Mustang Wheel Loader ML48T Service Manual (918139) – PDF DOWNLOAD

Mustang Wheel Loader ML48T Service Manual (918139) – PDF DOWNLOAD

DESCRIPTION:

Mustang Wheel Loader ML48T Service Manual (918139) – PDF DOWNLOAD

1 Operation
1.1 Important information on this service manual

• This service manual contains important information on how to service your machine safely, correctly and economically. Therefore, it aims not only at new users, but also serves as a reference for experienced users. It helps to avoid hazardous situations and reduce repair costs and downtimes.
• Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the Operator’s Manual. Careful and prudent work is the best way to avoid accidents! Operational safety and readiness of the machine do not only depend on your skill, but also on maintenance and service of the machine. Insist on using original authorized service parts when performing maintenance and repair work.
• This ensures operational safety and readiness of your machine, and maintains its value. Your authorized dealer will be pleased to answer any questions regarding the machine or this service manual.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Mustang Wheel Loader ML48T Service Manual (918139) – PDF DOWNLOAD

Operation
Important information on this service manual 1-1
Type decals and component numbers 1-2
Machine overview 1-4
Cab overview 1-5
Instrument panel, multifunctional lever and drive lever: overview 1-6
Specifications
Frame 2-1
Engine 2-1
Power train 2-2
Axles 2-3
Brakes 2-3
Steering 2-4
Work hydraulics 2-4
Pilot control 2-4
Loader unit 2-5
Electrical system 2-6
Fuse box on left and right of steering column 2-6
Main fuse box with relays 2-7
Relays 2-7
Tires 2-8
Weights 2-8
Sound levels 2-8
Vibration 2-8
Tightening torques 2-9
General tightening torques 2-9
Specific tightening torques 2-9
Dimensions 2-10
Maintenance
Fluids and lubricants 3-1
Maintenance decal 3-2
Explanation of symbols on
maintenance decal 3-2
Maintenance schedule Model 480T (overview) 3-4
Maintenance items 3-7
Introduction 3-7
Fuel system 3-8
Specific safety instructions 3-8
Refuelling 3-8
Stationary fuel pumps 3-8
Diesel fuel specification 3-8
Bleeding the fuel system 3-9
Replacing the fuel filter 3-9
Cleaning the fuel pump screen filter 3-9
Engine lubrication system 3-11
Checking and filling up the oil level 3-11
Changing engine oil 3-12
Replacing the engine oil filter
cartridge 3-13
Engine and hydraulic cooling system 3-14
Specific safety instructions 3-14
Cleaning the oil cooler 3-14
Table of contents
I-2 918139/AP0905
Table of contents
Air filter 3-15
Weekly check of air filter contamination 3-15
Weekly functional check of the
dust valve 3-16
Replacing the filter cartridge 3-16
V-belt 3-17
Checking the V-belt tension 3-17
Re-tensioning the V-belt 3-17
Gearboxes and axles 3-18
Checking and filling up the gearbox oil level 3-18
Changing the gearbox oil 3-19
Checking the oil level in the rear axle differential 3-20
Filling up the oil level 3-20
Changing the oil 3-20
Checking the oil level in the front axle differential 3-21
Filling up the oil level 3-21
Changing the oil 3-21
Planetary drives: Checking and filling up the oil level 3-22
Changing the oil 3-22
Hydraulic system 3-23
Specific safety instructions 3-23
Checking the hydraulic oil level 3-24
Filling up the hydraulic oil 3-24
Monitoring the hydraulic oil return filter 3-25
Important information for the use of biodegradable oil 3-25
Specific safety instructions
for pressure lines 3-26
Lubrication work 3-27
