Maintenance and Service Manual M-B Multi

Maintenance and Service Manual
M-B Multi-Service Vehicle (MSV)
MSV Generation
Units
MSV Divison
062015
1615 Wisconsin Avenue
P.O. Box 200
New Holstein, WI 53061
Phone: 800-558-5800
Fax: 920-898-4588
PN 904-183700
062015
PN904-183700
Table of Contents
Safety.............................................................................. 5
Hazard Definitions...................................................... 5
Identification of Safety Labels.................................... 5
General Safety........................................................... 6
Pre-Start-Up Safety.................................................... 6
Pressurized Systems Safety...................................... 6
The Manual................................................................ 6
Required Operator Training........................................ 6
Work Area................................................................... 7
Maintenance Safety.................................................... 7
Welding....................................................................... 7
General Information...................................................... 8
Introduction................................................................. 8
Machine Identification................................................. 8
Customer Service....................................................... 8
Vehicle Information..................................................... 10
Introduction............................................................... 10
Specifications .......................................................... 10
Dimensions............................................................... 13
Parts Manual Reference Layout............................... 14
Vehicle Identification................................................. 16
System Power.......................................................... 16
CAN Network............................................................ 16
Fuse Protection........................................................ 16
Attachment Controls................................................. 16
Speed Controls......................................................... 16
Wiring....................................................................... 16
Advanced Engine Diagnostics.................................. 17
Operation ..................................................................... 18
Quick Reference User Guide................................... 18
Plus+1® Controls...................................................... 19
Pre Start-Up ............................................................ 45
Start-Up Procedure.................................................. 45
Cold Weather Starting.............................................. 46
After Starting Engine................................................ 47
Safety Link................................................................ 47
Front Attachment Connections................................. 48
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
Maintenance................................................................. 51
Daily or Refueling..................................................... 51
First 50 Hours........................................................... 51
Every 50 Hours or Monthly....................................... 52
Every 500 Hours or 6 Months................................... 52
Every 1000 Hours or 1 Year..................................... 53
Every 2000 Hours or 2 Years................................... 53
Every 5000 Hours or 4 Years................................... 53
Lubrication Chart...................................................... 53
Oil and Filter Requirements...................................... 56
Maintenance............................................................. 56
Engine Coolant......................................................... 58
Intake Maintenance.................................................. 58
Fuel System Maintenance........................................ 59
Cab Lift..................................................................... 60
Ground Drive Maintenance...................................... 60
Ground Drive Filter................................................... 61
Power Take Off (PTO) Maintenance......................... 61
Power Take Off Driveshaft........................................ 63
Hydraulic Connections............................................. 65
Hydraulic System Maintenance................................ 65
Brake Maintenance.................................................. 67
Battery...................................................................... 68
Electrical System...................................................... 69
Accessory Terminal Strip.......................................... 72
Cab Ventilation......................................................... 73
Service.......................................................................... 74
Towing The MSV...................................................... 74
Brake Release Install............................................... 74
Troubleshooting Brakes............................................ 75
Testing The Ground Drive Pump.............................. 75
Ground Drive Pump Replacement........................... 77
Disc Brake................................................................ 84
Wheel Motors........................................................... 85
Auxilliary Pump......................................................... 85
Windshield Wiper..................................................... 87
Steering Column....................................................... 89
Main Hydraulic Tank................................................. 92
• 3 •
Table of Contents
Articulation Joint....................................................... 97
Low Pressure Manifold............................................. 97
Radio and 12 VDC Connections............................ 101
AC System............................................................. 101
Hydraulic Fitting Installation
Torque Recommendation....................................... 102
Fastener Torque Recommendation........................ 104
Replacement Parts.................................................... 107
Appendix..........................................................................
Hydraulic Diagrams.................................................A-1
Work Instructions............................................................
Replacing Front Wheel Motors................... WIAS 0084
Replacing the Frame Link Between Front and Rear
Frames....................................................... WIAS 0081
Installing the Break Release Kit................. WIAS 0083
Checking Parking Break Relief Pressure... WIAS 0086
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 4 •
Table of Contents
Safety
WARNING
Read this manual and any attachment owner’s
manuals before using this equipment. Failure
to do so can result in serious injury or death.
Call your dealer if you have any questions.
DANGER
DANGER
HAZARD DEFINITIONS
DO NOT GO NEAR
HYDRAULIC OIL LEAKS
For your safety, and to assure the long life of your
equipment, be sure you understand the following signal
words which will be seen throughout this manual:
• DANGER: Alerts you to an immediate hazard, which
will always result in severe personal injury and
possible death if it is not avoided.
• WARNING: Alerts you to a hazard which will result
in a serious personal injury or possible death in
some cases, if not avoided.
• CAUTION: Alerts you to a potential hazard which
may result in a serious personal injury if not
avoided. It also alerts against an unsafe practice
that will permanently damage equipment or
property.
• IMPORTANT: Points out a proper use that will avoid
damage to the machine, and/or will extend the life of
its parts.
• NOTE: Suggests how to use or adjust the
equipment for best product results.
When checking for hydraulic system
leaks, observe only.
HOT FLUID UNDER
PRESSURE
390-152998
DANGER
Never use your hands to check for
leaks.
Hydraulic oil from a pin hole leak
can puncture your skin and cause
serious injury, gangrene, or death.
If injured by hydraulic oil under
pressure, seek medical attention
immediately.
Oil can be hot and can cause severe
burns.
390-152995
CUTTING/SEVERING OF
FINGERS OR HAND - FAN
390-152993
DANGER
WARNING
Uneven terrain at
higher speeds may
cause vehicle to
become unstable
To prevent serious injury or death
from pinching:
• Keep all persons and objects clear
while any part of this machine is in
motion.
IDENTIFICATION OF SAFETY LABELS
390-157201
Safety labels are strategically located around the vehicle
to prevent potential hazards. The labels are a permanent
part of the equipment. If they become separated from
the product or illegible, contact M-B Companies Inc.
for no-cost replacements. Understand the information
the labels are communicating before operating or
maintaining the equipment.
390-157200
WARNING
DANGER
ROTATING DRIVELINE HAZARD
To prevent serious injury or death from
rotating driveline:
• Keep all guards in place when operating.
• Keep hands, feet, hair and clothing away
from moving parts.
390-157202
WARNING: HIGHER ROLLOVER RISK
EMERGENCY
PUSH TO STOP
PULL TO RUN
Avoid Abrupt Maneuvers
and Excessive Speed
Travel at Low Speed
When Turning
HOT SURFACE
390-152994
WARNING
390-134607
Always Wear Safety Belt
NO RIDERS OR
HANGERS ON
390-172409
390-152996
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 5 •
Safety
GENERAL SAFETY
PRESSURIZED SYSTEMS SAFETY
• This manual should be available during operation.
• Extra copies of this manual are available for
purchase through the M-B Customer Service
Department.
• To avoid serious injury or death, do not modify
equipment. Any modifications made to equipment
can be dangerous and can void equipment warranty.
• Never defeat a safety device to make a task easier.
• Never deface or remove factory-installed safety
labels. If a label ever becomes lost, damaged, or
illegible, report this condition to a supervisor and
obtain a replacement label from the Customer
Service department of M-B Companies, Inc.
• Always wear proper apparel when operating
equipment; safety glasses, face shield or goggles,
ear protection, and dust mask. Tie hair back. Never
wear loose clothing or jewelry that could get caught
in moving parts.
• Never operate equipment with covers or guards
removed. Rotating parts can cause severe injury.
Keep hands, feet, hair, jewelry and clothing away
from all moving parts.
• Understand the operation of hydraulic and
pneumatic controls.
• Understand which adjustments are operator and
which are maintenance adjustments.
• Always shut OFF equipment when left unattended.
• Never operate or work around equipment if under
the influence of alcohol, drugs or medications.
PRE-START-UP SAFETY
• Install any covers or guards which may have been
removed for shipping purposes or maintenance.
• Before starting equipment, walk around equipment,
making a visual inspection that all safety devices
are properly installed and secured.
• Check that all hardware, fasteners, hydraulic fittings,
etc. are in good condition and properly fastened.
Replace any fatigued or damaged items with proper
replacements.
• Personnel who are not required to be in the
work area should be kept away. Never start the
equipment unless you are absolutely certain that
everyone in the area is clear of the machine and
aware it is being started.
• Follow the manufacturer’s recommended start-up
procedure.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• Do not disassemble a pressurized system unless
properly trained and equipped with adequate
tooling.
• Familiarize yourself with the proper method of
relieving pressure from pneumatic or hydraulic
systems. Never perform maintenance on, or
disassemble, pressurized systems without first
locking out power to these systems and then
relieving pressure to them.
• Oils and fluids can be very hot under pressure.
Use caution and allow the system to cool before
beginning maintenance work.
• Never operate or pressurize one of these systems
with worn or damaged components. Replace hoses,
fittings, valves or other components which appear
defective.
• Never adjust pressurized systems beyond
recommended levels to achieve higher operating
pressures.
THE MANUAL
It is the purpose of this manual to provide complete
instructions for service, maintenance disassembly,
repair,and installation of the mechanical components for
the M-B Multi-Service Vehicle.
Directional Reference
All reference to left, right, front, or rear are given from
the operator in the operator position and facing the
direction of your unit.
REQUIRED OPERATOR TRAINING
Original purchaser of this unit was instructed by the
seller on safe and proper operation. If unit is to be used
by someone other than original purchaser; loaned,
rented or sold, ALWAYS provide this manual and any
needed safety training before operation.
The Operator Must Understand:
• How to operate all controls
• The functions of all controls
• How to STOP in an Emergency
• Speed Ranges
• 6 •
Safety
WORK AREA
MAINTENANCE SAFETY
• ALWAYS check overhead and side clearances
carefully before operation. ALWAYS be aware of
traffic when operating along streets and curbs.
• Keep area of operation clear. Stay alert for hidden
hazards.
• DO NOT run engine in an enclosed area. Always
provide good ventilation.
• Abnormal Vibrations are a warning of trouble.
Striking a foreign object can damage unit. Stop
unit and engine. Wait for all moving parts to stop.
Inspect unit and make any necessary repairs before
restart.
• Protect eyes, face, and head from objects that may
be thrown from unit. Wear appropriate hearing
protection.
• Avoid Sharp Edges. Sharp edges can cause
serious injury. Wear gloves to service unit when
handling sharp edges.
• ALWAYS keep hands and feet away from all moving
parts during operation. Moving parts can cause
serious injury or death.
• Be aware of the surroundings. Look for blind spots
from which pedestrians or vehicles may suddenly
appear.
• Locate the emergency stop on the vehicle.
• Do not operate in crowded pedestrian areas. This
equipment may cause serious injury or death if
safety rules are not followed.
• The M-B Multiple Service Vehicle (M-B MSV)
uses a level gauge. The gauge helps the operator
determine the angle or slope of the surface being
driven on. The gauge shows percent of grade.
WARNING
During normal operation the M-B MSV must
not exceed 30% grade to either side. Adding
any attachment to the M-B MSV will affect the
safe maximum grade.
• Do not remove guards while operating. After
maintenance work, be sure all guards and other
safety devices are installed and in proper working
order.
• Never clean, lubricate, or adjust equipment while it
is moving, has the potential to move or when engine
is running.
• Always release pressure from pressurized systems
before disassembling.
• Allow ample time for heated components to cool
before working on or working close to them. Use
temperature sticks or other appropriate devices to
test temperatures.
• ALWAYS maintain unit in safe operation condition.
• Check the conditions of the unit at the end of each
day and repair any damage or defects.
• Keep all fasteners properly torqued and in safe
operating condition.
• Before maintainance, adjustments, or service
(except where specifically recommended), shut off
engine, and secure from moving.
Storage
ALWAYS clean and lubricate equipment before extended
storage. Clean and lubricate equpment every 6 months
during prolonged storage.
WELDING
Before welding on a machine/unit equipped with an
electronic engine, the following precautions should be
observed:
• Turn the engine control switch to the OFF position.
• Disconnect the negative battery cable at the battery.
If a better disconnect switch is provided, open the
switch.
• Connect the welder ground cable directly to the
member to be welded. Place the ground cable
clamp as close as possible to the weld to reduce the
possibility of welding current damage to bearings,
hydraulic components, electrical components and
ground straps. Do not use electrical components,
the ECM, or electronics ground stud for grounding
of the welder.
• Protect wiring from welding debris or splatter.
Figure 1
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 7 •
Safety
General Information
INTRODUCTION
CUSTOMER SERVICE
Thank you for choosing M-B Companies, Inc. as your
equipment manufacturer and supplier. As part of our
commitment to total customer satisfaction, we have
strived to ensure that the information contained within
this manual is complete and representative of the
equipment you have purchased. The manual cannot,
however, anticipate every possible contingency to be
met in the installation, operation and maintenance for
your equipment. If you require additional information
not included in this manual, please contact our Service
Department at:
Customer Service Department
c/o M-B Companies, Inc.
1615 Wisconsin Ave.
PO Box 200
New Holstein, WI 53061
Phone: 1-888-558-5801 or 1-800-558-5800
Fax: 920-898-4588
The serial number on your equipment is essential
for proper service support. When contacting M-B
Companies regarding service support, always provide
the product serial number. This number is located on
the identification plate mounted on your equipment,
and should also have been recorded in the Machine
Identification section.
Customer Service Department
c/o M-B Companies, Inc.
1615 Wisconsin Ave.
PO Box 200
New Holstein, WI 53061
Phone: 1-888-558-5801 or 1-800-558-5800
Fax: 920-898-4588
MACHINE IDENTIFICATION
Each machine manufactured by M-B Companies, Inc.
has an identification plate mounted to it as shown in
Figure 2. This plate contains the serial number of your
M-B equipment. This information is important to have
available when communicating with M-B.
Vehicle
Certification Label
Figure 2
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 8 •
General Information
Manufacturer’s Limited Warranty
The M-B Companies, Inc. warrants all its M-B MSV products to be free from defects in materials and workmanship for
12 months, to begin with the delivery of said product to its original owner. This warranty is not transferable without the
written consent of M-B.
M-B will, at its own expense and without expense to the owner, replace all failed parts for and make all repairs that
may be required by reason of workmanship or material in any part of the assembly of the product and associated
components.
Upon notice in writing, M-B will promptly repair or replace all defective or damaged items delivered under the contract.
The batteries, tires, rubber materials, brushes and material normally consumed in operation, and major components
such as engines, air compressors, and hydraulic pumps and motors are excluded from this warranty but shall, in any
event, be guaranteed by M-B to the extent of any warranty received from its supplier.
Any components replaced under warranty will be warrantied for the remainder of the original warranty. Replaced
components do not restart the warranty period.
If requested by M-B, products or parts for which a warranty claim is made are to be returned, transportation prepaid,
to M-B’s factory. Any improper use, operation beyond capacity, or substitution of parts not approved by M-B, or
alteration or repair by others in such a manner as in M-B’s judgement materially and/or adversely affects the product
shall void this warranty.
This warranty does not apply to defects caused by damage or unreasonable use while in the possession of the
owner, including but not limited to: failure to provide reasonable and necessary maintenance, normal wear, routine
tune-ups or adjustments, improper handling or accidents, operation at speed or load conditions contrary to published
specifications, improper or insufficient lubrication, or improper storage.
The M-B Companies, Inc. shall not be liable for consequential damages of any kind, including, but not limited to,
consequential labor costs or transportation charges in connection with the replacement or repair of defective parts, or
lost time or expense which may have accrued because of said defect.
THE M-B COMPANIES DO NOT MAKE ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A
PARTICULAR PURPOSE. THE ONLY WARRANTY MADE BY M-B COMPANIES IS AS SET FORTH HEREIN. THIS
WARRANTY CANNOT BE EXTENDED, BROADENED OR CHANGED EXCEPT IN WRITING BY AN AUTHORIZED
OFFICER OF M-B COMPANIES, INC.
(M-B’s total liability hereunder in no event shall exceed the purchase price of the product.)
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 9 •
General Information
Vehicle Information
INTRODUCTION
Radial Snow Tire
This section provides information that is specific to the
M-B MSV. Each sub-section describes a component or
system to give the reader a reasonable understanding
of the topic. If a more in-depth knowledge is needed,
contact M-B Companies Customer Support.
