New Holland Construction – Small Articulated Loader
ML12/ML12 T – R2303
Contents
Preface … 3
Language … 3
Related documents … 3
OEM documentation overview … 4
Icons and signal words used in the document … 4
Tools … 5
Illustrations … 5
Version history … 5
Typographical conventions … 6
Abbreviations … 6
Terminology … 7
1 Safety … 15
1.1 Service-related safety instructions … 15
1.1.1 General safety instructions … 15
1.1.2 Safety instructions for service below the lifting arm … 15
1.1.3 Safety instructions for service on the transmission … 15
1.2 Approved trainer … 16
1.3 Approved service engineer … 16
2 Description … 17
2.1 Engine … 17
2.1.1 Overview … 17
2.1.2 Lubrication system … 18
2.1.3 Fuel injection system … 19
2.1.4 Cooling system … 20
2.1.5 Stop solenoid … 20
2.1.6 Fuel feed pump … 20
2.1.7 Engine oil filter … 21
2.2 Electrical system … 22
2.2.1 Schematic overview … 22
2.2.2 Electrical diagram … 22
2.2.3 Fuses and relays … 23
2.2.4 Ground connections … 25
2.3 Hydraulic system … 26
2.3.1 Hydraulic diagram … 26
2.3.2 Overview of the drive hydraulics … 26
2.3.3 Overview of the steering hydraulics … 27
2.3.4 Overview of the work hydraulics … 28
2.3.5 Drive pump … 29
2.3.6 Work pump … 30
2.3.7 Wheel motors … 30
2.3.8 Main control valve … 31
2.3.9 Lift cylinder … 32
2.3.10 Tilt cylinder … 32
2.3.11 Steering cylinder … 33
2.3.12 Hydraulic steering unit (incl. priority valve) … 33
2.3.13 Attachment lock cylinder … 35
2.3.14 Valve manifold … 36
2.3.15 6/2-diverter valve (if applicable) … 37
2.4 Transmission and wheels … 37
2.4.1 Overview … 37
2.4.2 Inching system … 38
2.5 Frame … 39
2.5.1 Sliding plates overview … 39
3 Maintenance … 41
3.1 General maintenance instructions … 41
3.2 Performing a test drive … 42
3.3 Ordering parts … 42
3.4 Servicing below the lifting arm … 42
3.4.1 Installing the safety bracket on the ML12/ML12 T … 42
3.4.2 Storing the safety bracket on the ML12/ML12 T … 43
3.5 Accessing parts … 44
3.5.1 Accessing the wire harness and frame drive hydraulics area … 44
3.5.2 Tilting the driver’s seat … 45
3.5.3 Accessing the work hydraulics (bottom) … 45
3.5.4 Accessing the steering unit … 46
3.5.5 Accessing the drive pump … 46
3.5.6 Accessing the battery … 47
3.6 Panolin synthetic hydraulic oil (if applicable) … 47
3.6.1 Requirements … 48
3.6.2 Sample method … 48
3.6.3 Test intervals … 49
3.7 Maintenance schedules … 49
3.7.1 Maintenance: quick reference … 49
3.7.2 Maintenance before delivery … 51
3.7.3 Maintenance after the first 50 hours … 54
3.7.4 Maintenance every 250 hours … 55
3.7.5 Maintenance every 500 hours … 55
3.7.6 Maintenance every 1000 hours … 57
3.7.7 Maintenance every 1500 hours … 57
3.7.8 Maintenance every 3000 hours … 57
3.7.9 Maintenance every 1 year … 58
3.7.10 Maintenance every 2 years … 59
3.7.11 Maintenance every 6 years after hydraulic hose production date … 59
3.8 Maintenance tasks … 60
3.8.1 Engine … 60
3.8.2 Cooling system … 61
3.8.3 Fuel system … 61
3.8.4 Hydraulic system … 62
3.8.5 Electrical system … 63
3.8.6 Cabin and controls … 63
3.8.7 Transmission and wheels … 64
3.8.8 Frame … 64
3.8.8.1 Lubrication schedule lifting arm … 65
4 Checks, cleaning and functional tests … 67
4.1 Cabin and controls … 67
4.1.1 Checking the ROPS-FOPS structure … 67
4.1.2 Testing the steering system … 67
4.1.3 Checking the steering wheel … 67
4.1.4 Testing the steering column … 67
4.1.5 Checking the steering column lock … 68
4.1.6 Testing the driver’s seat … 68
4.1.7 Testing the rotating beacon (if applicable) … 68
4.1.8 Checking OPM (operator manual) presence … 68
4.2 Engine, cooling and fuel system … 68
4.2.1 Testing the stop solenoid … 68
4.2.2 Cleaning the main air filter and the safety air filter … 68
4.2.2.1 Removing the main air filter (and safety air filter) … 69
4.2.2.2 Cleaning and inspecting the main air filter (and safety air filter) … 69
