Terex Mhl360 e User manual

Operating Instructions

MHL360 E

BSB50000

Mobile hydraulic loading machine

MHL360 E

Vehicle IDno. starting

360310 / 4075-4200

Year of manufacture starting

2014

Version

17.07.2014 en (englisch)

Original operating instructions

Original EC Declaration of Conformity

(Machinery Directive 2006/42/EC)

Manufacturer: Terex® Deutschland GmbH

Industriestrasse 3, 76669 Bad Schönborn, Germany

Terex® Deutschland GmbH hereby declares that the machine named below

General designation: Loading machine (developed from hydraulic excavator)

Model/Type: MHL360 E

Serial number: 360310/4075 >

conforms to the relevant requirements of Machinery Directive 2006/42/EC

Person authorized to compile the documentation

Name: Christian Engelhardt

Address: Industriestrasse 3, 76669 Bad Schönborn, Germany

It also declares conformity to the following EC Directives:

•Directive 2004/108/EC - Electromagnetic Compatibility

•Directive 97/68/EC, version 2010/26/EC - Measures against the emission of gaseous and

particulate pollutants from internal combustion engines to be installed in non-road mobile

machinery

•Directive 2000/14/EC - Noise emission in the environment by equipment for use outdoors

Sound power level measured on representative machines: 101.8 dB(A)

Guaranteed sound power level: 104 dB(A)

Conformity assessment procedure applied: Appendix VIII

Notified body involved: ID no. 0515

DGUV Test, Prüf- und Zertifizierungsstelle

Fachbereich Bauwesen

Landsberger Strasse 309, 80687 Munich, Germany

The following technical standards have been applied:

•EN 474-1:2013+A4:2013 - Earth-moving machinery - Safety -

Part 1: General requirements

•EN 474-5:2013+A3:2013 - Earth-moving machinery - Safety -

Part 5: Requirements for hydraulic excavators

•EN 13309:2010 - Construction machines - Electromagnetic compatibility of machines with

internal on-board electrical systems

Dealer:

OVERVIEW OF CHAPTERS

MHL360 E

The TEREX | Fuchs operating instructions consist of 9 chapters intended for different target

groups:

Page No

Theme

Target group

FOREWORD

Operating staff

Inspection and maintenance personnel

Repair staff

SAFETY AND ACCIDENT PREVENTION

Operating staff

Inspection and maintenance personnel

Repair staff

TECHNICAL INFORMATION

Operating staff

Inspection and maintenance personnel

Repair staff

DISPLAY AND CONTROL ELEMENTS

Operating staff

Operating staff must be familiar with the con-

tent of the operating instructions and the use

of this or comparable machines.

WORKING

Operating staff

Operating staff must be familiar with the con-

tent of the operating instructions and the use

of this or comparable machines.

RECOVERY, LOADING AND TRANSPORT

Operating staff

Inspection and maintenance personnel

Repair staff

CARE AND MAINTENANCE

Operating staff

Inspection and maintenance personnel

Repair staff

Inspection, maintenance, and repair staff

must have expert knowledge as well as ex-

perience of how to inspect, maintain, and

repair this machine or comparable machines.

TROUBLESHOOTING

Operating staff

Inspection and maintenance personnel

Repair staff

APPENDIX

Operating staff

Inspection and maintenance personnel

Repair staff

MHL360 E

CONTENTS

MHL360 E

1 Foreword ...................................................................................................................1.1

1.1 General information........................................................................................................ 1.1

1.2 Intended use .................................................................................................................. 1.1

1.2.1 Misuse ..................................................................................................................... 1.2

1.3 Introduction .................................................................................................................... 1.2

1.4 Warranty and maintenance ............................................................................................ 1.2

1.5 Type plates and vehicle identification number ................................................................ 1.3

1.5.1 Loading machine ..................................................................................................... 1.3

1.5.2 Diesel engine and exhaust system........................................................................... 1.3

1.6 Environmental standards................................................................................................ 1.4

1.7 Notes on using the operating instructions....................................................................... 1.4

1.7.1 References to pictures and items............................................................................. 1.4

1.7.2 Abbreviations and terms .......................................................................................... 1.4

