Page 1 Operating Instructions Mobile Hydraulic Loading Machine MHL331 D Vehicle ID No. starting at 331110 / 1130 - 1409 Year of manufacturing beginning 2007 Version 05.11.08 en (englisch)
Page 3 OVERVIEW OF CHAPTERS The TEREX | Fuchs operating instructions consist of 10 chapters aimed at different staff members: Chapter Subject Staff members Operating staff FOREWORD Inspection and maintenance staff Repair staff Operating staff SAFETY AND ACCIDENT Inspection and maintenance staff...
Page 5 CONTENTS Foreword ........................1.1 General ..........................1.1 Proper use ........................1.1 Abbreviations and terms ....................1.2 Introduction ........................1.2 Warranty and maintenance ....................1.2 Environmental standards ....................1.3 Notes on using the operating instructions .................1.3 1.7.1 References to pictures and items................1.3 1.7.2 Dangers and important notes..................1.3 1.7.3 Pictograms .........................1.4 Operating instructions provided by outside suppliers ............1.8...
Page 7 FOREWORD 1 specifications manufacturer Foreword contained in these operating instructions must be complied with. General Before using machine timber The MHL 331 Mobile Hydraulic Loading rehandling, consult the manufacturer. Machine was thoroughly tested before it left the factory. The final inspection showed that Any usage above and beyond that specified all parts are in perfect working order and that here and any non-compliance with the...
Page 8 Insist that only original TEREX | Fuchs spare parts are used in the event of any repair work. In this way, you will have a product of lasting high quality, thereby ensuring that your machine maintains its original condition.
Page 9 FOREWORD 1 The vehicle identity number as well as data on vehicle type and manufacturer can be found on the identification plate (1/1). The vehicle identity number is in addition struck on the undercarriage (1/2). ATTENTION The vehicle type and the vehicle identity number must...
Page 10 1 FOREWORD 1.7.3 Pictograms The table below explains the meaning of the pictograms on the operator control panel. Functions and displays marked (*) are optional. Display Description Functionality Description Symbol (Indicators) Symbol (Switches) Dual assignment: Coolant temperature Parking brake Hydraulic oil temperature Charge air temperature Swing brake In an emergency only: bypass...
Page 11 FOREWORD 1 Display Description Functionality Description Symbol (Indicators) Symbol (Switches) Transmission control Reversing fan mode * slow/fast Engine control error / Close range cut-off (dipperstick) preheat display Windshield wiper/washwipe Fuel reserve indicator (upper window section) Windshield wiper/washwipe Display oscillating axle released (lower window section) Automatic central lubrication system –...
Page 12 1 FOREWORD Display Description Functionality Description Symbol (Indicators) Symbol (Switches) Fuel gauge Blower 120% 100% Load display * MHL 331...
Page 13 FOREWORD 1 The table below explains the meaning of the pictograms on the machine. Symbol Description Symbol Description Safety distance Hydraulic oil Danger of injury Fuel Suspension point for Lashing point loading by crane No pressure jet! Emergency lowering of cab Air conditioning MHL 331...
Page 14 Supplementary heating Eberspächer Copyright These operating instructions are the copyright of the TEREX | Fuchs GmbH. These operating instructions are intended for use by personnel responsible for operation, maintenance, repair and supervision of the machine. These operating instructions may not, either in...
Page 15 CONTENTS Safety and Accident Prevention................2.1 Declaration of conformity ....................2.1 General safety requirements ..................2.1 2.2.1 Equipment and attachment parts................2.2 2.2.2 Safety instructions for replacing the xenon lamp (optional)........2.3 Avoiding crushing and burns ..................2.4 Avoiding fire and danger of explosion ................2.5 Safety instructions for placing into operation ..............
Page 17 SAFETY AND ACCIDENT PREVENTION 2 2 Safety and Accident Prevention General safety requirements • Become familiar with operating Working with the machine involves potential dangers to life and limb, which you may instructions before the machine is placed encounter owner, operator into operation for the first time.
Page 18 TEREX | Fuchs. through the windshield. • If there are no instructions to the contrary The necessary technical materials must be made available to TEREX | Fuchs for this for maintenance and repair jobs, proceed as purpose. follows: −...
Page 19 SAFETY AND ACCIDENT PREVENTION 2 2.2.2 Safety instructions for replacing the xenon lamp (optional) • Always switch the headlamp off and disconnect it from the supply voltage before changing the lamp. • Never grasp into the lamp socket. • The electrical connection between head- lamp and ballast conducts high-voltage and must not be separated.
Page 20 2 SAFETY AND ACCIDENT PREVENTION • There is a risk of being crushed by the lift Avoiding crushing and burns frame due to the movement of the cab, • Do not work under the loading equipment since the operator in the cab cannot see all unless it is resting safely on the ground or is areas fully.
Page 21 SAFETY AND ACCIDENT PREVENTION 2 Safety instructions for placing into Avoiding fire and danger of explosion operation • Turn the engine off when refueling. • Every time before placing the machine into • When refueling or charging the batteries, operation, perform a thorough walk-around avoid smoking and working with open inspection of the machine.
Page 22 2 SAFETY AND ACCIDENT PREVENTION Instructions for working safely Safety requirements for starting • Before starting, check all indicator lamps • Before starting work, become acquainted with special features of the work site, and instruments to make certain they are working properly, move all operating levers special requirements and warning signals.
Page 23 SAFETY AND ACCIDENT PREVENTION 2 • Report all operating faults and make certain • In terrain with a poor overview and necessary repairs performed whenever necessary, have a guide help immediately. you. Have only one person assigned to give you signals. •...
Page 24 2 SAFETY AND ACCIDENT PREVENTION • Before setting off, find out about the route to Transporting the machine safely be taken, especially in regard to limits for • Use only suitable transport and lifting width, height and weight. equipment with sufficient carrying capacity. •...
Page 25 SAFETY AND ACCIDENT PREVENTION 2 2.10 Towing the machine safely • Always observe the correct procedure. See chapter "Recovery, loading and transport" in the table of contents in these operating instructions. • Before the machine can be towed, the power shift gear must be set to neutral position (idle running).
Page 26 2 SAFETY AND ACCIDENT PREVENTION • In 2.11 Load hook applications load hook applications, personnel attaching loads shall only approach the DANGER boom with machine operator’s permission and only from the side. Staying under suspended loads is • The machine operator is only to give his forbidden.
Page 27 SAFETY AND ACCIDENT PREVENTION 2 • If safety equipment needs to be dismantled 2.12 Measures ensure safe maintenance to fit equipment or perform maintenance or repairs, it must be reattached and tested • Do not perform any maintenance work or immediately after the maintenance and repairs that...
Page 28 2 SAFETY AND ACCIDENT PREVENTION • Ensure that fuels, lubricants and coolants as • Always support the machine so that any well as replaced parts are disposed of in an shifting of weight will not endanger standing environmentally proper manner. stability.
Page 29 SAFETY AND ACCIDENT PREVENTION 2 • Work on electrical equipment must only be performed by an electrical specialist or trained persons under the supervision of an electrician in accordance with technical electrical regulations. • When working on parts conducting voltage, second person press...
Page 30 2 SAFETY AND ACCIDENT PREVENTION − damage or deformation to the hose fitting 2.13 Hydraulic hoses and hydraulic hose lines that reduce the stability of the fitting or the hose/fitting connection, • Repairs to hydraulic hoses and hydraulic − hose coming loose from the fitting, hose lines are forbidden! −...
Page 31 SAFETY AND ACCIDENT PREVENTION 2 • When climbing down stand with your face to 2.14 Elevating cab the machine and use the three-point • Place the machine on a level and horizontal support. Climb down so far that you can surface.
Page 32 2 SAFETY AND ACCIDENT PREVENTION 2.14.1 Cab rock guard Loading machines are only to be used where there is a danger of falling objects when the cab is equipped with cab rock guards (FOPS). If there is a danger that material can strike the cab from the front, then a front protective roof grating must be fitted.
