

918133/AP0405

Fuse no.

Rated current (A)

Protected circuit

F17

70 A

– Main fuse

F18

40 A

– Preheating/start fuse (starter)

Relay no.

Protected circuit

K 16

– High current relay preheating

K 17

– High current relay starting

K 32

– Time lag relay for cutoff solenoid

K 33

– High current relay cutoff solenoid

33-9

Electrical system

33.10

Overview: Board

kl15

x5/x2/x4 wiring harness 207412

x5

K1

x6 wiring harness/ roof 209336

x3 plug (white) wiring harness/engine – frame 207413

x3 K7

K31

x6

K5

K12 K11

K4 x2

x4

x1 K3

k18

x7

K6

Assignment: plug base k3, k4, k5, k7, k13, k14, k31 86

Earth

87 87a K13

33-10

x1 plug (white) wiring harness/engine – frame 207413

K14

85

Assignment: plug base k11, k12

15 30

30 87a

86 30

31

87a 87 30 85

Only k31

918133/AP0405

Electrical system

33.11

Plug and socket connection: Wiring harness 209336 frame – cab

x16 socket wiring harness – frame (209336)

P01 plug wiring harness – cab 207414

918133/AP0405

33-11

Electrical system

33.12

Plug and socket connection: Wiring harness 209336 instrument panel Plug and socket connections located in steering console Plug and socket connection: drive lever – multifunctional lever

x10.1

x10.2

x17.1

x17.2 x9

x17 plug and socket connection Connection: white – red

Plug and socket connection: instrument panel

Lighting (fuel level indication)

Cigarette lighter Fuel level indicator

33-12

Indicator

S15 switch (hazard warning system)

918133/AP0405

Electrical system

33.13

Plug and socket connection: wiring harness 207414 – working light/rotating beacon VT/GN rear right working light

Dummy plug

Plug and socket connection: rear rotating beacon (connection green cable) Dummy plug

918133/AP0405

33-13

Electrical system 33

Electrical system

No. 1

From X1 (1) 18 pole plug (K14 (87))

To

Color mm2

No.

From

Y7 (1) solenoid valve 3rd control circuit electric (lock)

BN/YE 1.0

29

X3 (9) 22 pole plug (F3 5 A)

30

X3 (10) 22 pole plug (F3 5 A)

To

Color mm2

No.

From

To

Color mm2

E4 rear left light

GY/BK 1.0

57

M1 starter

G1 alternator

RD

X12 rear socket (7/58 L) rear light

GY/BK 1.0

58

Y4 (2) 1st/2nd speed range solenoid valve

Ground

BK

1.0

59

B1 fuel level sensor

Ground

BK

1.0

10.0

2

X1 (2) 18 pole plug (K13 (87))

Y8 (1) solenoid valve 3rd control circuit electric (unlock)

BN/BK 1.0

31

B2 horn

BN/YE 1.5

3

X3 (7) 22 pole plug (X10.2 steering-column control lever)

X1 (14) 18 pole plug (K4 (87))

Y2 (1) solenoid valve forward

GN/VT 1.0

60

32

B2 horn

Headlight, left, 6 pole plug (1)

BK

1.0

4

X3 (20) 22 pole plug (K3, (87))

B3 backup warning system

WH/VT 1.0

X1 (4) 18 pole plug (K3 (87))

Y3 (1) solenoid valve reverse

WH/VT 1.0

61

33

B2 horn

Ground

BK

1.5

5

X3 (13) 22 pole plug (F2, 7.5 A)

E5 (56a) 6 pole plug (3) high beam (right)

WH

1.5

X1 (3) 18 pole plug (S1, (50a) preheating start switch) K17 (86) high current relay start

BU/BK 1.0

62

34

Y7 (2) solenoid valve 3rd control circuit electric

Ground

BK

1.0

6

X3 (11) 22 pole plug (F9, 7.5 A)

E5 (56b) 6 pole plug (2) low beam (right)

YE

1.5

X1 (6) 18 pole plug (X9 steering-column control lever) Y4 (1) solenoid valve 1st/2nd speed range GY/GN 1.0

63

35

Y8 (2) solenoid valve 3rd control circuit electric

Ground

BK

1.0

7

X3 (15) 22 pole plug (F1, 7.5 A)

E6 (56a) 6 pole plug (3) high beam (left)

WH/BK 1.5

X1 (16) 18 pole plug (S11 switch 4th control circuit

Y5 (1) solenoid valve 4th control circuit

Pink

1.0

64

36

Y5 (2) solenoid valve 4rd control circuit electric

Ground

BK

1.0

8

X3 (21) 22 pole plug (F8, 7.5 A)

E6 (56b) 6 pole plug (2) low beam (left)

YE/BK 1.5

X1 (10) 18 pole plug (H8 hydraulic oil pressure indicator)

S18 pressure switch hydraulic oil

BU/YE 1.0

65

37

Y6 (2) solenoid valve 4th control circuit electric

Ground

BK

1.0

H15 6 pole plug (5) turn indicator (right)

BK/WH 1.0

66

X11 front socket (31)

Ground

BK

1.5

9

X3 (12) 22 pole plug (X10.1 (7) steering-column control lever)

X1 (8) 18 pole plug (H7 hydraulic oil temperature indicator)

S20 temperature switch hydraulic oil

BU/RD 1.0

38

X3 (16) 22 pole plug (X10.1 (7) steering-column control lever)

H16 turn indicator (rear right)

BK/WH 1.0

67

Headlight, right, 6 pole plug (1)

Ground

BK

1.5

68

K32 4 pole plug timer cutoff solenoid

K16 (85) high current relay preheating

BK

1.0

39

X3 (14) 22 pole plug (X10.1 (7) steering-column control lever)

X12 rear socket (4/R) turn indicator

69

K16 (85) high current relay preheating

Ground

BK

1.0

70

Y3 (2) solenoid valve forward

Ground

BK

1.0

40

X3 (19) 22 pole plug (X10.1 (6) steering-column control lever)

H13 6 pole plug (5) turn indicator (front left) BK/GN 1.0

71

Y2 (2) solenoid valve reverse

Ground

BK

1.0

72

X12 rear socket (31)

ground

BK

1.5

41

X3 (17) 22 pole plug (X10.1 (6) steering-column control lever)

H14 turn indicator (rear left)

73

B3 backup warning system

Ground

BK

1.0

74

E2/H16 rear light/turn indicator (right)

Ground

BK

1.0

X3 (22) 22 pole plug (X10.1 (6) steering-column control lever)

X12 rear socket (1/L) turn indicator

75

E4/H14 rear light/turn indicator (left)

Ground

BK

1.0

76

43

Y1 cutoff solenoid

Ground

BK

2.5

X3 (1) 22 pole plug (F15, 7.5 A)

Alternator G1 (IG) (terminal 15)

RD/BK 1.0

77

44

S18 pressure switch hydraulic oil

Ground

BK

1.0

Power supply board

F17 (80 A) main fuse

RD

10.0

78

45

S20 temperature switch hydraulic oil

Ground

BK

1.0

ground, board

ground

BK

4.0

79

46

Y10 (2) solenoid valve load stabilizer

Ground

BK

1.0

F17 (80 A) main fuse

M1 starter

RD

10.0

80

47

Y11 (2) solenoid valve load stabilizer

Ground

BK

1.0

F18 (40 A) preheating fuse

F17 (80 A) main fuse

RD

6.0

81

48

Y12 (2) solenoid valve hose burst valve

Ground

BK

1.0

F18 (40 A) preheating fuse

K17 (30) high current relay start

RD

6.0

82

49

Y13 (2) solenoid valve driving direction identification Ground

BK

1.0

F18 (40 A) preheating fuse

K16 (30) high current relay preheating

RD

4.0

83

50

---

---

--

---

F18 (40 A) preheating fuse

K33 (30) cutoff solenoid relay

RD

4.0

84

51

---

---

--

---

K33 (86) cutoff solenoid relay

K32 4 pole plug timer cutoff solenoid

RD/WH 1.0

85

Alternator G1 2 pole plug (terminal 15)

