Mahindra ML 120 3535 User manual

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OPERATOR’S MANUAL
PARTS CATALOGUE
INSTALLATION INSTRUCTIONS
GEAR
'35' Series 3535/4035
ML 120

Includes:Operator’s Manual, Parts
Catalogue and Installation Instructions
Mahindra, Ltd
Model ML120
Front End Loader
1503-1139
February 2008
35 Series 4WD, Model - 3535 & 4035 Loader June’08

2
WARRANTY CONDITIONS
Warranty Coverage:
Mahindra, Ltd, Inc., herein referred to as Mahindra, undertakes to replace or repair any part of a Mahindra loader
where damage has been proven to be caused by defects in material or workmanship.
This Warranty is valid for a period of 1 year for all hydraulic components and attachments and for a period of 2
years for all other loader components from the date of the original retail sale. Parts replaced or repaired under the
terms of this Warranty are guaranteed only until the original warranty expires.
It is further understood and agreed that the defect should be immediately reported to the Selling Dealer. The
Selling Dealer will generally perform Warranty repairs or replacements and the Purchaser shall deliver the
Mahindra Loader to the Dealer’s place of business for repair. In the event Purchaser is located more than 75
miles from the Selling Dealer, any Mahindra Dealer authorized to sell and service Mahindra Products may
perform the repair at its dealership.
The obligation of Mahindra to the Purchaser under this Warranty is limited to the repair or replacement of
defective parts by an authorized Mahindra dealer. Repair or replacement in accordance with this Warranty shall
constitute fulfillment of all liabilities of Mahindra and the Selling Dealer in respect to Mahindra Loaders.
There are no warranties beyond those which expressly appear herein. Any implied warranty of
merchantability or fitness for a particular purpose is specifically excluded here from.
Warranty Provisions:
Mahindra’s liability under this Warranty is subject to the observance by the Purchaser of the following provisions:
- The purchaser shall at all times in the operation of any Mahindra Product, use those brands and grades of
lubricating oils, lubricants or fuel and spare parts officially approved by Mahindra.
- The Mahindra Loaders shall have been used in accordance with the procedures specified in the Operator’s
Manual. This Warranty does not extend to damage resulting from misapplication, abuse, misuse, failure to
perform maintenance, negligence, fire, accidents or changes or faulty mounting carried out by the Purchaser.
When making a Warranty exchange of parts, the Purchaser shall compensate Mahindra for the time that the
parts have been used if they have been exposed to extreme wear.
- Compensation is not paid for physical harm, deadlock, resulting damages, or other losses.
- To obtain warranty service, the Purchaser must (1) report the product defect to an authorized Mahindra
dealer and request repair within the applicable warranty term and (2) present evidence of purchase or date of
original use.
- The Warranty shall be void if the Mahindra Loader has been altered or repaired outside of a Mahindra
dealership in a manner, which, in the sole judgment of Mahindra, affects its performance, stability, or
reliability.
- The customer shall be responsible for transportation expenses for the Mahindra Loader to the dealership or
travel of dealer personnel to customer location for Warranty repair. The customer shall also pay any premium
for overtime labor requested by the customer.
- Temporary repairs or additional costs due to the work being performed after normal working hours will not be
compensated.
- The above warranty is in lieu of all other warranties on Mahindra’s behalf and neither party assumes any
other liability in connection with Mahindra’s Products.
- Any dispute arising between Mahindra and the Purchaser concerning the liability of Mahindra under this
warranty shall be subject to the laws of the State of Texas.
Right To Make Design and Product Changes:
Mahindra reserves the right to make changes in the design and other changes in its Mahindra Products at any
time without incurring any obligation with respect to any product previously ordered, sold or shipped.
35 Series 4WD, Model - 3535 & 4035 Loader June’08

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CONGRATULATIONS
You are now the proud owner of a MAHINDRA Loader. This loader is a product of quality
engineering and manufacturing. It is made of fine materials and under a rigid quality control
system. It will give you long, satisfactory service. To obtain the best use of your loader, please
read this manual carefully. It will help you become familiar with the operation of the loader and
contains many helpful hints about loader maintenance. The immediate use of new techniques in
the manufacture of products may cause some small parts of this manual to be outdated.
Mahindra dealers will have the most up-to-date information. Please do not hesitate to consult with
them.
SAFETY ALERTS
This symbol, the industry’s "Safety Alert Symbol," is used throughout this manual and on labels to warn of the
possibility of personal injury. When you see this symbol, carefully read the messages and be alert to the
possibility of injury or death. It is essential you read these instructions and safety regulations before you attempt
to assemble or use this unit.
DANGER: Indicates an imminently hazardous situation, which if not avoided, will result in death or
serious injury.
WARNING: Indicates a potentially hazardous situation, which if not avoided, could result in death
or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
IMPORTANT: Indicates that equipment or property damage could result if instructions are not
followed.
NOTE: Gives helpful information.