Page 33 CONTENTS Technical Data ......................3.1 Dimensions ........................3.1 General structure ......................3.3 Diesel engine ........................3.4 Electrical system .......................3.4 Hydraulic system.......................3.5 Travel drive ........................3.6 Rotation drive ........................3.6 Undercarriage ........................3.6 Brakes ..........................3.7 3.10 Driver's cab ........................3.7 3.11 Control ..........................3.8 3.12 Service weights .........................3.8 3.13 Permissible loads ......................3.8 3.14 Sound level values according to directive 2000/14/EC and DIN ISO 6395 Appendix A ...3.8 3.15 Vibrations ..........................3.9 3.16 Official homologation ......................3.9...
Page 35 TECHNICAL DATA 3 Technical Data Dimensions Fig. 2 Dimensions (dimensions in mm) with 9.00-20 tires MHL 331...
Page 36 3 TECHNICAL DATA Fig. 3 Transport dimensions (dimensions in mm) TRANSPORT DIMENSIONS Dimensions mm Loading equipment 11 m Loading equipment 12 m 9950 9900 1300 1300 5250 4280 3195 3195 2650 3100 MHL 331...
Page 37 TECHNICAL DATA 3 General structure Front axle (steering) Rear axle (oscillating) Two-speed power shift gear with a variable speed axial piston motor 4-point outriggers Counterweight Boom cylinder Elevating cab Cab lift frame Box-type boom Dipperstick cylinder Dipperstick Cactus grab Fig. 4 General structure MHL 331...
Page 38 3 TECHNICAL DATA Diesel engine Manufacturer and model Deutz TCD 2012 L06 2V Design 6-cylinder in-line engine Control EMR III Method of operation 4-cycle Diesel, common rail open-combustion- chamber injection, turbo charger, charge air cooling Engine performance 114 kW Rated speed 2000 rpm Stroke displacement 6.0 l...
Page 39 TECHNICAL DATA 3 Hydraulic system Main pump Variable displacement pump in the open circuit Pump capacity: max. 380 l/min at 2000 rpm Working pressure: max. 360 bar The pump is regulated by the amount of current required and thus pumps only the amount of oil actually required by the consumers.
Page 40 3 TECHNICAL DATA Travel drive The hydrostatic travel drive is controlled by a variable speed axial piston engine with a directly attached brake pedal valve with a flange connection on the two-speed power shift gear. All-wheel drive via propeller shafts between the drive transmission and the axles.
Page 41 TECHNICAL DATA 3 Brakes Service brake A hydraulically activated single-circuit brake system that works on all four pairs of wheels. Parking brake Electrically or hydraulically activated disk brake on the drive transmission that transfers power to the front and rear axles. 3.10 Driver's cab Elastically bearing, variably adjustable up and down hydraulically to a viewing height of...
Page 42 3 TECHNICAL DATA 3.11 Control The loading machine is equipped as standard with an ISO control see chapter 5.1. 3.12 Service weights Service weights 22 – 23.5 t 3.13 Permissible loads Permissible gross vehicle weight 23.5 t Permissible axle load, front 12 t Permissible axle load, rear 12 t...
Page 43 TECHNICAL DATA 3 3.15 Vibrations Weighted r.m.s. value of acceleration of upper limbs is below 2.5 m/s². Weighted r.m.s. value of acceleration of seat area and feet is below 0.5 m/s². 3.16 Official homologation Certification in accordance with CE guidelines. MHL 331...
Page 44 3 TECHNICAL DATA 3.17 Working zone of the machine 3.17.1 Working range diagram (11 m loading equipment) Loading equipment: box-type boom 6.5 m, dipperstick 4.4 m and cactus grab Fig. 5 Working range diagram (11 m loading equipment) 3.10 MHL 331...
Page 45 TECHNICAL DATA 3 3.17.2 Table of carrying capacity (11 m loading equipment) The carrying capacity values are stated in metric tons (t). The pump pressure for this table is 360 bar. The figures are 75 % of the static overturning limit or 87 % of the hydraulic lifting force, in compliance with DIN ISO 10567, marked (°).
Page 46 3 TECHNICAL DATA 3.17.3 Working range diagram (12 m loading equipment) Loading equipment: box-type boom 6.5 m, dipperstick 5.45 m and cactus grab Fig. 7 Working range diagram (12 m loading equipment) 3.12 MHL 331...
Page 47 TECHNICAL DATA 3 3.17.4 Table of carrying capacity (12 m loading equipment) The carrying capacity values are stated in metric tons (t). The pump pressure for this table is 360 bar. The figures are 75 % of the static overturning limit or 87 % of the hydraulic lifting force, in compliance with DIN ISO 10567, marked (°).
Page 48 CAUTION Unapproved changes in the design, additional equipment and work attachments of TEREX | Fuchs products may result in damage to the machine. Note that changes must be approved in writing by the manufacturer. Without such permission our warranty expires, as does our product liability for any resulting consequential damages.
Page 49 TECHNICAL DATA 3 3.19 Fuels, lubricants and coolants Conscientiously following the requirements for lubrication, level checks and changing fuels, lubricants and coolants will ensure increased reliability and service life of the machine. It is especially important to perform the various oil changes regularly and at the recommended intervals and to observe the specified lubricant qualities.
Page 50 Grab gear 0.7 l Transmission oil (TEREX | Fuchs 0.4 m³ – 0.8 m³) ATTENTION The filling quantities specified in the filling quantities table are only approximate values. The level must be checked in the corresponding assembly after every oil change or refill.
Page 51 Before changing oils, please ask your TEREX | Fuchs dealer for more details. Power shift gear, wheel Transmission oil Titan Supergear SAE 80W-90 SAE 80W-90...
Page 52 Warrantee conditions as well changing guideline KLEENOIL PANOLIN AG should be observed. Do not mix biodegradable oils of different suppliers. Before changing oils, please your TEREX | Fuchs dealer for more details. 3.18 MHL 331...
Page 53 CONTENTS Control and Display Elements................. 4.1 First commissioning ......................4.1 Cab control and display elements ..................4.2 4.2.1 Four-way control lever, left..................4.2 4.2.2 Four-way control lever, right..................4.4 4.2.3 Control elements ......................4.6 Operator control panel in cab....................4.8 4.3.1 Multifunction monitor ....................4.10 4.3.1.1 Structure of the main control display ..............4.11 4.3.1.2 Menu levels of the multifunction monitor .............4.14 Engine ..........................4.17...
Page 54 CONTENTS 4.7.7 Emergency hammer....................4.34 4.7.8 Fire extinguisher (optional)..................4.34 4.7.9 Windshield wiper ......................4.35 4.7.10 Windshield washwipe system ..................4.35 Cab with hydraulic elevation ...................4.36 4.8.1 Before placing into operation ...................4.36 4.8.2 During operation.......................4.36 4.8.3 Driving with elevated cab ..................4.36 4.8.4 Switching off the machine ..................4.36 4.8.5 Positioning the cab....................4.37 4.8.6...
Page 55 CONTROL AND DISPLAY ELEMENTS 4 Control and Display Elements First commissioning If you are not yet familiar with the control and display elements of this machine, read this chapter carefully operating before machine. This chapter deals with all functions. • Before traveling and working with the machine it is necessary to thoroughly familiarize yourself with the control and display elements.
Page 56 4 CONTROL AND DISPLAY ELEMENTS Cab control and display elements 4.2.1 Four-way control lever, left rotated by 180° in the illustration Fig. 9 Four-way control lever, left MHL 331...
Page 57 CONTROL AND DISPLAY ELEMENTS 4 Four-way control lever, left = Push-button for magnet system (optional) P1 = Push-button for flasher right/left = Dead man’s button (optional) Machines for the Italian market must be equipped with a dead man’s button. All hydraulically controlled work movements (raise/lower boom, extend/retract dipperstick, swing uppercarriage, extend/retract outrigger) can only be enabled if the dead man’s button is pressed.