Lubricating the rear axle oscillation-type bearing 3-27
Lubricating the planetary drive
bearing 3-27
Lubricating the pivots on the loader unit 3-28
Lubricating the loader unit 3-28
Checking the wear pads 3-28
Maintenance of attachments 3-29
Maintenance of the brake system 3-29
Specific safety instructions 3-29
Checking/filling up the brake fluid level 3-29
Tire maintenance 3-30
Daily checks 3-30
Weekly checks 3-30
Changing wheels 3-31
Disassembly 3-31
Fitting the wheels 3-31
Electrical system 3-32
Specific safety instructions 3-32
Service and maintenance work at regular intervals 3-33
Cables, bulbs and fuses 3-33
Alternator 3-33
Battery 3-33
General maintenance work 3-34
Cleaning 3-34
General instructions for all areas of the machine 3-34
Cleaning inside the cab 3-35
Cleaning the outside of the machine 3-35
Cleaning the engine compartment 3-35
Screw connections 3-35
918139/AP0905 I-3
Table of contents
Pivots and hinges 3-36
Heating 3-36
Cleaning the dust filter of the heating system 3-36
Engine
BF4M 2011/ F4M 2011 engine: overview 4-1
Engine oil cooling 4-2
Fuel system 4-3
Engine level 2 (Tier II) 4-4
Checking and adjusting valve tip clearance 4-5
Replacing the fuel injection pump 4-6
Turning off minus compensation 4-11
Heating connection 4-11
Removing/mounting the cylinder head 4-12
Sealing the bleeder valve 4-15
Intake/exhaust manifold 4-15
Engine trouble 4-15
Power train
Variable-displacement pump 125 mph (20 km/h) 5-1
Hydraulic motor – hydraulic connections 125 mph (20 km/h) 5-2
Hydraulic motor – control element 125 mph (20 km/h) 5-3
Power train circuit with cooling 125 mph (20 km/h) 5-4
Power train diagram 125 mph (20 km/h) 5-5
Inching valve (left-hand side access) 5-6
Inching valve (component parts) 5-7
Test report 125 mph (20 km/h) 5-8
Towing and transporting the machine 5-9
Safety instructions 5-9
Towing 5-9
Adjustment work on power train 5-10
Starting speeds 5-10
Adjusting boost pressure 5-10
Adjusting pilot pressure 5-10
Hydraulic resistance (characteristic curve) of the pump 5-11
High pressure/drive pressure 5-12
Secondary valves Fwd – Rev 5-13
Pump output/diesel output 5-13
Control initiation on hydraulic motor 5-14
Adjustment for wheel speed 125 mph (20 km/h) 5-15
ECO speed 25 mph (40 km/h high speed) 5-16
Variable-displacement pump (40 km/h) 5-16
Variable-displacement pump test ports 5-17
ECO speed hydraulic motor 5-18
Positions of test port set screws 5-19
I-4 918139/AP0905
Table of contents
ECO speed power train 25 mph (40 km/h): diagram 5-20
25 mph (40 km/h) test report 5-21
Control initiation M3: settings 5-22
Control initiation M4: settings 5-23
Wheel speed: settings 5-24
Axles
Type decal – axle 6-1
Front axle screw connections 6-2
Rear axle screw connections 6-3
Drain, fill and check plug – front axle 6-4
Drain, fill and check plug – rear axle 6-5
Tightening torques lb-ft (Nm) – front axle 6-6
Tightening torques lb-ft (Nm) – rear axle 6-7
Sealing work 6-8
Input flange – front axle: sealing work 6-8
Input flange – rear axle: sealing work 6-9
Brake cylinder – front axle 6-10
Planetary carrier – planetary drive: sealing work 6-13
Planetary carrier – axle tube: sealing work 6-16
Sealing ring in axle tube: sealing work 6-18
Gearbox 125 mph (20 km/h):
sealing work 6-21
Differential lock 6-22
Self-locking differential 6-22
Differential cage with lock 6-23
Brakes
Brake circuit 7-1
Brake diagram 7-2
Bleeding the service brake 7-3
Important information on the brake system 7-3
Bleeding the brake system with bleed equipment 7-3
Parking brake: overview 7-4
