Manual M542 part1

34 OPERATION INSTRUCTIONS
ENGINE AND DRIVING COMMANDS, SWITCHES AND GAUGES (INSTRUMENT PANEL)

(Continued)
To re-set the Steering System Ignition Key Hole

For only 4-Wheel Drive Machines. Starts with the ignition key shown as A. It has four
positions. Ignition key can be pulled out only in O
WARNING position.
4-wheel steering should be re-set at least once a O- To stop the engine, bring it to O position. Make
day. Otherwise, steering system function may sure that transmission is in neutral, attachments
diminish. are down, and parking brake is on.
I- When the ignition key is in this position, it gives

Steering should be re-set during following times; electricity to all circuits except battery, lights and
emergency warning lights. (Lights and emergency
a In the beginning of each work time. warning lights always have electrical power.) When
the ignition key is left in II or III position, it
b At least once a day automatically goes back onto this mode.
c When you have problems with steering II- Holding the key in this position, you heat the
induction coil to start the engine in cold weather.
d After driving 24 km or more on 2-wheel drive mode. Do not hold the key in this position longer than 15
seconds.
Apply the following before you re-set the steering
system: III- Starts engine starter
1 Select 2-wheel Drive Steering Note: Do not run the starter longer than 20
Sensors on the axles prevent the change of the seconds at each time. Let the starter cool for at
drive mode until all wheels straightened up or least two minutes between two attempts.
are in straightforward position. For this reason,
the mode you selected and driving mode
indicator will be different.
2 Run the engine until the rear wheels get

straighten up
It moves to 2-wheel drive, when the wheels are
straight and mode light turns on.
3 Select 4-wheel drive mode again.

Front and rear wheels are lined up.

(Continued)
Steering Wheel Tilting Adjustment Interior light of the Cab

Unlock the steering wheel column by turning the arm, To turn the interior light on, push the switch A.
shown as B, counter- clockwise. When you push any side of the switch on, light goes
off.
WARNING
If you stay out of the cab for a long time, make sure
the light is off.
Before starting to drive the machine, make sure
the steering column in its place and locked.
Adjust the steering wheel’s position. Tighten the

handle to prevent loosing of the column.
NOTE: Locking position of arm B can be changed.

Pull the arm and put it in the desired position.
-

(Continued)
Indicators
1- Temperature gauge of cooling system
When the ignition key is in O position, except
emergency warning indicators, all indicators stop. It shows the temperature of the engine coolant.
As the temperature goes up, the dial moves up
Side Instrument Panel slowly.
Operating indicators and adjustments are located on Engine should run continuously between 80-100
the side of the operator’s seat for easy usage of the °C. Over 100 °C, engine temperature takes the
switches and better vision. system into the critical status. When the
temperature reaches 110 °C, machine should be
safely parked, and the temperature should be
dropped. Side panel starts giving sound and
O
visual warnings when the temperature is 110 C.
80 °C thermostat should be used in the engine
cooling system. When the temperature reaches
81 °C, thermostat activates the cooling system.
2-a Engine Speed Gauge
It shows the engine speed in revolution per

On the instrument panel, there are visual and sound minute (rpm). Gauge shows the engine speed up
warning systems which are; to 4000 rpm in a circular scale. This scale divided
into 40 equal intervals and every interval
1. Engine water temperature gauge corresponds to 100 rpm. Engine idling speed is
2. Engine speed and operation time gauges around 800-1000 rpm. While working with the
3. Fuel level gauge Backhoe, increase the engine speed up to 1800
4. Engine water temperature lamp rpm by using cruise control.
5. Engine oil pressure lamp
6. Transmission oil temperature lamp 2-b Operation Timer
7. Battery charge lamp
8. Transmission oil pressure lamp It registers the total engine operation time. It is
9. Parking brake lamp necessary to count the total working time to
10. Parking lamp determine the maintenance time.
11. Air filter warning lamp
12. Engine pre-heating lamp
13. Crabwise cruising lamp 3 Fuel Gauge
14. 4-WS lamp
15. Fuel lamp It shows the fuel level in the fuel tank. Make sure
the fuel tank does not become completely empty;
Fuses are inside the fuse box on the instrument otherwise, air goes in the fuel system.
panel.
On the instrument panel ,Rearwindow

defrost,wiper,front/rear working light,warning light, 2/4
wheel drive, and cruising mode buttons are located.
(Only M544 Backhoe/Loader).

(Continued)
Front instrument panel

Warning Lights with Sound
Note: If any of the following lights on during operation,

stop the machine safely. Do not use the machine until
the problem is resolved.
7- Battery charge lamp

While starting the engine, battery-recharging circuit
goes off; light turns on and comes back in a few
seconds after the engine starts.
9- Parking brake lamp

While the machine is moving back and forth, if the
emergency brake is on, alarm buzzer may also
on.
5- Engine Oil Level is Low.