1.8 Operating instructions provided by outside suppliers...................................................... 1.4

1.9 Copyright........................................................................................................................ 1.4

2 n Safety and Accident Prevention.........................................................................2.1

2.1 General safety notes ...................................................................................................... 2.1

2.1.1 Safety Alert Symbol ................................................................................................. 2.1

2.1.2 Signal word .............................................................................................................. 2.1

2.1.3 Structure of the safety instructions........................................................................... 2.1

2.2 Safety signs and color symbols ...................................................................................... 2.2

2.2.1 Locations on the machine ........................................................................................ 2.2

2.3 General ........................................................................................................................ 2.11

2.4 Declaration of conformity.............................................................................................. 2.11

2.5 General safety.............................................................................................................. 2.11

2.5.1 Avoiding crushing and burns.................................................................................. 2.12

2.5.2 Avoiding fire and explosion .................................................................................... 2.13

2.5.3 Safe operation despite obscured view ................................................................... 2.13

2.5.4 Putting the machine into operation safely .............................................................. 2.14

2.5.5 Starting the machine safely.................................................................................... 2.14

2.5.6 Safe working with the machine .............................................................................. 2.15

2.5.7 Parking the machine safely.................................................................................... 2.16

2.5.8 Transporting the machine safely ............................................................................ 2.16

2.5.9 Towing the machine safely .................................................................................... 2.17

2.5.10 Hoisting (optional).................................................................................................. 2.17

2.5.11 Residual risk .......................................................................................................... 2.18

2.6 Safe maintenance of the machine................................................................................ 2.18

2.6.1 General safety ....................................................................................................... 2.18

2.6.2 Safety instructions for replacing the (optional) XENON lamp ................................. 2.18

2.6.3 Cleaning the machine............................................................................................ 2.20

2.6.4 Repairs on the machine ......................................................................................... 2.20

2.6.5 Electrical system.................................................................................................... 2.21

2.6.6 Hydroaccumulators................................................................................................ 2.21

2.6.7 Hydraulic hoses and hose lines ............................................................................. 2.21

CONTENTS

MHL360 E

2.7 Lubricants, coolants and fuels...................................................................................... 2.23

2.7.1 Refrigerant............................................................................................................. 2.23

2.8 Cab which can be raised and moved forwards ............................................................. 2.23

2.8.1 Cab protective grating............................................................................................ 2.23

2.8.1.1 FOPS/Protective roof grating conforming to DIN EN ISO 3449-II...................... 2.23

2.8.1.2 FOPS/Front protective roof grating conforming to DIN EN ISO 10262 .............. 2.24

2.9 Equipment and attachment parts ................................................................................. 2.24

2.9.1 Retrofitting an electric motor .................................................................................. 2.24

2.9.2 Additional devices (wireless, mobile, radio)............................................................ 2.24

3 Technical data ..........................................................................................................3.1

3.1 General structure ........................................................................................................... 3.1

3.2 n Working range of the machine .................................................................................. 3.2

3.2.1 Working range diagram (16.5 m loading equipment) ............................................... 3.2

3.2.2 Table of carrying capacity (16.5 m loading equipment)............................................ 3.3

3.2.3 Working range diagram (18 m loading equipment) .................................................. 3.4

3.2.4 Table of carrying capacity (18 m loading equipment)............................................... 3.5

3.2.5 Working range diagram (18 m loading equipment cranked) .................................... 3.6

3.2.6 Carrying capacity table (18 m loading equipment cranked)...................................... 3.7

3.3 Dimensions .................................................................................................................... 3.8

3.3.1 Uppercarriage and undercarriage ............................................................................ 3.8

3.3.2 Work equipment 16.5 m and 18 m........................................................................... 3.9

3.3.3 Loading equipment 18 m cranked.......................................................................... 3.10

3.4 Technical data.............................................................................................................. 3.11

3.5 Equipment (optional) .................................................................................................... 3.13

3.6 Work attachments ........................................................................................................ 3.14

