Mahindra 2615, Operator'S Manual & Installation Instructions

Page 1: ...contactus almats com Click here to go on INDEX Main Menu OPERATOR S MANUAL INSTALLATION INSTRUCTION ML106 Series ...

Page 2: ...Includes Operator s Manual and Installation Instructions Mahindra USA Model ML106 Front End Loader for Model 2615 Tractor 1503 1031 16 Series Model 2816 ...

Page 3: ...fficially approved by Mahindra The Mahindra Loaders shall have been used in accordance with the procedures specified in the Operator s Manual This Warranty does not extend to damage resulting from misapplication abuse misuse failure to perform maintenance negligence fire accidents or changes or faulty mounting carried out by the Purchaser When making a Warranty exchange of parts the Purchaser shal...

Page 4: ...ew this manual and all safety messages contained within This safety symbol indicates important safety messages in this manual When you see this symbol carefully read the message that follows and be alert to the possibility of personal injury or death 16 Series Model 2816 ...

Page 5: ...der Specifications 8 Introduction 9 Tractor Preparation 10 11 Loader Operation 12 15 Loader Removal 16 17 Loader Mounting 18 19 Lubrication and Maintenance 20 21 Trouble Shooting 22 25 Torque Tightening Chart 26 Installation Instructions 27 34 16 Series Model 2816 ...

Page 6: ...ne of your tractor make sure all operating controls are in park lock or neutral position Operate controls only when seated in the operator s seat Equip your tractor with a ROPS cab or frame for your protection See your tractor operator s manual for correct seat belt usage A frequent cause of personal injury or death is persons falling off and being run over Do not permit others to ride on your tra...

Page 7: ...clearance between raised equipment and overhead power lines Add recommended rear tire liquid weight or rear wheel weights for increased stability A loader attachment should be transported in a low position at slow ground speeds Make turns slowly and use the tractor brakes cautiously A loaded attachment in the raised position alters the center of gravity location of the machine and increases the po...

Page 8: ...cals with soap and water and dry with a soft cloth 3 Replace damaged or missing safety decals with new decals from your Mahindra Dealer 4 If a component with a safety decal s affixed is replaced with a new part make sure new safety decal s are attached in the same location s as the replaced components 5 Mount new safety decals by applying on a clean dry surface and pressing air bubbles to outside ...

Page 9: ...2 lb Cycle Times sec RPM 1 000 1 500 2 000 2 900 Full Raise Boom 7 2 4 7 3 7 2 8 Lower Boom 3 6 3 0 3 6 2 2 Dump Bucket 2 5 2 2 1 9 1 9 Retract Bucket 4 2 2 8 2 2 1 8 Relief Valve Pressure Setting 2 050 PSI Rated Flow Tractor System 7 8 GPM Hydraulic System Tractor pump w loader control valve Lift Cylinders Bore x Stroke 1 75 x 18 00 Bucket Cylinder Bore x Stroke 1 75 x 14 00 Attachment used for S...

Page 10: ...is recommended to ensure safe operation of tractor and loader Refer to the Safety Precautions section of this manual for information concerning safety Consult your dealer for further information Warranty Registration The Delivery and Warranty Registration forms must be filled out and signed to validate your warranty protection The items on the form under I hereby Acknowledge should be read and und...

Page 11: ...e added by installation of Three Point Hitch mounted ballast CAUTION Certain specific conditions may not permit safe use of loader at loader rating or may require more careful restricted operation at the rated load Refer to Tractor Operator s Manual for specific recommendations on counterweighting tractor ROPS System The tractor must be equipped with an approved ROPS System to ensure adequate oper...

Page 12: ...intained at equal pressure within the recommended tire inflation range Unequal rear tire inflation can prevent loader attachment from contacting the ground across its full width Wheel Tread Settings Tractor front wheel tread settings must be restricted to wheel tread spacing recommended in the Tractor Operator s Manual Front Counterweight Use of front counterweight is not recommended when tractor ...

Page 13: ...t off Keep the unit clean and perform regular service Observe safety messages whenever cleaning servicing or lubricating We urge you to follow this advice 1 Read and understand this manual as well as the Tractor Operator s Manual 2 Remember and observe the Safety Precautions brought to your attention in this manual the tractor manual and on the machinery itself 3 Use good common sense in the every...

Page 14: ...d against rust and contamination which may cause damage to the cylinder rods or hydraulic system Cold Weather Operation For smooth operation in cold weather let the tractor warm up SLOWLY cycle the lift and bucket cylinders several times to warm the oil in the hydraulic system The loader may operate erratically until the hydraulic oil has warmed to operating temperatures CAUTION Operate controls o...