SPECIFICATIONS
Cummins QSB4.5 Teir 3 Turbo Diesel
110 @ 2500 RPM
115 @ 2300 RPM
Battery Size
17.2 to 1
Suction Fan Cooled Radiator
Cooling System Capacity
3 gallons (11.3 L)
Fuel Tank Capacity
Inside Turning Radius
66" (168 cm) Radial Snow Tire,
76" (193 cm) Turf Tire
CAT 1 or CAT 2
Front Module Type
Sauer Danfoss
MC50-20
MC38-10
Rear Module Type
Sauer Danfoss
MC50-22
MC24-10
Display Type
Sauer Danfoss
DP 610 LX
Power Output Module
Joystick Type
Custom Fabricated Steel Construction
Reinforced Wheel Motor Design
45 degrees
Oscillation
15 degrees
Caster/Camber
0.5 degrees / 1.0 degrees
Overall Length
157" (398 cm)
13" (33 cm) winter, 11" (28 cm) summer
(2) Copper Bussman MVEC Modules
31M-000-0J
Suregrip LGGM-UUbUbUGGRG-02-B2J/
JM P2-J19-02
(1) 4 Position joystick w/ dual trigger
ROPS certified to ISO 3471 and
SAE J1040C at 12,000 lbs
Articulation
Ground Clearance
116" (294 cm) Radial Snow Tire,
126" (320 cm) Turf Tire
19 gallons (71.9 L)
Chassis
Type
Outside Turning Radius
1125 CCA
Delco Remy, 3 phase, 12 volt, 95 Amp,
1125 CCA Battery
Compression Ratio
Cab
33/16LL500 10 Ply Rating
275 cu-in (4.5 L)
Rated Horsepower
Cooling
Turf Tires
Electronic Controls
Displacement
Charging System
10.5/80-18 10 Ply Rating
Front Three Point Hitch
Engine
Type
LT275-70R18
Lug Tires
(4) 3 Position momentary toggle switches
(4) Momentary push buttons
2 Way Radio
Auxiliary Lighting
(Optional)
12V power and memory quick hook up
10A front
10A rear
Front End Connector
6 outputs, (4) 4A and 2 (15A)
Rear End Connector
6 outputs, (4) 4A and 2 (15A)
Ground Drive
Drive Motors
Poclain MS05, 2-speed,
Hydraulic Wheel Motors
Track Width
50" (127 cm) winter,
60" (152 cm) summer
Traction Control
All Wheel Drive with Pressure Locking
Differential
Wheel Base
83" (210.8 cm)
Ground Speed
0 to 10 MPH Work Mode,
0 to 21 MPH Transport Mode
Height
Winter 82" (208 cm) top of cab and
89" (226 cm) top of beacon
Summer 80" (203 cm) top of cab and
87" (221 cm) top of beacon
Cab Width
48" (121.9 cm)
Curb Weight
6680 lbs (3330 kg)
Front or Rear Axle
Rating
8000 lbs (3635 kg)
Gross Combined Weight
Rating (GCWR)
12,000 lbs (5436 kg)
Gross Vehicle Weight
Raiting (GVWR)
12,000 lbs (5436 kg)
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
Ground Drive Pump
Make/Model
Pressure
• 10 •
Sauer Danfoss Series 90
75cc Axial Piston Pump
Electronic Displacement Control
5600 psi (386 bar)
Vehicle Information
Hydraulic System
Tank Capacity
Total Fluid Capacity
18 gal (68L)
Approximately 28 gal (106 L)
Auxiliary Hydraulics
Auxiliary Pump Make/
Model
Hydraulic Volume
Operating Pressure
Front Quick Couplers
Eaton Model 70423 (Standard)
31 GPM (117.4 Lpm) adjustable, standard
2800 psi (193 bar) maximum
Low Flow (5 gpm 18.9 Lpm max)
- 2 pairs of 9/16" quick couplers
High Flow (31 gpm 117 Lpm max)
- 1 pair of 1-1/16" quick couplers
Case Drain - 1-9/16" male quick coupler
Chassis Manifold
(optional) (Rear)
Low Flow (5 gpm 18.9 Lpm max)
- 2 pairs of 9/16" orb fittings
Power Take Off
Clutch
Dry type, electronic-over-hydraulic
Spline
6 spline 1-3/8" diameter
RPM Front PTO
540 @ 2200 RPM
Hitch Capacities
Towing Capacity
6000 lbs (2721 kg)
Tongue Weight Capacity
2000 lbs (907 kg)
Front Lift Capacity
6000 lbs (2721 kg)
Accumulator
Nitrogen filled to 650 psi (44.8 bar)
Cooling System
Fan Size
20" (51 cm) Rear Mounted - Suction
Eng Radiator
35 x 24" x 4" - Suction
AC System
Refrigerant Charge
Lubricant Charge
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
R-134a, 1 lb 2 oz
8 oz PAG oil
• 11 •
Vehicle Information
NOTES
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 12 •
Vehicle Information
DIMENSIONS
Figure 3
NOTE
Overall height and ground clearance
is dependant on the radius of the tires.
Dimensions given are based on 32 inch radial
tires.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 13 •
Vehicle Information
PARTS MANUAL REFERENCE LAYOUT
1
8
5
12
3
4
6
10
7
22
14
24
2
26
9
13
30
27
23
29
22
17
21
20
14
16
18
19
Figure 4
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 14 •
Vehicle Information
PARTS MANUAL REFERENCE TABLE
Layout Callouts
Parts Manual
Reference Page
1
Exterior CAB
12
2
Auxiliary Manifold
14
3
Windshield
16
4
Door
18
5
Right Console
20
6
Joystick
22
7
Brake Assembly/Throttle
24
8
HVAC
26
9
Steering
28
10
Cab Interior
30
11
Rear Compartment
32
12
Exterior
34
13
Cooling Assembly
36
14
Fuel and Hydrualic Tanks
38
15
Chassis
40
16
Front Frame
42
17
Front Drive
44
18
Hitch
46
19
Midsection
48
20
Rear Frame
50
21
Left Rear Ground Drive
52
22
Right Rear Ground Drive
54
23
Rear Manifolds
56
24
Engine
58
25
Fuel, Air Intake and Exhaust Side Two
60
26
Engine Electrical Side One
62
27
Engine Electrical Side Two
64
28
Harness and Cable
66
29
PTO
68
30
Clutch
70
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 15 •
Vehicle Information
VEHICLE IDENTIFICATION
FUSE PROTECTION
The Vehicle Certification Label attached to the vehicle
contains specifications and capacities for this unit. Do
no operate the M-B MSV outside these specifications.
Figure 5 shows an example of the label.
The electrical system is protected by fuses of various
sizes located in the rear control panel in the engine
enclosure and under armrest of the cab.
ATTACHMENT CONTROLS
All attachment hydraulic functions, PTO engagement,
and some vehicle control selections are controlled by the
SDC+1 joystick and Sauer Danfoss Control System.
SPEED CONTROLS
Vehicle controls include the engine throttle and a foot
pedal. Each of these are set using the SDC+1 screens
and the joystick to deliver a controlled variable voltage to
an actuator.
Engine speed is controlled by an electronic control
module provided by the engine manufacturer. The
operator in the cab uses SDC+1 screens and joystick
which are networked to the Electronic Control Module
(ECM) to set desired engine operating speed.
The auxiliary hydraulic flow rate is controlled from the
operators position in the cab by means of the SDC+1.
The ground drive speed is controlled by means of the
foot pedal. A variable current is delivered to an electronic
displacement control (EDC) on each hydraulic pump for
the particular function. The variable current determines
the angle of the pump swash plate which in turn
determines pump displacement.
WIRING
Wiring in the system is color and number coded for ease
of tracing, maintenance, and troubleshooting.
390-157208
Figure 5
SYSTEM POWER
The M-B MSV system uses 12-volt power from a single
battery pack. The alternator and voltage regulator
maintain battery charge and voltage.
CAN NETWORK
A Controller Area Network (CAN) is used on the M-B
Multi Service Vehicle to control all hydraulic and engine
functions. The CAN is designed with software switches
that compliment other switches and the joystick.
Together, this system activates electric solenoids that
control hydraulic valves. The main interface to the
system is the Sauer Danfoss Plus+1 (SDC+1).
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 16 •
Vehicle Information
ADVANCED ENGINE DIAGNOSTICS
The engine has diagnostic information that can
be viewed using the SDC+1 displays. The engine
manufacturer provides a second level of diagnostic
information. Refer to the engine documentation for
hardware requirements and access to that level. The
communication port is located below the right side arm
rest.
Cummins Diagnostic Port
Figure 6
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 17 •
Vehicle Information
Operation
HOW TO START
•
•
•
•
Quick Reference User Guide
Sit in seat, fasten seatbelt and insert key.
Turn key to ON. Wait for screen to display STARTUP (10 seconds).
Place foot on brake and turn key to START position.
Hold key in START position for a couple of seconds to start the engine.
If key is turned to START too soon, the tractor will not start.
The key must then be reset by turning it to OFF - leave off for 5 seconds and
then back to ON.
SHUTDOWN
• Turn off PTO.
• Turn off hydraulics.
• Turn key to OFF and release seatbelt
to exit tractor.
Headlight
High Beam
Left Turn
Signal
Forward
Neutral
Reverse
Right Turn
Signal
Switch between
Work and
Transport mode
PARKING BRAKE
• Engages/Disengages automatically
when pressing and releasing
accelerator pedal.
FORWARD/REVERSE
• Using the joystick, push the 3rd
toggle switch from the left UP for
forward or DOWN for reverse.
GREEN
when PTO
engaged
Indicates
Engine Fault
THROTTLE (Work Mode)
• Use the 2nd toggle switch from the
left on joystick to throttle UP (push
upward) or to throttle DOWN (pull
downward).
Indicates
Non-Critical
Fault
RAISE/LOWER FRONT
ATTACHMENT
• While tractor is running, pull back on
joystick to raise front attachment.
• Lower attachment by pushing forward
on joystick.
Forward - Front Hitch Down
Throttle Up/Down
Up - Aux 5A
Down - Aux 5B
Parking Brake
ON/OFF
Backward - Front Hitch Up
Shift Forward/Reverse
Up - Aux 4A
Down - Aux 4B
ON/OFF REAR ELECTRICAL/
HYDRAULIC ATTACHMENTS
• Turn rear electrical attachment (IE
Sprayer) ON and OFF with 1st toggle
switch on left.
• Turn rear hydraulic ON and OFF with
1st toggle switch on right.
Float mode
On/Off
Aux 3A
Left - Aux 1A
Trigger Up - Aux 2A
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
Aux 3B
• 18 •
Right - Aux 1A
Trigger Down - Aux 2B
Operation
Operation - Plus+1® Controls
Open Screen
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 19 •
Operation
Main Menu Screen
Button
Function
1
Access Transport Mode (Refer to Page 19 )
2
Access Work Mode (Refer to Page 21 )
3
Access Joystick Setup (Refer to Page 23)
4
Access Front Inputs, Outputs, and MVEC Status Screens Use Up and Down arrows to access each section (Refer to Pages 24-26)
5
Access Calibration Screen (Refer to Page 27)
6
Access Attachment Selection Screen (Refer to Pages 28-29)
7
Access Password Screen - If showing “PW OK” Password access has be granted (Refer to Page 30)
8
Access Rear Inputs, Outputs, and MVEC Status Screens Use Up and Down arrows to access each section (Refer to Page 31-33)
Up and Down arrow keys will cycle through the screen functions as well.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 20 •
Operation
Transport Mode Screen
Button
Function
2
Turns on cruise control function of MSV. To engage cruise control press “OK”. To disengage press brake pedal or “OK” button
again. To return to foot pedal throttle (FP Throttle) arrow down. Pressing okay will activate joystick throttle control.
3
Activates low speed, pressing again will return to high speed mode
4
Access to faults screens (Refer to page #)
5
Brings MSV to idle. Pressing again brings MSV back to last RPM level
6
Access to work screen mode – may have to reduce speed
7
NOT USED
8
Returns to Main Menu
Activates beacon light controls. Pressing “OK” turn on/off beacon light.
Arrow down again to access rear work light controls. Pressing “OK” will turn on /off the rear work lights, if equipped.
Icons in uppers left corner of screen will light up red when a warning has occurred. A beep with occur every minute when a warning light is illuminated.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 21 •
Operation
Transport Screen Icons
Left Signal Indicator
Low Fuel Warning
Right Signal Indicator
High Engine Temperature
Vehicle Drive Status
Service Hydraulic Filter
Headlight High Beam Indicator
Oil Pressure Warning
Hour Meter
Low Batttery Voltage
Alarms Display
High Hydraulic Oil Temperature
Engine RPM
Parking Break Engaged
Seat Belt
Vehicle Speed
Engine Fault
Glow Plugs
System Faults
Main Menu
System receiving signal from
engine ECM
Cruise
Fuel Gauge
Foot Pedal Throttle
Hi/Low Range Selection
Engine Coolant Guage
Lights - select to turn on
Engine Oil Gauge
Indicates when in High Speed
Low Battery Gauge
Quick Stop - Quick Idle
Hydraulic Oil
Vehicle Ground Drive
Current horsepower load being
used by engine
Operator is present
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 22 •
Operation
Work Mode Screen
Button
Function
1
Press to select creep mode, press “OK” to engage creep mode. Utilize creep mode to connect attachments.
Press again to select diff lock mode, press “OK” to engage. Diff lock is used to reduce wheel slippage, use only under 7 MPH.
2
Turns on cruise control function of MSV. To engage cruise control press “OK”. To disengage
press brake pedal or “OK” button again.
Press again to activate foot pedal throttle, press “OK” to engage
3
Energizes PTO icon. Press “OK” to activate PTO icon. MSV must be under 1200 RPM to activate
4
Access to faults screens (Refer to pages 35-36)
5
Brings MSV to idle. Turns off any attachment.
Pressing again will return MSV to previous RPM and turn back on the attachments that were previously on.
6
Access to transportation screen mode
7
Access to weight transfer setup screen.
Must have weight transfer function selected.(Refer to page 34)
8
Returns to Main Menu
Activates beacon light controls. Pressing “OK” turn on/off beacon light.
Arrow down again to access rear work light controls. Pressing “OK” will turn on /off the rear work lights, if equipped.
Arrow down again to activate weight transfer function (Refer to page 34)
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 23 •
Operation
Work Screen Icons
Left Signal Indicator
Quick Stop - Quick Idle
Right Signal Indicator
Vehicle Ground Drive
Vehicle Drive Status
Speed too high. Switch to Work
Mode. Must stop to switch modes.
Headlight High Beam Indicator
Alarms Display
Spray/Spreader on (green)
Speader Speed 0-6
Seat Belt connected (green)
Setup Weight Transfer
Seat Belt not connected
Aux 3A on (green)
Parking Break Engaged
Hitch in Float Mode (green)
Current horsepower load being
used by engine
Voltage
Engine RPM
Fuel Level
Vehicle Speed
Main Menu
Creep Mode ON (green)
Pressure level to ground drive
Diff lock engaged (green)
Lights - select to turn on (green)
Cruise engaged (green)
Foot Pedal Throttle active
(green)
Weight Transfer engaged (green)
PTO RPM
PTO engaged (green)
Adjustment for Weight Transfer
Amount of weight on front hitch
Engine Fault
Function being operated by joystick
System Faults
Current front and rear attachment
selection
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 24 •
Operation
Joystick Setup Screen
Button
8
Function
Returns to Main Menu
Cycle through each function. Press “OK” to select function. Press up/down again to place the position of the function.
Function must not be active on other selections. Place NA on the functions you do not want to use. Functions 3, 4, 5 and 6
cannot be moved.
The numbers on the left side of each function are the default numbers. Place the number in the right to set back
factory default. Functions 19, 20, and 21 are bonus functions that must be assigned an unused number.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 25 •
Operation
Front Input Screen
Button
Function
8
Returns to Main Menu
4
Press to highlight Front Inputs
Cycle through Front Inputs, Outputs and MVEC
OK
Press to access highlighted option
Displays the status of the front inputs.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 26 •
Operation
Front Output Screen
Button
Function
8
Returns to Main Menu
4
Press to highlight Front Inputs
Cycle through Front Inputs, Outputs and MVEC
OK
Press to access highlighted option
Displays the status of the front ouptuts and what voltage or current it is modulating.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 27 •
Operation
Front MVEC Screen
Button
Function
8
Returns to Main Menu
4
Press to highlight Front Inputs
Cycle through Front Inputs, Outputs and MVEC
OK
Press to access highlighted option
Displays the status of the front MVEC.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 28 •
Operation
Calibration Screen
Button
Function
1
Resets foot pedal settings. Allows you to recalibrate foot pedal
2
Resets hydraulic filter notice
3
Cycles between slow, medium and high ground drive ramping
4
Cycles between slow, medium and high ground drive ramping
5
Resets steering cylinders
8
Returns to Main Menu
Change screen brightness
Change tire size
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 29 •
Operation
Attachment Selection Screen
Button
Function
1
Front attachment selection
Arrow up/down to cycle through attachments. Press and hold “OK” for three seconds to select attachment
2
Press and hold to reset front attachment
5
Rear attachments selection
Arrow up/down to cycle through attachments. Press and hold “OK” for three seconds to select attachment
6
Press and hold to reset rear attachment
7
Access attachment setup screen. This function is only accessible with password clearance from the main menu screen.