1 pole plug

RD/BK 1.0

86

Alternator G1 2 pole plug (D+)

1 pole plug

BU

10

X1 (9) 18 pole plug (H6 engine oil pressure indicator) S19 pressure switch engine oil

11

X1 (7) 18 pole plug (H6 coolant temperature indicator) S21 temperature switch coolant

BU/WH 1.0

12

X1 (12) 18 pole plug (P2 fuel level indication)

B1 fuel level sensor

VT/BU 1.0

13

X1 (11) 18 pole plug (S1 (19) preheating)

K16 (86) high current relay preheating

BU/GY 1.0

14

X1 (13) 18 pole plug (S16 (1) parking brake switch)

K17 (85) high current relay start

BK

15

X1 (5) 18 pole plug (F10, 5 A)

Y1 cutoff solenoid

BK/WH 1.0

16

X1 (16) 18 pole plug (S11 switch 4th control circuit)

Y6 (1) solenoid valve 4th control circuit electric

Pink

1.0

17

X1 (15) 18 pole plug (H1 alternator charge indicator) Alternator G1 (D+)

BU

1.0

BU/GN 1.0

1.0

18

X1 (18) 18 pole plug (load stabilizer switch)

Y12 (1) solenoid valve hose burst valve

RD/GN 1.0

19

1 pole plug (switch driving direction identification)

Y13 (1) solenoid valve driving direction identification

GN/VT 1.0

20

X1 (17) 18 pole plug (load stabilizer switch)

Y10 (1) solenoid valve load stabilizer

WH/RD 1.0

21

X1 (17) 18 pole plug (load stabilizer switch)

Y11 (1) solenoid valve load stabilizer

WH/RD 1.0

22

X3 (18) 22 pole plug (K5, (87))

X11 front socket (54)

RD/YE 1.5

23

X3 (3) 22 pole plug (F4 5 A)

X11 front socket (58R) clearance light

GY/RD 1.0

24

X3 (4) 22 pole plug (F4 5 A)

E1 (4) 6 pole plug, front right parking light

GY/RD 1.0

25

X3 (5) 22 pole plug (F4 5 A)

E2 rear right light

GY/RD 1.0

26

X3 (2) 22 pole plug (F4 5 A)

X12 rear socket (5/58 R) rear light

GY/RD 1.0

27

X3 (6) 22 pole plug (F3 5 A)

X11 front socket (58L) clearance light

GY/BK 1.0

28

X3 (8) 22 pole plug (F3 5 A)

E3 (4) 6 pole plug, front left parking light

GY/BK 1.0

42

BK/WH 1.0

BK/GN 1.0 BK/GN 1.0

52

K17 (87) high current relay start

K32 4 pole plug timer cutoff solenoid

RD

1.5

53

K33 (85) cutoff solenoid relay

K32 4 pole plug timer cutoff solenoid

YE

1.0

54

K17 (87) high current relay start

M1 starter

RD/BK 6.0

55

K33 (87) cutoff solenoid relay

Y1 cutoff solenoid

RD/BK 2.5

56

K16 (87) high current relay preheating

R1 preheating facility

BU

1.0

4.0

Legend: Wiring harness 207412

33-14

918133/AP0405

Electrical system

65

Y6

23

4th control circuit 2 3

1

2

24

4

E1/E5/H15

2

Load stabilizer

1

3

-

Main fuse box

Y10 79

63

Hose burst valve

Y8

18 1

16 40

12

28

10

35

8 6

18

2

14

X

3 35

60

6

2 36

40

5

1

28

4

81

Y12

Headlight (left)

36 61/66 62/63 79/80

4 2

Y7

2

1

1

Headlight (right)

3

5

1

15 6

2

2

3 1

11 9

62

1

7 5

10 8

1

2

9

13 12

1

11

3

14 19

5

3rd control circuit 44

X1

13

6

37

3

1

20

Plug (white)

15

67

34

Y11 80

19

7

33

2

33 67

21

82

17 16

3

34

64

Driving direction Y13 identification

17

37

66

6

20 21 18

X11

27

24 2

1st/2nd speed range Y4

7

16

3

Y5

2

1

58

Front socket

22

3 1

4 2

45/58 67

-

68515253

51505553

14 5 4852 54

60

64/65 81/82

E3/E6/H13

Ground III

Plug (white)

B2

X3 19 17 15 13 11 9 7 5 3 1

36 42 40 32 41 22 35 38 33 39 34 37 29 30 31 28 25 27 23 24 43 26

K32

11 43/85

20 18

86

X

16

44

53

87 55

52

68

51

K 17 8752/54

53

5

86 50 85 30

86

30 14 85 48

K 16 F 18

87 56 13 30 86

49

47

49

48

50

68 69

85

F 17

46 44

47

S21

85

G1

14 72/76

12 10

59/69

73/74

70/71

75/78/77

Ground I

8 6 4

1743 8685

K 33

51

22

K 32 57

45

B1

2

Reverse

34101s33_09.iso 12

Fuel level sensor

Pressure switch (engine oil)

4

59

1

10

S 19

2

Y3

3

21

17 86

Horn

46/47

49/50 47/48

Starting/preheating

Temperature switch (coolant)

Alternator

60/61 31

6813 56 49 69

54

57

46

70 25

54

M1

38

Starter

74 3

Forward 77

1

Y2 S18

71

S20 Pressure switch (hydraulic oil) 9

78

Temperature switch (hydraulic oil)

3

73 32

E4/H14

2

8

76

15

73 32

B3

Backup warning system

55 29 41 75

76

X12

Y1

15 55

Cutoff solenoid

56

R1

Rear light/turn indicator (left)