It turns on when the engine oil pressure is too
low. It goes off after the engine starts.
8- Transmission Fluid Pressure is Low.

It turns on when transmission fluid pressure is
too low. It goes off after the engine starts.
4- Water Temperature is High

It turns on when the engine coolant is 1- Voltmeter
overheated. 2- Batery charge lamp
3- Engine oil pressure lamp
6- Transmission Fluid Temperature is High 4- Low beam headlights lamp
It turns on when transmission fluid is overheated 5- High beam headlights lamp
6- Flasher lamp
11- Air Filter is Clogged (side ınstrument panel) 7- Parking brake lamp
It turns on when engine air filter is clogged. 8- Transmission temperature lamp
9- 2-WS lamp
10- Hazard warning switch
11- Clock
12- Speedometer (Not available in all models)
HEATING CONTROLS
Heating system is controlled by the switches below.
A- 2-speed fan switch

B- Temperature control switch
C- Air Condition switch (Optional)
Heating Controls
Hot air can be blown to the windshield, and to the floor
With the control B, heat can be adjusted. A heating
switch A controls a two-speed fan.
Heater Control
Turning the switch B to the right increases the heat, to
decrease, turn it to the left.
Heater Fan (Two-Speed)

To start the fan, turn the switch A. It starts with the
ignition switch.
Air Condition
For start the air condition, push the button C and start
the fan also with turning the switch A.
LOADER CONTROLS
Standard Bucket Hydraulic Speed Control

Loader bucket is controlled with only one lever in When hydraulic speed button is pushed (HSC),
standart machines. When torque separating button, causing the oil flow from the second section of the
which is located on the lever is pushed, engine and hydraulic pump, it is drained straight into the
transmission disengages resulting increase in hydraulic tank. This control is used for:
loader performance.
1 Provides more power when the loader try to lift in
For each function of the loader; lifting, unloading, a stack.
forward unloading, back unloading, control lever is
moved in ‘+’ directions 2 While driving on a normal road, since the engine
gains more power, fuel saving becomes more
For compound functions, bar should be moved in effective.
four sub-directions these are ‘x’ directions. Such as,
loader is lifted by pulling the bar back, for back 3 While placing the things, speed of Backhoe goes
turnover, it should be pulled to the left. down.
So that, by pulling the control lever both back and While driving on the highway, push the rocker
left, lifting the loader and tilting the bucket are switch “ON” to use HSC. Light turns on when HSC
performed at the same time. is in use.
Loader’s speed depends on how fast you move the

control bar. Faraway the control bar is pushed,
faster the speed of the loader becomes.
On the top of the control lever, it is described with

symbols on a sticky label that which lever motion
activates the loader. Symbols and control lever
motions are explained in the further parts.
LOADER CONTROLS
(Continued)
Loader Bucket Forward Overturning
Lifting To tilt the bucket forward as shown in C, push the

stick to the right.
To lift the bucket as shown in A, pull the stick all the
way back. As it is rising, it’s angle with the ground Backward overturning
remains constant. This is because of parallel
connections on the boom. To tilt the bucket back as shown in D pull the stick to
the left.
Lowering
To lower the bucket as shown in B, push the stick

forward. Bucket keeps its’s angle with the ground as
explained in the lifting part.
LOADER CONTROLS
(Continued)
Loading Bucket (Continued) 6 Purposed Opening/Closing Bucket
Releasing In the machines installed with a 6-purposed

opening/closing bucket, in addition to the standard
WARNING control lever, there is another lever. First standard
lever works the way it was explained in the previous
pages. Second lever operates 6-purposed
If the loader arm is released from a level which is opening/closing bucket.
higher than the ground, loader goes down to
ground and it moves just over the ground as if it is In order to make combined motions, both levers should
“swimming” while cruising. You do not have any be used at the same time. Motions of the leverss and
control over the speed of the loader’s downward their functions over the bucket are shown on the
motion. plastic sticker on the top of the levers.
Always push the loader lever down, before releasing Opening Bucket
the loader.
Push the lever forward to open the bucket as shown in
When you want the bucket move freely over the E.
ground, push the lever as much as it can go and leave
it in that position. While passing through lowering Closing Bucket
position, you feel a weak pressure.
Pull the lever to close the bucket as shown in F.
LOADER CONTROLS
(Continued)
Bucket Leveling Position