4 Display and control elements..................................................................................4.1

4.1 Display and control elements in the cab ......................................................................... 4.2

4.1.1 Cab overview ........................................................................................................... 4.2

4.1.2 Four-way control lever ............................................................................................. 4.4

4.1.3 Control panel ........................................................................................................... 4.5

4.2 Operating concept.......................................................................................................... 4.6

4.2.1 Control units overview.............................................................................................. 4.6

4.2.2 ISO control system .................................................................................................. 4.7

4.2.3 Fuchs control system ............................................................................................... 4.8

4.2.4 O&K control system ................................................................................................. 4.9

4.2.5 Liebherr control system.......................................................................................... 4.10

4.2.6 ISO control system: Steering with a four-way control lever (optional)..................... 4.11

4.2.7 Fuchs control system: Steering with a four-way control lever (optional) ................. 4.12

4.2.8 O&K control system: Steering with a four-way control lever (optional) ................... 4.13

4.2.9 Liebherr control system: Steering with a four-way control lever (optional).............. 4.14

4.2.10 Multifunction display............................................................................................... 4.15

4.2.10.1 Structure ........................................................................................................... 4.15

4.2.10.2 Display screens................................................................................................. 4.15

4.2.10.3 Operating states................................................................................................ 4.15

CONTENTS

MHL360 E

4.2.11 Multifunction button with ECO and Power Mode .................................................... 4.16

4.2.11.1 Function and application ................................................................................... 4.16

4.2.11.2 Mode setting following engine start ................................................................... 4.16

4.2.11.3 Switch the mode functions ................................................................................ 4.16

4.2.11.4 Multifunction button functions............................................................................ 4.17

4.2.12 Navigation and input .............................................................................................. 4.18

4.2.12.1 Sensitive areas.................................................................................................. 4.18

4.2.12.2 The focus .......................................................................................................... 4.18

4.2.12.3 Focus and multifunction display ........................................................................ 4.18

4.2.12.4 Focus and multifunction button ......................................................................... 4.19

4.2.12.5 Exiting a display screen..................................................................................... 4.20

4.3 Overview multifunction display - menu structure .......................................................... 4.21

4.4 Overview of symbols .................................................................................................... 4.23

4.4.1 Main control display symbol ................................................................................... 4.23

4.4.2 Function menu ....................................................................................................... 4.25

4.5 Main control display screens ........................................................................................ 4.26

4.5.1 Main control display ............................................................................................... 4.26

4.5.2 Speed and FINE MODE menu............................................................................... 4.28

4.5.3 Gear shift ............................................................................................................... 4.29

4.5.4 Operating hours, date, time, fuel consumption....................................................... 4.30

4.5.5 Function menu ....................................................................................................... 4.31

4.5.6 Rear view camera.................................................................................................. 4.32

4.5.7 Magnet system (optional)....................................................................................... 4.33

4.5.7.1 Normal magnet system display with operating mode selection menu................ 4.33

4.5.7.2 Comfort magnet system display........................................................................ 4.34

4.5.8 Reversing fan (optional)......................................................................................... 4.35

4.5.9 Main menu display screens.................................................................................... 4.36

4.5.10 Main menu............................................................................................................. 4.36

4.5.11 Display settings...................................................................................................... 4.37

4.5.12 Service menu......................................................................................................... 4.38

4.5.13 Diagnostics menu .................................................................................................. 4.39

4.5.13.1 CANopen diagnostics........................................................................................ 4.39

4.5.13.2 Operating hours ................................................................................................ 4.40

4.5.13.3 ECU diagnostics................................................................................................ 4.41

4.5.13.4 ECU diagnostics: DM1 ...................................................................................... 4.41

4.5.13.5 LMB/HRB diagnostics ....................................................................................... 4.42

4.5.13.6 Grease lubrication system diagnostics .............................................................. 4.43

4.5.13.7 Magnet system diagnostics ............................................................................... 4.44

4.5.13.8 System information ........................................................................................... 4.45

4.5.14 User settings (optional).......................................................................................... 4.45