SAFETY
Most tractor and/or loader equipment accidents can be avoided by following simple safety precautions.
The safety information given in this manual does not replace safety codes, insurance requirements, federal, state,
and local laws. Make sure your machine has the correct equipment required by your local laws and regulations.
Understand that your safety and the safety of other persons are measured by how you service and operate this
loader.
Know the position and operations of all controls before you try to operate. Make sure you check all controls in a
safe area before starting.
Read this manual completely and thoroughly and make sure you understand all controls. All equipment has a
limit. Make sure you are aware of the stability and load characteristics of this loader before you begin operation.
This safety alert symbol indicates important safety messages in this manual. When you see this
symbol, carefully read the message that follows and be alert to the possibility of personal injury or
death.
35 Series 4WD, Model - 3535 & 4035 Loader June’08

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SAFETY PRECAUTIONS
READ MANUALS AND DECALS
1. Read and understand both the tractor and the loader Operator Manuals and all decals before using the
loader.
2. Lack of knowledge can lead to accidents.
3. It is the loader owner’s responsibility to make sure anyone operating the loader reads and understands
this manual first before operating the machine.
4. Follow all safety, operating, and service instructions.
5. Replace damaged or illegible safety labels. See following pages for required labels.
ROPS AND SEAT BELT
6. Equip your tractor with an approved rollover-protective structure (ROPS) or ROPS Cab and seat belt for
your protection.
7. ROPS (Roll-Over Protective Structures) and seat belt equipped tractors are recommended for operator
use in all loader operations.
8. Operator should wear safety hard hat, safety glasses, safety shoes, and other PPE. Avoid wearing loose
clothing or jewelry that may catch in moving parts.
9. Use seat belt as specified by tractor/ROPS manufacturer.
YOURSELF
10. Do not stand, walk, or work under a raised loader bucket or attachment unless it is securely blocked and
held in position.
11. Operate controls only when properly seated in the operator’s seat.
12. Only one person, the operator, should be on the machine when it is in operation.
13. Accidental movement of valve handle/handles or leak in the hydraulic system could cause the loader to
drop, or attachment to dump, causing severe injury.
OTHERS
14. Do not allow anyone in loader work area, under raised loader, or to reach through the loader boom when
the bucket or attachment is raised.
15. A frequent cause of personal injury or death is persons falling off and being run over. Inadvertent
movement of the loader or attachment could result in serious injury or death.
16. Do not permit others to ride on your tractor, loader, bucket, or any attachment.
17. Do not lift or carry anyone on buckets, forks, probes, or any other portion of the loader or loader
attachments.
18. Do not allow children or unqualified persons to operate equipment.
PREPARATION
19. Move the wheels to the tractor manufacturer’s widest recommended settings to increase stability.
20. For better stability, always use a tractor equipped with a wide front axle, never use a tractor equipped with
a tricycle type front axle.
21. Add rear ballast or rear weight to the tractor to compensate for the load and increase stability.
22. Add recommended rear tire liquid weight or rear wheel weights for increased stability.
23. Do not modify, alter, or permit anyone else to modify or alter the loader, any of its components, or any
loader function without first consulting a Mahindra dealer.
24. Assemble, remove, and reinstall the loader only as directed in this manual. Failure to do this could result
in serious personal injury or death.
25. The loader may shift during shipping and handling, making it unstable on the pallet. Support loader with
an overhead hoist or other suitable means prior to removing bands or attaching straps securing loader to
pallet. Failure to do so could result in accidental tip-over of the loader that could cause serious injury to
you and/or bystanders.
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SAFETY PRECAUTIONS
BEFORE OPERATION
26. Before starting the engine of your tractor, make sure all operating controls are in park lock or neutral
position.
27. Be certain lights and safety markings, as provided by the tractor manufacturer, are clean and operating
when transporting the tractor/loader on public roads. Be certain that the Slow Moving Vehicle (SMV)
emblem is visible. Check with local law enforcement for specific requirements.
28. Rear tractor ballast is required after installation of loader on the tractor. To allow for proper steering of the
tractor always remove 3-point weight when the loader is parked from the tractor. Never operate the unit
with the loader parked. Failure to follow these instructions could cause loss of steering causing personal
injury and damage to property.
OPERATION
29. Add wheel ballast and/or rear weight to counterbalance tractor/loader for stability at maximum loader
capacity.
30. Additional counterweight requirements will vary with loader attachments and equipment application.
31. Move and turn the tractor at low speeds.
32. Carry loader boom at a low position during normal operation.
33. Never travel at high speeds with bucket loaded.
34. Use caution when operating the loader with a raised bucket or attachment.
35. Avoid driving over loose fill, rocks, holes, or anything that may be dangerous for loader operation or
movement.
36. Allow for the loader length when making turns.
37. Use caution when handling loose or unstable loads.
38. Gradually stop the loader boom when lowering or lifting loads.
39. When using remote hydraulic tractor valves on some tractors, the loader lift and dump cylinders will
continue moving unless the valve handle/handles are manually returned to neutral, or until relief pressure
is reached at the ends of piston strokes. Observe the bucket movement and maintain control with valve
handle/handles.