8
Returns to Main Menu
Each selection illuminate in red when a fault is registered.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 30 •
Operation
Attachment Selection Screen
Once you have your attachment selected on the attachment selection screen you can access the attachment setup
screen only with password clearance from the main menu screen.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 31 •
Operation
Password Screen
Button
Function
Button
Function
1
#1
#9
2
#2
#0
3
#3
OK
Submit Password
4
#4
esc
Returns to Main Menu
5
#5
6
#6
7
#7
8
#8
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 32 •
Operation
Rear Input Screen
Button
Function
8
Returns to Main Menu
4
Press to highlight Rear Inputs
Cycle through Rear Inputs, Outputs and MVEC
OK
Press to access highlighted option
Displays the status of the rear input and frequency.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 33 •
Operation
Rear Output Screen
Button
Function
8
Returns to Main Menu
4
Press to highlight Rear Inputs
Cycle through Rear Inputs, Outputs and MVEC
OK
Press to access highlighted option
Displays the status of the rear output and frequency.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 34 •
Operation
Rear MVEC Screen
Button
Function
8
Returns to Main Menu
4
Press to highlight Rear Inputs
Cycle through Rear Inputs, Outputs and MVEC
OK
Press to access highlighted option
Displays the status of the rear MVEC.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 35 •
Operation
Weight Transfer Screen
Button
Function
1
Reset weight transfer configuration by holding for two seconds
2
Save settings
3
Return to work mode screen
Decrease weight transfer
Increase weight transfer
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 36 •
Operation
Faults Screen
Button
Function
1
Access to Engine Faults
2
Access to Front MVEC Faults
3
Access to Front Control Faults
6
Access to Rear MVEC Faults
7
Access to Rear Control Faults
8
Access to Return to Main Menu
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 37 •
Operation
Faults Screens
Front MVEC Faults Screen
When highlighted in RED shows an active fault
Rear MVEC Faults Screen
When highlighted in RED shows an active fault
Front Control Faults Screen
When highlighted in RED shows an active fault
Rear Control Faults Screen
When highlighted in RED shows an active fault
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 38 •
Operation
Operation - Attachment Selection Examples
The following examples apply once the initial attachment setup has been performed by M-B or a factory trained MSV dealer.
This setup includes adjusting outputs to the optimum levels.
Selecting the Ribbon Snow Blower Attachment
Connect the Ribbon Snow Blower and the hydraulic hoses to the desired auxiliary hydraulics.
Button
6
Function
Attachment Selection screen
Button
Function
2
Press and hold for two seconds to reset front attachment
1
Front attachment selection
Press two times to highlight MSV PTO Ribbon Blower
OK
8
Press and hold for three seconds to set attachment
Return to Main Menu
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 39 •
Operation
Selecting the Ribbon Snow Blower attachment (continued)
Button
2
Function
Enter Work Mode
Button
3
OK
User Defined
Function
Select PTO, Engine RPM must be below 1200 RPM to activate PTO.
Press “OK” to use PTO (engages Impeller), PTO RPM shows above PTO icon. Increase PTO RPM’s by increasing engine
RPM’s.
Press user defined button on joystick to turn on Aux 3A function to engage ribbon.
Increase engine RPM to desired speeds and begin using attachments.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 40 •
Operation
Operation - Attachment Selection Examples
The following examples apply once the initial attachment setup has been performed by M-B or a factory trained MSV dealer.
This setup includes adjusting outputs to the optimum levels.
Selecting the Rear Spreader Attachment
Connect the Rear Spreader and the hydraulic hoses.
Button
6
Function
Attachment Selection screen
Button
Function
6
Press and hold for two seconds to reset rear attachment
5
Rear attachment selection
Press three times to highlight MSV Spreader
OK
8
Press and hold for three seconds to set attachment
Return to Main Menu
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 41 •
Operation
Selecting the Rear Spreader Attachment (continued)
Button
2
Function
Enter Work Mode
Button
User Defined
Function
Press user defined button to engage Aux 4A to turn on rear spreader.
Increase engine RPM to desired speeds and begin using attachments.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 42 •
Operation
Operation - Weight Transfer Example
The following examples apply once the initial attachment setup has been performed by M-B or a factory trained MSV dealer.
This setup includes adjusting outputs to the optimum levels.
Initial set up of the Weight Transfer feature
After your attachments are connected and set up follow these steps. Steps need to be done when switching between
attachments.
Button
2
Function
Work mode screen
Button
Function
Arrow down three times
OK
Press “OK” to turn on Weight Transfer
7
Access Weight Transfer setup screen
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 43 •
Operation
Initial set up of the Weight Transfer feature (continued)
Button
1
Joystick
Forward
Function
Hold for two seconds to reset weight transfer
Push joystick forward to activate weight transfer
Press multiple times until attachment begins to raise
Press until attachment stops rising. This sets 100% of the attachment weight on the hitch.
2
Press to save settings
3
Return to Work Mode screen
Button
Function
Decrease weight transfer (decreases weight on front wheels)
Increase weight transfer (increases weight on front wheels)
Increase engine RPM to desired speeds and begin using attachments.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 44 •
Operation
Operation
PRE-START UP
WARNING
Before performing any of the following
inspections, make sure that the vehicle engine
is shut down, the ignition key is removed, and
all personnel in the work area are aware that
the equipment is being inspected and must not
be started.
Never check for hydraulic leaks by hand.
Hydraulic fluid under pressure can penetrate skin.
Inspect all hydraulic lines for evidence of
leaking, loose fittings, and frayed or damaged
hoses.
Check hydraulic cylinders for broken or loose
parts, especially cotter pins on the hydraulic
cylinders.
Check the hydraulic oil level. A sight gauge
is located on the side of the reservoir for this
purpose. Add fluid as necessary.
All access doors are secured in place.
Visually inspect for fluid leaks under the vehicle.
Check engine fluids.
IMPORTANT
The engine will not start unless
Plus+1® is ready. Turn the key to
ON and wait for Plus+1® to start up
(approximately 15 seconds). If the key
is turned to START before Plus+1® is
ready, the key must be reset. Turn the
key to OFF for 10 seconds and back to
ON. When Plus+1® is ready the engine
preheater will be ready. The engine can
then be started.
NOTE
If temperature is below 10°, turn key ON for
10 seconds, turn key OFF for 10 seconds and
then back ON. This will help with starting.
Trying to start the engine prior to the Startup screen
appearing may cause delays. Engine will not crank until
manifold heater is at starting temperature. Colder temps
will cause delays.
1. Start the engine.
2. Use Plus+1® to determine if the correct attachments
are configured in the controls
3. With the engine idling, operate the attachments until
the system warms up.
4. Return to the main screen for operation.
Check for faults on screen.
Inspect attachments for damage and proper
connection.
START-UP PROCEDURE
Key Switch
The key switch on the steering column is used to
initialize Plus+1® controller and start the engine. The
engine will not start until Plus+1® has booted up and the
intake manifold heater has properly warmed.
To start the MSV the operator must be seated. Turn
the key switch to the on position. Watch the screen of
Plus+1®. After an M-B splash screen the start up screen
will appear. Turn the key to start the engine.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 45 •
Operation
COLD WEATHER STARTING
Before Starting the Engine
NOTE
Do not use a torch to heat a compartment.
This causes fires, burns wiring, gaskets and
seals, or melts protective plastic.
When using canvas covers, do not install
them near exhaust systems. This helps to
prevent fires.
Manually Sprayed Ether Starting Aids
DANGER
Do not use manually sprayed
Ether starting aids. Using
a spray type starting aid
may cause the air intake to
explode and cause personal
injury.
Intake Air Heater
The engine has a grid heater in the air intake tube just
before the intake manifold. This heater is controlled as
needed by the engine electronics. Do not bypass or
force the heater on.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 46 •
Operation
AFTER STARTING ENGINE
SAFETY LINK
Whenever a machine has been parked for a long period
of time, some of the systems will cool to below normal
operating temperatures. Always warm the machine
systems before operating the machine at full operation
Damage to engine valve control components can result
from engine operation for short intervals during operation
in very cold weather conditions. If the engine is not
allowed to warm completely, the engine can be damaged
by repeated starting and stopping.
To avoid damage, always run the engine until the coolant
temperature is at least 180°F (82°C).
After the engine is warm, warm up the other systems.
Start with the hydraulics. Run the engine at less than
one-third throttle, and slowly move the control lever to
lift the attachment. Initially, lift the control lever for a
few inches (centimeters). Lower the attachment slowly.
Continue the sequence: raising, lowering, extending, and
retracting. Extend the travel during each cycle. Perform
this operation for all hydraulic circuits. Alternate between
all of the attachments.
Exercise the transmission and the power train. If you
cannot move the control for the transmission, perform
the following steps:
• Engage the parking brake or apply the brake pedal.
• Run the engine slightly above LOW IDLE.
• Shift the transmission several times from
FORWARD to REVERSE.
Release the brake. Move the equipment forward
and backward for several feet (meters). Exercise the
machine for several minutes.
To reduce the total warm up time, start exercising the
entire machine before you complete the hydraulic warm
up time.
Operate under light load until the systems reach normal
operating temperatures.
If the engine temperature is not high enough enclose the
engine and block the radiator. A thermostat that opens
at a higher temperature will not increase the engine
temperature if the engine is not under load.
To prevent seal damage and gasket damage, keep the
engine crankcase breather pipe clear of blockage.
In extreme conditions, use a canvas over the engine
compartment. Heat the engine area with a space
heater. This will aid in starting the engine. Extending the
canvas over the hydraulic components will provide initial
warming of the components.
The chassis for the MSV articulates or pivots in the
middle. This is used to help maneuver the MSV and
provides a smaller turning radius.
During maintenance it is advisable to lock-out the
articulation of the chassis.
To lock the Chassis:
1. Pull straight ahead to align the chassis.
2. Locate the safety link on the frame behind the cab
(Figure 7 Safety Link Open).
3. Pull out the removable pin (Figure 8).
4. Swing the link to meet the back half and insert the
pin.
When the safety link is not in use, it should be stored
against the front frame.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
Removable
Pin
Safety Link
• 47 •
Figure 7 Safety Link Open
Figure 8
Operation
FRONT ATTACHMENT CONNECTIONS
Front Hitch Connections
IMPORTANT
For best performance each
attachment must be setup by M-B
or your authorized MSV dealer
prior to use.
Some attachments may be different. Review the
instructions with each attachment. Hydraulic, PTO, and
electrical connections may also be needed for proper
attachment use.
The attachment hitch has two hooks with hitch clamps.
Up and down movement is supplied by two hydraulic
cylinders.
The hitch hooks will slide side-to-side to align with various
attachments.
CAUTION
If the attachment is not centered on the vehicle
damage may occur. Keep the hitch hooks
tightened in place. The hydraulic hoses must
be kept clear from all interference points. Make
sure to install hitch plate at each end of hitch.
Part #401-162657
Clamp Lock
Hook
Open
Lock Pin
Locking Bolt
Figure 9
To connect an attachment:
1. Pull the MSV close to the attachment.
2. Adjust the hooks side-to-side as needed using the
locking bolt on the back side. Pull the handle forward
to open the clamp locks.
3. Drive the MSV forward with the hooks lowered.
Putting the MSV in Creep Mode will assist in this.
4. The hooks should fit into the arms of the attachment.
Lift the hitch in position so the hooks engage and lift
the attachment.
5. Push the clamp locks back completely.
6. Insert the safety pins. Most attachments will have
a top link as a third connecting point. This link is
normally used to level the attachment.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 48 •
Operation
Front Power Take Off (PTO)
The front attachment PTO is accessed thru a panel under
the operators feet (Figure 10).
Universal Joint
of PTO Shaft
WARNING
Turn the engine off before opening the access
panel.
Remove the panel.
PTO Spline
PTO Access
Panel
Figure 13
Replace the access panel before starting the engine.
Hydraulic Connections
Figure 10
The drive spline is visible
NOTE The spline (Figure 11) should have a coating
of grease before attaching the PTO shaft.
Drive
Spline
At the front of the MSV there are three pair of
connections. Each pair has a line out and a line in. The
connections are matched for each pair. Attachments are
connected and Plus+1® controls are set to control the
proper auxiliary ports. See Attachment Manual for proper
connections. Also refer to Plus+1® Controls section in
this manual.
Aux 3A
Aux 1B
Quick Disconnect
Quick Disconnect
Aux 1A
Quick Disconnect
Locking
Groove
Figure 11
The PTO shaft is inserted from the front of the MSV
(Figure 12).
Line the universal joint up with the spline and push
together. Make sure the locking device or universal joint
has compressed in groove of PTO shaft (Figure 13).
Case Drain
Quick Disconnect
Aux 2A
Quick Disconnect
Electrical
Plug
PTO Shaft
Aux 2B
Quick Disconnect
Aux 3B
Quick Disconnect
Figure 14
Figure 12
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 49 •
Operation
Rear Hydraulic Connections (Optional)
The rear of the MSV may have two pair of optional
hydraulic connections (Figure 15). Each pair has a
line out and a line in. Attachments are connected and
Plus+1® controls are set to control the proper auxiliary
ports (See Plus+1®).
NOTE
Some attachments will require these
connections to make them operational.
Aux 5B
Aux 4B
Aux 5A
Aux 4A
Figure 15
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 50 •
Operation
Maintenance
DAILY OR REFUELING
Preventative Maintenance
Procedure
Type/Specification
Engine Oil Level
Check Level/Correct As Needed
Valvoline Premium Blue 15W-40 or equivalent API
CH-4/SJ Rated
Reference Page
Level must read between the dipstick high and low
markings.
Engine Coolant Level
Check Level/Correct As Needed
Fleetguard Complete™ or equivalent
Heavy Duty All Season Meets GM6038M Chemical
Composition
Hydraulic Fluid Level
Check Level/Correct As Needed
Total Dynatrans MP - Hydraulic Tractor Fluid
(Product Code 1-14100) or equivalent
28.3 API Gravity (weight)
Grease Fittings
Grease
Chevron Texaco Multifak® MEP 2 or equivalent
NLGI Grade 2, Ambient Temp.