72 26 30 3942

Rear socket

Preheating

33.14

918133/AP0405

Rear light/turn indicator (right) E2/H16

Wiring harness 0113300310

33-15

Electrical system 59/60

Multifunctional switch

Parking brake switch

57/58

X10.1 X10.2

5 11 1 42

34 2 6 63 62 33 7 3 61 50 8

S16

35 3 36 6

- 4 51

12 54 4

37 1 45 4

47 46 45 37 36 35

10

15

20

30 31

49

62

6

49 a L

9

S15

Hazard warning light switch 58

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

33-16

9 4

6

3

10 1

4

1

11 5

Black

2

X4 17

31 23

18

15

29 17

16

13

32 30

14

11

28 25

12

9

16 27

10

7

20 65

8

5

24 18

6

3

- 21

4

1

26 15

Black

2

21

15

7 5

2 18

Heating

9

3

3 1

-

-

47 48 49 50 41 46 42 37 39 40 63 38 52 43 36 44 35 33 51 45 34

22 20 18 16 14 12

Black

10 8 6 4 2

Preheating start switch

43 44 57 44 43 1

2

41 6 5 66 67 21

3 66

66 2 5 5

58

41 1 6 4

X17 1 pole plug (steering-column control lever, left, drive) X2 (4) 14 pole plug (1st/2nd speed range) GY/GN 1.0 X8 (4) 6 pole plug (control lever) X2 (9) 14 pole plug (K12, (S14)) BN/YE 1.0 X8 (1) 6 pole plug (control lever) X2 (11) 14 pole plug (K11, terminal 30) BN/BK 1.0 S16 (3) 3 pole plug parking brake switch X2 (6) 14 pole plug (ground K4/K3) BN 1.0 X9 (5) 6 pole plug (steering-column control lever, left, reverse) X2 (2) 14 pole plug (K3, (86)) WH/VT 1.0 X9 (4) 6 pole plug (steering-column control lever, left, X2 (12) 14 pole plug (K4, (86)) GN/VT 1.0 forward) --------------------------------------------X15 (1) 2 pole plug float position solenoid X2 (8) 14 pole plug (F12, 15 A) WH/BU 1.0 S15 (4) 7 pole plug hazard warning light switch (49) X2 (5) 14 pole plug (K6 (+) turn indicator BK/WH/ 1.0 relay) RD S15 (5) 7 pole plug hazard warning light switch (49a) X2 (3) 14 pole plug (K6 (C) turn indicator BK/WH/ 1.0 relay) GN X10.1 (5) 8 pole plug (steering-column control lever, right)X2 (1) 14 pole plug (K6 (C) turn indicator relay)WH/RD 1.0 S16 (1) 3 pole plug parking brake switch X2 (10) 14 pole plug (K17 (85) starting BN/VT 1.0 relay) 15 pole plug (9) H10 (turn indicator machine) X2 (7) 14 pole plug (K6 (R) turn indicator relay) WH/GN 1.0 S15 (1) 7 pole plug hazard warning light switch (15) X2 (14) 14 pole plug (F15, 7.5 A) RD/BK 1.5 S1 (5), terminal 15 (preheating start switch) X4 (2) 18 pole plug (K1 (86) RD/BK 1.0 S1 (8), terminal 19 (preheating start switch) X4 (9) 18 pole plug (K16, (86) preheating relay) BU/GY 1.0 S1 (1), terminal 50a (preheating start switch) X4 (16) 18 pole plug (K17, (86) starting relay BU/BK 1.0 S1 (2), terminal 30 (preheating start switch) X4 (6) 18 pole plug (F5, 10 A) RD 2.5 ---------------------------------------------E12 instrument lighting fuel level indication X4 (7) 18 pole plug (F4, 5 A) GY/RD 1.0 E11 lighting cigarette lighter X4 (4) 18 pole plug (F3, 5 A) GY/BK 1.0 ---------------------------------------------15 pole plug (5) H9 rear attachment turn indicator X4 (18) 18 pole plug (K6, (R2)) BK/BU 1.0 indicator 15 pole plug (7) H1/P1 charge function indicator X4 (5) 18 pole plug (G1, (D+)) BU 1.0 P2 (G) 3 pole plug fuel level indication X4 (12) 18 pole plug (B1 fuel level sensor) VT/BU 1.0 15 pole plug (4) H2 high beam indicator X4 (1) 18 pole plug (E6 (56a) high beam (left) WH 1.0

M4

- 3 67 6

48

Color mm2

57

3

Drive lever

Cigarette lighter

To

8

5

11

S1

18

X17 1

61 62

48

10

1

49

5

4

10

--

15

65

49

64

R

30b 30

2

3

59

7

1

66 67

9 10 14

61

14

32 38

17 16

Instrument panel lights

29

17

23 - 59 15

9

7

16

5

10

7

13

60

60

2 12 13 8

17

8

28

12

9

19

6

4

26 13 28 14

15

No. 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

X9

X17.1

67

X15 56

X17.2

From 15 pole plug (2) H3 parking brake indicator 15 pole plug (14) H4 preheating indicator 15 pole plug (3) H5 coolant indicator

39 40

For Model 280

2

1

X8

8

To

Color mm2

X4 (10) 18 pole plug (K17, (85)) BN/WH 1.0 X4 (11) 18 pole plug (K16, (86)) BU/GY 1.0 X4 (15) 18 pole plug (S21 coolant pressure BU/WH 1.0 switch) 15 pole plug (8) H6 engine oil pressure indicator X4 (14) 18 pole plug (S19 engine oil BU/GN 1.0 pressure switch) 15 pole plug (6) H7 engine oil temperature indicator X4 (17) 18 pole plug (S20 hydraulic oil BU/RD 1.0 temperature) BU/YE 1.0 15 pole plug (12 H8 hydraulic oil pressure indicator) X4 (13) 18 pole plug (S18 hydraulic oil pressure switch) X10.1 (7) 8 pole plug (steering-column control lever, right) X5 (3) 22 pole plug (turn indicator, right) BK/GN 1.0 X10.1 (6) 8 pole plug (steering-column control lever, right) X5 (2) 22 pole plug (turn indicator, left) BK/WH 1.0 X10.2 (3) 8 pole plug (steering-column control lever, right) X5 (6) 22 pole plug (F8/F9 (7.5 A)) YE 1.5 X10.2 (6) 6 pole plug (steering-column control lever, right) X5 (8) 22 pole plug (F1/F2 (7.5 A)) WH 1.5 X10.2 (1) 6 pole plug (steering-column control lever, right) X5 (11) 22 pole plug (B2 horn) BN/YE 1.5 15 pole plug (13) power supply X5 (10) 22 pole plug (F10, 5 A) RD/BK 1.0 X8 (2) 6 pole plug (control lever) X5 (12) 22 pole plug (F10, 5 A) OG 1.0 X8 (3) 6 pole plug (control lever) X5 (12) 22 pole plug (F10, 5 A) OG 1.0 X9 (1) 6 pole plug (steering-column control lever, left, drive) X5 (16) 22 pole plug (F13, 7.5 A) RD 1.0 X10.1 (1) 8 pole plug (steering-column control lever, right) X5 (14) 22 pole plug (F11, 15 A) GY/GN 1.5 M4 (1) 3 pole plug heating fan/2nd speed X5 (7) 22 pole plug (S5 (1) heating switch) RD/WH 1.5 M4 (2) 3 pole plug heating fan/1st speed X5 (5) 22 pole plug (S5 (5) heating switch) RD/YE 1.5 X10.2 (4) 6 pole plug (steering-column control lever, right) X5 (1) 22 pole plug (M5 washer pump) GN/BK 1.0 X10.2 (5) 6 pole plug (steering-column control lever, right) X5 (13) 22 pole plug (S4 light switch) WH/BK 1.0 X10.2 (2) 6 pole plug (steering-column control lever, right) X5 (19) 22 pole plug (F7, 25 A) WH 1.5 E11 cigarette lighter X5 (20) 22 pole plug (F6, 25 A) RD/BK 1.5 S15 (3) 7 pole plug hazard warning light switch (30) X5 (17) 22 pole plug (F5, 10 A) RD/YE 1.5 X10.1 (3) 8 pole plug (steering-column control lever, right) X5 (15) 22 pole plug (front wiper) GN/WH 1.0 X10.1 (4) 8 pole plug (steering-column control lever, right) X5 (4) 22 pole plug (M2, (53a)) GN/BK 1.0 3 pole plug (+) fuel level indication, power supply X5 (10) 22 pole plug (F10, 5 A) RD/BK 1.0 ------------------------------------------------------------

No. 54 55 56 57 58 59 60 61 62 63 64 65 66 67

3

4

52

52

2

27

25

5

1

29 30 38 13

X

25

4

27 24 32 12

Fuel level indication

26

14

3 6

X5

5

2

65 31 64 11

24

G

1

7 8 9

X

6

23 6

1 2 3 4 5 6

X

12 54 4

13

Indicator

From

23

64 14

11

47 2 46 5

34 33 11 51 50 42 62 61 63

No.