40. Travel speed should be such that complete control and machine stability is maintained at all times. Where
possible, avoid operating near ditches, embankments, and holes. Reduce speed when turning, crossing
slopes, and on rough, slick or muddy surfaces.
41. A loader attachment should be transported in a low position at slow ground speeds. Make turns slowly
and use the tractor brakes cautiously. A loaded attachment in the raised position alters the center of
gravity location of the machine and increases the possibility of mishaps.
42. Be careful during loading, transporting, and stacking to minimize rolling bales and tractor tip over.
43. Do not use buckets, forks, or other attachments without bale retaining devices.
44. Operate the tractor and loader such that complete control and machine stability is maintained at all times.
45. When using a loader, be alert of bucket or attachment position at all times. Loader in raised position with
bucket or attachment rolled back can dump material onto tractor causing damage or injury to tractor
and/or operator.
LARGE HEAVY OBJECTS
46. Never use loader for handling large heavy objects, such as large round or rectangular bales, logs, and oil
drums unless loader is equipped with attachment that is designed to handle such objects.
47. Handling large heavy objects can be extremely dangerous due to danger of rolling the tractor over.
48. Handling large heavy objects can be extremely dangerous due to danger of upending the tractor.
49. Handling large heavy objects can be extremely dangerous due to danger of the object rolling or sliding
down the loader boom onto the operator.
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SAFETY PRECAUTIONS
50. If you must handle large heavy objects, protect yourself by using caution, moving slowly, and avoiding
bumps and rough ground.
51. If you must handle large heavy objects, protect yourself by never lifting load higher than necessary to
clear the ground.
52. If you must handle large heavy objects, protect yourself by adding rear ballast to the tractor to
compensate for weight of load.
53. If you must handle large heavy objects, protect yourself by never lifting large heavy objects that may roll
or fall on the operator.
54. Never lift any load from any point of the loader with a chain, rope, or cable unless loader is equipped with
a Factory approved attachment that was designed and built for this type of lifting. Always follow lifting
instructions included with these attachments.
55. Use only Factory bale probe or bale retaining devise handler attachment when handling round bales.
56. Do not handle large square bales without a retaining device handler attachment.
57. Do not use buckets, forks, or other attachments without bale retaining devices.
58. Do not use loader for handling large, heavy objects such as logs, tanks, etc.
SLOPES
59. Stay off of slopes too steep for safe operation.
60. Shift down before you start up or down a hill with a heavy load.Avoid "free wheeling."
61. Use extreme caution when operating on a slope.
62. Always operate up and down the slope, never across the slope.
ELECTRICAL
63. Avoid contact with overhead wires, power lines, and obstacles when loader bucket or attachment is
raised.
64. Electrocution from power lines can occur with or without contact.
65. Check for underground utilities before digging below grade level.
66. Contact with overhead power lines can cause severe electrical burns or death from electrocution. Make
sure there is enough clearance between raised equipment and overhead power lines.
HYDRAULIC
67. Do not tamper with the relief valve setting. This will void warranty and could cause damage to loader
and/or tractor.
68. Escaping hydraulic fluid under pressure can have sufficient force to penetrate the skin, causing serious
personal injury. Do not use HANDS to search for suspected leaks. If injured by escaping fluid, obtain
medical treatment immediately.
69. Visually check for hydraulic leaks and broken, missing, or malfunctioning parts. Never use your hand to
check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. Escaping
hydraulic fluid or diesel fuel leaking under pressure can have sufficient force to penetrate the skin and
cause serious infection or other personal injury. If injured by leaking fluid, seek medical attention
immediately.
70. To prevent personal injury, relieve all pressure before disconnecting fluid lines.
71. Before applying hydraulic pressure, make sure all hydraulic connections are tight and components are in
good condition.
72. Be sure to purge all the air from the hydraulic system before attempting to raise or lower this machine.
73. When using remote hydraulic tractor valves on some tractors, the loader lift and dump cylinders will
continue moving unless the valve handle/handles are manually returned to neutral, or until relief pressure
is reached at the ends of piston strokes. Observe the bucket or attachment movement and maintain
control with valve handle/handles.
74. Raised loader or boom can fall due to hydraulic system failure.
75. To avoid serious injury or death: Block up or securely support loader and boom before working
underneath.
76. To avoid serious injury or death: Purge all air from hydraulic system before attempting to raise or lower
loader or boom.
77. To avoid serious injury or death: Stand clear if lowering or raising loader or boom.
78. Do not use hand or skin to check for hydraulic leaks. Use cardboard or wood. Wear eye protection.
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SAFETY PRECAUTIONS
79. High pressure oil leaks can penetrate skin causing serious injury and gangrene. Consult a physician
immediately.