Push the bucket leveling button which is at the side
panel.Bring the bucket to the backwards overturning
position.Give a small motion to the lever in opposite side
for forwards overturning position.Loader bucket will
come to its leveling position and stop automatically.
When the end of the moving stick A is at the same level
with the sensor B, front bucket is in the ground level
position.
STABILIZER CONTROLS
Stabilizer Controls
WARNING
Stabilizers
While the stabilizers are being lowered, people
around can be run over and materials which
remains underneath the stabilizers can be
damaged. Make sure the people are away from the
area and nothing should be under the stabilizers.
WARNING
While running the stabilizer controls, you should

be seated in the operator’s seat.
Do not run the stabilizers from outside the

machine; otherwise, you can be injured when the
machine moves.
Before you start to run the backhoe, stabilizers

should be down. If not, the machine rocks. Each
stabilizer has its own control and each one can be
controlled individually.
In order to level up the machine and to lighten the

weight off the rear wheels, lower both stabilizer
down. To level the machine and to make it stable,
use the loader bucket as well as the stabilizers.
Before you start moving, lift up both stabilizing

pedestals.
Lifting Stabilizers
In order to lift up the stabilizers, pull the lever towards

the front of the machine as shown in A and C.
Lowering Stabilizers
To let the stabilizers down, push the levers towards

the back of the machine as in B and D.
When the machine is on the slope, to stabilize the

machine, you may have to use one or both stabilizers.
BACKHOE CONTROLS
MST Plus (‘+’) Signed Control Lifting Boom
WARNING To lift the boom, push the lever towards the front of the
machine, as in A. Before lifting the boom, make sure
that there is not any obstacle over the backhoe to
Do not operate the backhoe from outside the prevent lifting.
machine. You may be squeezed under the
backhoe.
Lowering Boom
Machines working with MST Plus (‘+’) signed control,
has two backhoe control levers. The one shown with In order to lower the boom as in B, push the lever
13 (left lever) operates the boom and swinging towards the back of the machine.
motion. Right lever (14) operates dipperstick and
bucket. Pedestals Pedestal Controls are operated
as it was instructed in the (Operating Chapter).
For each motion of dipper, both arms should be

moved in “+” position. For combined motions, levers
should be moved in four sub-directions (‘’x’’).
In order to have more productive work, both levers

should be used together. Speed of the backhoe
depends on how fast you move the levers. Digger’s
speed is proportional with the levers how far they are
pushed and pulled.
It is indicated on the sticky label that what motions

the Beko does, which arm is used. Symbols, arm,
and Beko motions are instructed in the further pages.
BACKHOE CONTROLS
(Continued)
MST Plus (‘+’) Signed Control Lowering the Dipperstick

(Continued)
In order to bring the dipper arm into the position shown
Turning Left in E, pull the lever towards the front of the machine.
To turn the boom shown as in C, move the lever to Note: Some DIGGER attachment can hit the boom,
your left. when they are pulled back more than they are
supposed to be. Consider this point, before you start
Note: when some DIGGER buckets and attachments using different attachments.
are turned extremely, they may hit the stabilizers.
Consider this point, before you start using the Moving the Dipperstick forward
attachments.
In order to push the dipper arm as shown in F, move
the lever towards the back of the machine. Before
Turning Right lifting the arm, make sure that there is not any
obstacle over the backhoe to prevent lifting.
To turn the boom shown in D, move the lever to your
right.
BACKHOE CONTROLS
(Continued)
MST Plus (‘+’) Signed Control (Continued) Telescopic Arm/Breaker (if installed)
Closing Bucket Some models have breaker and telescopic-arm-motion

pedal. This pedal is used to operate the attachments to
To close the bucket as shown in G, move the lever to mechanical slide, telescope, and auxiliary attachments.
the left.
Pedal is in a shape of a pendulum and operated with
Opening Bucket the heel and the tip of the foot. Operating speed
depends on how much the pedal is pushed down.
To open the bucket as shown in H, move the lever to Attachments can stay in any position, until moved by
right the pedal.
Kingpost (Tightening) Clamps
Before starting any excavation work, kingpost should

be clamped to the rails. See Sliding Beko sideways
(Operating Chapter) for detailed information about how
Kingpost and rear excavating system are moved.
Releasing the Clamps
To unlock the clamps, push the button on the

instrument panel.
Tightening Clamps
In order to tighten the clamps,open the rear bucket until

its end position and push the button on the instrument
panel before you leave the lever.
BOOM AND ROTATION LOCKS
Boom Lock
We recommend that boom lock and rotation lock
should be installed before driving.
Every day, make sure that boom lock completely

installed and the boom is secured.
WARNING
If you operate control handles from outside, you

may cause yourself or others to be injured or to
be killed. Operate the control handles always
when you are inside the cab and seated properly.
It is recommended that rotation lock be fastened

before fastening the boom lock.
Locking the Boom
1 Place the DIGGER exactly in the back of the

machine and lower the boom down.
2 Make sure the boom lock A is in completely

up position and if necessary, lift the control pin
inside the cab up to lift the lock.
3 Close the boom hammer (lift the boom)
4 Lower the control handle inside the cab and

lower boom lock A, make sure the boom lock is
completely passed through boom lugs.
5 Lower the boom slightly to tighten the lock.
Unlocking the Boom Lock
1 Raise the boom slightly to unlock the boom.
2 To lift the boom lock A, lift the control handle.