Page 15: ... CAUTION Do not stand walk or work under a raised loader unless it is securely blocked or held in position Accidental movement of a control lever or leak in the hydraulic system could cause the loader to drop or attachment to dump resulting in serious injury or death Important Contaminates in hydraulic oil can cause valve spools to stick Be alert when operating loader and follow your Tractor Opera...

Page 16: ...sary to follow the contour of the surface To activate the float position lower the bucket or attachment and push the control handle all the way forward into detent The valve will stay in float detent position until the operator manually pulls the control handle out of detent position to deactivate float REGENERATIVE DUMPING POSITION The loader valve has a Feel Position Regenerative Spool incorpora...

Page 17: ...eight from being applied to loader parking stands STEP 1 Position loader on hard level surface Raise boom Put bucket in dump position Lower the loader until front edge of bucket is on the ground and shut tractor off STEP 2 Remove parking leg from stored position and put it in the park position Secure using pin and keeper Parking Leg Location STEP 3 Raise loader and fully retract bucket Lower the l...

Page 18: ...ry extend the lift cylinders as required to raise the subframe clear of the rear mount Back the tractor up slowly until the subframe front crosstube is just clear of the Front Mount Observe the four 4 hoses valve tubelines to ensure they are not caught or stretched when backing away from loader Shift the control valve lift cylinder spool into the neutral position STEP 6 Check to ensure the subfram...

Page 19: ...ed to the control valve Note The tractor front mount should be aligned with the subframe front crosstube STEP 2 Shut the tractor OFF and connect the hydraulic couplings matching the color code rings STEP 3 Start the tractor and drive ahead slowly to position the subframe front crosstube into the Front Mount Note Activate the bucket cylinders and lift cylinders as required to align the subframe cro...

Page 20: ...ies clevis pins and hitch pin clips to both sides Secure hinges with the 1 2 flat washer lock washer and nut as shown typical each side Carriage Bolt Assembly and hardware STEP 6 Start the tractor raise the loader off the ground and put bucket in dumped position Lower loader to position bucket cutting edge on ground and shut tractor OFF Remove parking leg and place in storage position Hitch Pin Cl...

Page 21: ...ication and Maintenance Chart for quick reference to Maintenance Operations CAUTION Do not operate the loader if the fittings are leaking or if the hoses are damaged A sudden line burst could cause the mainframe to drop suddenly causing damage to the tractor or loader or injury to personnel CAUTION Operate the loader from the tractor seat only CAUTION Do not stand or walk under a raised loader Acc...

Page 22: ... Connections Check for leaks wear Daily 10 hours Lift and Bucket cylinder rod packings Check for seepage service as needed Daily 10 hours Pivot pin clips Check replace if missing Daily 10 hours Subframe hinge clamping bolts Check re torque if necessary Weekly 50 hours Loader mount hardware Check visually Weekly 50 hours Loader mount hardware Re torque Every 50 hours Cylinder Service Lift cylinders...

Page 23: ...plied from hydraulic pump Check system pressure Repair or replace pump Control valve linkage broken Inspect Repair as required Quick disconnect coupler s are not fully connected or Flow Check Check coupler connections Replace coupler s if necessary Hydraulic hose or tubeline blockage Check for evidence of damage to hoes or tubelines that would block flow of oil between cylinders and control valve ...

Page 24: ...on hoses tubeline kinked or pinched Check hoses and tubelines for evidence of restriction Lift cylinder piston assembly leakage Check cylinders for leakage Repair as needed Relief valve erratic or set below specifications Check and reset relief valve setting as needed Control valve leaking internally Bypassing fluid within valve Replace control valve and recheck operation Inadequate hydraulic pump...

Page 25: ...ty Reduce load Relief valve setting below specifications Check and reset valve setting as needed Hydraulic hose tubeline or quick disconnect coupler restriction Check for evidence of restriction in hydraulic oil flow Repair or replace defective components Cylinder Piston assembly leakage Check cylinders for leakage Loader drops with control valve spool in Centered position no external oil leakage ...

Page 26: ...striction in hydraulic hoses Hydraulic pump defective Refer to Tractor Operator s manual for recommended service procedures Replace hydraulic pump if determined to be defective Lift cylinder rods bend when lift cylinders extended Excessive shock load on lift cylinders during transport Replace defective parts Review and observe proper and safe operational practices Bucket cutting edge wear is uneve...

Page 27: ... Bolt head identification marks as per grade Manufacturing marks will vary Thick nuts must be used with Grade 8 bolts METRIC FASTENER ISO TORQUE CHART Note Use these torques unless special torques are specified Values are for UNC and UNF thread fasteners plated or unplated as received from supplier Fasteners can be dry or lubricated with normal engine oil Values do not apply if graphite moly disul...