80. Lower the loader or boom and release hydraulic pressure before loosening fittings.
AFTER OPERATION
81. Before leaving the tractor seat, lower attachment or loader boom to ground, stop engine, lock parking
brakes, put all controls in neutral, relieve hydraulic pressure, and remove key before leaving operator's
seat.
82. Before disconnecting hydraulic lines, relieve all hydraulic pressure.
83. Make sure all parked loaders on stands are on a hard level surface with all safety devices engaged to
prevent loader from falling and being damaged or injuring someone.
84. Always park loader with bucket attached to loader.
85. When a front loader is mounted on the tractor, enter and exit the operator’s seat only from left side of the
tractor.
86. Special care should be taken to park or store attachments with points or sharp edges in a safe manner.
87. Make sure all parked loaders are on a hard level surface. Engage all safety devices to prevent loader
from falling and being damaged or injuring someone. Do not repair loader if it is not mounted on the
tractor. Loss of hydraulic fluid or removal of parts could cause loader to collapse resulting in injury.
REPAIR
88. Visually check for hydraulic leaks and broken, missing, or malfunctioning parts.
Make necessary repairs before operation.
89. To keep mounting kit hardware from loosening during loader operation, hardware must be torqued to
specifications noted in operator manual.
90. Always wear safety goggles when servicing or repairing the machine.
91. When servicing or replacing pins in cylinder ends, bucket, etc., always use a brass drift and hammer.
Failure to do so could result in injury from flying metal fragments.
92. Never tow from any point of the loader with a chain, rope, or cable. Doing so could cause a roll over or
serious damage to the loader.
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DANGER, WARNING, AND CAUTION
DECAL SAFETY MESSAGES
0595-3000 WARNING DECAL
Add recommended rear wheel ballast and/or rear counter-weight for stability.
Move wheels to widest recommended setting to increase stability.
Move and turn tractor at low speeds.
In transport carry the load low.
Lower loader to the ground when parked.
Before servicing or adjusting equipment:
* lower loader to the ground.
* shut off engine.
Relieve hydraulic pressure before disconnecting oil lines.
Observe safety recommendations in Loader Operations Manual.
0595-3001 WARNING DECAL
Crushing Hazard
Stay away from under lift arms and bucket!
Do not stand or work under a raised loader.
Support bucket and lift arms before working under loader.
Lower loader to the ground before leaving seat.
0595-3002 DANGER DECAL
Keep machine clear of overhead power lines to avoid death or serious injury.
0595-3003 WARNING DECAL
To prevent rollback onto operator use special loader attachments for handling large objects such as stumps
and large round bales. Transport load as low as possible to avoid overturning.
0595-3004 WARNING DECAL
Read the operator’s manual for complete operating instructions and safety information before operating the
loader.
Be certain anyone operating the loader is aware of safe operating practices and potential hazards.
Operate the loader from the operator’s seat only.
Do not lift or carry anyone on loader or work from bucket or attachment.
Do not walk or work under raised loader or bucket or attachment unless it is securely supported.
Avoid loose fill, rocks, and holes; they can be dangerous for loader operation or, movement.
Use extra caution when working on inclines.
Avoid overhead powerlines or obstacles when loader is raised.
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DANGER, WARNING, AND CAUTION
DECAL SAFETY MESSAGES
0595-2190 CAUTION DECAL
To prevent bodily injury and loader instability when detaching loader, equip loader with a material bucket.
0595-3050 DANGER DECAL
To avoid serious injury or death:
Unload only on a level surface.
Keep bystanders clear of work area when loading and unloading bales.
0595-3051 WARNING DECAL
Do not operate without confirmation that coupler pins are fully engaged.
Loader attachment can fall off if not properly attached.
To avoid serious injury or death:
Only use loader manufacturer approved attachments.
Read all operators manuals and decals before operating. Follow all safety operating and service instructions.
Contact dealer for replacement parts.
0595-3052 WARNING DECAL
To avoid serious injury or death:
Do not use pallet fork attachment to lift large objects, round bales, or items that may roll or slide down loader
arms onto the operator.
Always transport loads with pallet forks low and level to ground.
Always keep pallet forks level when raising loads.
Avoid raising loads to full heights with pallet forks rolled back.
ROPS (Roll-Over Protective Structures) and seat belt equipped tractors are recommended for operator use in
all pallet fork operations.
Do not lift or carry anyone on buckets, forks, probes, or any other portion of the loader or loader attachments.
Do not allow riders on tractor, loader, or forks.
Avoid contact with electrical power lines by loader or attachments.
0595-3053 WARNING DECAL
Maximum load limit on combined pair of forks is 3700 pounds.
0595-3054 CAUTION DECAL
To avoid serious injury or death:
Read operators manual and decals before operating.
Follow all safety operating, and service instructions. Contact dealer for replacement.
Be careful during loading transporting, and stacking to minimize rolling bales and tractor tip over. ROPS (Roll-
Over Protective Structures) and seat belt equipped tractors are recommended for operator use in all bale
probe operations.
Do not allow riders on tractor loader or bale probe.