4.5.14.1 Reversing fan pause times (optional) ................................................................ 4.46

4.5.14.2 Set limits (optional)............................................................................................ 4.47

5 Operation ..................................................................................................................5.2

5.1 n Safety........................................................................................................................ 5.1

5.1.1 Protection function of the cab .................................................................................. 5.1

CONTENTS

MHL360 E

5.1.2 Armrest switch ......................................................................................................... 5.1

5.1.3 Emergency lowering of cab...................................................................................... 5.1

5.1.4 Emergency exit and emergency hammer................................................................. 5.2

5.1.5 Fire extinguisher (optional) ...................................................................................... 5.2

5.2 Preparations................................................................................................................... 5.2

5.3 Using climbing aids ........................................................................................................ 5.3

5.3.1 n Safety rules ........................................................................................................ 5.3

5.3.2 Cab access stairs .................................................................................................... 5.3

5.3.3 Maintenance ladder ................................................................................................. 5.5

5.4 The cab as workplace .................................................................................................... 5.6

5.4.1 Adjusting the operator's seat ................................................................................... 5.6

5.4.2 Using the safety belt ................................................................................................ 5.7

5.4.3 Adjusting the steering column.................................................................................. 5.7

5.4.4 Opening/closing the window .................................................................................... 5.8

5.4.4.1 Windshield .......................................................................................................... 5.8

5.4.4.2 Skylight ............................................................................................................... 5.9

5.4.4.3 Side windows ...................................................................................................... 5.9

5.4.5 Adjusting the sunblind.............................................................................................. 5.9

5.4.6 Switching interior lamp on as needed ...................................................................... 5.9

5.5 Starting and shutting down the diesel engine ............................................................... 5.10

5.5.1 n Safety rules ...................................................................................................... 5.10

5.5.2 Battery isolator switch ............................................................................................ 5.10

5.5.3 Starting the diesel engine ...................................................................................... 5.11

5.5.4 Switching off the diesel engine in a controlled manner .......................................... 5.13

5.5.5 Switching off the diesel engine in an uncontrolled manner..................................... 5.13

5.6 After starting................................................................................................................. 5.14

5.6.1 Checking the diesel particle filter status................................................................. 5.14

5.6.2 Carry out lamp test ................................................................................................ 5.16

5.6.3 Checking the control unit ....................................................................................... 5.17

5.6.4 Warming up the loading machine .......................................................................... 5.18

5.6.5 Adapting the loading machine to the work task ...................................................... 5.18

5.7 Setting the diesel engine speed and FINE MODE........................................................ 5.19

5.7.1 Specifying the diesel engine speed........................................................................ 5.19

5.7.2 Setting FINE MODE............................................................................................... 5.20

5.8 Cab heating and air conditioning .................................................................................. 5.21

5.8.1 General settings..................................................................................................... 5.21

5.8.2 Heating .................................................................................................................. 5.22

5.8.3 Air conditioning ...................................................................................................... 5.23

5.8.4 Bottle holder and lunchbox temperature control..................................................... 5.24

5.8.5 Supplementary heating (optional) .......................................................................... 5.25

5.9 Operating the headlights .............................................................................................. 5.27

5.9.1 Driving headlamps ................................................................................................. 5.27

5.9.2 loading equipment and cab roof working floodlights............................................... 5.27

5.10 Operating the windshield wipers................................................................................... 5.28

5.10.1 Switching on / off ................................................................................................... 5.28

CONTENTS

MHL360 E

5.10.2 Intermittent wiping preset....................................................................................... 5.29

5.11 Operating signals ......................................................................................................... 5.30

5.11.1 Direction indicators ................................................................................................ 5.30

5.11.2 Hazard warning lights ............................................................................................ 5.30

5.11.3 Horn....................................................................................................................... 5.30

5.11.4 Operating the rotating beacon (optional)................................................................ 5.30

5.12 Positioning the cab....................................................................................................... 5.31

5.12.1 n Safety rules ...................................................................................................... 5.31

5.12.2 Positioning the cab ................................................................................................ 5.32

5.13 Retracting or extending outrigger ................................................................................. 5.33