1

13

2

34001s33_10.iso

From

To

Color mm2

Ground, board S16 (2) 3 pole plug (parking brake switch) BK 1.0 -----------------------------------------------------------Ground, board X15 (2) 2 pole plug (float position) BK 1.0 Ground, board M4 (3) 3 pole plug (heating fan) BK 1.5 Ground, board Cigarette lighter BK 1.5 Ground, board 15 pole plug (15) indicator BK 1.0 Ground, board 3 pole plug (ground) fuel level indication BK 1.0 X10.1 (7) 8 pole plug (steering-column control lever, right) S15 (7) 7 pole plug hazard warning light switch (R) BK/WH 1.0 X10.1 (6) 8 pole plug (steering-column control lever, right) S15 (6) 7 pole plug hazard warning light switch (L) BK/GN 1.0 X10.1 (2) 8 pole plug (steering-column control lever, right) X5 (9) 22 pole plug (front/rear wiper) BU/GN 1.0 15 pole plug (11), (load stabilizer/hose burst valve indicator)X2 (13) 14 pole plug (load stabilizer/hose burst RD/YE 1.0 valve) 15 pole plug (1) 3rd control circuit indicator X4 (8) 18 pole plug (S14 3rd control circuit) VT 1.0 X9 6 pole housing (2) 1st/2nd speed range (340-01) X17.1 1 pole flat plug housing (natural GY/GN 1.0 colored) X9 6 pole housing (6) 1st/2nd speed range (341-01) X17.2 1 pole flat plug housing (red) GY/GN 1.0

33.15

Cab – wiring harness 207412

918133/AP0405

Electrical system

Working light (front left) N

BU 17

24

Working light (rear left) BU 1 2

N

BU 15

Washer system

BU

08

N

21 BU 13

19 N

08 21

N 18

11

13 11 9 7 5 3 1

7 8 6 3 - - 10 - 4 2 9 5 1

X6

1

1

2

2

3

3

4

4

10

5

5

8

6

6

6

7

7

4

8

8

14 12

2

Interior light

Socket housing

12/13/ 14

9

9

10

10

Socket housing

N

P

E 8 9 D4 M 5 C 3 A 1 F 14 10 L 6 7 B 11 G 12 2 H K 13 OC J

N

B K

02

C

03

D

04

E

05

F

06

F

G

07

G

H

08

9 1 1 8 2 9 21 0

14 15 16 17

Front wiper 25

10 22 23 24 25

A

C L

01

B

E

D

M

S

X 16

11

P

A

J

H

J

09

K

10

L

11

M

12

N

13

P

14

12

26 12

11

25

11 29

29 26 29

28

12 13 14

22

16 BU

01

23 N

28

Working light (front right) 03

02

06

07

04

20

05

Rotating beacon

27

Radio

34001s33_12.iso

Rear window heating

27 04

Rear wiper

05 20 28

33.16 No.

From

1 X6 (2) 14 pole plug (time lag relay) K31 2 X6 (3) 14 pole plug (blocking diode) 3 X6 (12) 14 pole plug (rear wiper switch) 4 X6 (6) 14 pole plug (rear wiper switch) 5 X6 (1) 14 pole plug 6 X6 (11) 14 pole plug 7 X6 (13) 14 pole plug (fuse) 8 X6 (14) 14 pole plug (working light switch) 9 X6 (4) 14 pole plug (rotating beacon switch) 10 X6 (8) 14 pole plug 11 X16(G) 14 pole plug (rear window ground) 12 X16(K) 14 pole plug (front wiper, working light ground) 13 X16(J) 14 pole plug (ground rear wiper, rotating beacon working light) 14 X16(C) 14 pole plug (radio ground)

918133/AP0405

33.17

Roof – wiring harness 209336 To

Color

X16 (F) 14 pole plug (heated rear GY window) X16 (H) 14 pole plug (washer pump) BU/GN X16 (D) 14 pole plug (rear wiper motor) BU X16 (E) 14 pole plug (rear wiper motor) BK/BU X16 (M) 14 pole plug (front wiper motor) GN/BK X16 (L) 14 pole plug (wiper) GN X16 (B) 14 pole plug (radio) RD/BK X16 (P) 14 pole plug (working light) GY/GN X16 (N) 14 pole plug (rotating beacon) OG X16 (A) 14 pole plug (interior light) GY Ground BK Ground BK Ground BK Ground

BK

mm2

No.

mm2

Color

2.0

1

1.0

GN

Interior light

2

1.0

RT/BK

3

1.0

BK

4

1.0

5 6

1.0 1.0 1.0 1.0 1.0 1.0 2.0 1.0 1.0 2.5 1.5 1.5 1.0

Assignment

Roof – wiring harness 207414

From

To

No.

mm2

Color

A

P01

P09

15

1.0

VT/GN

Assignment

From

To

Radio

B

P01

P02

16

1.0

Radio (+)

C

P01

P02

17

1.0

BU

Rear wiper (+)

D

P01

P04

18

1.0

BK

1.0

BU/BK

Rear wiper

E

P01

P04

19

1.0

BK

Rear working light (-)

D01

D11/P11

2.5

WH

Rear window heating

F

P01

P03

20

1.0

BK

Wiper (-)

D01

P04

7

2.5

BK

Rear window heating (-)

G

P01

P03

21

1.0

BK

Washer system (-)

D01

P10

8

1.0

GN/BK

Washer system

H

P01

P10

22

1.0

BK

Interior light (-)

D03

P09

9

2.0

BK

Connection 18, 19, 20, 21

J

P01

D01

23

1.0

BK

Headlight, right (-)

D03

D09/P07

10

2.0

BK

Connection 22, 23, 24, 25

K

P01

D03

24

1.0

BK

Headlight, left (-)

D03

D13/P12

11

1.0

GN

Front wiper

L

P01

P08

25

1.0

BK

Front wiper (-)

D03

P08

12

1.0

GN/BK

Front wiper (+)

M

P01

P08

13

1.0

GN

Rotating beacon

N

P01

D06/P06

14

2.0

VT

Connection 15, 16, 17

P

P01

D02

Reversing light

D02

D10/P11

VT/GN

Headlight (right)

D02

D08/P07

VT/GN

Headlight (left)

D02

D12/P12

Rotating beacon (-)

D01

D07/P06

33-17

Electrical system

F14

F11

F12

F16

F15

F13

5

S14 2 9

6 10

30

86 30

86

15 (86)

K4

1

30 86

K3 87

85 87

K5

K31

85

Board

31 (85)

S8 5 9 2 B

B 2 9

30

85

87

F4

9 5

S11

1

9 B

S9 10

3

87

K7

31

R2

R G K6 + C

B

10

5

1

9 10

9 B

1

S10

10

S5

B 1

5

V16

9

S7

B

V10

3

5

B 5

30

5 S6 10

V8

86 85

10 6

1

K1

F5

F6

10 1

F2 F1 F9 F8

F3

F7

3 6

S4

87

F10

1

10

9

V17

1

10

S13 B

9

V9

4

BK/WH

3

1

X7 30

86

2

86

30

K13

K14

85

H

12 6

1 11

H9

H1

P1

P2

H2

H3

H4

H6

H5

H7

ML C B

H8 BK

H11

I J DE

A

E10

E7

M

BK

E11

R2 M5

53a 53

M

M

M

31

31

E8

53

53a

H17

BK BK BK BK

BK

BK

BK

M4

BK

BK

S16 2

BK

H13

H15

N

V11 V12 BK

B3

P

E9

56b

RD/BK

E4

8

5 7 nc nc

X16

BK BK

E2

1

3

56b 56a

14 4

13

GY/GN OG

G F

10 9 nc nc

GN RD/BK

3

BK/BU

2

19 20 17 15 4 9 18

GN/BK

1 13

BU

8 11 10 12 16 14 2122 7 5

BU/GN

6

WH RD/BK RD/YE GN/WH GN/BK BU/GN

3

RD/YE GN/BK WH/BK

2

BK

Y9

BK

Y12

BK

Y11

BK

V13 Y10

T

BK

BK

S21

BK

V7 S20 T Y6

BK/WH/RD BK/WH/GN

V6 Y5

V15

BK

V3 Y4

V14

BK

V18 Y13

RD

RD

V5 Y8

BK 1,0

V4 Y7

RD

BK 1,0

F17

Y1

H14

13

2 56a

V1 V2 Y3 Y2

H16

E6

17

M3 M2

BK

E5

B2

14

VT/GN VT/GN VT/GN

E3

15

E12

BK

1

E1

H10

X15

11

BK BK

H18

BK BK

Q

BK

BK

BK

BK BK

BK

BK

BK

BK

BK

RD

B1

P

RD

30 86

X17

87 85

BK

87

30

K33 85

30

X11

X12 5/58R

7/58L

3/31

4/R

W1

1/L

X13

X17.1

8 7

X8 4

A1

1 2 3

87

YE

3 4

5 6

B4

B5

X14

RD

31 (85)