Avoid loading/unloading bales on sloping or uneven surfaces.
Avoid transporting with bales raised high. Keep bales tilted back and low to the surface while moving.
Approach, penetrate, and transport bales at low speeds. Reduce speeds on curves, hills rough ground, or
when turning.
Do not lift anything with bale probe except round bales.
Never raise round bale to full height with bale probe rolled back.
Park and store bale probe points pointed against bale, building, or other stable object.
0595-3144 3145 IMPORTANT DECAL
Loader attachment cylinders must be pinned to correct hole or cylinder damage will occur voiding warranty.
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SAFETY DECALS
Left Hand Bearing Box
Safety Decal Locations
Important: Safety decals 0595-3003 and 0595-3004 are
located on the loader LH bearing box and are visible as you
mount the tractor.
Care of Safety Decals
1. Keep safety decals clean and free of obstructing
material.
2. Clean safety decals with soap and water and dry with
a soft cloth.
3. Replace damaged or missing safety decals with new
decals from your Mahindra Dealer.
4. If a component with a safety decal(s) affixed is
replaced with a new part, make sure new safety
decal(s) are attached in the same location(s) as the
replaced components.
0595-3004
0595-3003
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Right Hand Bearing Box
Safety Decal Locations
Important: Safety decals 0595-3000, 0595-3001are located
on the loader RH bearing box. Danger decal 0595-3002 is
located on the boom crosstube.
Care of Safety Decals
5. Keep safety decals clean and free of obstructing
material.
6. Clean safety decals with soap and water and dry with
a soft cloth.
7. Replace damaged or missing safety decals with new
decals from your Mahindra Dealer.
8. If a component with a safety decal(s) affixed is
replaced with a new part, make sure new safety
decal(s) are attached in the same location(s) as the
replaced components.
Boom Crosstube
0595-3000
0595-3001
0595-3002
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TABLE OF CONTENTS
1. SPECIFICATIONS..............................................14
1.1. BUCKET SPECIFICATIONS.....................14
2. INTRODUCTION................................................15
3. INSTALLATION INSTRUCTIONS......................16
3.1. TRACTOR PREPARATION.......................16
3.2. MOUNTING KIT INSTALLATION..............18
3.3. LOADER INSTALLATION.........................23
3.4. HYDRAULIC INSTALLATION...................24
4. PRE-OPERATION INSTRUCTIONS..................34
4.1. HYDRAULIC FLUID..................................34
4.2. INITIAL LOADER OPERATION ................34
4.3. EXTERNAL LOADER VALVE ...................34
4.4. SINGLE HANDLE CONTROLLER............34
4.5. LOADER MOUNTED VALVE EQUIPPED
WITH SINGLE HANDLE CONTROLLER35
4.6. NEUTRAL POSITION ...............................35
4.7. FLOAT POSITION.....................................35
4.8. REGENERATIVE DUMPING POSITION..36
4.9. INITIAL LOADER OPERATION ................36
4.10. REMOVING AIR FROM HYDRAULIC
SYSTEM .................................................37
5. DAILY MAINTENANCE & LUBRICATION ........38
5.1. DAILY CHECKS........................................38
5.2. LOADER LUBRICATION AND SERVICE.39
6. OPERATING INSTRUCTIONS ..........................41
6.1. FILLING THE BUCKET.............................41
6.2. LIFTING THE LOAD .................................41
6.3. CARRYING THE LOAD............................41
6.4. DUMPING THE BUCKET .........................42
6.5. LOWERING THE BUCKET.......................42
6.6. OPERATING WITH FLOAT CONTROL....42
6.7. LOADING FROM A BANK ........................42
6.8. PEELING AND SCRAPING ......................43
6.9. LOADING LOW TRUCKS OR SPREADERS
FROM A PILE..........................................43
6.10. BACKFILLING.........................................43
6.11. HANDLING LARGE HEAVY OBJECTS..44
6.12. BACK GRADING OR DOZING MATERIAL45
6.13. PROHIBITED OPERATIONS..................46
7. DISMOUNTING THE LOADER..........................47
8. MOUNTING THE LOADER................................52
9. OPTIONAL GRILL GUARD...............................56
9.1. INSTALLATION INSTRUCTIONS.............56
10. SKID STEER TOOL CARRIER SYSTEM........57
10.1. RECOMMENDED LOADER FACTORY
APPROVED ATTACHMENTS.................57
10.2. NON-LOADER FACTORY
ATTACHMENTS......................................57
10.3. SKID STEER TOOL CARRIER SYSTEM
SERVICE & LUBRICATION....................58
11. INSTALLATION & OPERATION OF SKID
STEER TOOL CARRIER SYSTEM.................59
11.1. INSTALLATION INSTRUCTIONS ...........59
11.2. SKID STEER TOOL CARRIER HANDLES
IN DISENGAGED POSITION .................60
11.3. SKID STEER TOOL CARRIER HANDLES
IN ENGAGED POSITION .......................60
12. INSTALLING BUCKET OR ATTACHMENT TO
SKID STEER TOOL CARRIER .......................61
12.1. OPERATING INSTRUCTIONS ...............61
13. REMOVING BUCKET OR ATTACHMENT
FROM SKID STEER TOOL CARRIER............64
13.1. OPERATING INSTRUCTIONS ...............64
14. SKID STEER BUCKET ....................................65
14.1. SKID STEER BUCKET ...........................65