5.13.1 n Safety rules ...................................................................................................... 5.33

5.13.2 4-point outrigger .................................................................................................... 5.33

5.13.3 Individually controlled support (optional) ................................................................ 5.34

5.14 Locking or unlocking the oscillating axle....................................................................... 5.35

5.14.1 n Safety rules ...................................................................................................... 5.35

5.14.2 Locking and unlocking ........................................................................................... 5.36

5.15 Traveling ...................................................................................................................... 5.37

5.15.1 n Safety rules ...................................................................................................... 5.37

5.15.2 Setting the machine in motion................................................................................ 5.39

5.15.3 fully applied............................................................................................................ 5.41

5.15.4 Steering ................................................................................................................. 5.42

5.15.5 Driving downhill and uphill...................................................................................... 5.42

5.16 Charging ...................................................................................................................... 5.43

5.16.1 n Safety rules ...................................................................................................... 5.43

5.16.2 Positioning the loading machine ............................................................................ 5.44

5.16.3 Moving the loading equipment ............................................................................... 5.45

5.16.4 Turning and braking the uppercarriage .................................................................. 5.46

5.16.5 Operating the grab................................................................................................. 5.48

5.17 Hoisting (optional) ........................................................................................................ 5.49

5.17.1 General.................................................................................................................. 5.49

5.17.2 n Safety rules...................................................................................................... 5.49

5.18 Parking the loading machine ........................................................................................ 5.50

5.19 Important functions....................................................................................................... 5.52

5.19.1 Close-range expansion .......................................................................................... 5.52

5.19.2 Overload warning device for hoisting (optional) ..................................................... 5.54

5.19.3 Height limitation (optional) ..................................................................................... 5.55

5.19.4 Range limiting (optional) ........................................................................................ 5.57

5.19.5 Boom float function (optional) .................................................................................. 5.59

5.19.6 Increasing the operating pressure.......................................................................... 5.61

5.19.7 Auto-idling system ................................................................................................. 5.62

5.19.8 Auto-idling system with automatic engine shutdown (optional) .............................. 5.63

5.19.8.1 Operation .......................................................................................................... 5.63

5.19.8.2 Switching engine shutdown on/off ..................................................................... 5.64

5.19.8.3 Switch the automatic idling system on/off.......................................................... 5.64

CONTENTS

MHL360 E

5.19.8.4 Engine shutdown............................................................................................... 5.64

5.19.8.5 Starting the diesel engine after shutdown ......................................................... 5.64

5.19.8.6 Settings in the service menu ............................................................................. 5.64

5.19.9 Reversing fan mode (optional)............................................................................... 5.66

5.19.10 Disabling travel and work functions........................................................................ 5.68

5.19.11 Key switches (optional) .......................................................................................... 5.69

5.20 Additional equipment.................................................................................................... 5.70

5.20.1 Magnet system (optional)....................................................................................... 5.70

5.20.1.1 Magnetic plates ................................................................................................. 5.71

5.20.1.2 Selecting the display mode of the main control display ..................................... 5.72

5.20.1.3 Magnet system and diesel engine ..................................................................... 5.72

5.20.1.4 Operating the magnet system with the normal magnet system display ............. 5.73

5.20.1.5 Operating the magnet system with the comfort magnet system display ............ 5.76

5.20.2 Dozer blade (optional)............................................................................................ 5.79

5.20.3 Steering with a four-way control lever (optional) .................................................... 5.80

5.20.3.1 Seat contact switch ........................................................................................... 5.80

5.21 Monitoring the machine during operation ..................................................................... 5.81

5.21.1 Monitoring strategy ................................................................................................ 5.81

5.21.2 Coolant Temperature ............................................................................................. 5.82

5.21.3 Coolant level .......................................................................................................... 5.83

5.21.4 Oil pressure ........................................................................................................... 5.84

5.21.5 Charge air temperature.......................................................................................... 5.85

5.21.6 Air filter differential pressure .................................................................................. 5.86

5.21.7 Fuel prefilter........................................................................................................... 5.86