29.2°F (-34°C) to 360°F (121°C)
Fuel Filter - Water Separator
Drain
Hydraulic Cylinders
Inspect for broken or loose parts
Hydraulic Hoses
Inspect for leaking, loose fittings,
frayed or damaged hoses
Electrical Wires/Cables
Inspect for loose or damaged wires
Crankcase Breather Tube
Inspect
Air Intake Piping
Inspect
Radiator Screen
Inspect/Clean
Access Doors and Panels
Secured/In Place
Leaks Under the Vehicle
Inspect
Active Alarms on SDC+1
Check/Correct
FIRST 50 HOURS
Preventative Maintenance
Procedure
Type/Specification
Engine Oil
Replace
Valvoline Premium Blue 15W-40 or equivalent API CH-4/SJ Rated
Engine Oil FIlter
Replace
209-157677
Hydraulic Charge Pump Filter
Replace
Single Pump
MB Part 209-157683
Hydraulic Oil Return Filter
Replace
MB Part 209-163192
Dip Stick High to Low Mark Difference
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 51 •
Dual Pump
MB Part 209-186012
Maintenance
EVERY 50 HOURS OR MONTHLY
Preventative Maintenance
Procedure
Type/Specification
Reference Page
PTO Gear Box Lubricant Level
Check/Correct
SAE 80W 90 or 75W 90 with synthetic anti-foaming
agent
Tire Pressure
Check/Correct
Summer - 38 psi (262kPa) Max
Brake Fluid Level
Check/Correct
Engine Air Filter
Inspect/Clean
Cab Air Filter
Inspect/Clean
Bearings, Yokes and Shafts
Inspect
Engine Drive Belts
Check/Correct
Radiator Hoses
Check
Cooling Fan
Check
Battery Terminal Corrosion
Inspect/Clean
Electrical Guards in Place
Check
Hydraulic Charge Pump Filter
Replace
Single Pump
MB Part 209-157683
Hydraulic Oil Return Filter
Replace
MB Part 209-163192
Radiator
Inspect/Clean
AC Cooler
Inspect/Clean
Charge Air
Inspect/Clean
Oil Cooler
Inspect/Clean
Winter - 55 psi (379kPa) Max
3 DOT Must comply to Federal Standard #116 and
SAE J1703
Dual Pump
MB Part 209-186012
EVERY 500 HOURS OR 6 MONTHS
Preventative Maintenance
Procedure
Type/Specification
Engine Oil
Drain/Replace
Valvoline Premium Blue 15W-40 or equivalent
API CH-4/SJ Rated
Total Oil System Volume Approximately
11.6 QT (11.0 L)
Engine Oil Filter
Replace
M-B Part 209-157677
Engine Coolant - Antifreeze
Hydrometer Check/Correct
Fleetguard Complete™ or equivalent
Heavy Duty All Season meets GM6038M chemical composition
Minimum of -25°F (-32°C)
Fuel Filter - Primary
Replace
MB Part 209-157678
Fuel Filter - Water Separator
Replace
MB Part 209-157679
Engine Air Filter - Main Element
Replace
MB Part 209-157680
Cab Air Filter
Replace
MB Part 209-163257
PTO Gear Box Lubricant
Drain/Replace
SAE 80W 90 or 75W 90 with synthetic
anti-foaming agent
Gear Box & Clutch Splines
Grease Splines
(See Service Bulletin 2011-2)
Brake Pads
Inspect
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
Type Moly Super HV Red 228
Must use spline grease to prevent fretting
• 52 •
Maintenance
EVERY 1000 HOURS OR 1 YEAR
Preventative Maintenance
Procedure
Type/Specification
Ground Drive Filter - Charge
Pressure
Replace
Single Pump
209-157683
Ground Drive FIlter - Return
Replace
209-163192
Hydraulic Tank Strainers
(Ground Drive and Auxiliary
Outlet Lines)
Check/Clean
Cooling Fan Belt Tensioner
Check/Clean
Fan Hub, Belt Driven
Check/Clean
Reference Page
Dual Pump
209-186012
EVERY 2000 HOURS OR 2 YEARS
Preventative Maintenance
Procedure
Type/Specification
Hydraulic Fluid
Drain/Replace
Total Dynatrans MP - Hydraulic Tractor Fluid (Product
Code 1-14100) or equivalent
Reference Page
Engine Coolant - Antifreeze
Drain/Replace
28.3 API Gravity (weight)
Fleetguard Complete™ or equivalent
Heavy Duty All Season meets GM6038M chemical
composition Minimum of -25°F (-32°C)
Engine Vibdration Damper Rubber Condition
Check
Engine Vibration Damper Viscous
Check/Correct
Silicon Fluid
EVERY 5000 HOURS OR 4 YEARS
Preventative Maintenance
Procedure
Engine - Overhead Set
Adjust
Type/Specification
Brake Fluid
Drain/Replace/Bleed
3 DOT Must comply to Federal Standard #116 and SAE J1703
LUBRICATION CHART
Frequency
Moly Super HV Red
X
3. Front PTO Drive Assembly
3
Figure 17
1
Figure 24
5. Engine
1
Figure 21
6. Ground Drive Yoke
2
Figure 22
Figure 23
X
X
7. Front Hitch
2
Figure 18
X
X
8. Engine Cooant
1
Figure 19
X
9. Hydraulic Reservoir
1
Figure 19
X
10. Master Cylinder
1
Figure 20
X
M-B Multi-Service Vehicle
SAE 15W - 40 Valvoline
Premium Blue
X
X
4. Gear Box & Clutch Splines
©2015 M-B Companies Inc.
All Rights Reserved
FINA Transguard
Hydraulic Fluid
X
Amoco No. 80W 90
MOBILUX EP2
Dextron III
Fleetguard Compleat™
Annually
6 Months
Figure 25
Weekly (50 Hrs)
Refer to Figure #
Figure 16
2
Daily
Number of Locations
1
2. Door Hinge
Locations Refer to
Figure 38
1. PTO Gearbox
Lubrication Type
X
X
X
X
X
• 53 •
X
X
X
X
Maintenance
Point 1
Point 3
Figure 16
Point 9
Figure 17
Point 8
Figure 19
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
Point 7
Figure 18
Point 5
Point 10
Figure 20
• 54 •
Figure 21
Maintenance
Mounts to Front of Engine
Ground
Drive Pump
Gear Box
Point 6
Point 6
Figure 22
Figure 23
Point 4
Gear Box Spline
Figure 24
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
Hinge
Figure 25
• 55 •
Maintenance
OIL AND FILTER REQUIREMENTS
Oil and Filter Requirements
Engine Oil Type
Valvoline Premium Blue 15W-40 or
equivalent - API CH-4/SJ
Engine Oil Capacity
11.6 quarts, (11 liters)
Engine Oil FIlter Part
Number
209-157677
Primary Fuel Filter Part
Number
209-157678
Fuel Prefilter Part Number
209-157679
Air Filter Main Element Part
Number
209-157680
Air Filter Safety
209-157681
Engine Coolant Type
Fleetguard Compleat™ or
Equivalent - Heavy Duty All Season
meets GM6038M specifications
Minimum of -25°F (-32°C)
Engine Cooler Capacity
3 gallons (11.3 L)
AC Charge Oil
8.10 oz Oil Pag 150,
Charge 10 minutes @ 1400 RPM
AC Charge
1.75 lbs,
Low Side 15 psi, High Side 140 psi
Hydraulic Fluid Type
Total Dynatrans MP - Hydraulic Tractor
Fluid (Product Code 1-14100) or
equivalent 28.3 API Gravity (weight)
Hydraulic Fluid Capacity
25 gal (94.6 L)
Hydraulic Return Filter Part
Number
209-163192
Hydraulic Charge Filter
Part Number
Single Pump
MB 209-157683
Gearbox Fluid Type
SAE 80W 90 or 75W 90 with synthetic
anti-foaming agent
Gearbox Fluid Capacity
2.50 quarts
Cab Fresh Air FIlter
209-163257
Figure 26
2. Using low pressure forced air (30 psi nozzle), clean
the cooler intake (Figure 19) by blowing the area
out thoroughly from inside the engine compartment.
Forcing air or flowing water from the inside will force
debris out of the coolers.
Dual Pump
MB 209-186012
MAINTENANCE
WARNING
Never service the M-B MSV unless the vehicle
is completely shut down. Remove ignition key
to prevent starting of the equipment. Failure to
do so can result in serious injury or death.
Figure 27
3. Replace the guard.
NOTE
If necessary, the cooler intake can
be washed if forced air cleaning is
unsuccessful.
Cleaning the Cooler Intake
The cooler intake must be periodically cleaned to keep
the intake free of debris.
1. Remove the guard covering the cooler intake. This is
located at the rear of the vehicle (Figure 26).
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 56 •
CAUTION
High air or water pressure can bend the cooler
fins reducing the cooling ability.
Maintenance
6
5
3
2
9
4
1
8
7
Figure 28
1. 2. 3. 4. 5. 6. 7. 8. 9. Engine Intake From Cooler
Hyd Tank Cooling
Turbo Air Cooling
Engine Cooling
Screen
Backup Alarm
Turbo Discharge to Cooler
Coolant to Engine
AC Cooling
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 57 •
Maintenance
ENGINE COOLANT
Engine coolant levels should be checked frequently.
Whenever the engine hood is raised, look at the overflow
tank and check the level. Add coolant as needed. See
maintenance charts for coolant type.
To change the air filter:
1. Unscrew the air filter screw clamp and remove the
cover (Figure 31).
2. Slide the filter out of the housing and dispose of
properly (Figure 32).
NOTE The inside of the housing may need cleaning.
3. Insert a new filter.
4. Replace the cover and hand tighten the screw clamp
(Figure 31).
Figure 29
INTAKE MAINTENANCE
WARNING
The engine must be off.
Screw Clamp
Air Filter
The air filter should be replaced on a regular basis.
Dusty conditions will require more frequent replacement.
The air filter has a sensor that will send a warning to the
MDC if the filter requires service (Figure 30).
Figure 31
Figure 32
Figure 30
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 58 •
Maintenance
FUEL SYSTEM MAINTENANCE
WARNING
Make certain the engine is off. Use a catch
pan large enough to hold the contents of the
separator. Some fuel will drain out. The fuel is
flammable. Do not open the valve or separator
near fire or heat source. Use appropriate
storage containers and dispose of fuel
properly.
To change the fuel filter:
1. Unscrew the outer housing.
2. Remove the filter and insert a new one.
3. Replace the housing.
4. Tighten firmly by hand.
Fuel/Water Separator
The separator is located on the left side of the engine
toward the cab (Figure 33). Water can be drained from
the bottom by unscrewing the drain.
Water Drain
Figure 34
When a filter is replaced or when fuel system runs dry,
the fuel primer is used to prime or pressurize the fuel line
to the engine (Figure 35).
To prime:
1. Unscrew the knob on the fuel water separator.
2. Pump in/out until pressure is felt.
3. Push in and screw knob in to tighten.
Figure 33
NOTE
Drain water from the separator more often in
cooler temperatures.
Fuel Filter
WARNING
Make certain the engine is off. Use a catch
pan large enough to hold the contents of the
separator. Some fuel will drain out. The fuel
is flammable. Do remove the housing near
fire or heat source. Use appropriate storage
containers and dispose of fuel properly.
The fuel filter is located on the right side of the engine
(Figure 34).
Separator
Fuel Primer
Figure 35
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 59 •
Maintenance
CAB LIFT
Up/Down Toggle Switch
The operators cab pivots at the front. Lifting the cab will
allow access to several items for maintenance
(Figure 36):
• Battery
• Wiring Harness
• PTO Shaft
• Several Lube Points
Figure 38
GROUND DRIVE MAINTENANCE
Figure 36
To lift the cab:
1. Remove the two hold-down bolts (Figure 37).
2. Locate the up/down toggle switch and push up
(Figure 38).
The switch runs an electric motor with a screw extension
mechanism that will lift/lower the cab.
When lowering the cab:
• Be certain all wiring and hoses are secure and will
not be pinched.
• Stay clear when the cab is lowering.
• Be certain the cab is completely down before
tightening the hold-down bolts.
Hold-Down
Bolt
Figure 37
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
WARNING
Never service the M-B MSV unless the vehicle
is completely shut down. Remove the ignition
key to prevent starting of the equipment.
Failure to follow this instruction can result in
serious injury or death.
The hydraulic fluids for the Ground Drive and the
Attachments use the same reservoir. See Hydraulic
Reservoir.
The ground drive system is comprised of the pump,
several manifolds and four wheel motors.
The front wheel motors have a parking brake.
The parking brake engages whenever the drive pump is
off or when the operator controls call for it to be on. To
disengage the parking brake push the brake button on
the MDC.
NOTE The rear wheel motors do not have parking
brakes. It may be easier to access the front
wheel motors by lifting the cab.
The ground drive system is powered by a single
pump driven by the engine. The pump is a variable
displacement type. The foot pedal controls a rheostat
that sends a PWM signal to the pump
Engine RPM does not change the performance of the
pump under normal circumstances. It is possible for the
engine RPM to be so low that the pump does not reach
maximum. In this case the M-B MSV simply will not
reach top speed.
Maintenance of the drive system includes checking for
leaks and maintenance of the hydraulic reservoir.
• 60 •
Maintenance
GROUND DRIVE FILTER
To replace the pump filter:
1. Swing open the fuel tank door.
2. Remove the screws that hold the pump cover in
place.
3. Lift the close end of the cover and pull to release the
two tabs at the back of the enclosure.
4. Tilt the cover so the side near the radiators is up,
and pull the cover out.
5. Locate the pump filter (Figure 39).
6. Screw the old filter off. Be careful to catch any fluid
that may drip.
7. Lubricate the gasket on the new filter and screw it in
place. Tighten by hand.
8. Start the engine and check for leaks. Tighten filter as
needed.
9. Dispose of the old filter properly.
10. Replace the cover.
CAUTION
Dispose of the fluid properly.
5. Put new fluid in through one of the fill holes
(Figure 41) until it begins to run out the maximum
level hole (Figure 42).
6. Replace the plugs and wipe up any spillage.
Drain Plug
Figure 40
Top Fill Plug
Filter
Vent
Figure 39
POWER TAKE OFF (PTO) MAINTENANCE
PTO Case Fluid Change
The power take off case should have the fluid changed
periodically.
To drain the case fluid:
1. Place a catch pan below the plug at the bottom of
the case.
2. Remove the plugs (Figure 40).
3. Remove the case fill plug (Figure 41).
4. When the fluid has stopped draining, replace the
drain plug.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
Figure 41
• 61 •
Maintenance
To maintain the PTO system:
• Change the case fluids.
• Grease the driveshaft at the universal joints.
• Grease the driveshaft at the spline thru the access
panel in the operators cab.
If the clutch and gear box have been removed from
the engine, a tool is available to aid with reassembly.
Contact MB Technical Support for instructions on the use
of Tool Fix-163891 (Figure 43).
Maximum
Oil Level
Remove
Maximum
Level Plug
Engine
Figure 42
Power Take Off, Front
The PTO is driven by the engine through a gear
reduction transfer case (Figure 43). A drive shaft from
the front of the case goes to the front of the M-B MSV.
Two universal joints on the driveshaft accommodate the
articulating chassis of the M-B MSV.
The PTO is engaged using the joystick. The main screen
of the MDC will show the drive shaft is engaged. The
engine RPM controls the RPM of the PTO.
Clutch
Gear Box
Special Tool
Fix - 163891
Drive Shaft
Figure 43
CAUTION
The PTO cannot be engaged when the engine
RPM is higher than 1250 RPM.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 62 •
Maintenance
POWER TAKE OFF DRIVESHAFT
Some maintenance procedures will require the removal
of the PTO shaft. This section describes the removal and
installation of the PTO.
Remove
To remove the PTO shaft:
1. Place two jack stands under rear engine frame of
MSV and two jack stands under rear cab frame. Use
hydraulic floor jack between the two jack stands
supporting the frame under the cab as shown. Jack
stands and floor jack should be snug against the
frame, do not lift at this time.
Figure 46
5. Loosen the front and rear bearing collars on PTO
shaft under the cab by first loosening the set screw
using 3/16" Allen wrench. Position bearing collar
punch hole as shown (Figure 47). The collars will
move to the left (counterclockwise). Use a 3/16"
punch in collar's punch hole and strike with hammer.
Collar should now be loose. Collar is off-set and was
installed using a hammer in the opposite direction.
Figure 44
2. Remove the two rear cab mount bolts and lift cab
using electric lift.
3. Remove PTO U-joint bolt using a 3/4" box-end
wrench. PTO shaft may have to be supported so it
doesn't spin.
Figure 47
6. Once both collars are loosened, support the PTO
U-joint and slide the PTO shaft forward far enough to
get at the front articulation pin. Remove PTO U-joint
assembly.
Figure 45
4. Remove the two PTO U-joint set screws using a
3/16" Allen wrench.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 63 •
Maintenance
Install
To install the PTO shaft:
1. Install PTO U-joint to engine and finger start the bolt.
2. Slide PTO shaft through rear bearing and attach
to PTO U-joint. Shaft has a groove that will align
with set screw in U-joint. When in place, tighten set
screws with red loctite on the threads.
3. Remove U-joint bolt to apply red loctite and then
install and tighten using a 3/4" box-end wrench.
4. Position U-joint within 1/8" from the frame.
7. Slide front bearing collar onto the bearing and turn
counterclockwise until the collar gets snug. Insert a
3/16" punch in the punch hole as shown (Figure 50)
and strike punch with hammer forcefully. Bearing
collar should now be tight.
Figure 50
8. Apply red loctite to set screw and tighten.
9. Grease all points on the U-joints and PTO bearings.
10. Lower cab and install cab bolts.
11. Remove hydraulic jacks and jack stands.
Figure 48
5. Once positioned, slide the rear bearing collar onto
the bearing and turn counterclockwise until the collar
gets snug. Insert a 3/16" punch in the punch hole
as shown (Figure 49) and strike punch with hammer
forcefuly. Bearing collar should now be tight.
Figure 49
6. Apply red loctite to set screw and tighten.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 64 •
Maintenance
HYDRAULIC CONNECTIONS
HYDRAULIC SYSTEM MAINTENANCE
At the front of the MSV there are three pair of
connections. Each pair has a line out and a line in. The
connections are matched for each pair. Attachments are
connected and the SDC+1 controls are set to control
the proper auxiliary ports. See Attatchment Manual
for proper connections. Also refer to SDC+1 Controls
section in this manual.
Aux 1
Case Drain
Quick Disconnect
Quick Disconnect
Male
Male
Aux 1
Aux 3 Pressure
Quick Disconnect
Quick Disconnect
Female
Female
WARNING
Never service the M-B MSV unless the vehicle
is completely shut down. Remove the ignition
key to prevent starting of the equipment.
Failure to follow this can result in serious injury
or death.
System Description
All of the functions of the M-B MSV receive power
through hydraulic systems driven by the engine. This
engine drives two independent closed loop hydrostatic
systems, one for ground drive and one for the
attachment hydraulics. These systems use a common
hydraulic reservoir and cooler.