Steering
125 mph (20 km/h) steering circuit 8-1
125 mph (20 km/h) steering diagram 8-2
25 mph (40 km/h) steering circuit 8-3
25 mph (40 km/h) steering diagram 8-4
Hydraulic connections on servo stat 8-5
Pressure relief valve – servo stat: settings 8-5
Sealing the steering cylinder 125 mph/25 mph (20 km/h/40 km/h) 8-6
Adjusting the steering sensors 25 mph (40 km/h) 8-7
Hydraulic system
Test report 9-1
Control valve connections 9-2
Priority valve for work hydraulics and steering 9-2
Control valve (position) 9-3
918139/AP0905 I-5
Table of contents
Work hydraulics circuit 9-4
Connections: frame – loader unit disconnect 9-5
Loader unit hose routing 9-6
Pilot control unit: design 9-7
Pilot control circuit 9-8
Valve positions 9-9
Valve block for 3rd control circuit 9-10
Hose burst valve with load stabilizer: connections 9-11
Load stabilizer diagram 9-12
Load stabilizer with hose burst valve: diagram 9-13
Tilt and lift cylinder: sealing 9-14
Compensating and push-out cylinder: sealing 9-15
Control cylinder (quickhitch frame): sealing 9-16
Work hydraulics diagram 9-17
Electrical system
Ohm’s Law (current, voltage, resistance); power 10-1
Measuring equipment, measuring methods 10-1
Terminal description 10-3
Cable color coding 10-6
Other color codes (identical to IEC 757, edition 1983) 10-7
Relays 10-7
Use, mode of function 10-7
Terminal description on relay 10-7
Fuse box, relays: overview 10-8
Fuse box on left and right of steering column 10-8
Main fuse box with relays 10-9
Relays 10-9
Setting the safe load indicator 10-10
Description 10-10
Qualification 10-10
Necessary tools 10-10
General safety instructions 10-10
Description 10-11
Overview 10-11
Calibration 10-12
Setting the 0% point 10-12
Setting the 100% point 10-13
Calibration values 10-14
Adjusting signal volume 10-15
Functional check 10-15
Troubleshooting 10-16
Steering electronics 10-17
Instrument panel, fuse box, relays: overview 10-18
Wiring diagram: legend 10-20
Wiring diagram 10-21
Wiring harness 208587 engine – frame 125 mph (20 km/h): legend 10-22
Wiring harness: 208587 engine – frame 125 mph (20 km/h) 10-23
Wiring harness 208689 engine – frame 25 mph (40 km/h): legend 10-24
Wiring harness: 208689 engine – frame 25 mph (40 km/h) 10-25
Wiring harness 208659 for cab: legend 10-26
Wiring harness 208659 for cab 10-27
Wiring harness 208701 for cab (high speed) 10-28
Wiring harness 208700 for roof 10-29
Wiring harness for roof 10-30
I-6 918139/AP0905
Table of contents
Wiring harness 208562 on control lever base 10-31
Wiring harness 207409 for rear/clearance lights 10-32
Wiring harness 1000103376 Telescopic 10-33
Wiring harness 208111 for additional circuit (Optional) 10-34
Wiring harness 208609 (joystick) 10-35
Electronics between joystick and wiring harness 208609 10-35
Wiring harness 208589 for load stabilizer 10-36
Wiring harness 208676 for load stabilizer solenoid valve (option) 10-37
Wiring harness 207410 for control lever lock for long-haul travel 10-38
Wiring harness 207407 for lock for long-haul travel, instrument panel 10-39
Wiring harness 207411 for High Flow additional hydraulics (option) 10-40
Wiring harness 207997 for front socket (option) 10-41
Wiring harness 207999 for safe load sensor 10-42
Plug and socket connection: steering electronics –
steering-column control lever 10-44
Plug and socket connection: fuse box and left-hand side relays 10-45
Relay assignment (center) 10-46
Plug and socket connection: fuse box and right-hand side relays 10-47
Plug and socket connection: cab 10-48