Page 28: ...m x 35mm bolts and 9 16 lock washers on each side NOTE Remove Front Weight Carrier bracket if present prior to installation of Front Mount Also remove the ground cable from RH side of the tractor frame STEP 4 Install Front Mount as shown in first figure using four 4 5 8 x 1 3 4 bolts 5 8 flat washers 5 8 lock washers and 5 8 hex nuts Route Ground Cable to inside of Tractor Rail Secure to inside Tr...

Page 29: ...om left hole Attach Single Lever Control SLC w regen decal to back of valve stand as shown insuring float position detail is on top STEP 8 Attach a straight Hydraulic Adapter to all four hydraulic port indicated in the figure Attach a quick coupler to each hydraulic adapter as shown Mark the quick couplers with colored nylon ties as shown 1 Red Bucket Cyl Rod End 2 Yellow Bucket Cylinder 3 Blue Li...

Page 30: ...positioning it over boot mount 6 Thread Knob onto end of handle STEP 10 Attach 9 16 JIC male end of 1 4 x 40 hydraulic hose to loader tubing Mark the quick coupler end of each hose with colored nylon ties of individual color as noted below 1 Red top line 2 Yellow 2nd line from top 3 Green 3rd line from top 4 Blue bottom line Bundle hoses together and secure as shown using nylon ties provided with ...

Page 31: ...raulic Control Valve Stand and secure hoses as shown with a plastic tie strap supplied with loader kit STEP 13 When installing loader only on tractor attach a 90 hydraulic adapter to each port insuring proper orientation as shown in the figure to the right To install the 90 hydraulic adapters locate the three hydraulic ports located on the right hand side and in front of the rear mount and remove ...

Page 32: ...e illustration Line up cross tube with front mount and drive slowly forward until cross tube is seated in front mount as shown STEP 15 Lower loader onto Rear Mount Assemblies Attach Hinge Assemblies to Sub Frame with 1 2 x 4 Clevis Pin and secure with 3 32 Hitch Pin Clip on each side Secure subframe by locking hinge assemblies around Rear Mount Tube using 1 2 x 4 carriage bolt grade 5 1 2 Flat Was...

Page 33: ...ow 2 Bucket cylinder rod end Red 3 Lift cylinder rod end Blue 4 Lift cylinder base end Green Colors should match STEP 17 Position Hydraulic Hoses insuring they do not come in contact with loader frame Secure hoses in location shown using plastic tie strap supplied in loader kit 1 2 3 4 Secure 16 Series Model 2816 ...

Page 34: ... Clip STEP 19 Secure bucket to loader and cylinders using four 4 pivot pins and pivot pin clips two 2 each side The longest pivot pin should be used on the Bucket Cylinder Rod End right side and should also be used to attach the Bucket Level Indicator Rod Slip BLI Rod into BLI Tube before attaching with Pivot Pin Attach BLI Tube here Attach BLI Rod here see step 19 16 Series Model 2816 ...

Page 35: ...raise the bucket approximately 4 feet above the ground and cycle the bucket cylinders three times Lower the bucket to the ground Check the tractor hydraulic oil reservoir and fill as required Refer to the Tractor Operator s Manual for the proper hydraulic oil and the correct oil level Once the loader hydraulic system is charged continue to cycle the lift circuit and bucket circuit under no load co...

Page 36: ...mped on cylinder barrel at rod end Also see picture Figure 1 below for help in identifying your cylinder design 2 If your loader is equipped with cylinder part number 3160 2045 for lift cylinders and part number 3150 2055 for tilt cylinders refer to the following for exploded Cylinder Parts Drawing Parts List and cylinder hose requirements on pages 2 thru 4 Part numbers are stamped on cylinder bar...

Page 37: ...e Description Part No Qty 1 Tube Assembly 0100 2055 1 2 Nut 0530 2000 1 3 Piston 0405 2001 1 4 Seal Kit 0590 2016 1 5 Head 0330 2012 1 6 Retaining Ring 0560 2002 1 7 Spacer 0541 2001 1 8 Retaining Ring 0560 2005 1 9 Rod Assembly 0200 2055 1 16 Series Model 2816 ...

Page 38: ...e Description Part No Qty 1 Tube Assembly 0100 2043 1 2 Nut 0530 2000 1 3 Piston 0405 2001 1 4 Seal Kit 0590 2016 1 5 Head 0330 2012 1 6 Retaining Ring 0560 2002 1 7 Spacer 0541 2002 1 8 Retaining Ring 0560 2005 1 9 Rod Assembly 0200 2045 1 16 Series Model 2816 ...