Page 58 4 CONTROL AND DISPLAY ELEMENTS 4.2.2 Four-way control lever, right rotated by 180° in the illustration Fig. 10 Four-way control lever, right MHL 331...
Page 59 CONTROL AND DISPLAY ELEMENTS 4 Four-way control lever, right = Push-button for increasing the operating pressure P1 = Push-button for grab rotation to the right/left = Push-button for horn MHL 331...
Page 60 4 CONTROL AND DISPLAY ELEMENTS 4.2.3 Control elements KRAFTSTOFFVORRAT UNTER 5% 120% 100% °C MHL331 0 UPM 00 : 00 : 00 °C 00 : 00 : 00 Fig. 11 Control elements MHL 331...
Page 61 CONTROL AND DISPLAY ELEMENTS 4 Control elements = Lever for outrigger out/in = Armrest switch (work functions disabled) = Emergency lowering of cab = "Fine mode" potentiometer = Four-way control lever, left = Upward folding armrest = Service brake pedal, lockable = Travel pedal, forward = Travel pedal, reverse = Steering column lever for adjusting the angle of inclination...
Page 62 4 CONTROL AND DISPLAY ELEMENTS Operator control panel in cab Fig. 12 Operator control panel MHL 331...
Page 63 CONTROL AND DISPLAY ELEMENTS 4 Operator control panel 25 = Ignition lock 43 = Windshield wiper push-button (2-stage) (upper window section) 26 = Dozer blade toggle switch (optional) Buttons up: continuous wiping 27 = Rotating beacon toggle switch (optional) Buttons down: intermittent wiping Buttons up or down (hold): wash/wipe 28 = Magnet system toggle switch (3-stage) (optional)
Page 64 4 CONTROL AND DISPLAY ELEMENTS 4.3.1 Multifunction monitor After the machine is switched on the main control display appears on the multifunction monitor. The main control display remains on constantly as long as one of the function keys F 1 – F 6 is operated/pressed.
Page 65 CONTROL AND DISPLAY ELEMENTS 4 4.3.1.1 Structure of the main control display Symbol Item No. Explanation of the function Indicator (dual assignment): coolant temperature / hydraulic oil temperature (see also indicator 80 / 81) Lit to indicate high operating temperatures. A warning buzzer sounds at the same time.
Page 66 4 CONTROL AND DISPLAY ELEMENTS Service brake indicator Lights up when there is not enough reserve pressure. The brake is not ready for operation. The indicator and warning buzzer must go off about 10 seconds after the engine is started. If they do not, stop the machine immediately and check the brake system.
Page 67 CONTROL AND DISPLAY ELEMENTS 4 Engine coolant temperature (in °C) indicator Indicates numerically the coolant temperature of the engine. The background color of the symbol changes corresponding to the coolant temperature (see the table to the side). °C During operation, the background color of the symbol must be black. Background colors: In the range of 105 °C –...
Page 68 4 CONTROL AND DISPLAY ELEMENTS 4.3.1.2 Menu levels of the multifunction monitor Navigation through the menus ATTENTION In the menus a further sub-menu for a function is selected by moving a green arrow (F 4, F 5) and confirmed with OK (F 6). Alternatively turning the menu selection wheel corresponds to the arrow movements and pressure on the selection wheel for confirmation with OK.
Page 69 CONTROL AND DISPLAY ELEMENTS 4 Submenus DISPLAY ADJUSTMENT You can use the menu arrow keys (F 4, F 5) to set the overall brightness of the display, the menu language, the time of day, and the date on the multifunction monitor. Automatic switching back to the main control display can be switched on or off using the "AUTOMATIC ON/OFF"...
Page 70 4 CONTROL AND DISPLAY ELEMENTS "ELECTRONIC ENGINE CONTROL" DIAGNOSTICS Current engine data are displayed in this menu. SYSTEM INFORMATION The system information shows the current software statuses of the control components. You can press the (F 6) key to return to the main menu. 4.16 MHL 331...
Page 71 CONTROL AND DISPLAY ELEMENTS 4 Engine Before starting engine battery disconnect switch (14/1) must be switched on. The battery disconnect switch of the machine is located in the service section. ATTENTION Before placing the machine into operation, the inspections described in chapter 7.5 "Work before placing into operation"...
Page 72 4 CONTROL AND DISPLAY ELEMENTS 4.4.1.1 Cold start (normal start) • Insert the ignition key in the ignition lock (15/25). • Bring the engine speed control lever (15/18) KRAFTSTOFFVORRAT UNTER 5% to low idle position. 120% 100% °C • Turn the ignition key to position I. If the MHL331 0 UPM 00 : 00 : 00...
Page 73 CONTROL AND DISPLAY ELEMENTS 4 4.4.1.2 Hot start • Insert the ignition key in the ignition lock (15/25). • Bring the engine speed control lever (15/18) to low idle position. • Turn the ignition key to position I. If the display is in STANDBY, indicators (15/66) and (15/67) light up after about 5 seconds, otherwise after about 10 seconds.
Page 74 4 CONTROL AND DISPLAY ELEMENTS 4.4.2 Reversing fan mode (optional) Depending on the operating conditions of the machine, the cooling system • combined water-charge air cooler REVERSING FAN MODE 120% • hydraulic oil cooler 100% °C MHL331 0 UPM 00 : 00 : 00 °C can optionally be equipped with reversing fan 00 : 00 : 00...
Page 75 CONTROL AND DISPLAY ELEMENTS 4 4.4.3 Monitoring machine during operation • If the battery charge control indicator (18/66) or engine oil pressure indicator (18/67) light KRAFTSTOFFVORRAT up, switch off the engine immediately and UNTER 5% 120% 100% determine the cause, or call for service °C MHL331 personnel if necessary.
Page 76 4 CONTROL AND DISPLAY ELEMENTS • At a charge air temperature in the range of 100 °C – 105 °C, the red symbol (18/65) "Charge air temperature" in the main control display lights (this symbol takes precedence over the "Coolant/hydraulic oil temperature"...
Page 77 CONTROL AND DISPLAY ELEMENTS 4 4.4.3.1 Deactivating overheat protection The overheat protection can be deactivated using toggle switch (19/36). The machine can still be relocated and the loading equipment KRAFTSTOFFVORRAT UNTER 5% 120% moved. 100% °C MHL331 0 UPM 00 : 00 : 00 °C 00 : 00 : 00 CAUTION...
Page 78 4 CONTROL AND DISPLAY ELEMENTS 4.4.4 Load limit sensing control The machine is equipped with a load limit sensing control. The control includes: • an electronic control of the hydraulic pump • a sensitive adjustment of the response characteristic of the main drive functions (fine mode) Load limit sensing control protects the engine from speed pressures that are too high and...
Page 79 CONTROL AND DISPLAY ELEMENTS 4 4.4.6 Electronic Engine Control 4.4.6.1 Engine protection function Electronic Engine Control Electronic engine control protects the engine from speed pressures that are too high and thus from overloads for each engine speed selected. Depending on the severity of an error that has been detected, the engine can continue to run with some...
Page 80 4 CONTROL AND DISPLAY ELEMENTS 4.4.7 Notes for use in winter 4.4.7.4 Coolant Observe the following points and instructions Before the cold time of the year begins, the in the engine operating instructions for use in level of antifreeze protection must be checked winter: and if necessary adjusted to the requirements of ambient temperature (for the mixing ratio...
Page 81 CONTROL AND DISPLAY ELEMENTS 4 Operator's stand ATTENTION 4.5.1 Comfort driver’s seat To prevent damage to health, the individual driver’s weight setting WARNING should be checked and adjusted before placing the machine into adjust seat during operation. operation, you can lose control over the machine by unexpected seat (20/8) Handle for longitudinal adjustment of...