14.2. INSTALLATION INSTRUCTIONS TO SKID
STEER TOOL CARRIER ........................65
15. SKID STEER BALE SPEAR............................66
15.1. SKID STEER BALE PROBE...................67
15.2. ASSEMBLY INSTRUCTIONS .................67
15.3. INSTALLATION INSTRUCTIONS TO SKID
STEER TOOL CARRIER ........................67
15.4. OPERATING INSTRUCTIONS ...............67
16. SKID STEER PALLET FORK..........................68
16.1. SKID STEER PALLET FORK..................69
16.2. ASSEMBLY INSTRUCTIONS .................69
16.3. INSTALLATION INSTRUCTIONS TO SKID
STEER TOOL CARRIER ........................69
16.4. OPERATING INSTRUCTIONS ...............69
16.5. PARKING INSTRUCTIONS ....................69
17. OPTIONAL BALLAST BOX.............................70
18. LEAK DOWN INSPECTION.............................71
18.1. FRONT END LOADER FIELD LEAK
DOWN INSPECTION AND TEST ...........71
18.2. LEAKAGE TEST FOR LIFT CYLINDER
SEALS (Open Center Systems)..............72
18.3. LEAKAGE TEST FOR LIFT CIRCUIT
LOADER VALVE SPOOL........................74
18.4. LEAKAGE TEST FOR TILT OR BUCKET
CYLINDER, SEALS ................................74
18.5. TILT OR BUCKET CYLINDER VALVE
SPOOL LEAKAGE..................................75
18.6. ACCEPTABLE LIFT CYLINDER LEAK
DOWN RATES........................................76
18.7. ACCEPTABLE TILT OR BUCKET
CYLINDER LEAK DOWN RATES...........76
19. TROUBLE SHOOTING PROCEDURES..........77
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19.1. TROUBLE SHOOTING CABLES AND
SINGLE LEVER CONTROLLER ............81
20. TORQUE CHART.............................................82
21. PARTS MANUAL .............................................83
22. DECALS & MANUALS ....................................84
23. BOOM ASSEMBLY..........................................86
24. MOUNTING BRACKETS AND HARDWARE..88
25. HYDRAULIC CYLINDERS AND HOSES ........90
26. HYDRAULIC VALVE AND HARDWARE.........92
27. LIFT CYLINDER...............................................94
28. TILT CYLINDER...............................................95
29. LOADER VALVE..............................................96
30. SKID STEER TOOL CARRIER ATTACHMENT98
31. SKID STEER BUCKET ..................................100
32. SKID STEER PALLET FORK........................101
33. SKID STEER BALE SPEAR..........................102
34. OPTIONAL GRILL GUARD ...........................103
NOTES:
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P
1. SPECIFICATIONS
Model ML120
Front End Loader
For Use with
Models
3 Cylinder 35 Series
Tractors
SPECIFICATIONS OF LOADER:......................................................................................................................ML120
A. Maximum Lift Height to Pivot Pin...................................................................................................8’ 9" (105")
B. Maximum Lift Height under Level Bucket................................................................................8’ 4.5" (100.5")
C. Clearance with Bucket Fully Dumped .............................................................................................7’ 1" (85")
D. Reach at Maximum Lift Height (to Grill Guard) .........................................................................2’ 1/2" (24.5")
E. Maximum Dump Angle ..................................................................................................................40 degrees
F. Reach with Bucket on Ground............................................................................................................. 5’ (60”)
G. Maximum Rollback Angle ..............................................................................................................19 degrees
H. Digging Depth........................................................................................................................................ 3 3/8"
J. Overall Height in Carry Position ................................................................................................4’ 8"* (55.6"*)
L. Bucket Depth............................................................................................................................................. 21"
M. Bucket Height ............................................................................................................................................ 20"
N. Loader Bucket Pin to Front of Front Cutting Edge ................................................................................. 25.6"
P. Loader Bucket Pin to Bottom of Front Cutting Edge .............................................................................. 4.48"
U. Lift Capacity to Maximum Height at Pivot Pin.....................................................................................1960 lb.
Y. Breakout Force at Ground Line at Pivot Pin.......................................................................................3900 lb.
*Top of Arm with Bucket 12" off ground.
Specifications taken with Ag. Tires (12-16.5 front and 16.9 x 24 rear) with 72” skid steer bucket installed
on unit.
Cycle time 1000 rpm 1500 rpm 2000 rpm Full rpm
Raise time 10.1 sec. 7.7 sec. 6.1 sec. 4.9 sec.