86

RD/BK

RD/BK

BU BK

15 (86)

K32

RD/WH

RD

X17.2

WH/VT

87 85

49a

L

RD/BK BK/GN BK/WH RD/YE

K17

K16

49

31 58L 54 58R 15 R

BK

S15

BN/BK

BN/YE

RD 30 86

BK

BK

F18 RD

Wiring harness

S19

P

10

30

S1

S18

1

GY

15

12

5

X6

X5

6

4 3 18

RD/WH

19 50a

8 7

GY/GN

16

YE

WH/VT

2 9

BK/WH

BN/YE

22

BK/GN

GY/BK

19 17

BU/RD

GY/BK

21 12 16 14

BU/YE

GY/RD

GY/BK

15

BU/GN

GY/RD

11

BU/WH

BU/WH

13

BN/WH

20

BU/GY

7

VT/BU

10

WH

9

BK/BU

8

BU RD

2

BU/BK

5

VT GY/RD GY/BK

4

RD/BK BU/GY

6 18 3

BK/GN

1

BK/GN BK/GN

10

WH/BK

1

YE/BK BK/WH BK/WH BK/WH

3

YE

5

WH

7

GY/BK RD/YE GY/RD GY/RD

14

WH/RD

8

BU/BK

GY

X4

X3

2 12

BN/VT

6

WH/GN

11

BK/WH/RD BK/WH/GN

13

GN/VT

9

BN

4

WH/VT

PINK

18

RD/YE

GY/GN

12 11 13 5 15 17

BN/BK

WH/VT

BU/BK

7

GY/GN

GN/VT

9

BN/YE

BN/BK

8

RD/GN

BN/YE

10

VT/BU

16

BU/GY BK BK/WH BU WH/RD

6

BU/WH

3

BU/RD

4

BU/GN

14

BU/YE

2

WH BN/YE RD/BK OG RD

X2

X1 1

RD/BK

87

WH/BU

87

85

1

G1 BM1

R1

BK

BK

G2 -

3

X9

GN/VT

50 30 M

BU/WH

GY/GN

BK +

D+ B+ G 15

GY/GN

S17 RD

2

6

5

3

4

2

1

R

N

V

15

S3

15

1

3 2

5 1

(1)

(4)

53a

H

53c 53 53(II)

15

4

6

7

(3) (6) (5)(2)

31b

L

R

56b 56a

49

30 56

S2

X10.1 (X10.2)

33.18

33-18

Wiring diagram 0110010090

918133/AP0405

Electrical system

Ref.

Description

Section

Loc.

Ref.

A1 B1 B2 B3 B4 B5 E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 F1-F16 F17 F18 G1 G2 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H13 H14 H15 H16 H17 H18 K1 K3

Radio Fuel level sensor Horn Backup warning system Loudspeaker Loudspeaker Front right parking light Rear right light Front left parking light Rear left light High, low beam (right) High, low beam (left) Rear working light Front working light Front working light Interior light with switch Cigarette lighter with lighting Instrument lighting fuel level sensor Fuses Main fuse Preheating/start fuse Alternator Battery Alternator charge indicator High beam indicator Parking brake indicator Preheating indicator Coolant temperature indicator Engine oil pressure indicator Hydraulic oil temperature indicator Hydraulic oil pressure indicator Rear attachment turn indicator Machine turn indicator 3rd control circuit indicator Front left turn indicator Rear left turn indicator Front right turn indicator Rear right turn indicator Rotating beacon Hose burst valve indicator High current relay 70 A Reverse driving 40/60 A

X6/2 X1/2 X3/2 X3/2 X6/2 X6/2 X3/2 X3/2 X3/2 X3/2 X3/2 X3/2 X6/2 X6/2 X6/2 X6/2 X5/2 X4/2

Option

K4 K5 K6 K7 K13 K14 K16 K17 K31 K32 K33 M1 M2 M3 M4 M5 P1 P2 R1 R2 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S13 S14 S15 S16 S17 S18 S 19 S20 S20 S21 V1..V7

918133/AP0405

2 2 X4/2 X4/2 X4/2 X4/2 X4/2 X4/2 X4/2 X4/2 X4/2 X2/2 X4/2 X3/2 X3/2 X3/2 X3/2 X6/2 X2/2 1 X1/1

Option Option Option

Option Option Option

Option Option

Description

Forward driving 40/60 A Front socket 40/60 A Turn indicator relay Wiper speed (1) 40/60 A Unlock 40/60 A Lock 40/60 A High current relay preheating High current relay starting Time lag relay (5 min) Time lag relay (1 sec) cutoff solenoid High current relay cutoff solenoid Starter Front wiper motor Rear wiper motor Engine fan Washer pump Hour meter Fuel level indication Glow plug Heated rear window Preheating start switch Steering-column control lever, right Steering-column control lever, left Light switch Heating switch Working light switch Rotating beacon switch Load stabilizer switch Front socket switch Heated rear window switch 4th control circuit switch Continuous operation switch 3rd control circuit Functional switch 3rd control circuit Hazard warning light switch Parking brake switch Switch in control lever Pressure switch hydraulic oil Pressure switch engine oil Temperature switch hydraulic oil Temperature switch hydraulic oil Temperature switch coolant Suppressor diode

Section

X1/1 X3/1 X2/1 X5/1 X1/1 X1/1 2 2 X2/1 X1/2 X1/2 2 X6/2 X6/2 X5/2 X6/2 X4/2 X4/2 2 X6/2 X4/2 X5/2 X2/2 X6/1 X5/1 X6/1 X6/1 X1/1 X2/1 X2/1 X1/1 X1/1 X1/1 X2/2 X2/2 X2/2 X1/2 X1/2 X1/2 X1/2 X1/2 X1/2

Loc.

Option

Option Option Option Option Option

Ref.

Description

Section

V8,V9 V10.V12 V13.V15 V16,V17 V18 W1 X1 X2 X3 X4 X5 X6 X7 X8 X9 X10.1 X10.2 X11 X12 X13 X14 X15 X16 X17

Blocking diode Blocking diode Suppressor diode Blocking diode Suppressor diode Radio aerial Plug and socket connector engine/valves Plug and socket connector cab signal Plug and socket connector frame outputs Plug and socket connector instrument signals Plug and socket connector fuse terminal 15 Plug and socket connector fuse terminal 30 Plug and socket connector drive interlock 13 pole Plug and socket connector control lever Plug and socket connector steering column (drive) Plug and socket connector steering column (right) 8 poles Plug and socket connector steering column (right) 6 poles Front socket Rear socket Radio connection grey Radio connection brown Plug and socket connector float position Plug and socket connector roof wiring harness Plug and socket connector 1st/2nd speed range Plug and socket connector 1st/2nd speed range natural colored Plug and socket connector 1st/2nd speed range red Cutoff solenoid Solenoid valve forward Solenoid valve reverse Solenoid valve 1st/2nd speed range Solenoid valve 4th control circuit Solenoid valve 4th control circuit Solenoid valve 3rd control circuit Solenoid valve 3rd control circuit Magnet float position Solenoid valve – load stabilizer Solenoid valve – load stabilizer Solenoid valve hose burst valve off Solenoid valve driving direction identification

X1/1 X6/1 X1/2 X5/1 X1/2 X6/2

X17.1 X17.2 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11 Y12 Y13

Loc.

341-01

X2/2 X2/2

X3/2 X3/2 X5/2 X5/2 X2/2 X6/2 X2/2 X2/2

341-01

X2/2 X1/2 X1/2 X1/2 X1/2 X1/2 X1/2 X1/2 X1/2 X2/2 X1/2 X1/2 X1/2 X1/2

341-01

Option Option Option Option 341-01

Legend: Wiring diagram 0110010090

33-19

Electrical system

33.19

Plug 10.1

Cable colors: Steering-column control lever S2 and S3 to plugs 10.1, 10.2 and X9 Slot no.