Page 82 4 CONTROL AND DISPLAY ELEMENTS WARNING Before placing the machine into operation, the operator must fasten the two point safety belt. To ensure safety, the condition, functionality and fastening of the belt must be checked at regular intervals and damaged parts must be replaced immediately.
Page 83 CONTROL AND DISPLAY ELEMENTS 4 Heating and air conditioning The cab is equipped with a heating and air KRAFTSTOFFVORRAT UNTER 5% conditioning as standard features. They can 120% 100% °C MHL331 0 UPM 00 : 00 : 00 °C be used for heating, air conditioning and 00 : 00 : 00 venting the cab.
Page 84 4 CONTROL AND DISPLAY ELEMENTS 4.6.2 Supplementary heating (optional) The supplementary heating is located in the driver’s cab, on the right side under a sheet- metal cover. It serves for heating the cab. Any other use of the supplementary heating and of the associated timer is not permitted.
Page 85 CONTROL AND DISPLAY ELEMENTS 4 The following maintenance work must be carried out before each heating period: • Check the glow plug (23/1) for burn-off and replace if necessary. • Examine the fuel filter for clogging and replace if necessary. •...
Page 86 4 CONTROL AND DISPLAY ELEMENTS 4.6.3 Air conditioning operation ATTENTION ATTENTION Coolant must be visibly flowing with no bubbles in the sight glass (24/1) of The air conditioning only works when the fluid container while the engine is the engine is running. running and the air conditioning is at the highest level.
Page 87 CONTROL AND DISPLAY ELEMENTS 4 Driver's cab 4.7.1 Opening/closing the windshield windshield only opened completely. It is not possible to open it in stages. The windshield is released from the catch by pressing in both release levers (25/1) and can be pulled in under the cab roof. The windshield is released from the catch by pressing in both release levers (25/1) and can be brought back to the end position.
Page 88 4 CONTROL AND DISPLAY ELEMENTS 4.7.4 Cab door Push handle (26/1) upwards and open the cab door. ATTENTION If the cab door is opened to get in and out, it must be engaged in the catch (27/2) using the locking device (27/1).
Page 89 CONTROL AND DISPLAY ELEMENTS 4 4.7.9 Windshield wiper push-button (29/43) upper windshield has the following functions when the ignition is turned on: • Buttons up: continuous wiping • Buttons down: interval wiping • Buttons up or down (hold): wash/wipe When you release the push-button you return to the previous condition (continuous wiping, interval wiping or OFF position).
Page 90 TEREX | Fuchs. Order number of the support cause the cab to dip. This may result sleeve: 6090031600. in injuries of the driver (operator) or to incorrect operation of the machine.
Page 91 CONTROL AND DISPLAY ELEMENTS 4 4.8.5 Positioning the cab steplessly elevated hydraulically. KRAFTSTOFFVORRAT UNTER 5% WARNING 120% 100% °C MHL331 When the cab is being moved, and 0 UPM 00 : 00 : 00 °C 00 : 00 : 00 during driving and working, the left- hand armrest must be folded down and the cab door shut.
Page 92 4 CONTROL AND DISPLAY ELEMENTS Travel operation WARNING Absolutely comply with all safety instructions in chapter 2 before and during travel. DANGER Make sure before and during travel that no persons or obstructions are in the travel direction. Look to the rear before and during reversing.
Page 93 CONTROL AND DISPLAY ELEMENTS 4 4.9.1 Placing the machine in motion DANGER Starting in the wrong direction can KRAFTSTOFFVORRAT lead to serious accidents. Make sure UNTER 5% 120% 100% before driving where the steering axle °C MHL331 is located and steer the machine 0 UPM 00 : 00 : 00 °C...
Page 94 4 CONTROL AND DISPLAY ELEMENTS If the machine is stuck in difficult terrain, do not attempt to free it by rocking. See chapter 6 "Recovery, loading and transport" for how to proceed. Machines carrying loads with laterally shifted uppercarriage must travel exclusively on level paths and with the oscillating axle locked.
Page 95 CONTROL AND DISPLAY ELEMENTS 4 4.9.4 Steering The steering of the front axle of the machine is hydraulic. CAUTION In the event of steering malfunctions, stop work immediately, determine the cause (see Trouble-shooting) and call for service personnel if necessary. 4.9.5 Brakes •...
Page 96 4 CONTROL AND DISPLAY ELEMENTS 4.9.6 Driving and working floodlights • Parking light/headlamp toggle switch (34/40) Toggle switch (34/40) can be used to turn on the parking light as well as the KRAFTSTOFFVORRAT UNTER 5% headlamp. 120% 100% °C MHL331 1st stage: parking light 0 UPM 00 : 00 : 00...
Page 97 CONTROL AND DISPLAY ELEMENTS 4 4.10 Parking the machine CAUTION When switching off the machine, the KRAFTSTOFFVORRAT UNTER 5% work attachment must be let down 120% 100% carefully since the surface could be °C MHL331 0 UPM 00 : 00 : 00 damaged by the weight of the loading °C 00 : 00 : 00...
Page 98 4 CONTROL AND DISPLAY ELEMENTS DANGER When parking the machine, the uppercarriage must be in longitudinal direction compared undercarriage, and the cab must be lower position. dipperstick must positioned vertically and the open grab must be placed onto the ground (see fig. 36). Plates should be pushed under the grab tips.
Page 99 CONTENTS Work Operation......................5.1 Work operation........................5.1 5.1.1 Operation of loading equipment .................5.1 5.1.2 Operation – Increasing the operating pressure............5.1 5.1.3 Operation – 4-point outrigger ..................5.2 5.1.4 Disabling all travel and work functions ...............5.2 5.1.5 Oscillating axle lock release..................5.3 5.1.6 Key switch (optional) ....................5.4 5.1.6.1 Black key switch ....................5.4 5.1.6.2...
Page 101 WORK OPERATION 5 Work Operation Work operation The loading machine is equipped as standard with ISO control (fig. 37), upon which the following description is based. DANGER If the customer so wishes, the loading machine may be equipped with a special control. Your loading machine must therefore be checked to see whether or not a special control is installed.
Page 102 5 WORK OPERATION • If the service ladder is not closed and the 5.1.3 Operation – 4-point outrigger left armrest is folded up, all travel and work The 4-point outrigger is operated with lever functions are disabled. Indicator (40/76) (39/7). lights up.
Page 103 WORK OPERATION 5 5.1.5 Oscillating axle lock release The oscillating axle can be released with the toggle switch (41/37). If the oscillating axle is released, the indicator lamp in the switch (41/37) is lit along with indicator (41/75) and OSCILLATING AXLE RELEASED 120% the text message (41/77) "OSCILLATING...
Page 104 5 WORK OPERATION 5.1.6 Key switch (optional) 5.1.6.2 Blue key switch Blue key switch (41/29B) ⇒ reduce hydraulic Optionally, the machine may be equipped with two key switches (41/29A) and (41/29B). oil pressure or enable work movements with the diesel engine stopped 5.1.6.1 Black key switch Optionally, the machine may be equipped with Black key switch (41/29A) ⇒...
Page 105 WORK OPERATION 5 5.1.7 Close range cut-off (dipperstick) CAUTION When the dipperstick is moved (retracted) in Danger of damage! Avoid rapid the direction of the cab, it may come into the motions of the dipperstick if you are area around the cab with the suspended load. moving it close to the shut-off points.
Page 106 5 WORK OPERATION 5.1.7.1 Deactivating close range cut-off If the dipperstick needs to be extended towards the cab beyond its shut-off point, close range cut-off can be deactivated with toggle switch (42/38). Indicator lamp (42/38) is KRAFTSTOFFVORRAT UNTER 5% 120% long close-range cut-off...
Page 107 WORK OPERATION 5 5.1.9 Overload cut-off with warning function (optional) The overload cut-off with warning function sends an audible and visible alert whenever KRAFTSTOFFVORRAT machine’s load approaches UNTER 5% 120% 100% permissible maximum load due to a load °C MHL331 received.