4.2.2.3 Installing the main air filter, safety air filter and cover … 70
4.2.3 Checking the exhaust system … 71
4.2.4 Checking the fuel hoses … 72
4.2.5 Checking the V-belt … 72
4.2.6 Checking the cable connectors … 73
4.2.7 Checking the vibration dampers … 73
4.3 Electrical system … 74
4.3.1 Checking the electrical wiring … 74
4.3.2 Checking the fastening of the engine starter … 74
4.4 Hydraulic system … 75
4.4.1 Checking the hydraulic cylinders scraper … 75
4.4.2 Testing the cylinder seals … 75
4.4.3 Testing the lifting arm displacements … 76
4.5 Transmission and wheels … 77
4.5.1 Testing the parking brake … 77
4.6 Frame … 77
4.6.1 Checking the paintwork … 77
4.6.2 Checking the attachment lock position … 77
4.6.3 Checking the hinge pin bolts and spring pins … 79
4.6.4 Lubrication procedures telescopic lifting arm … 80
5 Measurements … 83
5.1 Cabin and controls … 83
5.1.1 Measuring the front automotive lights inclination … 83
5.2 Engine, cooling and fuel system … 83
5.2.1 Measuring the coolant freezing point … 83
5.2.2 Measuring the valve clearance … 84
5.2.3 Measuring the V-belt tension … 84
5.2.4 Measuring the glow plugs continuity … 84
5.2.5 Measuring the idle speed … 84
5.2.6 Measuring the thermostat valve opening temperature … 84
5.3 Electrical system … 85
5.3.1 Measuring the battery voltage … 85
5.3.2 Measuring the alternator supply voltage … 86
5.4 Hydraulic system … 87
5.4.1 Measuring the drive pump boost pressure … 87
5.4.2 Measuring the drive pump forward pressure … 88
5.4.3 Measuring the drive pump reverse pressure … 89
5.4.4 Measuring the main work pressure … 90
5.4.4.1 Measuring the main work pressure (With pressure gauge) … 90
5.4.5 Measuring the steering pressure … 91
5.5 Frame … 92
5.5.1 Telescopic lifting arm … 92
5.5.1.1 Sliding plates clearance (Front: top, left and right) … 92
5.5.1.2 Sliding plates clearance (Rear: bottom) … 92
6 Adjustments … 95
6.1 Cabin and controls … 95
6.1.1 Adjusting the front automotive lights inclination … 95
6.2 Engine, cooling and fuel system … 96
6.2.1 Bleeding the fuel system … 96
6.2.2 Draining the fuel tank … 97
6.2.3 Adjusting the valve clearance … 97
6.2.4 Adjusting the V-belt tension … 97
6.2.5 Adjusting the idle speed … 98
6.3 Electrical system … 98
6.3.1 Charging the battery … 98
6.4 Hydraulic system … 99
6.4.1 Adjusting the drive pump boost pressure … 99
6.4.2 Adjusting the main work pressure … 100
6.4.3 Adjusting the tilt cylinder load-holding valve … 101
6.4.4 Adjusting the lift cylinder load-holding valve … 102
6.5 Frame … 102
6.5.1 Adjusting sliding plates (Front) … 102
6.5.2 Adjusting sliding plates (Rear) … 103
7 Replacements … 105
7.1 Cabin and controls … 105
7.1.1 Replacing the safety roof … 105
7.1.2 Replacing the steering wheel … 107
7.1.3 Replacing the dashboard unit … 108
7.1.4 Replacing the steering column … 109
7.1.5 Replacing the floor plate … 110
7.1.6 Replacing the driver’s seat … 112
7.1.7 Replacing the joystick … 113
7.2 Engine, cooling and fuel system … 114
7.2.1 Replacing the engine oil … 114
7.2.2 Replacing the engine oil filter … 116
7.2.3 Replacing the fuel pre-filter … 117
7.2.4 Replacing the fuel filters … 118
7.2.5 Replacing the fuel sensor … 119
7.2.6 Replacing the main air filter and the safety air filter … 119
7.2.7 Replacing the complete air filter unit … 120
7.2.8 Replacing the coolant … 122
7.2.8.1 Antifreeze … 125
7.2.9 Replacing parts of the cooling system … 126
7.2.10 Replacing the combination cooler … 127
7.2.11 Replacing the V-belt … 132
7.2.12 Replacing the glow plug … 132
7.2.13 Replacing the vibration damper … 134
7.2.14 Replacing the fuel hoses … 134
7.2.15 Replacing the fuel feed pump … 135
7.2.16 Replacing the thermostat … 136
7.2.17 Replacing the pressure-relief valve of the combination cooler … 136
7.2.18 Replacing the combustion engine … 136
7.2.19 Replacing the impeller … 137