5.21.8 Hydraulic fluid temperature ....................................................................................5.87

5.21.9 Hydraulic oil level ................................................................................................... 5.88

5.21.10 Hydraulic oil filter (main and auxiliary circuits)........................................................ 5.89

5.21.11 Diesel particle filter soot loading ............................................................................ 5.90

5.21.12 Bypassing the shutdown function........................................................................... 5.91

6 Recovery, loading and transport.............................................................................6.1

6.1 Towing the machine ....................................................................................................... 6.1

6.1.1 Power shift gear....................................................................................................... 6.2

6.1.1.1 Diesel engine is stopped ..................................................................................... 6.2

6.1.1.2 Diesel engine is running during towing................................................................ 6.3

6.1.2 2-speed manual transmission .................................................................................. 6.4

6.2 Recovery of the machine................................................................................................ 6.5

6.3 Loading with a crane ...................................................................................................... 6.5

6.4 Flat bed trailer loading.................................................................................................... 6.7

7 Maintenance and service .........................................................................................7.1

7.1 n Safety and environmental protection ......................................................................... 7.1

7.1.1 Safety rules.............................................................................................................. 7.1

7.1.2 Safe working positions ............................................................................................. 7.2

7.1.2.1 Maintenance position .......................................................................................... 7.2

7.1.2.2 Upper carriage .................................................................................................... 7.2

CONTENTS

MHL360 E

7.1.2.3 Undercarriage ..................................................................................................... 7.2

7.1.3 Discharging residual pressure in the hydraulic circuit............................................... 7.3

7.1.4 Battery isolator switch .............................................................................................. 7.4

7.1.5 Regeneration key switch.......................................................................................... 7.4

7.2 General information........................................................................................................ 7.5

7.2.1 Maintenance and wearing parts ............................................................................... 7.5

7.2.2 Disposal of fuels, lubricants and coolants ................................................................ 7.5

7.2.3 Regular oil analyses................................................................................................. 7.5

7.2.4 Welding ................................................................................................................... 7.6

7.2.5 Crack test on the machine ....................................................................................... 7.7

7.3 Fuels, lubricants and coolants ........................................................................................ 7.8

7.3.1 Filling quantities ....................................................................................................... 7.9

7.3.2 Specifications for fuels, lubricants and coolants..................................................... 7.10

7.3.3 Alternative recommendations for other temperature ranges .................................. 7.12

7.3.4 Biodegradable hydraulic fluid PANOLIN HLP SYNTH 46....................................... 7.12

7.3.5 Notes for use in winter ........................................................................................... 7.13

7.3.5.1 Hydraulic oil ...................................................................................................... 7.13

7.3.5.2 Engine Oil ......................................................................................................... 7.13

7.3.5.3 Coolants............................................................................................................ 7.13

7.3.5.4 Note on options................................................................................................. 7.13

7.3.5.5 Battery .............................................................................................................. 7.13

7.3.5.6 Fuel................................................................................................................... 7.13

7.4 Jobs before putting the machine into operation............................................................ 7.14

7.4.1 Checking the engine oil level ................................................................................. 7.14

7.4.2 Fuel system ........................................................................................................... 7.15

7.4.2.1 Fuel level........................................................................................................... 7.15

7.4.2.2 Draining water from the fuel prefilter ................................................................. 7.16

7.4.3 Cooling system ...................................................................................................... 7.17

7.4.3.1 Coolant level in the engine cooling circuit.......................................................... 7.17

7.4.3.2 Checking the antifreeze .................................................................................... 7.18

7.4.4 Check hydraulic oil level......................................................................................... 7.18

7.4.5 Cleaning the cooler................................................................................................ 7.19

7.4.6 Tires ...................................................................................................................... 7.20

7.4.7 Oil level check........................................................................................................ 7.20

7.4.7.1 Checking positions ............................................................................................ 7.21

7.4.8 Electrical equipment .............................................................................................. 7.21

7.4.8.1 Lighting and warning equipment ....................................................................... 7.21

7.5 Overview of lubricating points....................................................................................... 7.22

