Mustang Compact Excavator ME80003 Service Manual (918170) – PDF DOWNLOAD

Mustang Compact Excavator ME80003 Service Manual (918170) – PDF DOWNLOAD

DESCRIPTION:

Mustang Compact Excavator ME80003 Service Manual (918170) – PDF DOWNLOAD

Introduction

• For your safety and continued proper operation, use only genuine MUSTANG® service parts. When ordering service parts, specify the correct part number, full description, quantity required, the unit model number and serial number. The model and serial number decal for this unit is located on the left chassis upright.
• “Right” and “Left” are determined from a position sitting on the seat and facing forward. Mustang Company reserves the right to make changes or improvements in the design or construction of any part of the unit without incurring the obligation to install such changes on any previously delivered units.
• Refer to the abbreviations table located on this page for the various fastener descriptions. Standard attaching hardware torque values are also provided on the inside back cover.
• If a part requires lubrication or a nonstandard torque value, it will be specified behind the part number description in parenthesis. Items shown in the parts list that do not have part numbers are shown for reference purposes only and are NOT available for purchase. Dimensions are in inches unless otherwise specified.

TABLE OF CONTENTS:

Mustang Compact Excavator ME80003 Service Manual (918170) – PDF DOWNLOAD

Operation
Important information about this service manual …………………………………………….. 1-1
Abbreviations/symbols ………………………………………………………………………………… 1-1
Identification of warnings and hazards ………………………………………………………….. 1-2
Designated use and exemption from liability ………………………………………………….. 1-2
Serial plates and component numbers ………………………………………………………….. 1-3
Serial number location ………………………………………………………………………………… 1-3
Engine number ………………………………………………………………………………………….. 1-3
Hydraulic pump identification number ……………………………………………………………. 1-4
Main valve block identification number ………………………………………………………….. 1-4
Travel drive identification number …………………………………………………………………. 1-4
Swivel unit identification number ………………………………………………………………….. 1-4
Machine: overview ……………………………………………………………………………………… 1-5
Cab overview …………………………………………………………………………………………….. 1-6
Cab legend ……………………………………………………………………………………………….. 1-7
Instrument panel overview …………………………………………………………………………… 1-8
Instrument panel legend ……………………………………………………………………………… 1-9
Engine compartment: overview ………………………………………………………………….. 1-10
Chassis: overview …………………………………………………………………………………….. 1-11
Tilting the cab ………………………………………………………………………………………….. 1-12
Tilting the cab up ……………………………………………………………………………………… 1-13
Tilting the cab down ………………………………………………………………………………….. 1-13
SAE operating controls (standard) ………………………………………………………………. 1-14
ISO operating controls (selectable) …………………………………………………………….. 1-15
Boom slew/auxiliary hydraulics pedal ………………………………………………………….. 1-16
Dozer blade …………………………………………………………………………………………….. 1-16
Throttle lever ……………………………………………………………………………………………. 1-17
Operator’s seat adjustments ………………………………………………………………………. 1-18
Ventilation ……………………………………………………………………………………………….. 1-20
Windshield ………………………………………………………………………………………………. 1-20
Cab door latch release ………………………………………………………………………………. 1-21
Interior light ……………………………………………………………………………………………… 1-21
Tool kit and cab jack handle ………………………………………………………………………. 1-21
Cab heat control ………………………………………………………………………………………. 1-22
Recirculated air mode ……………………………………………………………………………….. 1-22
Hydraulics/swiveling and boom rotation pedal adjustment ……………………………… 1-23
Battery master switch ……………………………………………………………………………….. 1-23
Specifications
Chassis …………………………………………………………………………………………………….. 2-1
Engine ………………………………………………………………………………………………………. 2-1
Hydraulic system ……………………………………………………………………………………….. 2-3
Undercarriage/swivel unit ……………………………………………………………………………. 2-4
Dozer blade ………………………………………………………………………………………………. 2-4
Electrical system ………………………………………………………………………………………… 2-5
Sound levels ………………………………………………………………………………………………. 2-7
Coolant compound table ……………………………………………………………………………… 2-7
Specific tightening torques …………………………………………………………………………… 2-7
General tightening torques ………………………………………………………………………….. 2-8
Dimensions ……………………………………………………………………………………………… 2-11
Lift capacities …………………………………………………………………………………………… 2-12
Lift capacity table (with extended dipper arm and counterweight) ……………………. 2-14
Geometry ………………………………………………………………………………………………… 2-15
Table of contents
I-2 918170/AP0805
Table of contents
Maintenance
General information care and servicing …………………………………………………………. 3-1
Care and servicing ……………………………………………………………………………………… 3-1
Maintenance safety …………………………………………………………………………………….. 3-2
Fluids and lubricants……………………………………………………………………………………. 3-3
Maintenance decal symbols …………………………………………………………………………. 3-5
Maintenance decal ……………………………………………………………………………………… 3-6
Maintenance schedule ………………………………………………………………………………… 3-7
General maintenance ………………………………………………………………………………… 3-10
Lubrication ………………………………………………………………………………………………. 3-12
Fuel system ……………………………………………………………………………………………… 3-13
Specific safety instructions …………………………………………………………………………. 3-13
Filling the fuel tank ……………………………………………………………………………………. 3-13
Fuel filter …………………………………………………………………………………………………. 3-14