Lower time 5.4 sec. 5.5 sec. 4.8 sec. 4.1 sec.
Dump time w/regen 5.5 sec. 4.5 sec. 4.2sec. 3.8 sec.
Rollback time 5.3 sec. 4.1 sec. 3.6 sec. 3 sec.
Lift Cylinder Dia. ..................................................................................................................... 2” x 1-1/4" Rod
Tilt Cylinder Dia. ..................................................................................................................... 2" x 1-1/4” Rod
Relief Valve Setting (Tractor relief)....................................................................................................2950 psi
Loader Package Weight ........................................................................................................................1425#
Specifications taken with Mounting Kit, Hose Kit, and 72" Skid Steer Bucket.
Specifications based on ASAE standards S301.3 and furnished for general information only as they can vary with different tractor
models. Specifications are subject to change without notice and without liability therefore.
1.1. BUCKET SPECIFICATIONS
BUCKET CAPACITY STRUCK CAPACITY RATED SIZE CAPACITY
72” Skid Steer Bucket 12.5 cu. ft. 16.3 cu. ft
J
H
D
B
C
G
E
F
A
U
Y
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2. INTRODUCTION
This manual provides safety, installation, operation, maintenance,
mounting, storing, and dismounting instructions for your new mid-
mount loader.
Your loader has been designed to give many years of satisfactory
service. Successful operation and long life of the loader depends, of
course, on proper operation and care. Please read this manual
carefully and follow the instructions. Correct operation and
maintenance will save much time and expense.
OBSERVE and follow all CAUTION, WARNING, and DANGER
instructions to help prevent personal injury and damage to the loader.
The reference to right hand (RH) and left hand (LH) used in this
manual refers to the position when standing at the rear of the unit
and facing forward.
If, at any time, you have a service problem with your loader or need
new parts, contact your local Mahindra dealer. Your dealer will need
the loader model number and serial number to give you prompt,
efficient service. The serial number plate is located on the LH inside
front area of boom.
Before operating loader, check that your Dealer has covered the following information with you:
Equipment has been completely assembled as directed.
Equipment has been functionally tested for proper operation.
Purchaser has been instructed in proper & safe operating methods:
Operators Safety Precautions
Tractor Wheel Tread-Tire & Inflation Recommendations
Tractor Hydraulic System & Loader Controls
Rear Ballast Recommendations
Hydraulic System Oil Level
Proper Loader Operation
Loader Removal
Loader Installation
Lubrication - Service Care
Storage
Warranty Coverage & Operators Manual explained to purchaser.
Mahindra ML120 Loader Serial Number Information
LOADER SERIAL NUMBER
DATE PURCHASED
DEALER NAME
TELEPHONE NUMBER
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3. INSTALLATION INSTRUCTIONS
CAUTION: Equip your tractor with a ROPS cab or frame for your protection. See your
tractor/ROPS Operator Manual for correct seat belt usage.
Read entire instructions before beginning to install the loader. Personal injury and machine damage may be
prevented if you read and understand these instructions and special safety messages.
When you are in the tractor seat looking forward, the RH and LH sides of the tractor and loader are the same as
your right hand and left hand.
3.1. TRACTOR PREPARATION
3.1.1. Tractor Front Tires
Use front tires of equal size and maintain equal pressure in each tire. The pressure of the front tractor tires must
be increased to the maximum approved pressure recommended by the tire manufacturer to compensate for
additional load placed on the tires with the Front End Loader. See your tractor Operator Manual. Adjust the front
tires to the widest recommended setting on adjustable models for maximum stability. Front end weights must NOT
be used while loader is on the tractor.
3.1.2. Tractor Rear Tires
Maintain equal pressure in each of the rear tires. Use the widest recommended rear wheel setting for maximum
stability.
3.1.3. Remove all loader components from shipping packaging.
WARNING: To avoid serious injury or death: Read before cutting bands or removing attaching
straps. The loader may shift during shipping and handling, making it unstable on the pallet.
Support loader with an overhead hoist or other suitable means prior to removing bands or
attaching straps securing loader to pallet. Failure to do so could result in accidental tip-over of
the loader that could cause serious injury to you and/or bystanders.
CAUTION: Lift and support all loader components safely.
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3.1.4. Recommended Rear Tractor Ballast
CAUTION: To help prevent rollover, use recommended rear tractor ballast and widest wheel
settings to maximize stability. See your tractor Operator Manual for recommendations
Rear tractor ballast is required after installation of loader on the tractor. Following is recommended ways to
ballast your tractor.
¾Install factory rear wheel weights to tractor.
¾Install a Mahindra weight box to tractor 3-point.
¾Install some type of 3-point attachment to tractor.
¾Install a Mahindra backhoe to the tractor.
NOTE: You may need to use one or a combination of the above rear ballast methods depending on your
tractor and loader application.
To check if your tractor is properly ballasted you should conduct the following rear axle weight check.