7.2.20 Replacing the stop solenoid … 137
7.2.21 Replacing the starter motor … 138
7.3 Electrical system … 138
7.3.1 Replacing the battery … 138
7.3.2 Replacing the battery switch … 140
7.3.3 Replacing the alternator … 141
7.4 Hydraulic system … 141
7.4.1 Replacing the hydraulic oil … 141
7.4.1.1 Draining the hydraulic oil tank … 142
7.4.1.2 Filling the hydraulic oil tank … 142
7.4.2 Replacing the complete hydraulic filter … 143
7.4.3 Replacing the hydraulic suction filters … 144
7.4.4 Replacing the hydraulic oil tank filler cap … 145
7.4.5 Replacing the work pump … 145
7.4.5.1 Replacing the single gear pump … 146
7.4.5.2 Replacing the double gear pump (optional) … 147
7.4.6 Replacing the drive pump … 148
7.4.7 Replacing the steering unit … 149
7.4.8 Replacing the main control valve … 150
7.4.9 Replacing the hydraulic hoses … 153
7.4.10 Replacing the hydraulic cylinders … 154
7.4.10.1 Replacing the lift cylinder … 154
7.4.10.2 Replacing the tilt cylinder … 156
7.4.10.3 Replacing the steering cylinder … 157
7.4.10.4 Replacing the attachment lock cylinder (2/2 valve) … 160
7.4.11 Replacing the cylinder seals … 161
7.4.11.1 Replacing the lift cylinder seals … 161
7.4.11.2 Replacing the tilt cylinder seals … 163
7.4.11.3 Replacing the steering cylinder seals … 165
7.4.12 Replacing the tube assemblies … 167
7.4.13 Replacing (parts of) the MCO manifold (if applicable) … 168
7.5 Transmission and wheels … 169
7.5.1 Replacing the throttle cable … 169
7.5.2 Replacing the monodasic elastic clutch … 169
7.5.3 Replacing the front wheel motor … 171
7.5.4 Replacing the rear wheel motor … 174
7.6 Frame … 176
7.6.1 Replacing sliding plates (Front) … 176
7.6.2 Replacing sliding plates (Rear) … 178
7.6.3 Replacing the complete lifting arm … 179
7.6.3.1 Replacing the standard lifting arm … 179
7.6.3.2 Replacing the telescopic lifting arm … 184
7.6.4 Replacing ball joints … 196
7.6.4.1 Replacing top ball joint … 196
7.6.4.2 Replacing lower ball joint … 197
8 Troubleshooting … 201
8.1 Troubleshooting procedure … 201
8.2 Complete machine … 201
8.2.1 Troubleshooting table … 201
8.3 Engine, cooling and fuel system … 201
8.3.1 Troubleshooting table … 201
8.4 Cabin and controls … 202
8.4.1 Troubleshooting table … 202
8.5 Electrical system … 202
8.5.1 Troubleshooting table … 202
8.6 Hydraulic system … 203
8.6.1 Troubleshooting table … 203
8.6.2 Forward or reverse drive pressure incorrect … 204
8.6.3 Telescopic/Tilt cylinder displacement outside of specifications … 205
8.6.4 Lift cylinder displacement outside of specifications … 206
9 Technical Data … 207
9.1 Consumables … 207
9.1.1 Fluid specifications … 207
9.2 Torque specifications … 207
9.2.1 Torque specifications of fasteners … 207
9.2.2 Torque specifications of special fasteners … 208
9.3 Clearance specifications … 208
9.4 Paint specifications … 208
9.5 Non-Destructive Testing (NDT) inspection standards … 209
9.6 Wear specifications … 209
9.7 Pressure specifications … 209
9.8 Other specifications … 209
9.9 Special tools specifications … 210
10 OEM Documentation … 211
10.1 Checks, cleaning and functional tests … 211
10.1.1 Test stop solenoid … 211
10.1.2 Check V-belt … 212
10.2 Measurements and adjustments … 213
10.2.1 Measuring and adjusting the valve clearance … 213
10.2.2 Measuring and adjusting the V-belt tension … 215
10.2.3 Measuring the glow plugs continuity … 215
10.2.4 Measuring the thermostat opening temperature … 216
10.2.5 Measuring the alternator supply voltage … 216
10.3 Replacements … 217
10.3.1 Replacing the V-belt … 217
10.3.2 Replacing the thermostat … 218
10.4 OEM Troubleshooting … 218
10.4.1 Electric … 218
10.4.1.1 Bearing … 219
10.4.1.2 Stator … 219
10.4.1.3 Rotor … 220
10.4.1.4 Slip ring … 221
10.4.1.5 Brush wear … 222
10.4.1.6 Rectifier … 223
10.4.1.7 IC-regulator … 223
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