BOOM AND ROTATION LOCKS
Rotation lock
We recommend that boom lock and rotation lock
should be installed before driving.
Every day, make sure that boom lock completely

installed and the boom is secured.
WARNING
If you operate control levers from outside, you

may cause yourself or others to be injured or to
be killed. Operate the control handles always
when you are inside the cab and seated
properly.
It is recommended that rotating lock be fastened

before fastening the boom lock.
WARNING
If two people will work, make sure that they are

experienced operators. In case of using
improper controls or rough usage of the controls
may cause injuries or fatality of the other
person.
Installing Rotation Lock
1 Move the DIGGER to the desired position.

Make sure the hole E and hole F are lined up.
Stop the engine.
WARNING
While sitting the cab, do not attempt to locate

and to lift the rotation fork pin. If you do that,
you will lean against the control levers of the
rear excavator. In case of those levers start
running by accident, you or others can be killed
or severely injured.
2 Pull the lock pin G from where it is and pass

through the lined up holes.
Unlocking Rotation Lock
1 Stop the engine
2 Pull out the locking pin G and place it in its

location.
BEFORE STARTING THE ENGINE

NOTICE c Clean oil, grease, and mud on the
If you use the machine in very cold or very hot pedals, control arms, and steering wheel.
weather then; read the instructions for Using in d Pay attention to your hands and shoes
Cold Weather and Hot Weather. (Operation are clean and dry.
Section)
WARNING
Haphazard items left inside the operator’s

1 Engage to the Parking Brake compartment may fall on you or roll on the
floor and injure you or get caught in to the
Parking brake should be engaged when the
control bars in this case; you may lose the
last time the machinery was parked. If it was
control of the vehicle.
not engaged, engage it now.
WARNING
e Remove or secure the haphazard items
inside to the operator’s compartment
Before lowering the attachments, inspect such as; food containers, water bottle,
that; there is not anybody around to the tools etc...
machine. Otherwise; they can be run over
or get caught in the connections. f Inspect ROPS/FOBS to see whether
there is any damage or not. If there is
any damage, contact your dealer, and
have it repaired. Sure that; all nuts are
available and tightened properly.
2 Lower the Attachments on the
Ground
g Check the operator’s compartment to see
Inspect both loader and backhoe buckets are if there are any loosened or fallen off
on the ground position or the bucket is in the nuts or bolts. If need, replace or tighten
transportation position. them.
h Check the seat belt and seat belt

3 Inspection Before Starting the equipment for any damage.
Engine
For your or others’ safety, and for longer work WARNING
life of the machine, inspect machine before
starting the engine.
If the seat belt is torn, if pulling motion is
a Make a through walk inspection before interrupted during extension of the belt, or if
starting the engine. Read (Operation the belt cannot be inserted into the buckle
Section) properly, replace the seat belt assembly.
Replace the seat belt assembly every 3 years
b Inspect the operator’s compartment for even if it passes visual inspection.
loose items and cleanliness.
WARNING
Never operate a lift truck with wet hands or

shoes. Never hold any controls with grease
on your hands. Your hands or feet will slide
off of the controls and cause an accident.
BEFORE STARTING THE ENGINE
WARNING 7 Fasten the Seat Belt
If you fasten the belt across your

abdomen, the belt injures your abdomen
in an accident.
a. Grip the plate (connector) of the belt

and pull the belt from the retractor.
Then insert the plate into the slot of the
buckle until a snap is heard. Pull on the
belt to confirm it is latched.
I Test the lights, warning lights, horn,
indicator lights, all switches, turn signals, b. Make sure the belt is not twisted.
emergency lights, wipers, and washer fluid
for proper operation.
4 Adjust the Seat

Adjust the seat to reach all driving controls.
Adjust the seat when you leaned back, you
should be able to push the brake pedal all the
way down to the floor.
5 Adjust Steering Column

Adjust the steering column to reach the
steering wheel and steering column
switches without stretching yourself out.
6 Adjust Rearview Mirror

Adjust the rearview mirror the way, to sit
properly, to see the back of the machine
clearly.
STARTING THE ENGINE

1 Read the previous page “before you start 5 Check the warning Lights
the engine” and follow the instructions.
Make sure that all lights are off after the
2 Put forward/reverse gear stick into neutral engine start. Do not force the engine until the
position. Engine will not start unless oil pressure low light goes off. Starting the
forward/reverse gear stick in neutral. engine fast, due to insufficient lubrication,
may damage the turbo charge. Make sure
3 Adjust the cruise control to minimum. that sound alarm buzzer is not on.
Maintain cruise control stick (16) in minimum

back engine position.
NOTICE
4 Start the Engine In case of any warning light does not go off or
stays on while the engine is running, Stop the
engine safely at the nearest place.
WARNING
6 Heat Hydraulic System