¾With 72” bucket installed on loader
¾With no operator on tractor
¾With bucket/loader pivot pin 12” off of ground with 1250# in bucket and bucket rolled back.
¾With ballast installed on rear of tractor.
¾Weigh rear axle of tractor.
Weight of rear axle should be a minimum of 25% of total unit weight when counterbalanced correctly. If your rear
axle weight does not meet this minimum specification change your tractor rear ballast until your tractor rear axle
weight is a minimum of 25% of total unit weight.
72” Bucket installed on
loader and rolled back
with 1250# in bucket
Bucket/Loader Pivot Pin
12” off of ground
Rear Axle weight must be a minimum of 25% of total unit weight
when counterbalanced correctly
CAUTION: To allow proper steering of the tractor always remove 3-point weight from tractor when
the loader is parked from the tractor. Never operate the unit with the loader parked and the
backhoe installed. Failure to follow these instructions could cause loss of tractor steering
causing personal injury and damage to property.
Front tractor weights must only be used when the loader is parked. Weights must be removed before remounting
loader or serious damage will occur to loader or tractor front axle due to excessive weight. The use of adequate
rear counterweight to counterbalance for maximum loader capacity is required for safe loader operation. Weight
added to the rear of the tractor provides better traction and easier, more efficient loader operation.
IMPORTANT: Do not exceed the maximum load capacity of the tires on your tractor. See Tire and Wheel
Specifications in tractor Operator Manual for more information.
NOTE: Rear tractor ballast must be added equally to tractor to allow loader bucket to set parallel to the
ground. After installation, check that the tire pressure is equal and the center of rear axle off of ground is
equal from right and left sides of tractor. This inspection must be done on a hard level surface.
No Operato
r
With
Rear
Ballast
Installed
12”
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3.2. MOUNTING KIT INSTALLATION
3.2.1. Position the tractor and loader on a hard level surface under a hoist.
3.2.2. Remove front weights from tractor if applicable.
IMPORTANT: Do not tighten any hardware until all components are attached onto the tractor.
CAUTION: Lift and support all loader components safely.
1. CRITICAL INFORMATION: To install the Disc-Lock
Washer, simply mate the cams together and place
between the bolt head and the bracket. As the bolt is
tightened, one center of the Disc-Lock Washer is seated
to bracket material and the other to the head of the bolt.
When the bolt elongates due to vibration and shock, the
bolt will attempt to rotate loose. As one center of the
Disc-Lock Washer tries to rotate with the bolt, the
interlocking cams work against each other. This will
increase the preload, further locking the assembly and
reducing the chance of bolt loosening.
Bolt Threads
Bracket Material and/or
hardened flatwasher
Disc-Lock Washer
(angled grooves must
be matched together)
Bolt Head
Flat Grooves Angular Grooves must
go toward bolt head be matched together
Flat Grooves go Angular Grooves
toward bracket material must be matched
3.2.3. Remove the tractor toolbox, right
hand tractor step, tractor tie down hooks
and six tractor engine bolts as indicated.
Discard tractor hardware. Remove tractor
tie down hook if equipped.
Remove these engine bolts
Remove Tractor Toolbox, right hand
Step and Tractor Tie Down Hooks
IMPORTANT: DO NOT REMOVE
THESE BOLTS
IMPORTANT: Proper use of flatwasher, disc-lock washer and lockwasher will ensure that bolt will not
bottom out in tractor castings. Be sure to follow detailed instructions on following page for correct
washer and bolt usage.
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3.2.4. Install RH engine spacer assembly
using two 14-2.0 x 35 mm bolts and 9/16”
disc-lock washers in two holes closest to
the front of tractor. Install four 14-1.5 x 65
mm bolts and 9/16” disc-lock washers in
remaining four holes.
RH engine spacer assembly
14-1.5 x 65mm Gr. 10.9 bolts,
9/16” Disc-Lock washers, 4 places
14-2.0 x 35mm Gr. 10.9 bolts,
9/16” Disc-Lock washers (Not visible
in photo)
These bolts must be torqued to 107 ft.
lbs. before continuing loader installation.
3.2.5. Using a hoist, install the right hand center
bracket to the tractor clutch housing using four ¾”-10 x
1.75” Gr. 8 bolts and ¾” disc-lock washers.
Then install four 5/8”-12 x 2.0” bolts and 5/8” disc-lock
washers in front four holes of center bracket and into
RH engine spacer assembly.
¾”-10 x 1.75” Gr. 8 bolts,
¾” Disc-Lock washers,
4 places
5/8”-12 x 2.0” Gr. 8.8 bolts,
5/8” Disc-Lock washers,
4 places
Right hand center bracket
RH Engine Spacer assembly
3.2.6. After installation check to make sure ¾” disc-lock
washers in center clutch housing areas are resting
against bracket material completely and there is no
weld interference with these disc-lock washers.
Make sure ¾” Disc-Lock Washers do not interfere
with weld in these areas
35 Series 4WD, Model - 3535 & 4035 Loader June’08