Description in diagram

Color

1

53a

BK/BU

2

53 ( II )

GY

3

53

GN

4

31b

BU

5

49

VT/WH

6

L

VT/GN

7

R

VT/RT

Slot no.

Description in diagram

Color

(1)

H

BN/YE

(2)

30

BK/VT

(3)

56b

YE

(4)

53c

BK/YE

(5)

56

WH/YE

(6)

56a

WH

Slot no.

Description in diagram

Color

1

15

BU

2

2

YE

3

N

VT

4

V

BU/YE

5

R

WH/GN

6

1

GY

8

Plug 10.2

Plug X 9

33-20

918133/AP0405

Cable routing from steering-column control lever S3 on left, starting plug X9

33

918133/AP0405

33.20

Cable number

Explanation:

(5 ) - 6 7 (1 ) (6 ) 6 6 5 (2 ) (7 ) 4 1 6 (3 ) (8 ) - - (4 )

• The number in brackets ( ) stands for the slot number on the plug • The number without brackets stands for the cable number

(No.)

No.

Color

to plug and socket connection Wiring harness drawing.

207412 X (No.) No. Color

7

41

RD

5

16

41

RD

6

66

GY/GN

2

4

1

GY/GN

1

6

6

GY/GN

3

6

GN/VT

2

12

6

GN/VT

1

14

3

GN/VT

2

5

WH/VT

2

2

5

WH/VT

1

4

4

WH/VT

1

67

GY/GN

Cable number with colour Wiring harness drawing.

207412

to plug and socket connection Wiring harness drawing.

207413

to plug and socket connection Wiring harness drawing.

X

X

(No.)

No.

Color

(No.)

No.

Fuse

Slot number

Other

Use

Color F 13 7.50 A

Power supply (+)

to K 4, terminal 86 to K 3, terminal 86

Y 4 magnet 1st and 2nd speed range Y 2 solenoid valve forward Y 3 solenoid valve reverse

Electrical system

33-21

Cable routing from steering-column control lever S2 on right, starting plug 10.1

Explanation:

Cable number

• The number in brackets ( ) stands for the slot number on the plug • The number without brackets stands for the cable number

Cable number with color Wiring harness drawing 207412 (No.) No. Color

(5 ) 1 1 4 2 (1 ) (6 ) 6 2 6 3 (2 ) (7 ) 6 1 5 0 (3 ) (8 ) - 5 1 (4 )

to plug and socket connection Wiring harness drawing 207412

to plug and socket connection Wiring harness drawing 207413/209336

to plug and socket connection Wiring harness drawing 209336

X

(No.)

No.

Color

X

X

(No.)

No.

Color

(No.)

No.

Color

to cab wiring harness 207414 X

(No.)

No.

918133/AP0405

42

GY/GN

5

14

42

GY/GN

2

63

BU/GN

5

9

63

BU/GN

3

50

GN/VH

5

15

6

GN/VH

6

11

6

GN

16

L

6

GN

L

11

GN

4

51

GN/BK

5

4

51

GN/BK

6

1

5

GN/BK

16

M

5

GN/BK

M

12

GN/BK

5

11

WH/RT

2

1

11

WH/RT

6

3

2

BU/GN

16

H

2

BU/GN

H

08

GN/BK

6

34

BK/WH

5

2

34

BK/WH

3

22

40

BK/GN

6

62

BK/GN

7

33

BK/GN

7

61

BK/WH

3

33

BK/GN

3

14

37

BK/ WH

Slot number

Other

Use

F11/15 A Relay K7 terminal 86

Fuse F11

Color

1

5

Electrical system

33-22

33.21

Rear socket X12 Hazard warning light switch S15 (6) L Rear socket X12 Hazard warning light switch S15 (6) L

Wiper 1st speed Front wiper terminal 53 (+) Front wiper terminal 53a (+) Washer system M5 (+) Left turn indicator (+) to hazard warning light switch terminal L Right turn indicator to hazard warning light switch terminal R

918133/AP0405

33.22

Cable routing from steering-column control lever S2 on right, starting plug 10.2

Explanation:

Cable number

• The number in brackets ( ) stands for the slot number on the plug • The number without brackets stands for the cable number

Cable number with color Wiring harness drawing 207412 (No.) No. Color 1 37 BN/YE 2 47 WH 3 35 YE

to plug and socket connection Wiring harness drawing 207412 X 5 5 5

(No.) 11 19 6

No. 37 47 35

Color BN/YE WH YE

4

45

GN/BK

5

1

45

GN/BK

5

46

WH/BK

5

13

46

WH/ BK

6

36

WH

5

8

36

WH

(3 ) 3 5 3 6 (6 ) (2 ) 4 7 4 6 (5 ) (1 ) 3 7 4 5 (4 ) ( ) - - ( )

to plug and socket connection Wiring harness drawing 207413 X (No.) No. Color 3 7 29 BN/YE 3

11

32

to plug and socket connection Wiring harness drawing 209336 X

(No.)

No.

Fuse

F7/25 A F 8/F 9/7.5 A 3

2

Use

Color

YE 6

Other

Slot number

BU/GN

F 1/F 2/7.5 A

to X 3 to X 16 (H) GN/ BK

Horn Lights 65b low beam Washer system (+)

S 4 light switch terminal 1 E 5/ E 6/56a high beam

Electrical system

33-23

Electrical system

Notes:

33-24

918133/AP0405

918133/AP0405

36

36

Hydraulics

36.1

Hydraulics diagram – pilot control Tilt cylinder

Control cylinder

Lift cylinder

I => main pressure relief valve

Tilt in Dump out

Lower

➥3336 psi (230 bar)

Raise

II => valve tilt cylinder base side

➥4061 psi (280 bar)

Unlock

III => valve tilt cylinder rod side

Lock

to tank

➥1740 psi (120 bar) IV => valve lift cylinder base side Tilt in

B1

A2

B3

B2

A3

T

X

A1

)

)

➥4351 psi (300 bar)

1

X1 P

Pump

2

X2

I P

Solenoid valve: 3rd control circuit actuated via switch in joystick.

Pilot pressure 435 psi (30 bar)

psi (230 bar)

II

)

)

)

B

A

P

T

4

IV

III

4361 psi (280 bar)

y8

1740 psi (120 bar)

Y2

3

Y1

4351 psi (300 bar)

Non-return valve y7

Lock lever (road travel)

Dump out Lower

Pressure accumulator for emergency lowering

34001s36_01.iso

36-1

Hydraulics

Boost pump

T

)

➥ y8 => lock ➥ y7 => unlock

3336

Hydraulics diagram – float position

Tilt cylinder

Hydraulics

36-2

36.2

Control cylinder

1 => circuit lift cylinder(right)

Lift cylinder

2 => 3rd control circuit (center) Control valve A1 B1 A3 B3

to -

3 => circuit tilt cylinder(left)

Joystick 2 4 3 1

2 3

1 Tilt in

A1

B1

A2

B2

B3

A3

1

2X2

X1 P

From priority valve From boost pump P

3481 psi (240 bar)

T

to tank 3

Y2

4361 psi (280 bar)

1740 psi (120 bar)

5366 psi (370 bar)

Dump out 918133/AP0405

Pilot control line 3rd control circuit

4

Y1

34001s36_03.iso

918133/AP0405

36.3

Hydraulic circuit: Pump – control valve – tank Breather filter (filler inlet) S 18 sensor (reflux filter)

Priority valve Reflux suction filter Test port

S 20 Temperature sensor

Drain plug

Reflux

Hydraulic pump (steering system/work hydraulics)

Hydraulics

36-3

34001e3602.iso

Overview: Control valve Lift cylinder 5366 psi (370 bar) (base side) Spool (lift cylinder)

Spool (3rd control circuit)

Hydraulics

36-4

36.4

Tilt cylinder 1740 psi (120 bar) (rod side) Spool (tilt cylinder)

Tie rod 20 lb-ft (27 Nm)

Output (hydraulic tank)

Input (hydraulic pump) Tilt cylinder 4061 psi 280 bar (base side)