7.5.1 Automatic central lubrication system for uppercarriage, loading equipment and

work attachment mounting..................................................................................... 7.25

7.5.2 Grab spherical plain bearing .................................................................................. 7.26

7.5.3 Filling the grease container on the uppercarriage .................................................. 7.26

7.5.3.1 Triggering an additional lubrication pulse .......................................................... 7.27

7.5.3.2 Lubrication when lubricating pump is faulty ....................................................... 7.27

7.5.4 Cab door................................................................................................................ 7.27

7.6 Monitoring, maintenance and inspection plans............................................................. 7.28

CONTENTS

MHL360 E

7.6.1 Initial inspection (delivery inspection)..................................................................... 7.28

7.6.2 Daily and weekly tasks........................................................................................... 7.29

7.6.2.1 Daily tasks......................................................................................................... 7.29

7.6.3 Weekly tasks ......................................................................................................... 7.30

7.6.4 Maintenance and inspection plan........................................................................... 7.31

7.7 Inspection and maintenance work ................................................................................ 7.35

7.7.1 Exhaust system with diesel particle filter................................................................ 7.35

7.7.2 Engine oil............................................................................................................... 7.35

7.7.2.1 Checking the engine oil level............................................................................. 7.35

7.7.2.2 Changing the engine oil .................................................................................... 7.36

7.7.2.3 Change the engine oil filter. .............................................................................. 7.37

7.7.3 Fuel system ........................................................................................................... 7.38

7.7.3.1 Fuel level........................................................................................................... 7.38

7.7.3.2 Electrical refueling pump (optional) ................................................................... 7.38

7.7.3.3 Changing fuel filters .......................................................................................... 7.40

7.7.3.4 Cleaning the fuel pre-filter ................................................................................. 7.41

7.7.3.5 Replacing the fuel pre-filter ............................................................................... 7.41

7.7.3.6 Draining water from the fuel system.................................................................. 7.43

7.7.3.7 Venting the fuel system..................................................................................... 7.44

7.7.4 Air cleaner ............................................................................................................. 7.45

7.7.4.1 Changing cartridges .......................................................................................... 7.46

7.7.4.2 Cleaning the main cartridge .............................................................................. 7.47

7.7.4.3 Replacing the safety cartridge........................................................................... 7.48

7.7.4.4 Checking the clean air line ................................................................................ 7.48

7.7.5 Cooling system ...................................................................................................... 7.48

7.7.5.1 Coolant level ..................................................................................................... 7.49

7.7.5.2 Checking the antifreeze .................................................................................... 7.49

7.7.5.3 Cleaning the cooler ........................................................................................... 7.49

7.7.5.4 Changing the coolant in the combined water-charge air cooler ......................... 7.49

7.7.6 Checking and adjusting valve lash......................................................................... 7.51

7.7.7 Belt drives.............................................................................................................. 7.51

7.7.7.1 General ............................................................................................................. 7.51

7.7.7.2 Replacing and tensioning V-ribbed belts ........................................................... 7.52

7.7.8 Venting the hydraulic pump ................................................................................... 7.53

7.7.9 Venting the pilot control ......................................................................................... 7.54

7.7.10 Venting the brake................................................................................................... 7.54

7.7.11 Venting the parking brake ...................................................................................... 7.55

7.7.12 Adjusting the play of the parking brake .................................................................. 7.56

7.7.13 Venting the oscillating axle cylinders...................................................................... 7.57

7.7.14 Hydraulic system ................................................................................................... 7.58

7.7.14.1 Check hydraulic oil level.................................................................................... 7.59

7.7.14.2 Changing hydraulic oil....................................................................................... 7.59

7.7.14.3 Return filters...................................................................................................... 7.61

7.7.14.4 Ventilation filter ................................................................................................. 7.62

7.7.14.5 Oil filter for grab (optional)................................................................................. 7.63

CONTENTS

MHL360 E

7.7.14.6 Oil filter in the slewing circuit ............................................................................. 7.63

7.7.14.7 Blocking off the hydraulic oil on the tank ........................................................... 7.64

7.7.15 Changing axle and transmission oil........................................................................ 7.65

7.7.15.1 Front axle differential......................................................................................... 7.65