9
2
1
Electrical Plug
Aux 2
Quick Disconnect
Male
Aux 2
Quick Disconnect
Female
3
Aux 3 Return
Quick Disconnect
Male
7
Figure 51
Attachments connected to the front of the MSV may
have hydraulic hoses that need to attach to the MSV.
The following table lists the size and manufacturer of the
quick couplers
9/16 ORB Female, 1/4 NPT
TIB 2511 N
9/16 ORB Male, 1/4 NPT
TIB 2521 N
1-1/16 ORB Female, 3/4 NPT
TIB 7511 U
1-1/16 ORB Male, 3/4 NPT
TIB 7521 U
M-B Multi-Service Vehicle
4
6
Front
Brand Name of Quick Coupler - TEMA IB Series
©2015 M-B Companies Inc.
All Rights Reserved
8
1. 2. 3. 4. 5. 6. 7. 8. 9. • 65 •
5
Figure 52
Return Filter
Low Level Float Switch
Sight Glass
Attachments Suction Strainer
Ground Drive Suction Strainer
Temperature Sensor
Engine Coolant Overflow
Access Panel
Fill Point
Maintenance
Checking and Adding Hydraulic Fluid
Filter
Hydraulic fluid level is monitored by the SDC+1 controls.
An alarm will be displayed on the SDC+1 screen if the
fluid level becomes low. A sight glass is also available to
visually check the fluid level (Figure 52, Item #3).
Filtering of the hydraulic fluid uses a return filter at the
top of the tank. The filter can be removed by unbolting
the top and lifting.
Suction strainers protect the drive and attachment
hydraulic systems. They are located near the bottom of
the tank. Notice that the intake for the attachments is
higher than the ground drive. This will help ensure the
ground drive will continue to function if the fluid level
gets low.
WARNING
Turn engine off to view the sight glass.
1. Remove the engine cover to gain access.
2. Observe the sight glass (Figure 53). The arrow
indicates the proper hydraulic fluid level.
3. If below level, add hydraulic fluid through the fill cap
(Figure 52) on the hydraulic filter housing until the
level shown in the sight glass is to the “full” arrow
indicator.
4. Replace the cap.
NOTE The sight glass is best viewed from the left
side of the vehicle looking over the cooling
fan.
Draining and Filling the Tank
To completely drain the hydraulic tank remove the drain
plug. The drain plug is located on the underside of the
tank (Figure 54). The access panel on the top of the tank
can be removed to allow cleaning of the tank. The tank
should be filled to the full reading on the sight glass.
Full Level
Sight Glass
Fluid Level
Figure 53
Cooling System
A hydraulic reservoir is a poor cooling system. To
prevent oil temperatures from reaching levels not
recommended by the component manufacturer’s, an oil
cooling radiator is mounted at the rear of the M-B MSV.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 66 •
Maintenance
Fill Point
Access Panel
Remove
SDC+1
display
and top
panel
Figure 55
Drain Plug
Master Cylinder
Figure 54
Figure 56
BRAKE MAINTENANCE
Master Cylinder
The master cylinder fluid reservoir is located in a
compartment behind the SDC+1 controller (Figure 55).
To access the reservoir:
1. Remove SDC+1 display by loosening center
mounting turn buckle.
2. Pull the display out of the way
3. The two screw-off caps are visible (Figure 56).
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 67 •
Maintenance
BATTERY
Brake Master Cylinder
Located Behind the MDC Display
Remove the battery from the unit before charging it.
WARNING
ELECTRIC SHOCK may result in injury and/or
damage to the unit.
DO NOT allow objects to come into contact
with both terminals at the same time.
REVERSE CONNECTIONS may result in
sparks which can cause death or serious
injury. ALWAYS connect positive (+) lead of
charger to positive (+) terminal, and negative
(-) lead to negative (-) terminals.
ALWAYS connect the positive (+) cable FIRST,
and the negative (-) cable SECOND.
Brake
Pedal
Figure 57
WARNING
EXPLOSIVE GASES from battery can cause
death or serious injury. ALWAYS keep open
flames, sparks, or smoking materials away
from batteries.
POISONOUS BATTERY FLUID contains
sulfuric acid and its contact with skin, eyes
or clothing can cause sever chemical burns.
ALWAYS wear safety glasses and protective
gear near battery.
DO NOT TIP any battery beyond 45° angle in
any direction.
Disc Brake
The disc brakes are accessed by removing the wheel
(Figure 58). The maintenance and repair is the same
as an automobile. The pads should wear evenly. If an
inspection shows uneven wear or the pads have less
than 1/16 inch of material then they should be replaced.
WARNING
Use jack stands with a suitable load capacity
when removing a wheel. The engine should be
off and at least one of the remaining wheels
should be blocked. The articulation safety link
should be locked to the rear frame to prevent
movement.
Battery Electrolyte First Aid
Refer to the Service section for replacement.
Brake
Pad
• Follow First Aid directions for contact with battery
fluid.
• External Contact: Flush with water.
• Eyes: Flush with water for at least 15 minutes and
get medical attention immediately!
• Internal Contact: Drink large quantities of water.
Follow with Milk of Magnesia, beaten egg, or
vegetable oil. Get medical attention immediately!
IMPORTANT In case of internal contact, DO NOT
induce vomiting!
Figure 58
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 68 •
Maintenance
ELECTRICAL SYSTEM
Cleaning Terminals
Keep battery and its terminals clean. Inspect monthly to
maintain best performance.
Remove corrosion from battery terminals and cable
connections with a wire brush, then wash with a weak
baking soda/water solution. After cleaning, apply a thin
coat of grease or petroleum jelly to terminals and cable
ends to retard corrosion.
Protecting Electrical Terminals
Charging
Always follow information provided on the battery by the
battery manufacturer. Contact battery manufacturer for
extensive instructions to charge battery.
IMPORTANT DO NOT fast charge. Charging at high
rates will damage or destroy battery.
Place unit on a level surface, shut off engine and raise
the cab to gain access to battery.
1. Disconnect negative (-) cable first, then positive (+)
cable.
2. Loosen strap and remove battery.
3. Place battery on bench or other well-ventilated place
where electrolyte spill will not create damage.
4. Connect positive (+) lead of charger to positive
(+) terminal, and negative (-) lead to negative (-)
terminal.
5. Charge the battery at 2-1/2 amps for 10 hours.
6. Reinstall battery into unit and connect positive (+)
cable first, then negative (-) cable.
There are several electrical terminals on the M-B MSV
that have no corrosion protection. A liquid tape should
be applied to these terminals to prevent corrosion. The
front-end and rear-end electrical connectors have rubber
boots. If these boots do not have a drain hole and the
connections are not protected by a liquid tape, they will
most likely corrode.
Service Bulletin MSV-2010-2 describes “Protecting
Unsealed Electrical Terminals”. Whenever a terminal
is exposed it should be cleaned and the liquid tape
protection reapplied. Follow instructions on liquid tape
product.
Connections of main concern are:
• Starter Motor - Located behind left rear fender
• Alternator - Located behind left rear fender
• Solenoids for starter, Grid Heater and Rear MVEC Located in the rear electrical compartment.
• Hydraulic Fluid Temperature Sender - Located
partway down on hydraulic tank between the fan
and fan shroud, swing fuel tank out to locate sender.
Battery Charger
Under normal conditions the engine alternator will
have no problem keeping the battery charged. When
unit has been idle for an extended period of time
without operation and the battery has been completely
discharged, a battery charger will be required for
recharging.
Before using a charger, you can attempt to recharge the
battery by jump starting the unit and allowing the engine
to run.
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 69 •
Maintenance
Front Electronic Controller
The Front Electronic Controller (front MVEC) is mounted
inside the operators cab under the right armrest
(Figure 59). Lift the armrest to gain access. A 5 Amp ATC
(automotive type) fuse protects the power wire to the
front MVEC.
Figure 84 shows the components and their locations.
Remove the cover of the MVEC to expose the relays
and fuses (Figure 61). To replace a relay or fuse pull the
old one straight out and plug in a new one.
NOTE When replacing relays observe the pin
locations.
Figure 61
MSV FRONT MVEC FUSES AND RELAY
FUSE SIZE
RELAY
DESCRIPTION
F1
20 A
R1
FAN LO
F2
20 A
R4
BEACON
F3
20 A
R7
WIPPER MOTOR (LOW)
F4
20 A
R2
FAN MED
F5
20 A
R8
WIPER MOTOR (HI)
F6
20 A
R6
FRONT CONNECTOR (C-1F) 3
F7
20 A
R3
FAN HI
F8
20 A
R5
FRONT CONNECTOR (C-1E) 2
F9
5A
DISPLAY PWR
F10
20 A
MODULE PWR (MASTER) MC 50
F11
15 A
MODULE PWR (MASTER) MC 50
F12
20 A
MODULE PWR (MASTER) MC 50
F13
15 A
MODULE PWR (MASTER) MC38
F14
30 A
CAB TILT/AIR RIDE
F15
15 A
RADIO/ACC
F16
10 A
JOYSTICK / DOME LIGHTS
5A
MVEC POWER FUSE - STANDARD AUTOMOTIVE
Figure 59
MVEC Power
Fuse 5 Amp
MVEC
Spare
Spare
Spare
Spare
5A
5A
15 A
20 A
ALL FUSES MINI AUTOMOTIVE ATM TYPE UNLESS SPECIFIED
80 Amp SPST Relay
Figure 62
Alarm
Figure 60
M-B Multi-Service Vehicle
©2015 M-B Companies Inc.
All Rights Reserved
• 70 •
Maintenance
Part of the front MVEC are the push-to-reset breakers. If
one of the breakers becomes "tripped" it can be pressed
to reset (Figure 63).
CAUTION
Do not repeatedly press breakers to reset
them. A breaker that trips out is an indication
of a fault in that circuit. Troubleshoot the circuit
and correct the problem.
Rear Electronic Controller
The Rear Electronic Controller (rear MVEC) is mounted
inside the engine compartment in front of the hydraulic
reservoir tank.
A 5 Amp ATC (automotive type) fuse protects the power
wire to the rear MVEC.
Figure 64 shows the components and their locations.
Remove the cover to expose the relays and fuses
(Figure 65).
To replace pull the old one straight out and plug in the
new one.
NOTE When replacing a relay observe the pin
locations.
MVEC Power Fuse 5 Amp
125 Amp
Fuse
Electrical
Center
(not shown - behind panel)
Start
Relay
Figure 63
Lable
Number
Description
2W MEM
CB11
Continuous power on Auxiliary power supply.
2W RADIO
CB10
Switched power on Auxiliary power supply.
WORK LT
CB9
Spare circuit breaker, extra #0070 supply
wire is located in harness.
WIPER PARK
CB8
Power for wiper.
STB PWR
CB5
Power for Hazards MC38 PIN 37
RADIO MEM
CB3
Memory power for AM/FM radio.
HORN
CB2
Washer and Horn Power
IGNITION
CB1
Ignition Power
Electronic
Controller
Relay
Fuse Holder
Rear
Electronic
Controller
200 Amp
Relay
Bladed Fuse and Holders
5 AMP
Preheat
Relay
Power to MVEC Controller
20 AMP
Power to PIN 36 MC38
20 AMP
Power to PIN 38 MC 38
20 AMP
Front Hitch Up/Down Option
Alaska Option (Bladed Fuse and Holders)
15 AMP
Low Beam Lights
15 AMP
High Beam Lights
15 AMP
Work Lights
Figure 64
Spare
Fuses
Figure 65
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• 71 •
Maintenance
ACCESSORY TERMINAL STRIP
The top right side of the operators cab dashboard has
a three pole terminal block. The terminal screws are
labeled as to their function (Figure 68).
• Two way radio memory (+) - provides low amperage
12 Vdc uninterrupted power for memory functions
• Two way radio power (+) - Provides 15 amp 12 Vdc
power for the radio. Turns off when key switch is off.
• Two way radio common (-) - goes to ground terminal
on battery.
Two Way Radio Common (-)
Two Way Radio Power (+)
Two Way Radio Memory (+)
Figure 66
Figure 68
MSV REAR MVEC FUSES AND RELAY
FUSE SIZE
RELAY
DESCRIPTION
F1
15 A
R1
AC CLUTCH
F2
20 A
R4
BACK-UP ALARM
20 A
F3
R7
REAR PLUG PIN 3
F4
5A
R2
REAR CLEAR
F5
5A
R8
ENGINE START
F6
5A
R6
REAR PLUG PIN 2
F7
5A
R3
FLOW DIVIDER
F8
5A
R5
REAR CONNECTOR / PIN 6
F9
5A
KEYON
F10
5A
STEER SENSOR POWER
F11
15 A
SC50-22 POWER
F12
15 A
SC50-22
F13
15 A
SC50-22
F14
5A
FUEL SENDER PWR
F15
20 A
REAR PLUG PIN 1
15 A
F16
Spare
Spare
Spare
Spare
5A
5A
15 A
20 A
-
5A
MVEC POWER FUSE - STANDARD AUTOMOTIVE
ALL FUSES MINI AUTOMOTIVE ATM TYPE UNLESS SPECIFIED
Figure 67
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• 72 •
Maintenance
CAB VENTILATION
Fresh air is drawn into the cab from the vent at the
top rear of the cab. A cartridge type air filter is used to
remove dust and debris. The filter should be inspected
and changed as needed.
To replace the air filter:
1. Remove vent by unscrewing the two nuts. Notice
that the top of the window is held in place by the
vent (Figure 69).
Remove Nuts
Bottom Edge
Holds Window In
Figure 69
2. After the cover is removed the filter cartridge can be
pulled out.
Figure 70
3. Replace with clean/new cartridge and install the
cover.
4. Tighten both nuts.
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• 73 •
Maintenance
Service
TOWING THE MSV
The MSV is driven by a ground drive hydraulic pump. All
four wheels have hydraulic motors. Only the two front
wheels have parking brakes.
To tow the vehicle the brakes must be released and the
drive bypass valve is opened.
WARNING
Do not operate the MSV with the manual brake
release installed.
If the vehicle is running, the parking brake will be
released when you press the accelerator. Using a
manual brake release will override the emergency and
the parking brake systems (Figure 71).
Towing the MSV with a manual brake release installed
must be kept below 2 mph and less than 500 ft.
Exceeding these limits will damage the wheel motors.
The damage can be identified and it will void all
warranties from the manufacturer.
Before starting this procedure the vehicle must be on
level ground with the wheels chocked.
The engine must be off with the key removed.
To override the parking brakes use the manual brake
release kit. This kit will install in the hydraulic lines.
Release the parking brakes by pumping the red handle
on the manual disconnect. Pump until the gauge reads
300 psi.
Figure 71
BRAKE RELEASE INSTALL
Refer to Work Instructions, WIAS 0083 in back of this
book.
WARNING
The pressure in the parking brake system
must be 300 psi. Under pressure will result
in the brakes overheating and damage to the
emergency brake system. Over pressure will
damage O-rings in the brake system.
With the gauge reading 300 psi, tow the MSV as
needed. Keep speed below 2 mph and the distance
should be less than 500 ft. The regular brake system will
continue to operate while towing.
When finished the bypass valve(s) must be closed and
the manual brake release kit will be removed.
Reconnect the hydraulic lines. Replace the plastic cable
tie on the connection. This will prevent the couplers from
accidently pulling apart.
The brake systems will operate normally.
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• 74 •
Service
TROUBLESHOOTING BRAKES
TESTING THE GROUND DRIVE PUMP
WARNING
An operator must be properly seated with
unobstructed ability to use the foot brakes.
1. Refer to Work Instruction , Checking Parking Brake
Relief Pressure.
2. To check coil, start machine.
3. Go to Work screen. Place machine in Forward.
4. Slightly place foot on accelerator until brake light
goes out.
5. Exit to Main Menu.
6. Press Button 8.
7. Use arrow Down Keys go to Rear Outputs. Press
OK.
8. Verify park brake release is on. If unit still does not
work:
9. Remove park brake coil from cartridge by removing
1/2 nut on top of coil. Install screwdriver in the inside
of coil. Repeat steps, 2, 3, and 4. The coil should
magnetize and you should feel resistance pulling the
screwdriver out of coil. If no resistance is felt, the coil
should be replaced. If resistance is felt the cartridge
could be bad. Replace cartridge and recheck.
Replacement Part Numbers
Cartridge
202-144080
Coil
702-133633
Pressure Relief Valve
200psi
202-144858
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The ground drive pump produces the hydraulic pressure
and flow to drive the wheel motors. The pump is driven
through a universal joint powered from the front of the
engine. Electrical signals control a solenoid on the pump
that directs fluid flow.