Fuel shut-off valve, fuel prefilter and water separator …………………………………….. 3-14
Purging air from the fuel system …………………………………………………………………. 3-15
Engine lubrication system ………………………………………………………………………….. 3-16
Changing engine oil and filter …………………………………………………………………….. 3-16
Coolant system ………………………………………………………………………………………… 3-18
Checking coolant level ………………………………………………………………………………. 3-18
Air cleaner service ……………………………………………………………………………………. 3-19
Dust valve functional check ……………………………………………………………………….. 3-20
Checking and adjusting V-belt tension …………………………………………………………. 3-21
Checking and adjusting air conditioning V-belt tension ………………………………….. 3-22
Pressure check ………………………………………………………………………………………… 3-23
Test report ……………………………………………………………………………………………….. 3-28
Hydraulic system ………………………………………………………………………………………. 3-31
Checking hydraulic oil level ………………………………………………………………………… 3-31
Checking hydraulic pressure lines ………………………………………………………………. 3-35
Track system ……………………………………………………………………………………………. 3-36
Changing final drive oil ………………………………………………………………………………. 3-36
Electrical system ………………………………………………………………………………………. 3-39
Battery …………………………………………………………………………………………………….. 3-40
Using a booster battery (jump-starting) ………………………………………………………… 3-40
Cab heater filter ……………………………………………………………………………………….. 3-42
Engine
4TNV98 engine: overview ……………………………………………………………………………. 4-1
Fuel system ……………………………………………………………………………………………….. 4-3
Removing the cylinder head cover ………………………………………………………………… 4-4
Checking and adjusting valve tip clearance ……………………………………………………. 4-4
Cylinder head bolt tightening order ……………………………………………………………….. 4-6
Checking the injection nozzles ……………………………………………………………………… 4-6
Checking the nozzle jet ……………………………………………………………………………….. 4-7
Injection timing …………………………………………………………………………………………… 4-8
Adjusting engine RPM ………………………………………………………………………………… 4-9
Checking compression ………………………………………………………………………………… 4-9
Checking the coolant thermostat ………………………………………………………………… 4-10
Checking the thermal switch ………………………………………………………………………. 4-10
Oil pressure switch ……………………………………………………………………………………. 4-11
Checking the coolant circuit ……………………………………………………………………….. 4-11
Engine troubleshooting ……………………………………………………………………………… 4-12
Hydraulic system
Hydraulic pump ………………………………………………………………………………………….. 5-1
Main valve block ………………………………………………………………………………………… 5-6
Drive counterbalancing system …………………………………………………………………… 5-14
Boom summation — raise ………………………………………………………………………….. 5-16
918170/AP0805 I-3
Table of contents
Check valve (load retaining valve) ………………………………………………………………. 5-17
Dipper arm cylinder summation ………………………………………………………………….. 5-17
Dipper arm check valve (load retaining valve) ………………………………………………. 5-18
Secondary pressure limiting valves for the auxiliary hydraulics (option) …………… 5-19
Pilot valves ………………………………………………………………………………………………. 5-20
Valves …………………………………………………………………………………………………….. 5-25
Travel drive up to serial no. AC 02793 ………………………………………………………… 5-32
Travel drive Auto 2-speed (starting serial no. AC 02957) ……………………………….. 5-34
Swivel unit ……………………………………………………………………………………………….. 5-37
Swivel joint ………………………………………………………………………………………………. 5-42
Breather filter …………………………………………………………………………………………… 5-43
Troubleshooting the hydraulic system …………………………………………………………. 5-44
Hydraulic diagram (legend) ………………………………………………………………………… 5-46
Hydraulic diagram …………………………………………………………………………………….. 5-47
Main valve block diagram ………………………………………………………………………….. 5-48
Electrical system
Ohm’s law (current, voltage, resistance); power ……………………………………………… 6-1
Measuring equipment, measuring methods ……………………………………………………. 6-1
Cable color coding ……………………………………………………………………………………… 6-2
Relays ………………………………………………………………………………………………………. 6-3
Electrical units ……………………………………………………………………………………………. 6-3
Fuse box in instrument panel ……………………………………………………………………….. 6-3
Main fuse box with relays ……………………………………………………………………………. 6-4
Relays ………………………………………………………………………………………………………. 6-4
Lubrication strip accessory power socket ………………………………………………………. 6-5
Joystick tip switches …………………………………………………………………………………… 6-5
Instrument panel overview …………………………………………………………………………… 6-6
Switches: overview …………………………………………………………………………………….. 6-7
Alternator ………………………………………………………………………………………………….. 6-8
Starter ………………………………………………………………………………………………………. 6-8
Wiring diagram legend ………………………………………………………………………………. 6-10
Wiring diagram …………………………………………………………………………………………. 6-11
Wiring harness legend: engine—chassis ……………………………………………………… 6-12
Wiring harness: engine—chassis ……………………………………………………………….. 6-13
Wiring harness legend: switches ………………………………………………………………… 6-14
Wiring harness: switches …………………………………………………………………………… 6-15
Wiring harness: cab roof ……………………………………………………………………………. 6-16
Wiring harness: armrest …………………………………………………………………………….. 6-17
Wiring harness: boom working light …………………………………………………………….. 6-18
Options
Air conditioning ………………………………………………………………………………………….. 7-1
Counterweight ……………………………………………………………………………………………. 7-9
Extended dipper arm ………………………………………………………………………………….. 7-9
Control circuit hydraulic coupling connections ………………………………………………. 7-10
3rd control circuit connections ……………………………………………………………………. 7-10
Auxiliary hydraulics connections …………………………………………………………………. 7-11

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