7.7.15.2 Rear axle differential ......................................................................................... 7.66

7.7.15.3 Wheel hub......................................................................................................... 7.66

7.7.15.4 Manual transmission ......................................................................................... 7.67

7.7.15.5 Swing gear ........................................................................................................ 7.68

7.7.16 Slewing joint........................................................................................................... 7.69

7.7.16.1 Checking the secure fastening of the slewing joint........................................... 7.69

7.7.17 Slip ring bodies (optional) ...................................................................................... 7.70

7.7.18 Heater and air conditioning air filter ....................................................................... 7.71

7.7.19 Supplementary heating .......................................................................................... 7.71

7.7.20 Wiper water ........................................................................................................... 7.72

7.7.21 Wiper blade ........................................................................................................... 7.72

7.7.22 Batteries ................................................................................................................ 7.73

7.7.23 Angular resolvers (optional) ................................................................................... 7.75

7.7.24 Overload warning device (optional)........................................................................ 7.76

7.8 Care and cleaning ........................................................................................................ 7.77

7.8.1 Rear view camera .................................................................................................. 7.78

7.8.2 Multifunction display............................................................................................... 7.78

7.9 Taking out of service .................................................................................................... 7.79

7.9.1 Preservation for temporary taking out of service.................................................... 7.79

7.9.2 During shutdown.................................................................................................... 7.79

7.9.3 After shutdown....................................................................................................... 7.79

7.9.4 Once the machine has been out of use for more than half a year.......................... 7.79

7.10 Disposal ....................................................................................................................... 7.80

8 Troubleshooting .......................................................................................................8.1

8.1 General information........................................................................................................ 8.1

8.2 Diesel engine ................................................................................................................. 8.2

8.2.1 Electronic engine control (EEC) ............................................................................... 8.2

8.3 Lowering the loading equipment when the motor has shut down ................................... 8.2

8.4 Emergency control ......................................................................................................... 8.3

8.5 Malfunctions in the central electrical system................................................................... 8.3

8.5.1 Fuse test.................................................................................................................. 8.3

8.6 Malfunctions in the magnet system ................................................................................ 8.3

8.7 Malfunctions in the load limit sensing control.................................................................. 8.4

8.8 Heater and air conditioning malfunctions........................................................................ 8.5

8.8.1 Air conditioning system ............................................................................................ 8.5

8.8.2 Supplementary heating ............................................................................................ 8.5

8.9 Table of malfunctions ..................................................................................................... 8.6

8.9.1 No steering .............................................................................................................. 8.6

8.9.2 No brake pressure ................................................................................................... 8.6

8.9.3 Insufficient braking power ........................................................................................ 8.6

8.9.4 Parking brake cannot be released ........................................................................... 8.6

CONTENTS

MHL360 E

8.9.5 No driving function ................................................................................................... 8.7

8.9.6 Sluggish acceleration and deceleration, too little pull............................................... 8.7

8.9.7 Regeneration does not start..................................................................................... 8.7

8.9.8 Loading equipment is not working............................................................................ 8.8

8.9.9 Drop in machine’s performance ............................................................................... 8.8

8.9.10 Machine working too slowly and hydraulic oil is becoming hot ................................. 8.8

8.9.11 Hydraulic oil exceeds max. admissible temperature................................................. 8.9

8.9.12 Swing brake does not lock ....................................................................................... 8.9

8.9.13 Uppercarriage does not rotate ................................................................................. 8.9

8.9.14 Hydraulic cylinders sustaining losses....................................................................... 8.9

8.9.15 Faults in the electrical system .................................................................................. 8.9

8.9.16 Malfunctions in the magnet system........................................................................ 8.10

8.9.17 Malfunctions in the central lubrication system ........................................................ 8.10

8.9.18 Work attachments.................................................................................................. 8.10

9 Appendix ...................................................................................................................9.1

9.1 Arrangement of fuses..................................................................................................... 9.1

9.2 Conversion factors ......................................................................................................... 9.4