Pump
Universal Joint
Mounting Plate
Figure 72
To test the pump:
1. Engage the articulation safety link to prevent
movement of the chassis.
2. Jack all four wheels off the ground and support the
vehicle with jack stands. The jack stands should be
located under the main frame at the four corners.
3. An operator must sit in the operators seat with the
seatbelt fastened.
4. Start the vehicle and run at low RPM. Shift to
forward with no pressure on the brake pedal. The
wheels should move in a forward rotation when foot
pedal is pushed.
5. Shift to neutral then reverse. The wheels should
move in a reverse rotation when foot pedal is
pushed. If the weels do not rotate or only drive in
one direction check the fluid level in the hydraulic
tank. Check the fuses for the solenoid. If those are
not blown remove the cover over the ground drive
pump.
• 75 •
Service
To remove the ground drive pump cover:
1. Open the fuel tank door.
2. Remove the screws that hold the cover in position
3. Lift the close edge of the cover and pull back.
This will pull two tabs out of slots at the rear of the
enclosure.
Tabs
Pump Cover
WARNING
All four wheels should rotate during this test.
The operator must be in the seat and ready to
apply the brakes.
All four wheels must be off the ground and
clear of all objects.
Use as low an RPM as possible for this test.
The top of the ground drive has an electrical connector
and a mechanical switch to activate the solenoid.
Test the mechanical switch first. With an operator in the
seat and the seatbelt fastened, start the engine.
Stay clear of the wheel because it should rotate. Locate
the manual lever on the top of the pump.
Electrical
Connector
Manual
Lever
Figure 73
4. Tip the edge toward the radiators up and pull the
cover out.
Figure 74
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Figure 75
Push the lever one way and the wheels should rotate.
Release the lever and it will return to the center. Push
the lever in the other direction and the wheels should
rotate in the other direction.
If the wheels rotate in both directions, then the hydraulic
system is functioning properly. The problem is likely in
the electrical signal.
If the wheels do not rotate, the ground drive pump is not
producing pressure and should be replaced.
Test the electrical signals by unplugging the connector to
the pump.
• 76 •
Service
Fan Shroud
Pump Cover
Electrical
Connector
Figure 76
By disconnecting pump plug, a fault should come on.
Reconnect plug. Sit in seat with seat belt on. Start
unit. Place unit in Forward, open Rear Outputs screen.
Accelerate to get wheels turning. Propel forward. FWD
EDC should display voltage reading. If wheels are not
turning, pump needs to be replaced.
IMPORTANT If hydraulic fluid level becomes low,
the attachments will stop functioning
before the ground drive pump starves
for fluid.
Figure 77
Removal
GROUND DRIVE PUMP REPLACEMENT
Location
The ground drive pump is driven directly by the engine
through a universal joint. The pump is located at the rear
of the vehicle between the engine fan and the cooling
radiators. Access to the pump requires removing the
pump cover.
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Fuel Tank
Wheel Well
To access the ground drive pump start by supporting the
frame with a jackstand. The jackstand should be located
under the frame.
The basic steps to remove the ground drive pump are:
• Remove engine covers, wheel well and air cleaner.
• Remove fuel tank.
• Drain hydraulic tank.
• Remove ground drive pump cover.
• Remove engine fan and spacer.
• Remove fan shroud.
• Disconnect electrical, mechanical and hydraulic
connections.
• Remove ground drive pump.
To remove the engine covers, wheel well and air cleaner:
1. Remove the engine cover front and rear and set them
aside.
2. Then remove the wheel.
3. Pull out the electrical connector to the air filter sensor.
• 77 •
Service
Connector
To remove the fuel tank:
WARNING
You may drain the fuel tank to remove weight.
The fuel is extremely flammable. Keep fuel
in approved containers. Handle only in open
vented areas. Clean up any spilled fuel
immediately.
Figure 78
4. Undo the hose clamps between the air cleaner and
the turbo.
5. Remove the clamp on the engine dipstick
(Figure 79).
1. Open the fuel tank door.
NOTE
The fuel lines are long enough to move
the fuel tank out of the way without
disconnecting them.
2. To move the fuel tank without removing the fuel
lines, cut all the cable tie clamps and remove the
metal guide bolted to the radiator frame.
Guide
Clamp
Figure 79
6. Unscrew the bolt behind the wheel and the left
fender. Open the clamp at the lower right. Lift the
wheel well and pull the air cleaner out of the tube.
NOTEThe wheel well can be removed without
removing the wheel. Removing the wheel is
not required but it will provide better access
to the front of the engine.
Electrical Connector
Figure 80
3. Disconnect the fuel sensor electrical connector.
4. Support the weight of the fuel tank. Remove the two
hinge bolts. Each bolt has a bushing that must be
present to allow proper hinge movement.
Upper
Bolt
Lower
Bolt
Figure 81
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• 78 •
Service
5. Move the fuel tank out of your way.
To drain the hydraulic tank:
When removing the drive pump, hydraulic lines will be
disconnected. To minimize spills drain the hydraulic tank.
3. Tip the edge toward the radiators upward and pull
the cover out.
WARNING
The hydraulic fluid is flammable. When
draining the fluid only use approved
containers. Handle only in open vented areas.
Clean up any spilled fluid immediately.
1. Place a catch pan under the hydraulic tank drain
plug.
2. Remove the drain plug and allow fluid to drain.
3. Remove the large vent plug on top of the return filter.
Figure 84
Figure 82
4. Replace the drain plug when empty.
To remove the ground drive pump cover:
1. Remove the screws that hold the cover in place.
2. Lift the close edge of the cover and pull back.
This will pull two tabs out of slots at the rear of the
enclosure.
Tabs
Pump Cover
To remove the engine fan and spacer:
1. Note or write down the path of the engine serpentine
belt.
2. Release tension on the belt by pulling the tension
pulley against the spring action. A 1/2-inch drive
socket wrench can be used in the square hole to
assist.
3. Pull the belt off of a pulley and release the tension
pulley.
4. Remove the bolts that hold the fan in place. Then
remove the fan and the spacer from the motor.
NOTE
The pulley on the engine will be held in
place by a second fan belt. Leave the
pulley in place. Also, notice the spacer is
held in place by a pilot shaft.
To remove the fan shroud:
The fan shroud has a number of hoses and tubes that
lay on top and are fastened in place. Some of these will
be removed.
Figure 83
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• 79 •
Service
Turbo
Tubes
Upper
Radiator Hose
Fuel Line
Clamp
Fuel Line
Cable Tie
Upper
Coolant
Hose
Figure 85
1. Start by removing the two metal air tubes for the
turbo. Unscrew the clamps at the radiator and slide
the rubber couplers onto the tube. Unscrew the
clamp at the other end. Remove the tubes.
IMPORTANT The openings for the turbo cannot
have foriegn material inside. Cover the
openings.
2. The fuel lines are held in place with cable tie and
a metal guide. These should have been removed
when the fuel tank was moved.
3. The top radiator hose can be left in place.
4. The radiator sensor wire at the top corner must be
unplugged. The wires will pull through the hole in the
fan shroud.
5. Remove the five bolts that hold the fan shroud at the
rear of the cavity.
6. Remove the remaining bolt above the coolant
sensor.
7. Remove the two bolts at the lower left.
8. The shroud should be loose. The shroud must be
forced over the coolant sensor before it will pull out.
9. Pull the shroud out. The coolant hose can be lifted
up to help with clearance.
NOTE
The fan shroud has two edge pieces that
must be kept in place for proper air flow
and noise reduction.
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Figure 86
To disconnect electrical, mechanical and hydraulic
connections:
The ground drive pump should be completely
accessable.
1. Disconnect the electrical connection.
Electrical
Connector
Hydraulic
Connection
3 Hydraulic
Connections
Figure 87
2. Four hydraulic connections must be removed. Catch
any fluid spills in a pan for proper disposal.
• 80 •
Service
Installation
To remove the ground drive pump:
Mounting
Bracket
U-Joint
Figure 88
1. A mounting bracket with four bolts must be unbolted.
Hold the nut from the bottom and unscrew the bolts.
2. Remove the four bolts from the universal joint to the
engine.
3. Use a lifting bracket (Figure 89) and the mounting
bracket as lift points. The pump can be pulled up.
CAUTION
The radiator is easily damaged. Protect the
cooling fins with heavy cardboard or a wooden
panel
Figure 89
4. When the universal joint is clear of the motor the
pump can be completely removed.
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The basic steps to install the ground drive pump are:
• Prepare the pump.
• Make connections for hydraulics and electrical.
• Install fan shroud.
• Install spacer, fan and belt.
• Mount fuel tank.
• Fill hydraulic tank.
• Mount wheel well and air cleaner.
• Replace engine covers.
To prepare the pump:
1. The new pump will have plugs in the hydraulic line
ports that must be removed.
2. Attach the lifting bracket and mounting bracket from
the old pump.
NOTE
The mounting bracket is a tight fit over a
ring. Pry the bracket off of the old pump
and press it onto the new one.
3. Tighten the bolts.
4. Use a heavy spline grease to cover the splined
shaft of the pump. Use the universal joint from the
old pump and slide it over the new pump flange.
Lubricate the two grease fittings in the U-Joint.
To make connections for hydraulic and electrical:
1. Lift the pump over the mounting area.
2. Connect the three hydraulic lines on the side of
the pump. The center line connects directly to the
hydraulic tank.
3. Set the pump in position and attach the fourth
hydraulic line to the top port.
4. Insert the bolts for the mounting bracket. Start the
nuts from below.
5. Position the U-Joint to match with the engine pully.
Insert the bolts and tighten.
6. Tighten the mounting bracket bolts.
7. Make the electrical connection to the pump.
• 81 •
Service
To install fan shroud:
1. The two edging strips must be in place.
Edging
Edging
2. 3. 4. 5. 6. Figure 90
Move the shroud into position between the radiators
and the engine. It will fit under the upper radiator
hose.
The coolant sensor wires must be guided through
the hole. Moving the shroud over the coolant sensor
will be a tight fit. Be careful to avoid cutting the
wires.
Once the shroud is in place finger start the five bolts
at the rear, the two bolts at the lower left and the
bolts by the coolant sensor.
Tighten all the bolts except the outside bolt at the
coolant sensor.
Replace the two metal tubes for the turbo cooling.
CAUTION
Inspect the turbo tubes, the inlets and outlets
for debris. Clean all dirt from the tubes. Foreign
material in the turbo tubing will damage the
engine.
7. Slide the rubber couplers in place. Tighten all the
clamps.
Tube Clamps
To install spacer, fan and belt:
1. Hold the spacer in place with the fan. Insert a bolt
into one of the holes.
2. Hold the spacer with fan in position. Finger start the
bolt into the flange on the engine.
3. Insert and finger start the remaining three bolts.
4. Tighten the bolts.
5. The belt is a serpentine style that will contact pulleys
from either side.
6. One pulley is a spring loaded idler pulley. Use a
1/2-inch drive socket wrench in the square hole to
push against the spring pressure.
Push In
Figure 92
7. Follow the diagram and place the belt in position.
8. Release the spring loaded pulley to complete the
installation.
To mount fuel tank:
WARNING
The fuel tank may contain fuel. Be prepared to
clean up spilled fuel during this activity.
1. Move the fuel tank into position lining up the top and
bottom hinge points. The hinge bolts have a bushing
that fits inside the pivot holes of the hinge.
2. Insert the bolt through one of the hinges and the
bushing. Finger start the nut. Repeat for the second
bolt.
3. Tighten the bolts. The fuel tank should move freely.
The hoses and wire harness can be connected and
put in place.
Figure 91
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• 82 •
Service
4. The guide for the fuel lines is placed around the
hoses. Bolt the guide in place using the bolt above
and outside the coolant sensor. When the guide is
tight the hoses must move freely as the fuel tank
door is opened and closed.
5. Use cable tie on all hoses and harnesses to hold
them neatly in position.
To fill hydraulic tank:
All hydraulic connections should be secure.
1. Check that the drain plug is in place and tight.
2. Fluid can be added through the vent plug on top of
the tank.
NOTE The ground drive pump and attached
hydraulic lines are likely filled with air. When
the pump is started up the fluid level in the
tank will drop.
Do Not Loosen
Lock Nut
Adjusting Screw
Reverse
Adjusting Screw
Forward
Adjusting Screw
Charge Pressure
Adjustment
To mount wheel well and air cleaner:
1. Lift the wheel well into position. If the air cleaner is
mounted you should insert the air cleaner tube into
place at this time.
2. Use the clamp at the lower right and the bolt inside
the wheel area to secure the wheel well.
3. Move the hose clamps in place and tighten.
4. Connect the electrical plug to the air sensor.
5. Clamp the engine dipstick to the bracket below the
air cleaner.
Replace engine covers. The assembly should be
complete. Before starting the engine, read through the
following section for pump start-up.
Reverse
Gauge Ports
Forward
Gauge Ports
Testing
The installation of the pump is complete. To test the
operation of the pump and set the relief valves refer to
the Sauer Danfoss Service Manual for Series 90 Pumps,
Publication 520L0818.
To adjust working pressures:
When the start-up procedure is complete attach the
charge pressure gauge, 0-1,000 psi (0-50 bar), to the
filter head. Attach gauges, 0-10,000 psi (0-1,000 bar), to
the two gauge ports (forward and reverse).
See Figure 93.
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Charge Pressure
Gauge Port
Figure 93
1. Start the MSV engine and run at idle. The charge
pressure should be approximately 450 psi (31 bar).
2. Move the vehicle forward against a solid wall.
3. Drive forward. The gauge for forward pressure
should read 5,500 psi (380 bar).
4. To make an adjustment, return the vehicle to low idle
in neutral position. Loosen the forward adjustment
lock nut. Turn the inner screw clockwise to increase
and counterclockwise to decrease pressure.
5. When pressure is correct, 5,500 psi (380 bar), hold the
adjusting screw stationary and tighten the outer nut.
6. For reverse back the vehicle against a solid wall
(you may want to put a board behind the bumper).
7. Drive in reverse and repeat the adjustment for the
reverse pressure.
• 83 •
Service
DISC BRAKE
To replace the brake rotor or brake pads, the wheel must
be removed. Jack the frame up to lift the wheel off the
ground. Use a jackstand under the frame for support.
WARNING
Use jack stands with a suitable load capacity
when removing a wheel. The engine should be
off and at least one of the remaining wheels
should be blocked.
Rotor
When bleeding the brakes, gain access to the master
cylinder in the cab. Remove fill caps.
NOTE Bleeding brake lines will consume a large
amount of brake fluid. Have at least a quart of
new approved brake fluid available (reference
Every 50 Hours page)
To bleed the brakes:
Use two people, one to step on the brake pedal and one
person to open/close the bleeder valve.
1. With the master cylinder full, open the bleeder valve.
2. Push the brake pedal slowly to the floor.
WARNING
Brake fluid will exit the bleeder valve. Be
prepared to catch the fluid in a container. Be
prepared to clean up any spills.
Caliper
Caliper Mounting Bracket
CAUTION
Do not re-use contaminated brake fluid in
the master cylinder. Small debris can clog
openings.
Figure 94
To replace brake pads:
1. Jack the wheel off the ground and support the M-B
MSV with a jackstand.
2. Remove the lug nuts and the wheel.
Inspect the pads for wear. If replacement is needed,
continue to step 3.
NOTE
If removing the calipers and brake pads, screw
one lug nut on a stud. This will hold the brake
rotor in position to help with assembly.
3. Remove both caliper bolts (Figure 94).
4. Using a prybar work the caliper out of the support.
Note the two spacers and their position.
5. Remove both brake pads.
6. To put in new brake pads, the piston must be pushed
back. A C-clamp can be used to slowly force it back
to the start position.
7. Replace the pads and place the caliper assembly
back into position.
NOTE
The caliper bolts should be clean when
inserting into the caliper and protective
boot.
8. Tighten the caliper bolts.
NOTE
Remember when stepping on the brakes for
the first time the pedal must be pumped up. If
the brake line was removed from the caliper
the brakes need to be bled to remove air.
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3. When the pedal is down hold it and close the
bleeder valve.
4. Let the pedal return to the top. Check the fluid level
in the master cylinder.
5. Repeat steps 1 thru 4 until all the exiting fluid is free
of air bubbles.
6. Repeat for the remaining wheels if needed.
7. Replace the wheel and tighten the lug nuts.
• 84 •
Caliper
Support
Caliper
Caliper Support
Bolt (2)
Spacer (2)
Caliper
Bolt (2)
Bleeder
Valve
Brake Line
Figure 95
Service
WHEEL MOTORS
4. Enter Attachment Selection screen. Energize Button
1. Make sure Item 2 - MSU PTO Snow Blower or 3 MSU PTO Ribbon Blower, is selected.
Please refer to Work Instructions WIAS 0084 for Series
2 & 3 machines.