Page 108 5 WORK OPERATION In case the load cut-off is triggered, the operator can bring the load closer to the machine by means of folding the dipperstick under, in order to reduce the overly high load pressure. load increasing work movements remain disabled until the machine is again operated within the permissible work range.
Page 109 WORK OPERATION 5 The overload warning and cut-off functions can be completely deactivated by means of the key switch (43/29A)! If the switch is in position I (the key cannot be pulled in this case), the load display is hidden in the multifunction monitor, there...
Page 110 5 WORK OPERATION Swinging and loading operations Observation following points essential: • Machine with outriggers up − When the outriggers are up, loads shall only be hoisted above the front or rear axle respectively, see table of carrying capacity. − When outriggers are up, the oscillating axle must not be locked for work operations;...
Page 111 WORK OPERATION 5 − Do not level the ground in front of the loading machine with the loading equipment by slewing the uppercarriage to and fro. − Neither push, knock nor beat with the grab. − Pay attention to hoses when lowering the grab into a shaft.
Page 112 5 WORK OPERATION Load hook applications See chapter 2.11 Magnet system (optional) 5.4.1 Operation of magnet system ATTENTION KRAFTSTOFFVORRAT UNTER 5% 120% magnet system should 100% °C MHL331 switched on only after attachment of 0 UPM 00 : 00 : 00 °C 00 : 00 : 00 the magnetic plate.
Page 113 WORK OPERATION 5 • Move the magnetic plate onto the material to be picked up. • Activate the magnet using push-button (46/P1) on the left-hand four-way control lever. LED 2 (see fig. 46a) in the magnet system (46/16) control device is lit. In order to achieve optimum performance when picking up material with the magnetic plate, only magnetize the plate immediately...
Page 114 5 WORK OPERATION 5.4.1.1 Magnet system control device LED flashing: Interface error: (MMI – Man/Machine Interface) This LED flashes if there is an error on the interface by means of which the magnet LED 1 Supply voltage present for magnet system communicates with the control system.
Page 115 WORK OPERATION 5 LED 5 Overload / short circuit – red error LEDs 7 Relative operating time of the magnetic plate (50 % green, 60 % indicator and 70 % yellow, 80 % – 100 % LED is illuminated: Overload red) –...
Page 116 5 WORK OPERATION 5.4.1.2 Malfunctions in the magnet system If malfunctions occur in the magnet system, write down the operating state on the display diodes of the magnet system control device. Please have this information available when you contact Customer Service. DANGER load must...
Page 117 CONTENTS Recovery, Loading and Transport ................6.1 Towing the machine ....................... 6.1 Recovery of the machine....................6.3 Safety requirements for loading with a crane ..............6.4 Flat-bed trailer loading ....................6.5 MHL 331...
Page 119 RECOVERY, LOADING AND TRANSPORT 6 Recovery, Loading and Transport Towing the machine The loading machine may be towed only in exceptional cases, for example to bring the machine away from a dangerous place for repair. Damage and accidents that arise when towing the loading machine can be covered under no circumstances warranty...
Page 120 6 RECOVERY, LOADING AND TRANSPORT Diesel engine is stopped: • Switch on the ignition (48/25). • Switch through the gears using toggle switch (48/42) approx. 10 x. transmission control is now pressureless. The gear is in neutral position. Releasing the parking brake: •...
Page 121 RECOVERY, LOADING AND TRANSPORT 6 Diesel engine is running during towing: • Switch off the diesel engine; switch on the ignition (48/25). • Switch through the gears using toggle switch (48/42) approx. 10 x. transmission control is now pressureless. The gear is in neutral position. •...
Page 122 • If required, the hoisting device may be • The ropes must be routed so that no obtained from TEREX | Fuchs. damage occurs to the cab or paneling. • Shackle (50/5) size 10 in compliance with DIN 82101 is recommended, in accordance DANGER with the weight of the machine.
Page 123 RECOVERY, LOADING AND TRANSPORT 6 Flat-bed trailer loading For transport on a flat-bed trailer, the machine must be lashed in place so that it cannot move. The machine is equipped with two lashing points on the undercarriage for this purpose (see fig.
Page 124 6 RECOVERY, LOADING AND TRANSPORT • Before you leave the machine, relieve all • Pay close attention driving under pressure lines. Move all operating levers electrical lines and bridges and driving into neutral positions and close the parking through tunnels. brake.
Page 125 CONTENTS Care and Maintenance ..................... 7.1 General information......................7.1 Regular oil analyses......................7.2 Letting off residual pressure in the hydraulic circuit ............7.3 Maintenance and wearing parts ..................7.4 Work before placing into operation ...................7.5 7.5.1 Checking the engine oil level ..................7.6 7.5.2 Fuel system........................7.7 7.5.2.1 Fuel level......................7.7 7.5.2.2...
Page 126 CONTENTS 7.8.2.4 Cleaning fuel pre-filter with integrated filter cartridge........7.33 7.8.2.5 Replacing fuel pre-filter with integrated filter cartridge ........7.34 7.8.2.6 Draining water from the fuel system..............7.35 7.8.2.7 Venting the fuel system..................7.35 7.8.3 Air filter ........................7.36 7.8.3.1 Changing cartridges ..................7.37 7.8.3.2 Cleaning the main cartridge ................7.38 7.8.3.3 Replacing the safety cartridge................7.39 7.8.3.4...
Page 127 CARE AND MAINTENANCE 7 Care and Maintenance ATTENTION General information The battery disconnect switch of the machine is located in the service good operating condition life section. Before working expectancy of the machine are largely electrical system, the electric circuit influenced by care and maintenance.
Page 128 No changes must be made to the results and as specified by test lab. hydraulic accumulators (welding, Your TEREX | Fuchs dealer will let you have drilling, opening it by force, etc.). an informative leaflet specifying oil test procedures, etc. Regular oil analyses...
Page 129 CARE AND MAINTENANCE 7 Letting off residual pressure in the hydraulic circuit CAUTION KRAFTSTOFFVORRAT When performing maintenance and UNTER 5% 120% 100% repair work on the hydraulic system, °C MHL331 0 UPM 00 : 00 : 00 the residual pressure in the hydraulic °C 00 : 00 : 00 circuit...
Page 130 7 CARE AND MAINTENANCE Maintenance and wearing parts ATTENTION You can find the list of maintenance and wearing parts in chapter 1.10 of the supplied spare parts catalogue. Keep a stock of maintenance and wear parts for inspections. Fuels, lubricants and coolants The machine’s life expectancy and operating condition are largely dependent upon the use of the specified fuels, lubricants and coolants...
Page 131 CARE AND MAINTENANCE 7 Work before placing into operation • Before parking the machine, turn the uppercarriage in travel direction. Move the dipperstick to a steep position if possible, and make sure the grab is open when it is placed on the ground (see fig. 36). •...
Page 132 7 CARE AND MAINTENANCE 7.5.1 Checking the engine oil level WARNING Engine oil is hot when the machine is at operating temperature. Avoid skin contact with hot oil or parts carrying oil. • The oil level of the machines that are positioned horizontally must be checked daily before starting work (with the engine turned off and after a short wait so the oil...
Page 133 CARE AND MAINTENANCE 7 7.5.2 Fuel system 7.5.2.1 Fuel level Check the fuel level on the fuel gauge (55/79). If the fuel in the diesel tank is below the KRAFTSTOFFVORRAT UNTER 5% 120% reserve quantity of 5 %, indicator (55/75) 100% °C MHL331...
Page 134 7 CARE AND MAINTENANCE 7.5.3 Cooling system 7.5.3.1 Coolant level in the engine cooling circuit WARNING The entire cooling system is hot and under pressure when the machine is running at operating temperature. Avoid touching parts with coolant or parts carrying coolant. There is a danger of burns.