Inhaling the exhaust gas may be dangerous
or may cause death. Make sure it is well To assist the hydraulic system to be heated,
ventilated and do not run the engine in run the backhoe for few times.
closed area. If possible, attach an extension
pipe to the exhaust pipe. If you start feeling
sleepy, immediately stop the engine. Leave NOTICE
the machine and go out side for fresh air.
New engines do not need BREAKING-IN.
Machine/engine should be kept running at
regular working harmony. When you try to break
NOTICE the engine in, surface of the piston cylinders will
If the outside temperature is 0 oC (32 oF) or be abraded and this will cause extreme oil
below, put the ignition key into “heating: consumption. Engines should never be idled for
position and heat the induction manifold for 15- a long time. (for instance, heating without a load
20 seconds. on)
a Lightly push the pedal shown as (3).
b Move the ignition key it to the start

position and hold it until the engine
starts.
NOTICE
If the engine does not start in 20 seconds then;
release the ignition key. Wait two minutes to
retry, for cool down the starter.
c Release the key as soon as the engine

starts, he will go back to “IGN” position.
Let your foot off the gas pedal slowly to
decrease the engine speed.
STARTING THE ENGINE WITH AN EXTERIOR BATTERY
WARNING NOTICE
Electrical system of this machine is 12 Volt
negative grounds. Any exterior electrical current
If the battery fluid is frozen, do not use the to be connected should be more than 12 volt.
battery. To prevent the fluid from freezing Connecting higher electrical source will damage
always keep the battery fully charged. the electrical system of your machine.
If you attempt to recharge a frozen battery or If you do not know the voltage of the exterior
try to start the engine with a frozen battery, source, contact your dealer. Do not try to jump-
battery may explode. start the machine, unless you are certain of the
voltage of the source.
Batteries release flammable gas, this may

cause an explosion. Do not smoke while How to Jump Start
checking fluid levels.
1 Parking brake should be engaged when the
last time the machinery was parked. If it was not
engaged, engage it now.
NOTICE
When you are trying to jump-start the machine
2 Turn off all switches in the cab.
with another machine, make sure that both
machines are not in contact with each other,
This eliminates the battery sparking. Turn off all WARNING
the circuits that are not connected to the ignition
key.
Before lowering the attachments, make sure
there is not anybody around the machine.
People around or on the top of the machine
WARNING can be run over or stuck between the
connections.
Do not directly connect exterior power
source to the ignition. If you do so, neutral
gear safety switch will be turned off. If the 3 If the bucket is not down, bring it down. When
machine is in the gear, it may cause the you move the control bars, it will automatically
machine move, resulting with injuries or
go down by its weight. Use the control bars to
fatalities.
adjust the speed of the bucket downward
motion. If your machine is installed with
protection valve to prevent hose breaks, you
Main cables should be in good condition and cannot bring the bucket down. In this case,
connect properly. Connect the other install safety support.
wires/cables one by one.
4 Connect the positive end of the jumper cable
and positive end of the battery of the machine;
Before connection, make sure that the end of connect the other end of the cable to positive
the battery is positive “+”. end of the exterior battery.
5 Connect the negative “-“end of the cable to an

Do not let metal wristwatch bands and appropriate location of the machine.
jewelry get close to wire connections and
battery connectors. If any short circuit 6 Read (Operation Section) to start the engine.
occurs, it may cause serious burns and may
damage the machine.
STARTING THE ENGINE WITH AN EXTERIOR BATTERY
WARNING
When the engine is in operation, in the

engine section, there are rotating parts.
Before disconnecting the cables, make sure
that your clothes, (jacket, shirt cuffs,
necktie) will not be stuck by those rotating
parts.
7 Disconnect the negative end of the cable

from the engine, then; disconnect the other end
from the exterior electric source.
8 Disconnect the positive “+” end from the

battery, later, disconnect the positive “+” end of
the cable from the exterior electric source.
PREPARING THE MACHINE FOR JOURNEY

While driving on the road or in the construction Pulled-In Position
site, there are local rules and safety regulations
identifying journey position of the machine. 1 Attachments should not exceed 2.5 meter that is
“Journey Positions on the Road and the total width of the machine. If any part is sticking
Journey Position in Construction Site” are out of the back frame, it should be signed with red
instructed in the further pages to assist you to and white strips.
apply those rules and regulations. These may
not be the ones being definitely applied. 2 Boom lock should be installed safely.
WARNING 3 In some areas, it is mandatory to have a prop

installed on the hydraulic cylinder of the bucket.
BEFORE STARTING THE JOURNEY ON THE 4 Attachments in the back of the machine should not
CONSTRUCTION SITE OR ROAD, MAKE be sticking out longer than 1 meter. If it exceeds 1
SURE THAT YOU AND YOUR MACHINE DO meter, a warning tag should be attached. If the
NOT VIOLATE RULES AND REGULATIONS. attachment is removed, revolving connection point
THIS IS YOUR RESPONSIBILITY. should be secured.
5 Balance if the machine should be maintained.