AUXILLIARY PUMP
The auxilliary pump is located behind the right side of
the engine in front of the wheel well.
The auxilliary pump provides hydraulic fluid pressure and
flow to the attachment connections. If the attachments
are not working properly check the fluid level in the
hydraulic tank. If hydraulic fluid runs low the attachments
will be the first items to be affected. A low hydraulic oil
warning should also be flasing on the screen.
To test the auxilliary pump:
1. Connect a flow meter to the front Aux 3 connections.
Figure 96
2. Start the engine. Enter Work Screen. Set engine
RPMs to 2500.
Figure 98
5. Enter Attachment Setup screen.
Figure 99
Verify that Aux 3A is at 100 percent. Repeat step 3
again. If flow is not 31gpm, enter Main Menu, select
Button 4. Select Front Output screen.
Figure 97
3. Energize Aux 3A button on joystick. The flow meter
should read 31gpm. If flow is not at 31gpm (5%
margin of error for flow divider). Enter Password
screen. Type in password (500).
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Figure 100
• 85 •
Service
Bolt
Support
Brackets
Figure 101
Energize Aux 3A again. Verify that Aux #A is at 1210 MA.
If flow is not 31 gpm. It is possible the auxillary pump
may need replacing.
NOTE Before replacing the auxillary pump,
check for obstruction in hydraulic tank,
intank,suction stainer, pinched hose to front
manifold block and hydraulic fluid level.
Figure 102
The auxilliary pump is visable. The mounting bolts
and hydraulic hoses are visable. The mounting plate
has a gasket type sealer that should hold the plate in
position.
Rear Bolts
Front Bolts
To replace the auxilliary pump:
1. Engage the chassis safety link to prevent
unexpected chassis movement.
2. Drain the hydraulic fluid from the hydraulic tank.
Replace the plug.
WARNING
Hydraulic fluid is flammable. Drain fluid into a
proper container for reuse or disposal.
3. Jack the right rear wheel off the ground. Use a
jackstand under the frame to support the vehicle.
4. Remove the wheel.
5. Unscrew the bolt inside the wheel well and lift the
wheel well up and out.
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Fluid Input Hose
Spacer
Figure 103
6. Place a drip pan below the auxilliary pump and
remove the three visable hydraulic lines.
7. Locate the forth hose behind the frame. This hose
must be removed but it may be easier if the auxilliary
pump is loose.
• 86 •
Service
To finish the installation:
1. Install the wheel well. Be carefull to insert the lower
edge into the two support brackets. Insert the bolt
and tighten.
2. Mount the wheel.
Clamp
WINDSHIELD WIPER
Location
the windshield wiper motor and fluid reservoir are
located inside the cab. They are mounted on the front
floor by the operators left foot.
Hose
Figure 104
8. Remove the two front and two rear mounting bolts.
Break the pump loose.
9. Finish removing the input hose. The pump should be
free from the engine. Contain and clean up any fluid
leaks
The installation of the replacement auxilliary pump is the
reverse of the removal.
To install the auxilliary pump:
1. Connect the input hose. You may wait to tighten the
clamp until the pump is mounted.
2. Insert and start the four mounting bolts. If the spacer
on the engine block became loose it must have new
sealer applied. The sealer must be oil proof. Apply
evenly on a clean surface between the spacer and
the engine block.
3. Tighten the mounting bolts.
4. Move the input hose clamp into position and tighten.
5. Attach the remaining three hydraulic hoses and
tighten.
6. Refill the hydraulic tank. The pump can be tested for
leaks and function.
To test the auxilliary pump:
1. With an operator in the seat with the seatbelt
fastened. Start the engine.
2. The test procedure can be used to test the new
pump.
3. A pressure gage or an attachment can be connected
to an auxilliary port to provide a test device.
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Wiper Motor
Cover
Fluid
Reservoir
Figure 105
The basic steps to remove the wiper motor are:
• Remove wiper arm.
• Remove windshield.
• Remove covers, reservoir and motor.
To remove the wiper arm:
1. The wiper arm is held on by two nuts and the washer
tube. Remove the two nuts. The small arm will pull
off. Remove the main arm by tilting the wiper away
from the windshield until it stays out. With spring
pressure removed the arm should easily pull off.
2. The tube for the washer fluid runs through the arm
tension spring and onto a barbed connection. Pull
the tube off of the connection and pull out through
the spring.
NOTE If the washer reservoir contains fluid it will
sipon out through the tubing. Empty the
reservoir or catch the fluid in a container
• 87 •
Service
3. Remove the flange by prying off the wedge. Then
unscrew the main nut. Remove the remaining two
bolts. The flange should seperate.
Main Nut
Wedge
To remove the covers, reservoir and motor:
Three covers need to be removed; the reservoir cover,
the motor cover and the cover panel to the side and in
the front of the steering wheel.
1. Remove the cover panel by removing the plate along
the bottom of the windshield. Then the cover panel
will lift out. The bottom edge has a lip that pulls free
from behind the windshield frame.
Remove Plate
Cover Panel
Figure 106
To remove the windshield:
1. Unscrew all of the outside nuts that hold the
windshield in place. Then remove the frame. The
lights do not need to be removed.
2. Set the frame aside.
3. The windshield glass has a rubber seal that covers
the outside edge. The glass will rest on the seal at
the bottom. Pull the windshield away from the frame
of the vehicle. Leave the rubber edge in place. Set
the windshield aside.
Figure 107
2. The cover over the reservior has four screws that
hold it in. Remove the screws.
3. Lift the cover. Disconnect the electrical plug and pull
the reservior with the tube outward.
4. The cover over the motor has side screws that are
then removed. Lift the cover.
5. Disconnect the wiring to the wiper motor and remove
the motor.
Figure 108
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• 88 •
Service
STEERING COLUMN
Removal
The basic steps to remove the steering column are:
• Remove wiper arm.
• Remove windshield.
• Remove cover panel.
• Disconnect electric connectors and hydraulic lines.
• Unbolt steering column.
To remove the wiper arm:
1. The wiper arm is held on by two nuts and the washer
tube. Remove the two nuts. The small arm will pull
off. Remove the main arm by tilting the wiper away
from the windshield until it stays out. With spring
pressure removed the arm should easily pull off.
2. The tube for the washer fluid runs through the arm
tension spring and onto a barbed connection. Pull
the tube off of the connection and pull out through
the spring.
NOTE If the washer reservoir contains fluid it will
sipon out through the tubing. Empty the
reservoir or catch the fluid in a container
3. Remove the flange by prying off the wedge. Then
unscrew the main nut. Remove the remaining two
bolts. The flange should seperate.
Main Nut
Wedge
Figure 109
To remove the windshield:
1. Unscrew all of the outside nuts that hold the
windshield in place. Then remove the frame. The
lights do not need to be removed.
2. Set the frame aside.
3. The windshield glass has a rubber seal that covers
the outside edge. The glass will rest on the seal at
the bottom. Pull the windshield away from the frame
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of the vehicle. Leave the rubber edge in place. Set
the windshield aside.
To remove the cover panel:
1. Remove the cover panel by removing the plate along
the bottom of the windshield. Then the cover panel
will lift out. The bottom edge has a lip that pulls free
from behind the windshield frame.
Remove Plate
Cover Panel
Figure 110
When the cover panel is removed the hydraulic
connections and the electrical plugs are accessable.
Electrical Connectors
Hydraulic Connections
Steering Motor
Figure 111
To disconnect the electrical connectors:
1. Pull the electrical harnesses outward.
2. Push the two halves together and twist apart.
3. Move the harnesses out of the way.
To disconnect the hydraulic lines:
• 89 •
Service
NOTE
You may want to mark the connections as to
their location.
Mounting Bracket
Connecting Flange
CAUTION
When the hydraulic connections are opened it
is likely that fluid will leak out. Use a catch pan
and be prepared to clean up any spills.
The hydraulic connections must be completely removed
at the motor housing to allow removal of the steering
column. Remove all five connections. Plug hose ends
and cap adapters.
To unbolt the steering column:
1. Remove the four bolts from the flange under the
flexable rubber boot.
2. Pull the steering column up and out.
Installation
The basic steps to install the steering column are:
• Install the steering orbital pump.
• Bolt the steering column in place.
• Connect the hydraulic lines and electrical
connectors.
To install the steering orbital pump :
The side of the steering orbital pump with the four
connections will face to the right side of the vehicle.
1. Position the steering orbital pump against the
connecting flange. The mounting bracket should be
in place.
2. Start the four bolts with lock washers. Tighten the
bolts.
Figure 112
To bolt the steering column in place:
The electrical wiring should be routed through the
mounting bracket and the notch in the mounting flange.
1. Feed the wires through the opening.
2. Place the steering orbital pump and the mounting
flange through the opening. The hydraulic
connections will face to the right.
3. Place bolts through the mounting bracket and secure
to the mounting flange. Tighten the bolts.
4. Before connecting the hydraulic lines be certain the
transducers are plugged in.
Transducers
Figure 113
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• 90 •
Service
Refer to the hydraulic diagrams in the back of this
manual. To connect the hydraulic lines and electrical
connectors:
1. Connect the two back hydraulic lines first. The top
line will fit best routed around the front of the bottom
line. Tighten both lines.
2. Connect the front bottom line, then the front top line.
Tighten both lines.
3. Connect the hydraulic line at the front of the steering
orbital pump.
Figure 116
Finish the assembly by installing the cover panel.
Position the windshield with the trim seal in place. Place
the frame (retainer) over the studs and bolt evenly in
place.
Figure 114
4. Position the two electrical harnesses and complete
the two connections.
Figure 115
5. Route the electrical harness inside the opening to
allow the cover panel to be bolted in place
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Service
MAIN HYDRAULIC TANK
Location
The hydraulic tank is located at the right rear of the MSV.
It has several connections and holds the hydraulic fluid
filter.
Oil Level Sensor
Figure 118
Drain Plug
Figure 117
Inspection of the tank
The main component of the tank is the filter, it is
changed on a regular interval and should not present
operation problems. If the fluid becomes contaminated
the tank is drained and the filter will be changed. An
inspection panel is located on the top surface.
Removal
In the event where the hydraulic tank must be removed,
the basic steps are:
• Remove cover over the ground drive pump.
• Drain the tank.
• Remove top fan shroud .
• Remove the front half of the wheel well.
• Disconnect the oil level sensor.
• Disconnect the tubes to the cooling radiator.
• Remove filter.
• Disconnect the two suction lines.
• Disconnect the three hydraulic lines.
• Unbolt the tank and lift out.
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• 92 •
Service
To remove the ground drive pump cover:
1. Open the fuel tank door.
2. Remove the screws that hold the cover in position
3. Lift the close edge of the cover and pull back.
This will pull two tabs out of slots at the rear of the
enclosure.
Tabs
Pump Cover
2. Remove the drain plug. Allow fluid to drain. The
hydraulic lines of the MSV will drain for an extended
period of time. If you wish to remove connections
immediately be prepared to plug or elevate the
hoses.
To remove the fan shroud:
1. Remove the bolts from the top of the shroud.
2. Lift the shroud and set it aside.
Fan Shroud
Figure 119
4. Tip the edge toward the radiators up and pull the
cover out.
Figure 121
Remove the front half of the wheel well:
1. Jack the right rear wheel off the ground. Use a
jackstand under the frame to support the vehicle.
2. Remove the wheel.
3. Unscrew the bolt inside the wheel well and lift the
wheel well up and out.
Bolt
Figure 120
To drain the tank:
1. Place a catch pan under the tank.
Support
Brackets
WARNING
Hydraulic fluid is flammable and must be
disposed of properly. Be prepared to clean up
any spills.
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Figure 122
• 93 •
Service
To disconnect the oil level sensor:
The oil level sensor is located on the top surface of the
tank, toward the cooling radiators. Disconnect the wires
and secure them.
To disconnect the tubes to the cooling radiator:
1. Locate the top connection. Hold the inside fitting in
place. Unscrew the outer nut.
2. Loosen the tube connection at the filter head.
To disconnect the suction lines:
1. Locate the two lines at the bottom of the tank.
2. Unscrew the two clamps shown. The bottom hose
has a third clamp that does not need to be loosened.
Loosen
Clamps
Loosen
Connections
Remove Nuts
Figure 123
The tubes will be removed later in the procedure.
To remove the filter:
1. Remove the four nuts at the base of the filter head.
2. Lift the head and pull the tube free.
NOTE The mating surface of the filter head has an
O-ring that must be reused.
3. Lift the filter out and place in a pan to drain.
Figure 124
3. Pull the top hose free. The bottom hose will pull free
when the tank is removed.
To disconnect the three hydraulic lines:
1. Locate the connections by the sight gage.
2. Hold the inside fitting and unscrew the outside nuts.
CAUTION
If the filter is to be replaced, dispose of the old
one properly. The oil soaked filter is flammable.
Figure 125
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Service
To lift the tank out:
1. Remove the three bolts at the top rear by the cooling
radiator.
2. Remove the two bolts at the lower center inside the
engine compartment.
3. Remove two bolts at the very bottom to the frame.
4. Remove the two bolts on the flange by the overflow
reservoir.
5. Unscrew the three mounting nuts and remove the
overflow reservoir.
6. Lift the tank out. When the tank is removed the
supply hose to the ground drive pump will be
pulled free.
2. Insert mounting bolts in four locations and finger
start the fasteners for all four locations.
• Top rear by the radiator - 3 bolts/nuts/washers
• Bottom studs - 2 bolts/nuts
• Bracket on frame near suction line connections 2 bolts/nuts
• Flange next to the fluid reservoir - 2 bolts/nuts
3. Tighten all the mounting bolts/nuts.
To connect the hydraulic lines:
1. Position and tighten both clamps on the bottom
suction hose.
2. Push the hose for the aux pump over the fitting and
tighten the clamp.
Installation
The installation of the hydraulic tank is the reverse of the
removal. The basic steps are:
• Mount the tank in position.
• Connect the hydraulic lines and two suction lines.
• Connect tubes to the cooling radiator.
• Install the filter.
• Connect the oil level sensor.
• Remount the wheel well.
• Attach the top shroud.
• Fill the tank.
• Replace ground drive pump cover.
To place the tank in position:
1. Move the tank into position. The bottom suction
connection should have a piece of hose clamped
at the tank. A second clamp should be on the tube
for the ground drive pump. This connection will be
completed as the tank is positioned.
Tighten
Clamps
Figure 127
3. Connect the three hyd lines next to the sight gage.
Tighten the fittings by holding the inside fitting and
tighten the outside nut.
Hose to
Ground Drive
Pump
Figure 126
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Figure 128
4. Check the connection for the lower radiator. Be
certain it is connected and tight (Figure 185).
• 95 •
Service
Figure 131
3. Place the shaft and sping into the center opening of
the filter.
Figure 129
5. Insert the top tube into the connection at the top of
the radiator (Figure 130). Position the nut but do not
tighten. The other end is connected when installing
the filter head.
Spring
Shaft
Figure 132
4. The filter cover has an O-ring that must be cleaned
then covered with clean silicone. Check that the two
plugs are installed and tight.
O-ring
Figure 130
To install the filter:
1. Clean the gasket around the filter opening. Place the
gasket over the studs.
2. Place the filter onto the opening with the filter
opening facing up.
Plug
Figure 133
5. Be certain the nuts are in place on the tube to the
radiator. Place the filter head over the studs while
inserting the tube into the fitting.
6. Start the four nuts that hold the head down. Check
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• 96 •
Service
that the tube is in place. Tighten the four nuts evenly.
Then tighten both tube connections.
To connect the oil level sensor.
1. Locate the wires from the sensor on the top surface
of the tank.
2. Make the connection into the wiring harness.
3. Position the wheel well in place. Be certain the
wheel well is behind the bottom support brackets.
Insert the bolt and tighten.
4. Attach the top cooling shroud using the bolts that
were removed earlier.
To mount the overflow reservoir:
1. Connect the hose to the reservoir.
2. Slide the reservoir over the studs.
3. Finger start the nuts with washers. Tighten evenly.
To install the ground drive pump cover:
1. Insert the two tabs at the back of the enclosure.
2. Bolt the cover in place.
3. Close the fuel tank door.
To fill the tank:
1. Be certain the drain plug is screwed in and tight.
2. Check all connections for tightness.
3. The tank has an inspection plate that can be
removed for access to the inside of the tank. This
opening should not be used for filling the tank. If
this plate is removed be certain the gasket is clean
before replacing the plate.