Page 135 CARE AND MAINTENANCE 7 7.5.3.2 Checking the antifreeze Check the level of antifreeze protection before the beginning of the cold season. ATTENTION Always use an antifreeze with anti- corrosion protection. The antifreeze level is set to approx. -35 °C at the factory.
Page 136 7 CARE AND MAINTENANCE 7.5.5 Cleaning the radiator The machine is equipped with separate radiators combined water-charge cooling and the hydraulic oil. CAUTION Engine overheating can result in damage to the machine. Clean the radiators carefully of any dirt that has become attached.
Page 137 CARE AND MAINTENANCE 7 7.5.6 Tires DANGER Repair work on the wheels, for example dismantling tires from the rim or fitting them onto the rim, may be performed only by specialists and with suitable assembly tools. When working on the tires make sure that the machine is parked safely and has been secured against rolling away (chocks)!
Page 138 7 CARE AND MAINTENANCE 7.5.7 Checking the oil levels in axles, wheel hubs and power shift gears For filling quantity, oil specification and change intervals, see chapter 3.19 "Fuels, lubricants and coolants" and chapter 7.7.3 "Maintenance and inspection plan". WARNING Oil is hot when the machine is at operating temperature.
Page 139 CARE AND MAINTENANCE 7 7.5.8 Electrical equipment The lighting and warning equipment as well as the function of the indicator lamps, must be checked prior to use. 7.5.8.1 Batteries The batteries are located in the service section in front of the diesel engine under the covering plate.
Page 140 7 CARE AND MAINTENANCE Removing the battery • Remove the cover. • Disconnect first the negative cable (-) and then the positive one (+). • Loosen the clamping bracket and lift the battery. Installing the battery • Place the battery in the machine. •...
Page 141 CARE AND MAINTENANCE 7 7.5.8.3 Slip ring bodies (optional) There is a slip ring body on the rotary transmission that responds sensitively to moisture. A layer of oxide can form on conducting surfaces that inhibits the flow of current. Electrical consumers undercarriage will not longer receive an adequate supply of electrical current, which...
Page 142 7 CARE AND MAINTENANCE Overview of lubricating points Fig. 66 Overview of lubricating points 7.16 MHL 331...
Page 143 CARE AND MAINTENANCE 7 Lubricating point Qty. Remarks Elevating cab bearing Box-type boom bearing automatic Boom cylinder bearing central lubrication Dipperstick bearing uppercarriage Dipperstick cylinder bearing Slewing joint (ring gear, toothing) Work attachment mounting bearing Cab door hinge Engine hood hinge Service ladder hinge manual Outrigger foot bearing...
Page 144 7 CARE AND MAINTENANCE 340-1350-065 340-1350-067 Fig. 67 Steering gear case Fig. 69 Oscillating axle Steering gear case: 4 lubricating points Oscillating axle: 1 lubricating point 340-1350-066 Fig. 68 Steering cylinder Steering cylinder: 4 lubricating points 7.18 MHL 331...
Page 145 CARE AND MAINTENANCE 7 7.6.1 Lubrication of the ring gear slewing 7.6.1.3 Cleaning the vent valve joint Unscrew and clean the vent valve (70/6) every quarter. • The level of grease in the ring gear must be checked every quarter. •...
Page 146 7 CARE AND MAINTENANCE 7.6.2 Automatic central lubrication ATTENTION system for uppercarriage, loading equipment and work attachment Grease must be free from impurities and its viscosity shall not change mounting over time. Grease additives, such as The machine is equipped with an automatic molybdenum disulfide, shall not be central lubrication...
Page 147 CARE AND MAINTENANCE 7 7.6.2.2 Triggering additional lubrication The operator may trigger additional lubrication at any time in the function menu (see fig. 72). Select the fourth level with the menu arrow (F 5) on the multifunction monitor or with the menu selection wheel. An additional lubrication pulse is triggered by operating the F 4 key in the lower level.
Page 148 7 CARE AND MAINTENANCE Monitoring, maintenance and inspection plans 7.7.1 Initial inspection (transfer inspection) Work to be performed by trained dealer or service personnel: Item Test method Chapter Check whether machine-specific operating instructions are in the machine — Check the engine oil level 7.5.1 Check the coolant level 7.5.3...
Page 149 CARE AND MAINTENANCE 7 7.7.2 Daily and weekly tasks 7.7.2.1 Daily tasks Inspection and maintenance work to be performed by operating staff: Item Test method Chapter Check the hydraulic oil level 7.5.4 Check the engine oil level 7.5.1 Check the coolant level 7.5.3 Check the fuel pre-filter in the fuel line for water and accumulation of sludge and 7.5.2.2...
Page 150 7 CARE AND MAINTENANCE 7.7.2.2 Weekly tasks Inspection and maintenance work to be performed by operating staff: Item Test method Chapter Clean the cooling fins of the water-charge air cooler and hydraulic oil cooler 7.5.5 If there is a heavy accumulation of dust, shorten the cleaning intervals. Otherwise the result could be engine damage.
Page 151 CARE AND MAINTENANCE 7 7.7.3 Maintenance and inspection plan Work to be performed by trained dealer or service personnel: O = Checking, maintenance Operating hours X = Replace Perform work with machine at operating temperature! Check whether machine-specific operating instructions are in the machine Change engine oil Replace the engine oil filter Drain water from fuel tank...
Page 152 Power shift gear: oil check or oil change Replace hydraulic oil tank ventilation filter Test run and test work Initial inspection cards and return to TEREX | Fuchs 3) The intervals should be shortened in dusty ambient conditions. 7.26 MHL 331...
Page 153 CARE AND MAINTENANCE 7 O = Checking, maintenance Operating hours X = Replace Perform work with machine at operating temperature! Wheel hubs, front and rear axles: oil check or oil change Differential, rear and front axles: oil check or oil change O = Checking, maintenance Operating hours X = Replace...
Page 154 7 CARE AND MAINTENANCE Inspection and maintenance work 7.8.1 Engine oil All inspection and maintenance work not contained here should be performed as described in the separately supplied diesel engine operating instructions. 7.8.1.1 Checking the engine oil level WARNING Engine oil is hot when the machine is at operating temperature.
Page 155 CARE AND MAINTENANCE 7 ATTENTION Collect the old oil in a suitable container dispose compliance with environmental regulations. • Remove the oil drain hose (73/2) and screw the protective cap onto the drain valve (73/1). • Replace the engine oil filter (see chapter 7.8.1.3).
Page 156 7 CARE AND MAINTENANCE 7.8.2 Fuel system 7.8.2.1 Fuel level • Check the fuel level on the fuel gauge (76/79). KRAFTSTOFFVORRAT UNTER 5% 120% 100% °C • If the fuel in the diesel tank is below the MHL331 0 UPM 00 : 00 : 00 °C reserve quantity of 5 %, indicator (76/75)
Page 157 CARE AND MAINTENANCE 7 For refueling, proceed as follows: • Open the tank cover on the fuel tank (pressure equalization!). • Remove the cap (77/1) from the intake adapter (77/2). • Mount the intake hose on the intake adapter (77/2). •...
Page 158 7 CARE AND MAINTENANCE 7.8.2.3 Replace the fuel filter insert Replace as described in chapter 7.7.3 "Maintenance and inspection plan". • Place a suitable container under the fuel filter. • Clean the outside of the fuel filter housing (78/1). • Loosen and unscrew the filter housing cover (78/2) using a standard tool W/F 36.
Page 159 CARE AND MAINTENANCE 7 7.8.2.4 Cleaning fuel pre-filter with integrated filter cartridge chapter 7.7.3 "Maintenance inspection plan". ATTENTION All maintenance work on the fuel pre- filter must be carried out only with the engine shut off. • Switch off the engine. •...