Main pressure relief valve 3481 psi (240 bar) Pilot control caps 918133/AP0405

918133/AP0405

36.5

Hydraulic ports on control valve

Priority valve

Test port (steering)

Test port (HP steering) Solenoid valve (pilot control 3rd control circuit) Reflux (4th control circuit)

Test port (work hydraulics)

Tilt cylinder 4061 psi (280 bar) (base side)

Main pressure relief valve 4061 psi (280 bar) Hydraulics

36-5

Hydraulic circuit pilot control Push button (actuation of 3rd control circuit lock)

Joystick

Lock lever pilot pressure mounted on steering column on the left (close during road travel)

Hydraulics

36-6

36.6

Control valve A1 B1 A3 B3

to -

Control valve

to

A2 B2

-

Open

Joystick 2 4 3 1 Solenoid valve (3rd control circuit) B A

Closed 3

P 4

2

T

Return (pilot pressure)

1

3

4 2

A1 T

A3

1

Pressure accumulator (emergency lowering)

T

Non-return valve

P

A2 B2

P

B3

B1

B A 918133/AP0405

Test port [boost pressure pilot control 34001e3608.iso 435 psi (30 bar)] Solenoid valve

918133/AP0405

36.7

Sealing the lift cylinder

Secure the locking screw [hexagon socket ø 0.118'' (3 mm)] with

Piston w/f 45 332 lb-ft (450 Nm)

Guide bushing

Tab washer

Loctite 242

34001e3609.iso

☞ Disassembly/assembly: • Remove the tab washer • Unscrew the guide bushing with a spanner wrench (hook spanner wrench) • Extract the piston rod complete with guide bushing and piston • Remove the locking screw on the piston [hexagon socket ø 0.118 (3 mm)] • Remove the piston with fork wrench w/f 45 • Replace all seals with new ones (sealing kit) • Assembly in the reverse order

36-7

Hydraulics

➥Install the piston with torque 332 lb-ft (450 Nm) ➥Fit the locking screw with Loctite 242

Sealing the tilt cylinder

Secure the locking screw [hexagon socket ø 0.118'' (3 mm)] with

Hydraulics

36-8

36.8

Piston w/f 42

Guide bushing

295 lb-ft (400 Nm)

Loctite 242

34001e3610.iso

☞ Disassembly/assembly: • Remove the tab washer • Unscrew the guide bushing with a spanner wrench (hook spanner wrench) • Extract the piston rod complete with guide bushing and piston • Remove the locking screw on the piston [hexagon socket ø 0.118'' (3 mm)] • Remove the piston with fork wrench w/f 42 • Replace all seals with new ones (sealing kit) • Assembly in the reverse order

➥Install the piston with torque 295 lb-ft (400 Nm) ➥Fit the locking screw with Loctite 242

Tab washer

918133/AP0405

918133/AP0405

36.9

Sealing the quickhitch cylinder

Circlip

Seal (piston rod)

Piston seal Guide tube

Guide band

Tapped hole M8

☞ Disassembly/assembly: • Remove the circlip • Drive out the piston with an impact extractor M 8 • Replace all the seals of the piston rod with new ones

➥– see section 36.9.1, Sealing: Quickhitch cylinder piston rod on page 36-10 • Fit the piston seal with a conical adapter

➥– see section 36.9.2, Assembly tools on page 36-10

36-9

Hydraulics

• Assembly in the reverse order

Hydraulics

Hydraulics

36

36.9.1

Sealing: Quickhitch cylinder piston rod General instructions Follow these instructions before fitting the seals:

☞ Check whether the piston rod is bevelled. If this is not the case, use an assembly sleeve

☞ Debur sharp edges, apply radii or chamfer, cover thread tips ☞ Remove processing residues as chips, dirt or other particles and clean all parts carefully.

☞ Warm up Turcon rings in oil or water [to about 176° to 248° F (80 to 120° C)] to extend and reshape them much more easily

307s3670.eps

☞ Grease or lubricate the rod for easier assembly. Make sure the lubricant does not affect the sealing material used. In case of grease lubrication: Do not use grease containing solid components, i.e. molybdenum disulfide or zinc sulphides!

☞ Do not use sharp-edged assembly tools Assembly in closed grooves We recommend using auxiliary assembly tools (circlip pliers) for Turcon and polyurethane seals. Follow these instructions if no auxiliary tools are available:

☞ Compress the sealing ring as shown opposite ☞ Insert the compressed sealing ring into the groove and press it against the groove in the direction of the arrow

☞ Once the sealing ring is inserted, reshape the seal with your fingers by pressing it back into the groove

☞ Calibrate with a drift bevelled 10 to 15° over a length of about 1.18'' (30 mm)

36.9.2

Assembly tools

Assembly sleeve for fitting the piston seal Polished surface

Calibrating sleeve for reshaping the piston seal

307s3660.eps

Polished surface

307s3665.eps

36-10

918133/AP0405

Overview: Loader unit

36

918133/AP0405

36.10

Assembly prop (standard assembly)

3rd control circuit

Tilt cylinder

Cover

Lift cylinder

Spool port on right

Spool port at center

Spool port on left

Solenoid valve 3rd control circuit

34001e3605.iso

Hydraulics

36-11

34001e36_05.iso

Hydraulic circuit 4th control circuit

Hydraulics

36-12

36.11

Return blue Feed red Pressure relief valve [adjustable 2610 psi (180 bar)]

Pressure line (4th control circuit)

Pressure line (priority valve)

Pressure line 21 qt (20 L) from 3rd control circuit

Return blue Feed red

Reflux 918133/AP0405

Test port 4th control circuit 2610 psi (180 bar)

34001e3607.iso

Flow divider [fixed adjustment at 21 qts./21 qts. (20L/20L]

Hydraulic pump 42 qts. (40 L) (steering system/work hydraulics/4th control circuit)

918133/AP0405

36.12

Hydraulics diagram: 4th control circuit – solenoid valve without contact (neutral circulation)

From the control valve 21 qts. (20 L)

Radiator

Quickhitch cylinder Return blue (front)

Feed red (front)

X

Test port 4th control circuit 21 qts. (20 L)

X

Solenoid valve

Control valve

1/2

4

Flow divider Return suction filter 3

Hydraulic pump

A2

B2

V = 0.98 ccm/U

(16 ccm/U) Q = 11 gpm (40 L/min)

A T

2610 psi (180 bar)

T

Q = 5 gpm (20 L/min)

3480 psi

(240 bar)

Y5

A P

Q = 5 gpm (20 L/min)

P

Y6 P = 24 hp (17,8 kw) 3480 psi (240 bar)

B

36-13

Return blue (rear)

Feed red (rear)

Hydraulics

34001s36_04.iso

Hydraulics diagram: 4th control circuit – solenoid valve with contact

From the control valve 21 qts. (20 L)

Hydraulics

36-14

36.13

Feed red 21 qts. (20 L) either front or rear)

Radiator

Quickhitch cylinder

Return blue (front)

X

Test port 4th control circuit 21 qts. (20 L)

X

Solenoid valve

Control valve

1/2

4

Flow divider

3

Return suction filter Hydraulic pump

A2

B2

V = 0.98 ccm/U

(16 ccm/U) Q = 11 gpm (40 L/min)

A 2610

T

psi

(180 bar)

T

Q = 5 gpm (20 L/min)

3480

psi (240 bar)

Y5

A P

Q = 5 gpm (20 L/min)

P

Y6 P = 24 hp (17,8 kw) 3480 psi (240 bar)

B

• If no consumers are connected, the oil is driven back to the tank via the pressure relief valve

34001s36_05.iso

918133/AP0405

Return blue (rear)

Feed red (rear)

918133/AP0405

36.14

Hydraulics diagram: 3rd + 4th control circuit – solenoid valve with contact From the control valve 21 qts. (20 L)

Feed red 42 qts. (40 L) either front or rear)

Radiator

Quickhitch cylinder

Return blue (front) X

Test port 4th control circuit 21 qts. (20 L)

X

Solenoid valve

Control valve

1/2

4

Flow divider Return suction filter 3

Hydraulic pump

A2

B2

V = 0.98 ci/U

(16 ccm/U) Q = 11 gpm (40 L/min)

A 2610

T

psi (180 bar)

Q = 5 gpm (20 L/min)

T

3480 psi

(240 bar)

Y5

A P

Q = 5 gpm (20 L/min)

P

Y6 P = 24 hp (17,8 kw) 3480 psi (240 bar)

B

42 qts.

