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
1
FOREWORD
Operating staff
Inspection and maintenance personnel
Repair staff
2
SAFETY AND ACCIDENT PREVENTION
Operating staff
Inspection and maintenance personnel
Repair staff
3
TECHNICAL INFORMATION
Operating staff
Inspection and maintenance personnel
Repair staff
4
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.
5
WORKING
Operating staff
Operating staff must be familiar with the con-
tent of the operating instructions and the use
of this or comparable machines.
6
RECOVERY, LOADING AND TRANSPORT
Operating staff
Inspection and maintenance personnel
Repair staff
7
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.
8
TROUBLESHOOTING
Operating staff
Inspection and maintenance personnel
Repair staff
9
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
5.19.8.2 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