Page 160 7 CARE AND MAINTENANCE 7.8.2.5 Replacing fuel pre-filter with integrated filter cartridge Replace as described in chapter 7.7.3 "Maintenance and inspection plan". ATTENTION All maintenance work on the fuel pre- filter must be carried out only with the engine shut off. 350-1130-081 ATTENTION Fig.
Page 161 CARE AND MAINTENANCE 7 7.8.2.6 Draining water from fuel system chapter 7.7.3 "Maintenance inspection plan". Water must be drained from the fuel system through the fuel tank and the fuel pre-filter daily. ATTENTION Collect the fuel-water mixture in a suitable container. 331-1130-081 Fuel tank Fig.
Page 162 7 CARE AND MAINTENANCE 7.8.3 Air filter CAUTION All maintenance work on the air filter KRAFTSTOFFVORRAT UNTER 5% pipe must be carried out only with the 120% 100% engine shut off! Do not start the °C MHL331 0 UPM 00 : 00 : 00 °C engine while the main cartridge and 00 : 00 : 00...
Page 163 CARE AND MAINTENANCE 7 7.8.3.1 Changing cartridges Replacing the main cartridge • Open the support brackets (83/1) and remove the cover (83/2) with the dust emptying valve (83/5). • Remove the dirty main cartridge (84/1) by carefully turning and tipping and dispose of the cartridge.
Page 164 7 CARE AND MAINTENANCE 7.8.3.2 Cleaning the main cartridge max. 5 bar ATTENTION Only blow out, never wash or brush out the main cartridge. When blowing out, take care to ensure that dust does not land on the inside of the main cartridge.
Page 165 CARE AND MAINTENANCE 7 7.8.3.3 Replacing the safety cartridge CAUTION Do not clean the safety cartridge and, once it has been removed, do not use it again. • Open the support brackets (83/1) and remove the cover (83/2) with the dust emptying valve (83/5).
Page 166 7 CARE AND MAINTENANCE 7.8.4 Cooling system The machine is equipped with separate radiators combined water-charge cooling and the hydraulic oil. 7.8.4.1 Coolant level See chapter 7.5.3.1 "Coolant level in the engine cooling circuit" 7.8.4.2 Checking the antifreeze See chapter 7.5.3.2 "Checking the antifreeze" 7.8.4.3 Cleaning the radiator See chapter 7.5.5 "Cleaning the radiator"...
Page 167 CARE AND MAINTENANCE 7 • Unscrew the coolant drain plug (88/1) on the cylinder block and properly dispose of the coolant in compliance with environmental regulations. • If necessary, rinse the cooling system with clean water. • Install the drain plug on the engine again and screw the protective cap onto the drain valve.
Page 168 7 CARE AND MAINTENANCE 7.8.5 Checking V-ribbed belts Replace as described in chapter 7.7.3 "Maintenance and inspection plan". CAUTION Rotating V-ribbed belts pose danger of injury. Only check and tighten the V-ribbed belts when the engine is stopped. Secure the engine against being started without authorization.
Page 169 CARE AND MAINTENANCE 7 7.8.5.1 Replacing and tensioning V-ribbed belts • Switch off the engine and remove the ignition key. • Operate the battery disconnect switch. • Place a ½" square spanner into the dent (90/1) of the tensioning pulley and press the tensioning pulley into the direction of arrow until the drill holes are positioned one over the other (see fig.
Page 170 7 CARE AND MAINTENANCE 7.8.5.2 Replacing and tensioning V-belt of the air conditioning compressor • Switch off the engine and remove the ignition key. • Operate the battery disconnect switch. • Loosen the fastening screws (92/1-3), do not screw them out completely. •...
Page 171 CARE AND MAINTENANCE 7 7.8.7 Venting the hydraulic pump The hydraulic pump must be vented for work on the pump or for changing oil in the hydraulic system. For this purpose loosen the leakage oil hose (93/1) and let the air escape, as soon as hydraulic oil flows out connect the leakage oil hose again.
Page 172 7 CARE AND MAINTENANCE 7.8.10 Venting the parking brake chapter 7.7.3 "Maintenance inspection plan". ATTENTION Collect the drained oil with a suitable container. The old oil must not be spilled on the ground. Dispose of old oil properly! • Operate and lock the service brake pedal (97/11).
Page 173 CARE AND MAINTENANCE 7 7.8.12 Venting oscillating axle cylinders ATTENTION OSCILLATING AXLE RELEASED Collect the drained oil with a suitable 120% 100% container. The old oil must not be °C MHL331 0 UPM 00 : 00 : 00 °C spilled on the ground. Dispose of old 00 : 00 : 00 oil properly! •...
Page 174 7 CARE AND MAINTENANCE 7.8.13 Hydraulic system For filling quantity, oil quality and change intervals, see chapter 3.19 "Fuels, lubricants and coolants" and chapter 7.7.3 "Maintenance inspection plan"; also chapter "Regular oil analyses". Maintenance work on the hydraulic system is limited mainly to the hydraulic oil tank.
Page 175 CARE AND MAINTENANCE 7 7.8.13.1 Checking the hydraulic oil level See chapter 7.5.4 "Checking the hydraulic oil level" 7.8.13.2 Replacing hydraulic oil ATTENTION Change the hydraulic oil at operating temperature. • Retract all hydraulic cylinders. • Switch off the diesel engine. 331-1130-100 •...
Page 176 7 CARE AND MAINTENANCE 7.8.13.3 Hydraulic oil – return filter Replace as described in chapter 7.7.3 "Maintenance and inspection plan". KRAFTSTOFFVORRAT UNTER 5% ATTENTION 120% 100% °C MHL331 After a major repair job, replace the 0 UPM 00 : 00 : 00 °C 00 : 00 : 00 filter insert after the trial run.
Page 177 CARE AND MAINTENANCE 7 • Unscrew the screen element (103/7) and clean with a neutral detergent. • Using a compressed-air pistol, blow out from the outside to the inside. • Screw on the new filter element with the cleaned sieve element. •...
Page 178 7 CARE AND MAINTENANCE 7.8.13.5 Blocking off the hydraulic oil on the tank To enable repairs to the intake line, the hydraulic pump or the hydraulic lines to be undertaken without having to drain the oil from the tank, the oil supply line to the main pumps can be blocked off.
Page 179 CARE AND MAINTENANCE 7 7.8.14 Changing axle and transmission oil For filling quantity, oil quality and change intervals, see chapter 3.19 "Fuels, lubricants and coolants" and chapter 7.7.3 "Maintenance inspection plan"; also chapter "Regular oil analyses". The axle oil must be changed at operating temperature.
Page 180 7 CARE AND MAINTENANCE 7.8.14.1 Front axle differential ATTENTION The wheel hubs and axle casings (differentials) of the steering axle have separate oil chambers. Checking the axle oil level • Remove the check and filler plug (106/1). If necessary add oil. Changing axle oil 340-1350-105 •...
Page 181 CARE AND MAINTENANCE 7 7.8.14.3 Wheel hub ATTENTION The wheel hubs and axle casings (differentials) have separate chambers. Checking the oil level • Turn the wheel until the drain plug (108/2) on the hub is at the bottom. • Remove the check and filler plug (108/1). If necessary add oil.
Page 182 7 CARE AND MAINTENANCE 7.8.14.5 Swing gear ATTENTION The swing gear with integrated multi- disk brake is maintenance-free. It is lubricated by the hydraulic circuit. Therefore, the oil does not have to be changed. main bearing equipped with and sealed by its own separate "life-long"...
Page 183 195 Nm 23 Nm ATTENTION Use only original TEREX | Fuchs screws when replacing the slewing ring screws (110/4). Grease the slewing ring screws (110/4) on the thread and under the screw head with multi-purpose grease before screwing them in.
Page 184 7 CARE AND MAINTENANCE Care and cleaning ATTENTION The machine must be cleaned on a suitable surface with an oil separator. • The machine must not be cleaned with a steam-jet appliance high-pressure cleaner in the first two months after it is placed into operation or after it has been newly painted.