While driving either on the road or in the
construction site, there are to positions that the 6 Stop/tail/signal lights ( on both sides) should be
BACKHOE can be put in. seen clearly
1 “Pulled-In” position that the backhoe (A) is 7 Hydraulic clamps should be installed.
placed in the back of the machine in a
crosswise position.
2 “Centrally Disconnected” position that the

backhoe (B) is in a position sticking out of
the center and out of the back of the
machine. All machines mounted from the
center should be in this position during the
journey.
Selection of the proper journey position will

vary to the type of the journey, your machine,
and the equipment attached to the BAKHOE.
BACKHOE Equipments
Before starting the journey, disconnect all the
backhoe equipments. If the machine is driven
on the road with attachments, rules listed for
“Pulled-In” and “Centrally Dislocated” positions
should be applied.
Centrally Disconnected Position

1 Attachments should not change the balance
of the machine, in other words, at least 20 %
of the total weight of the machine should be
on the front axle.
2 BAKCHOE should be centered over the rear

frame and secured with a hydraulic clamp.
(This is only for side sliding machines.)
3 Boom lock should be installed in safe way.
4 In some areas, it is mandatory to have a

proper installation for hydraulic cylinder of
the bucket.
An extension tag/light should be installed. If the

attachments are disconnected, revolving
connection point should be secured and rear
extension tag/light should still stay installed.
Journey Position On The Road. Journey Position on the Road
Make sure that you have read and understood 4 Position the digger, there are to possible
the information given in the previous page. The positions. See page 39
following recommendations mean that; they are
the rules strictly to be applied. Please comply 5 Install boom and rotating locks.
with the related local laws.
6 If the rear digger is centered on the rear
chassis, install a tag/light on the bucket. Tag
NOTICE light should be plugged in, check it.
The machines that do not have headlights and
turn signal lights are designed for the 7 If the attachments are installed, secure them.
construction site usage. You will be violating For instance, install tooth protectors etc. If
the local laws, if you happen to drive these the forks are placed, bring them into fork
machines on the highway. transporting position.
1 Secure the BACKHOE bucket placing it NOTICE

inside the front loader bucket. If attached, In some countries, it is illegal not to have tooth
use the chair that is attached with a shovel. protectors on the bucket. Make sure you comply
Before starting the journey, bucket should with the local laws of your location.
be taken.
2 Turn the bucket all the way back. It should 8 When brakes applied, stoplights should come
be placed 300mm above the road. on. All pedestals should be up. Check them.
It is driver’s responsibility to apply the Highway 9 Select the following driving and towing
Vehicles Regulations. Some recommendations positions (According to machinery type):
are given in the following to be applied for a Wheel Drive Machines – “Two wheel
guiding purpose. Drive–All wheel brakes”.
Discover, beforehand, the bridges and similar
overpasses on the road that may be damaged b 4 Wheel Drive Machines – “Two wheel
by your machine. drive”.
To assure that the equipment in the moving
position, use the blocking tool (The one 10 Turn on the flashing light.
described)
11 Check if all headlights and flashing lights are
Do not use the blockage for lifting. working and clearly visible. Do not use your
machine in case both stoplights are in
3 Install the blockage to wrap around the left operative.
or right arm of the loader and secure it as
shown in D.
Journey Position in Construction

Site
The following recommendations do not mean
that they are the rules strictly to be applied.
Please comply with the related local laws.
1 Turn the bucket all the way back. It should

be placed 300mm above the road as shown
in C
2 Position the backhoe, there are two possible

positions.
3 If attachments are installed, secure them.

When you do not use the forks to transport
load, position them in a stacking position
4 Install boom and revolving locks.
5 All pedestals should be up, check them.
6 4 Wheel steering machines.
Select the most appropriate steering mode

according the work and land type.
7 Select the drive mode according to the work

and land conditions.
TESTING THE PARKING BRAKE

14 During this test, if the machine moved, adjust
WARNING the parking brake and test it again. See
Parking Brake Adjustment (MAINTENANCE
Ensure all routine health and safety section).
precautions are observed before operating
machines.
NOTICE
If you have any questions, while conducting
Before you testing the parking brake, make this test or about the adjustment of the parking
sure there is nobody around the machine. brake, contact your dealer.
WARNING
1 Get on the machine, fasten your seat belt, and
park it on a flat and dry surface.
Never operate a machine with a defective
2 Fully apply the parking brake. parking brake.
3 Start the engine, and bring the attachment to