Page 39: ...Description Part No Qty 1 Hydraulic Cylinder Lift 3160 2045 2 2 Hydraulic Cylinder Tilt 3150 2055 2 3 Hydraulic Hose Assembly x 18 21106506018 4 4 Hydraulic Hose Assembly x 44 21106506044 2 5 Hydraulic Hose Assembly x 26 21106506026 2 1 4 5 3 3 2 2 16 Series Model 2816 ...

Page 40: ... CYLINDER 3160 2049 Reference Description Part No Qty 1 Rod Assembly 0200 2061 1 2 Tube Assembly 0100 2063 1 3 Piston 0405 2009 1 4 Gland 0330 2017 1 5 Locknut 0530 2007 1 6 Zerk 0530 2008 2 7 Seal Kit 0590 2024 1 16 Series Model 2816 ...

Page 41: ... CYLINDER 3150 2069 Reference Description Part No Qty 1 Rod Assembly 0200 2062 1 2 Tube Assembly 0100 2064 1 3 Piston 0405 2009 1 4 Gland 0330 2017 1 5 Locknut 0530 2007 1 6 Zerk 0530 2008 2 7 Seal Kit 0590 2025 1 16 Series Model 2816 ...

Page 42: ...Description Part No Qty 1 Hydraulic Cylinder Lift 3160 2049 2 2 Hydraulic Cylinder Tilt 3150 2069 2 3 Hydraulic Hose Assembly x 18 21506506018 4 4 Hydraulic Hose Assembly x 44 21506506044 2 5 Hydraulic Hose Assembly x 26 21506506026 2 1 4 5 3 3 2 2 16 Series Model 2816 ...

Page 43: ...rial Number 043417976 and after for ML106 Loader Serial Number 043217581 and after for ML110 1 If your loader is equipped with a Nimco manufactured valve refer to your Loader Operator s Manual for Installation and Operation Instructions 2 If your loader is equipped with a Prince manufactured valve use the following Installation and Operation Instructions 16 Series Model 2816 ...

Page 44: ... 5 16 x 3 4 bolt and 5 16 lock washer in top left hole and two 2 5 16 x 3 4 bolt 5 16 lock washer and 5 16 flat washer in bottom left slot and right slot Attach Single Lever Control SLC w regen decal to back of valve stand as shown insuring float position detail is on top STEP 3 Attach a female quick coupler to all four hydraulic ports indicated in the figure Mark the quick couplers with colored n...

Page 45: ...ties Handle Cable Tie SLC Rubber Boot Lock Nut Knob Secure Form 1503 1067 Page 5 of 11 LOADER INSTALLATION STEP 6 Attach 3 8 x 42 hoses with fittings to the Power Beyond IN and Out ports on the Hydraulic Control Valve Route the hoses down the outside of Hydraulic Control Valve Stand and secure hoses as shown with a plastic tie strap supplied with loader kit STEP 7 When installing loader only on tr...

Page 46: ... 1 4 x 40 21003406040 4 5 Hydraulic Hose Assembly 3 8 x 42 22108506042 3 6 Plastic Tie Strap 0554 1013 4 7 Color Code Tie Strap Blue 0554 2001 2 Red 0554 2002 2 Yellow 0554 2003 2 Green 0554 2004 2 8 Hex Head Cap Screw 1 2 x 1 1 2 0545 2106 2 9 Flat Washer 1 2 0543 2009 1 10 Lock Washer 1 2 0544 2012 2 11 Hex Head Nut 1 2 0555 2004 2 12 Hex Head Cap Screw 5 16 x 3 4 0545 2024 3 13 Lock Washer 5 16...

Page 47: ...LIC VALVE ASSEMBLY Reference Description Part No Qty Hydraulic Valve complete 0580 6091 1 1 Valve Body Not Serviceable 1 2 Spool Not Serviceable 2 3 Seal Kit 0580 6096 1 4 Load Check Poppet 0580 6097 2 5 Load Check Spring 0580 6098 2 6 Load Check Plug 0580 6099 2 7 Pipe Plug 0580 6100 1 16 Series Model 2816 ...

Page 48: ...ever Control Kit complete 1409 3076 1 1 Spool Stud 1409 3077 1 2 Rod End 1409 3078 1 3 Adapter Plate 1409 3079 1 4 Cap Screw 0563 2387 3 5 Rod End Assembly 1409 3080 2 6 Hex Nut 0555 2000 3 7 Cap Screw 0563 2008 2 8 Spool Lock Clevis 1409 3081 1 9 Cap Screw 0563 2003 1 10 Washer 0543 2005 1 11 Boot not shown 1409 3083 1 12 Handle Kit not shown 1409 3082 1 16 Series Model 2816 ...