Page 185 CARE AND MAINTENANCE 7 7.10 Shutdown 7.10.1 Preserving machine temporary shutdown CAUTION order prevent damage (corrosion, etc.) from storage during shutdown periods over three months, certain preservation measures must be taken. Preservation measures: • We recommend keeping the machine in a dry, dust-free room during the storage period.
Page 186 7 CARE AND MAINTENANCE 7.10.2 During shutdown When the machine is out of use for six months, after this time all assemblies must be brought operating temperature maneuvered for approx. 15 minutes. Beforehand, the anti-corrosion coat must be removed from the piston rods, and the openings of the air filter pipe and the exhaust pipe freed.
Page 187 CONTENTS Trouble-shooting ...................... 8.1 General ..........................8.1 Drive engine ........................8.1 Lowering the loading equipment when the engine has shut down........8.1 Malfunctions in the central electrical system..............8.1 8.4.1 Fuse test ........................8.2 Malfunctions in the magnet system...................8.2 Load limit sensing control ....................8.3 8.6.1 Bypassing the load limit sensing control ..............8.3 8.6.2 Activating the load limit sensing control ..............8.3...
Page 189 TROUBLE-SHOOTING 8 Trouble-shooting General Malfunctions are often the result of incorrect handling of the machine, the use of unsuitable fuels, lubricants and coolants, or irregular maintenance. The following table presents a summary of a range of malfunctions and their possible causes.
Page 190 8 TROUBLE-SHOOTING 8.4.1 Fuse test The central electrical system includes a push- button (112/1) that can be activated to perform a fuse test when the ignition is turned on. Faulty fuses are indicated by LEDs (112/2) that are lit red. Malfunctions in the magnet system ATTENTION Do not switch off the engine of the...
Page 191 TROUBLE-SHOOTING 8 Load limit sensing control 8.6.1 Bypassing the load limit sensing control In order to ensure that the engine continues to operate in the event of load limit sensing control malfunctions, load limit sensing control can be disconnected. During this emergency service, the machine’s use is limited.
Page 192 8 TROUBLE-SHOOTING Trouble-shooting table Possible cause Remedy 8.7.1 No steering Oil supply to pump interrupted. Check suction line and repair. Hydraulic pump defective. Have the pump examined by a specialist for mechanical damage. Replace the entire hydraulic pump. Priority valve defective. Have priority valve checked by a specialist;...
Page 193 TROUBLE-SHOOTING 8 Possible cause Remedy 8.7.5 No driving function Faulty drive engine. Check the drive engine. Too little hydraulic oil in tank. Top up hydraulic oil to mark on sight glass. Hydraulic pump has failed. Have the pump examined by a specialist for mechanical damage.
Page 194 8 TROUBLE-SHOOTING Possible cause Remedy 8.7.7 Loading equipment is not working All travel and work functions are disabled. Release the travel and work functions (see chapter 5.1.4 "Disabling all travel and work functions"). Armrest switch faulty. Check the armrest switch and repair or replace if necessary.
Page 195 TROUBLE-SHOOTING 8 Possible cause Remedy 8.7.10 Hydraulic oil exceeds max. permissible temperature Thermostat in fan motor defective. Replace thermostat. Hydraulic oil level is too low. Top up hydraulic oil to mark on sight glass. Oil cooler dirty or faulty. Clean oil cooler, check and replace if necessary.
Page 196 8 TROUBLE-SHOOTING Possible cause Remedy 8.7.14 Malfunctions in the magnet system In the event of malfunctions in the magnet Have the fuses checked by a specialist and system, e.g. no magnetizing or no de- eliminate defects. magnetizing function. 8.7.15 Work attachments Grab does not open or close, or opens Check quick coupling, replace if required.
Page 197 CONTENTS Appendix ........................9.1 Arrangement of fuses..................... 9.1 Conversion factors ......................9.4 MHL 331...
Page 199 APPENDIX 9 Appendix Arrangement of fuses CAUTION Use only original fuses. Electrical fuses must never be bypassed or repaired. The table below shows the fuses and relays in the central electrical system: Fuse number Release Terminal Functionality current designation 50 A Terminal 30 Master fuse terminal 30 70 A...
Page 200 9 APPENDIX Fuse number Release Terminal Functionality current designation F 29 Terminal 15 EMR3 main relay control F 30 25 A Terminal 15 EMR3 main relay F 31 Terminal 15 Power relay activation K 1 F 32 10 A Terminal 15 Air conditioning condenser M 1 F 33 10 A...
Page 201 APPENDIX 9 Arrangement of the relays Relay number Functionality Central electrical system Power relay terminal 15 Engine environment Power relay pre-heat relay Operator control panel board (switch above) K 1, K 2, K 3 Fan stage 1 – 3 Working floodlight on roof Parking light Central electrical system board EMR3 main relay...
Page 202 9 APPENDIX Conversion factors Pressure 100 Kpa 14.5 psi 10 psi 68.95 Kpa 0.6895 bar Flow l/min 0.0353 cfm gallon (Brit.)/min 0.1605 cfm Distances = 39370 in 3280.8 ft 1093.6 yd 0.62137 mile 0.53996 n mile 10 mm 1000 m Weight 2.205 lb 35.27 Oz...
Page 203 CONTENTS Special Equipment ....................10.1 10.1 Multi-purpose stick ......................10.1 10.1.1 Transport dimensions with multi-purpose stick ............10.1 10.1.2 Working zone of the machine...................10.2 10.1.2.1 Working range diagram (10.7 m loading equipment) ........10.2 10.1.2.2 Table of carrying capacity (10.7 m loading equipment) ........10.3 10.2 Dozer blade.........................10.4 10.2.1...
Page 205 SPECIAL EQUIPMENT 10 Special Equipment The parts and functions described in this chapter are special equipment, which may differ from standard equipment. It may happen that the functions described in the operating instructions are supplemented by functions described in this chapter. Chapters 1 to 9 of these operating instructions are valid despite special equipment.
Page 206 10 SPECIAL EQUIPMENT 10.1.2 Working zone of the machine 10.1.2.1 Working range diagram (10.7 m loading equipment) Loading equipment: box-type boom 6.5 m, multi-purpose stick 4.0 m and sorting grab Fig. 116 Working range diagram (10.7 m loading equipment) 10.2 MHL 331...
Page 207 SPECIAL EQUIPMENT 10 10.1.2.2 Table of carrying capacity (10.7 m loading equipment) The carrying capacity values are stated in metric tons (t). The pump pressure for this table is 360 bar. The figures are 75 % of the static overturning limit or 87 % of the hydraulic lifting force, in compliance with DIN ISO 10567, marked (°).
Page 208 10 SPECIAL EQUIPMENT 10.2 Dozer blade 10.2.1 Dozer blade for 4-point outrigger The dozer blade (118/1) can be used to clear small loose objects lying on an even surface to the side (for example scrap or pieces of wood). The blade can be positioned at a "floating"...
Page 209 SPECIAL EQUIPMENT 10 Operating the dozer blade Four-way control lever, left 1 = Push-button for magnet system 2 = Push-button for flasher left 3 = Push-button for flasher right 4 = Push-button for to raise the dozer blade 8 = Dead man’s button Fig.
Page 210 10 SPECIAL EQUIPMENT Four-way control lever, right 1 = Push-button for increasing the operating pressure 2 = Push-button for grab rotation to the left 3 = Push-button for grab rotation to the right 4 = Push-button for to lower the dozer blade 8 = Push-button for horn Fig.
Page 212 Hauptverwaltung / Verkauf / Kundendienst Head Office / Sales / After Sales Service Sièges Administratif / Vente / Service Après-Vente Terex Deutschland GmbH Geschäftsbereich Terex Fuchs 76669 Bad Schönborn GERMANY Fon.: ++49 (0) 72 53 / 84-0 Fax: ++49 (0) 72 53 / 84 411 E-Mail: Info@fuchs-terex.de...

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