normal cruising position. Uncertified modifications on axle ratios,
weight of the machine, size of the wheels
4 Push down hard foot brake pedal. and tires, may negatively affect the
performance of the parking brake.
5 Select forward drive mode.
WARNING
If the machine starts to move during the

following test, immediately apply the foot
brakes and reduce the engine speed.
6 While testing the parking brake:
7 Push the brake lever slightly forward until, the

parking brake warning light goes off.
8 Release the foot brake pedal slowly.
9 If the machine did not move, provide the rpm

to 1500 by pushing the gas pedal. Machine
should not move.
10 Do not conduct this test longer than 20

seconds.
11 Bring the engine to idle and put the gear into

neutral.
12 Bring the emergency brake from half pulled

position to completely pulled position.
13 Lower the attachments and stop the engine.

SETTING THE MACHINE IN MOTION
Operation Exercise UNDER NO CIRCUMSTANCES, rear axle

ventilation hole should be plugged; this may
decrease the effectiveness of the brakes.
NOTICE
Machine can be operated in any speed gear.
However, while driving uphill, do not use high- Limited Slip Differential (LSD)
speed gear; do not force the engine without a
reason. Using very high speed causes This option is preferred in some machines to
overheating the oil of torque converter. increase the power under heavy conditions. This
occurs with the transfer of the present driving
torque over the diminishing wheel from spinning
wheel. Limited Slip Differential works
While you are moving the machine, always keep
automatically and it should not be confused with
it under control. Be vigilant for obstacles and
differential locks.
possible hazards.
Skidding of a wheel indicates that the limited slip
WARNING
is exceeded. When it is operated on the high
absorbent surfaces (concrete etc), noise or
To rest your feet, do not put your feet on the sound can be heard, especially when it is locked
brake pedal. in full gear. Amount of the noise varies to the
weight of the machine, surface conditions, and
usage angles. The noise coming from LSD does
Do not drive the machine in neutral. You not indicate that there is a malfunction on the
cannot have a complete control over the axle.
vehicle. Driving the machine in neutral will
damage to the transmission gear.
NOTICE
After heated the engine and tested the
Before driving the downhill, select the parking brake, take actions as instructed in
necessary gear. While driving downhill, use the following.
the same speed gear that you use while
driving uphill. Do not up shift the gear while
driving uphill. If you are driving a machine
1. Check your seatbelt and seat.
with an automatic transmission, before
driving downhill select low gears manually.
Make sure that your seat belt is fastened and
your seat is adjusted properly.
While driving downhill, if the load is going to 2. Select 2 or 4 wheel drive. ,
push the machine, shift it to the first gear
before you start.
NOTICE
To prevent the acceleration on the downhill, Do not use 4-wheel drive on the highway or
use brake pedal. hard surfaces. This will cause the tires overheat
and excessive fuel consumption.
Drive into deep mud with the first gear, and

front wheels should be straightforward. 3. Select the desired steering mode.
(only for 4 wheel steering machines)
There is a ventilation hole on both front and WARNING

rear axles. If the machine is operated in deep
water (e.g. above the level of the ventilation)
When you make a turn with 4 wheel steering
make sure that water does not go in those
mode, the rear end of the machine will be
holes. flung. Check and see if there is enough
space, before you make the turn.
SETTING THE MACHINE IN MOTION

By using the marching selection switch, NOTICE
select the required mode. Do not forget that As you select forward or reverse gear, a light
marching mode will temporarily stay on the will come on to remind you that the parking
selected mode until the rear wheels go into brake is still on.
straightforward mode.
d Release the parking brake.

NOTICE
Crabwise Marching is not available in M542
machines. WARNING
To control the engine speed, use the gas

pedal. While driving, do not use the cruise
1 Shift in gear control to control the speed.
WARNING e After making sure that you can set in

motion safely, push the gas pedal, after
letting your foot off the brake pedal.
While the machine is in motion, do not shift Machine will start moving slowly
the gear from high to low instantaneously
(e.g. from 4th to 1st) Otherwise, the machine WARNING
will lose speed very rapidly, you or others
may be hurt or killed. Slow the engine
speed down on each shifting down. While the machine run slowly. Check the
steering and brakes if is there any problem
then stop the machine as soon as possible.
Select the desired speed gear by using gear Do not start the machine until the problem is
stick. eliminated.
2 Set in motion selecting forward/reverse

mode.
WARNING
When you are driving the machine, and if

you are using the forward/reverse stick, this
may cause injuries or fatalities of others.
Machine will instantly change the direction
of travel without warning the people in the
area. Please thoroughly comply with the
instructions given for proper use of this
mode.
a Make sure that the attachments are in

one of the journey position.
b Push the brake pedal all the way down.
c Remove the gear stick from

forward/reverse locked mode and select
forward or reverse mode. (Read note).
STOPPING THE MACHINE AND PARKING