(20 L)

• If no consumers are connected, the oil is driven back to the tank via the pressure relief valve

Feed red (rear)

36-15

Connected attachment 42 qts. (40 L)

Hydraulics

34001s36_06.iso

Return blue (rear)

Hydraulics

Hydraulics

36

36.15

Test and setting instructions for work hydraulics

IMPORTANT! Run the vehicle warm to operating temperature [about 122° – 140° F (50° – 60° C)] before taking any measures or making any settings.

☞ Adjust valves only with the engine at a standstill

36.15.1

Test report

Model: ____________________

Test conditions: Test features:

Prod. no. variable displacement pump ____________________

Prod. no. variable displacement motor ____________________

Rated oil temperature: Notes:

Serial no. ___________________

122° – 140° F (50° – 60° C)

Rated value: (rpm)

Min. idling speed

1025 – 1075

Max. idling speed

2565 – 2615

Work hydraulics

Max. engine speeds

3408 – 3480 psi (225 – 235 bar)

Tilt pressure

At lower n 1025 – 1075 rpm

1668 – 1958 psi (115 – 135 bar)

Steering pressure

Max. engine speeds

175 – 190

Wheel speed

Max. engine speeds 19 sec over 100 m

18 km/h = 140 – 150

Oil purity/oil sample

Serial no. end figure

max. 18/14

Loader unit lowering

At Toil = 122° F (50 °C)

Lift cyl. max. 2'' (50 mm); Tilt cyl. max.

2'' (50 mm)

Pcyl = 1450 psi (100 bar) T = 10 min

Nom. value: (rpm)

✔

Additional hydraulic additional control circuits (optional version only) Displacement: additional front control circuit

2611 psi (180 +10 -5 bar) service pressure at max. engine speeds

20 gpm (75 L/min)

Displacement: additional rear control circuit

2611 psi (180 +10 -5 bar) service pressure at max. engine speeds

20 gpm (75 L/min)

Displacement: additional front control circuit + rear 4th control circuit

2611 psi (180 +10 -5 bar) service pressure at max. engine speeds

20 gpm (75 L/min front or 20 gpm (75 L/min) rear

36-16

918133/AP0405

Hydraulics

36.15.2

Legend for hydraulics diagram

Ref.

Description

1

Hydraulic steering system

2

Valve block 145/7.25 psi (10 bar/0.5 bar)

3

Front axle steering cylinder

4

Rear axle steering cylinder

5

Drain coupling

6

Drive – variable displacement pump

7

Priority valve (steering system)

8

Hydraulic pump V = 1.37 in³/rev (22.5 cm³/rev) Q = 14 gpm (52 L/min)

9

Drive – hydraulic motor

10

Hydraulic temperature switch

11

Hydraulic oil tank

12

Hydraulic reflux suction filter

13

Hydraulics radiator

14

Pressure switch

15

Ventilation – hydraulic oil tank

16

Control valve

17

Solenoid valve 3rd control circuit

18

Tilt cylinder

19

Control cylinder (quickhitch facility

20

Lift cylinder

21

Pilot control unit:

22

Hydraulics lock lever (road travel)

23

Pressure accumulator (emergency lowering)

918133/AP0405

36-17

Hydraulics 36

Hydraulics

5 18

13

20

19

X

T2

Y3

b

a

PS

B MB

X

>

X

X B

>

(22,5 ccm/U) Q= 13.7 g/min (52 l/min)

G

X2

S

X

X1 P

9 A

M1

a

P

T A1 B1

X

R

21

A MA

X

LS

B3 A3

3

X

)(

X1 T

V= 0.37 ci /U P= 30 hp (6,1 ccm/U) (22,3 kw) Q= 3.7 g/min (14 l/min)

6

(28 ccm/U) Q= 17 g/min (65 l/min)

a

A2 B2

8

X 3

V= 1.7 ci /U

P

a

3

V= 1.37 ci /U

1

L

U

X1 X3

G

T

X

L T2

Y2

3336

psi 230

EF

)(

bar)

)(

)(

7

2

7.25 psi (0,5 bar)

P

bar) B1

b

Y2

12

15

psi

(0,5

3.0

A

)

B

(0,2

bar)

B2

(

(

(

(

10

T

11

T

22

T

4 (

(

X

(

(

Hydplan341_01.iso

36.15.3

918133/AP0405

X2

17

bar) psi

145 psi (10 bar) B2

Y1

T

P

3

b

4351 psi (300 bar)

S4 )

)

7.25 psi (0,5 bar) B1

P1

7.25 X

10 bar

psi

b

1740 psi (120 bar)

(2,5

X

A2

P

)

A1

14

A 36.2

4061 psi (280 bar)

)

LS

16

)

CF

23

Hydraulics diagram

36-18

918133/AP0405

41

41

Heating

41.1

Heating circuit: overview

Heater nozzle (front window)

Temperature controller

Heater nozzle (leg room)

Heater (mounted underneath steering column trim)

Reflux (water circuit)

Lock lever

Intake filter

Feed (water circuit)

41-1

Heating

34001e4100.iso

Heating Notes:

41-2

918133/AP0405

Notes:

918133/AP0405

Heating

41-3

Heating

Notes:

41-4

918133/AP0405

TORQUE SPECIFICATIONS Use these torque values when tightening hardware (excluding locknuts, and self-tapping, thread-forming, and sheet metal screws) unless otherwise specified.

UNIFIED NATIONAL THREAD

GRADE 2

GRADE 5

GRADE 8

DRY

LUBED

DRY

LUBED

DRY

LUBED

8-32 8-36 10-24 10-32

19* 20* 27* 31*

14* 15* 21* 23*

30* 31* 43* 49*

22* 23* 32* 36*

41* 43* 60* 68*

31* 32* 45* 51*

1/4-20 1/4-28 5/16-18 5/16-24

66* 76* 11 12

50* 56* 9 9

9 10 17 19

75* 86* 13 14

12 14 25 25

9 10 18 20

3/8-16 3/8-24 7/16-14 7/16-20

20 23 32 36

15 17 24 27

30 35 50 55

23 25 35 40

45 50 70 80

35 35 55 60

1/2-13 1/2-20 9/16-12 9/16-18

50 55 70 80

35 40 55 60

75 90 110 120

55 65 80 90

110 120 150 170

80 90 110 130

5/8-11 5/8-18 3/4-10 3/4-16

100 110 175 200

75 85 130 150

150 180 260 300

110 130 200 220

220 240 380 420

170 180 280 320

7/8-9 7/8-14 1-8 1-12

170 180 250 270

125 140 190 210

430 470 640 710

320 360 480 530

600 660 900 1000

460 500 680 740

METRIC COARSE THREAD

GRADE 8.8

GRADE 10.9

GRADE 12.9

DRY

LUBED

DRY

LUBED

DRY

LUBED

M6-1 M8-1.25 M10-1.5

8 19 37.5

6 14 28

11 27 53

8 20 39

13.5 32.5 64

10 24 47

M12-1.75 M14-2 M16-2

65 103.5 158.5

48 76.5 117.5

91.5 145.5 223.5

67.5 108 165.5

111.5 176.5 271

82 131 200

*All torque values are in lb.-ft. except those marked with an * which are in lbs.

For metric torque value (N·m) multiply ft-lbs value by 1.355 or the lb.-in. value by 0.113.

®

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

918133/AP0405

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

PRINTED IN USA