4. Fill the tank with hydraulic fluid.
5. Close the fill point cover.
Inspection Opening
Oil Level Switch
Fill Point
Figure 134
To check for hydraulic leaks the ground drive pump
cover can be left off. After running the engine for a few
minutes, turn it off and check for leaks.
The system should be ready to use. When first starting
the MSV, check for leaks.
ARTICULATION JOINT
See Work Instruction, WI AS 0081 in back of
book.
LOW PRESSURE MANIFOLD
Location
The hydraulic coils and manifold for the low pressure
hydraulic system are located on the right side of the
MSV. It is in front of the rear wheel and below the
exhaust muffler.
The manifold controls pressure for the PTO clutch, the
parking brakes in the front wheel motors and the HI/LO
transport speed.
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Service
Pressure
Valve
Transport Speed
Parking Brakes
Figure 137
PTO Clutch
Figure 135
Testing
The working pressure should be between 200-225 psi.
1. Locate and remove the connection to the PTO clutch
(Figure 136).
2. Install a pressure guage capable of reading 300 psi
on the hose.
3. Start the engine and engage the PTO. The gauge
should read 200-225 psi.
4. Use the pressure valve to adjust (Figure 137).
Rotate the valve until the gauge reading is within
range.
NOTE
If the gauge is reading zero for one (not all)
of the controlled units, the operation of the
coil should be checked.
Connection to PTO
Manifold
from Manifold
Figure 136
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Service
SV2 PTO
Engage
SV1
HI/LO Shift
SV3 Parking
Brake Release
Front
PRRV-2
High
PRRV-1
Low
Figure 138
Figure 140
4. Use Arrow Down key, go to Rear Outputs, press OK.
Low Pressure Manifold Series 3
If one of the three systems is not working the coils can
be checked for operation.
To check Hi Lo Shift
1. Start machine.
2. Go into Transport screen. Verify High Speed is on
(high speed is yellow when on).
Figure 141
Verifiy High Speed Value is on. If unit still doesn't work:
5. Remove transport coil from cartridge by removing
1/2 nut from top of coil. Install screwdriver in the
inside of coil. Repeat steps 1 and 2. The coil should
magnetize and you should feel resistance pulling
the screwdriver out of the coil. If no resistance,
the cartridge could be bad. Replace cartridge and
recheck.
Figure 139
3. Go to Main Menu. Select Rear (push button #8).
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• 99 •
Service
5. Remove PTO coil from cartridge by removing 1/2
nut from top of coil. Install screwdriver inside of coil.
Repeat steps 1 and 2. The coil should magnetize
and you should feel resistance when pulling
screwdriver out of coil. If no resistance is felt the coil
should be replaced. If resistance is felt, the cartridge
could be bad. Replace cartridge and recheck.
To Check PTO
1. Start machine.
2. Go to Work screen. Press button #3.
Figure 142
PTO should turn green. Press OK to turn on.
3. Go to Main Menu, select button #8.
Figure 143
4. Use Arrow Down key, go to Rear Outputs. Press OK.
Figure 144
Verify PTO clutch valve is ON. If unit still does not work.
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Service
RADIO AND 12 VDC CONNECTIONS
AC Component Testing
Location
Component
Operation
Fan Switch
3 speeds, located
on steering
console.
Check switch function by
listening for the heater fan
and electrically using Vehicle
Diagnostics/Front Input #4
Main Menu.
AC Switch
On/Off, located on
steering console.
Will luminate when switch is
on. Use Vehicle Diagnostics/
Front Diagnostic/Front MVEC.
Heater
Control
Warm or Cold
position, located by
joystick.
Control has a cable running
to a valve in engine coolant
line for heater. Manually check
valve and cable by removing
side panel next to seat.
Heater Fan
3 speed fan located
behind seat in a
heater box.
If fan switch operates
incorrectly, heater fan wires
need to be tested for power.
If power is correct replace fan
motor.
Thermo
Switch
On/Off located
behind seat in a
heater box.
Check switch for operation.
Switch will be open if to cool
(checking in cold weather).
If switch is not operating,
test the wires for power. Use
Vehicle Diagnostics/Input
MC38-10 AC Thermal Switch.
AC Dryer
On/Off located on
front frame under
cab.
Check switch for operation.
Switch will not function with
low refrigerant charge. If
switch is not operating, test
the wires for power. Use
Vehicle Diagnostics/MC50-20
AC Dryer Switch.
Compressor
Clutch
Belt driven On/Off,
located on rear of
engine.
Check for power on red wire.
Test by providing 12 volts
directly to compressor. If
clutch does not turn on, it is
likely the clutch is bad. Use
Vehicle Diagnostics/Rear/
Rear MVEC AC Clutch Relay.
AC Belt
Drives the
compressor from
engine.
Make sure belt is not slipping.
Belt should have 1/4" to 1/2"
deflection.
Condensor
Cools refrigerant,
located on rear of
engine radiator.
Look for physical damage or
signs of leaks.
Refrigerant
and Oil
Used in cooling
system. Lubricates
for proper cooling.
If all components check good,
have refrigerant checked by
authorized installer.
The radio is a standard automotive style. It is located to
the right of the steering wheel. Just below the radio is a
standard 12 VDC accessory outlet.
A 12 VDC fused terminal strip is just to the right of the
radio. To make connections, follow the polarity as shown
on the decal.
To remove the radio, unscrew the four screws. The radio
and bracket will lift up.
Figure 145
AC SYSTEM
CAUTION
Always have system charged and maintained
by a certified refrigeration installer.
NOTE
For fastest cooling the fresh air vent should
be closed.
Testing
Figure 146
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Service
HYDRAULIC FITTING INSTALLATION
TORQUE RECOMMENDATION
Table 1: For 37° & 45° (Machined or Flared) and MegaSeal®
Si ze
Dash
Steel
Fractional
(In.)
Ft-Lbs.
B r as s
Newton-Meters
Ft-Lbs.
Newton-Meters
Min.
Max.
Min.
Max.
Min.
Max.
Min.
Max.
-4
1/4
10
11
13
15
5
6
6-3/4
9
-5
5/16
13
15
18
20
7
9
10
13
-6
3/8
17
19
23
26
12
15
17
20
-8
1/2
34
38
47
52
20
24
27-2/3
33
-10
5/8
50
56
69
76
34
40
46-1/3
55
-12
3/4
70
78
96
106
53
60
72-1/3
82
-16
1
94
104
127
141
74
82
100-1/2
111
-20
1-1/4
124
138
169
188
75
83
101-1/2
113
-24
1-1/2
156
173
212
235
79
87
107
118
-32
2
219
243
296
329
158
175
214
237
Table 2: For Flat-Face “O” Ring Seal (Steel)
Size
Ft-Lbs.
N ew t o n - M et er s
Dash
Fractional
(In.)
Min.
Max.
Min.
Max.
-4
1/4
10
12
14
16
-6
3/8
18
20
24
27
-8
1/2
32
40
43
54
-10
5/8
46
56
60
75
-12
3/4
65
80
90
110
-14
7/8
65
80
90
110
-16
1
92
105
125
240
-20
1-1/4
125
140
170
190
-24
1-1/2
150
180
200
245
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Table 3: For SAE O-Ring Boss (Steel) & Gates Adapterless
Ft-Lbs.
Working Pressures
4,000 psi (27.5 Mpa)
and below
Size
Newton-Meters
Working Pressures
4,000 psi (27.5 Mpa)
and below
Ft-Lbs.
Working Pressures
Above 4,000 psi (27.5
Mpa)
Newton-Meters
Working Pressures
Above 4,000 psi (27.5
Mpa)
Dash
Fractional
(In.)
Min.
Max.
Min.
Max.
Min.
Max.
Min.
Max.
-3
3/16
–
–
–
–
8
10
11
13
-4
1/4
14
16
20
22
14
16
20
22
-5
5/16
–
–
–
–
18
20
24
27
-6
3/8
24
26
33
35
24
26
33
35
-8
1/2
37
44
50
60
50
60
68
78
-10
5/8
50
60
68
81
72
80
98
110
-12
3/4
75
83
101-1/2
113
125
135
170
183
-14
7/8
–
–
–
–
160
180
215
245
-16
1
111
125
150
170
200
220
270
300
-20
1-1/4
133
152
180
206
210
280
285
380
-24
1-1/2
156
184
212
250
270
360
370
490
Table 4: Maximum Recommended Torque for dry NPTF (Tapered) Pipe Threads*
Size
Ft-Lbs.
N e w t o n - M et er s
-2
20
25
-4
25
35
-6
35
45
-8
45
60
- 12
55
75
- 16
65
90
- 20
80
110
- 24
95
130
- 32
120
160
*NOTES:
1.
The torque values obtained from tightening pipe threads can vary considerably
depending on thread condition. Adequate sealing can occur at values much lower than
the maximum values listed above. Only enough torque to achieve adequate sealing
should be used.
2.
When using a male tapered pipe thread with a female straight or parallel pipe thread,
maximum values are 50% of those listed in the table.
3.
If threaded sealant is used, maximum values shown should be decreased by 25%
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Service
FASTENER TORQUE RECOMMENDATION
Table 5: Torque for Standard Fasteners
FNL
Grade 2
Grade 5
Grade 8
Grade 9
G9
Nominal
Dia.
Threads
per inch
(in.)
Tightening Torque
Tightening Torque
Tightening Torque
Tightening Torque
Lubed
Dry
Plated
Dry
Plain
Lubed
Dry
Plated
Dry
Plain
Lubed
Dry
Plated
Dry
Plain
Lubed
Dry
Plated
Dry
Plain
K = 0.15
K = 0.17
K = 0.20
K = 0.15
K = 0.17
K = 0.20
K = 0.15
K = 0.17
K = 0.20
K = 0.15
K = 0.17
K = 0.20
Unified Coarse Thread Series
1/4
20
49 in-lbs
59 in-lbs
66 in-lbs
76 in-lbs
86 in-lbs
101 in-lbs
107 in-lbs
122 in-lbs
143 in-lbs
126 in-lbs
143 in-lbs
168 in-lbs
5/16
18
101
122
135
157
178
209
221
251
295
259
294
346
3/8
16
15 ft-lbs
18 ft-lbs
20 ft-lbs
23 ft-lbs
26 ft-lbs
31 ft-lbs
33 ft-lbs
37 ft-lbs
44 ft-lbs
38 ft-lbs
43 ft-lbs
51 ft-lbs
7/16
14
24
29
32
37
42
49
52
59
70
61
70
82
1/2
13
37
44
49
57
64
75
80
90
106
94
106
125
9/16
12
53
63
70
82
92
109
115
130
154
135
153
180
5/8
11
73
87
97
113
126
150
159
180
212
186
211
248
3/4
10
129
155
172
200
227
267
282
320
376
331
375
441
7/8
9
125
160
167
322
365
429
455
615
606
633
604
710
1
8
187
225
250
483
547
644
681
722
909
799
905
1065
1-1/8
7
266
319
354
596
675
794
966
1095
1288
1132
1283
1510
1-1/4
7
375
450
500
840
952
1121
1363
1545
1817
1597
1810
2130
1-1/2
6
652
783
869
1462
4657
1950
2371
2688
3162
2779
3150
3706
Fine Thread Series
1/4
28
56 in-lbs
68 in-lbs
75 in-lbs
87 in-lbs
99 in-lbs
116 in-lbs
123 in-lbs
139 in-lbs
164 in-lbs
144 in-lbs
163 in-lbs
192 in-lbs
5/16
24
112
135
150
174
197
231
245
278
327
287
325
383
3/8
24
17 ft-lbs
20 ft-lbs
23 ft-lbs
26 ft-lbs
30 ft-lbs
35 ft-lbs
37 ft-lbs
42 ft-lbs
49 ft-lbs
43 ft-lbs
49 ft-lbs
58 ft-lbs
7/16
20
27
32
36
41
47
55
58
66
78
68
78
91
1/2
20
41
49
55
64
72
85
90
102
120
105
120
141
9/16
18
59
71
78
91
103
121
126
146
171
151
171
201
5/8
18
82
99
110
127
144
170
180
204
240
211
239
281
3/4
16
144
173
192
223
253
297
315
357
420
369
418
492
7/8
14
138
165
184
355
403
474
502
568
669
588
666
784
1
14
210
252
280
542
614
722
765
867
1020
896
1016
1195
1-1/8
12
298
357
397
668
757
890
1083
1227
1444
1269
1439
1693
1-1/4
12
415
493
553
930
1055
1241
1509
1710
2012
1768
2004
2358
1-1/2
12
734
880
978
1645
1865
2194
2668
3024
3557
3127
3544
4169
Torque values for 1/4 and 5/16-in series are in inch -pounds. All other torque values are in foot-pounds
Torque values calculated from formulas T=KDF, where
K = 0.15 for “lubricated” conditions
K = 0.17 for zinc plated and dry conditions
K = 0.20 for plain and dry conditions
D = Nominal Diameter
F = Clamp Load
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Table 6: Torque-Tension Relationship for Metric Fasteners
Class 4.6
4.6
Class 8.8
8.8
Class 10.9
10.9
10.9
Class 12.9
Nominal
Dia.
Tightening Torque
Pitch
(mm)
Tightening Torque
Tightening Torque
Tightening Torque
Lubed
Dry
Plated
Dry
Plain
Lubed
Dry
Plated
Dry
Plain
Lubed
Dry
Plated
Dry
Plain
Lubed
Dry
Plain
K = 0.15
(ft-lbs)
K = 0.17
(ft-lbs)
K = 0.20
(ft-lbs)
K = 0.15
(ft-lbs)
K = 0.17
(ft-lbs)
K = 0.20
(ft-lbs)
K = 0.15
(ft-lbs)
K = 0.17
(ft-lbs)
K = 0.20
(ft-lbs)
K = 0.15
K = 0.20
3
0.5
0.28
0.32
0.38
0.73
0.82
0.97
1.0
1.2
1.4
1.2
1.6
3.5
0.6
0.44
0.50
0.59
1.1
1.3
1.5
1.6
1.9
2.2
1.9
2.5
4
0.7
0.66
0.74
0.87
1.7
1.9
2.3
2.4
2.7
3.2
2.8
3.8
5
0.8
1.3
1.5
1.8
3.4
3.9
4.5
4.9
5.5
6.5
5.7
7.6
6
1
2.3
2.6
3.0
5.8
6.6
7.7
8.3
9.4
11
9.7
13
6
1.25
2.1
2.3
2.7
5.3
6.0
7.0
7.6
8.6
10
8.8
12
7
1
3.8
4.3
5.0
9.7
11
13
14
16
19
16
22
8
1
5.9
6.6
7.8
15
17
20
22
24
29
25
34
8
1.25
5.5
6.2
7.3
14
16
19
20
23
27
24
31
10
1.25
11
13
15
29
33
39
42
48
56
49
66
10
1.5
11
12
14
28
32
37
40
45
53
47
62
12
1.25
21
23
28
53
60
71
76
86
101
89
119
12
1.5
20
22
26
51
58
68
73
82
97
85
113
12
1.75
19
21
25
49
55
65
70
79
93
81
108
14
1.25
26
29
34
66
75
89
95
106
127
111
148
14
1.5
28
32
37
72
82
96
103
117
138
121
161
14
2
30
34
40
78
88
104
111
126
148
130
173
16
1.5
50
57
67
129
146
171
184
208
245
215
287
16
2
47
53
62
121
137
161
173
196
230
202
269
18
1.5
73
82
97
187
212
249
266
303
357
313
417
18
2.5
65
73
86
167
189
222
239
270
318
279
372
20
2.5
91
104
122
236
267
314
337
382
449
394
525
Clamp load calculated as 75% of the proof load for specified bolts.
All Torque values are listed in foot-pounds
Torque values calculated from formulas T=KDF, where
K = 0.15 for “lubricated” conditions
K = 0.17 for zinc plated and dry conditions
K = 0.20 for plain and dry conditions
D = Nominal Diameter
F = Clamp Load
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Torque wrenches may have an adapter attached to
help reach a bolt or nut. Use the following formula to
recalculate the reading of the torque wrench.
Torque Wrench
Adapter Drive
Centerline
Handgrip Centerline
(Predetermined)
Wrench Drive
Centerline
L
E
Formula:
TxL
=Y
L+E
Example: ( with “E” as plus dimension)
Desired Torque T = 135 lb. In.
Y = Unknown
Original Length L = 10.0 In.
Extension E = 1.5 In.
135 x 10
10 + 1.5
Y=
=
1350
11.5
= 117.39
Y = 117 lb In.
Final reading on torque wrench
Figure 147
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Replacement Parts
For a complete listing of replacement parts, refer to the
Parts Manual 904-163124 Rev. C for Series 1 Units
Parts Manual 904-162429 Rev. F for Series 3 Units
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Replacement Parts