Stop the machine on a dry and flat surface to 5 Lower the loading arms and the rear digger
prevent any hazard and accidents. If the down. It is recommended that the rear digger
machine is parked with the rear digger sticking should be put in the position as shown in A
out, it is recommended that you need to make (bucket should be open all the way, tooth of
sure there is enough parking space. the boom and bucket extended)
6 It is recommended that the machines with
turbo charge engines should keep running for
WARNING at least 2-3 minutes at 1000 rpm. This way,
turbo charge will be cooled.
Improperly parked machine can move by
itself without needing the operator. Apply 7 Before leaving the machine, make sure all
the instructions in this manual for proper switches are turned off. If necessary, leave
parking. the accident warning and sidelights on. Pull
the ignition key out.
1 Let your off the gas pedal and push the
brake pedal down. So that, machine will 8 While you get off the machine use the steps,
make a smoothly stop. Apply the force to the and the rail handles. Close all windows and
brake pedals until the emergency pedal is lock door. Make sure that radiator cap is
pulled. locked as well.
WARNING WARNING
Parking brake should not be used to slow While you get on or get off the cab, you
the machine down, except the emergency always should be facing the machine. Your
cases. Otherwise, the effectiveness of the shoes and hands should be clean and dry;
parking brakes will not be sufficient. otherwise; you slide and fall down.
If you use the parking brake for emergency
conditions then change the both brake
pads. 9 After the complete of a work cycle, or you
leave the machine, take the battery-isolating
2 Fully apply the parking brake. Make sure the key out. (if it is available), See; Battery
brake light is on. And then stop apply force (Maintenance Section)
on the brake pedals.
WARNING
Do not attempt to get off the machine that is

under the motion.
3 Push the forward/reverse gear stick to

neutral. Make sure the stick is in lock
position.
4 Lower the stabilizing until they touch the
ground.
WARNING
Make sure that there is not any crowd

around the machine before you lower the
attachments. People who are on the top in
the immediate area can be squeezed or
caught by the attachments.
USE OF ATTACHMENTS AND SAFETY OF CONSTRUCTION SITE

In this chapter, some techniques are instructed
to maintain to work the attachments fruitfully. At
WARNING
the same time, pay attention aspects of safe
working. Before you start working the machine, Water Pipes
read this chapter carefully. Do exercises using Before starting to use the machine, contact
the attachments, until you learn what their the water works and find out if there are any
functions are. water pipes underneath the construction
site. If there is any, provide a map indicating
Inform your colleagues what you will do and their locations and comply with their
where you will be working. If there is a heavy instructions.
work density at the construction site, use a
signaler.
We recommend that you should comply with the
Do not forget that your machine is vehicle that
related local laws and regulations about the
has a movement capability. In possible
safety measures.
conditions, bring your machine into a position
that can have the effectiveness and safety
together. If you have to make a choice between WARNING
effectiveness and safety, remember this:
SAFETY COMES FIRST Electric Power Lines

If you get the machine or the attachments
Select the suitable attachment for work. Do not too close the power lines, you can get
use bigger bucket for stony area. Otherwise, electric shock and or have very serious
you will overload the system and will reduce burns. We recommend that you assure that
the work life of attachment. you comply with the local laws and
regulations about working in the immediate
Safety Check List area of the electric power lines.
Underground Electric Cables

WARNING
Before using the machine, make contact with
the electric company to find out if there are
General Construction Safety any electric cables under the construction
site.
Inspect the area, before you start to work. If
the ground under the machine collapses or Air Electric Lines
the pile falls over the machine, either you
have injuries or are killed. Look around if While working under the electric lines, there
there are any holes, invisible residues, logs, is a certain distance between the machine
or metal things etc. Any of these reasons and the lines. You can find out by asking the
can cause you to lose the control of the electric company.
machine.
New work In the old construction Site

Legal Responsibility
There may be hazardous materials such as;
You and/or your company can be held asbestos, poisonous chemicals or similar
responsible for damaging the installations hazardous materials. If you reveal any
of public establishments. It is your container or come across with tocsin
responsibility to know the location of cables material, stop the machine and inform the
or pipes belonging to the public chief.
establishments that your machine can
damage.
USE OF ATTACHMENTS AND SAFETY OF CONSTRUCTION SITE
WARNING Accept every piece of cast iron you find as a

pipe until it is proved wrong.
Old gas pipes can be damaged by the
Communication moving heavy-duty vehicles above them.
Miscommunication may result with
accidents. If there are two or more people WARNING
working on the machine, notify everyone of
what you are doing. Make sure that they LEAKING GAS IS EXTREMELY EXPLOSIVE
away from the machine before you start, When you suspect gas leakages, notify the
examples for the dangerous area, such as; gas company, and warn the personnel. Ban
wheeling and their belts, attachments and smoking, make sure all open fires
their connections, all area in the back and extinguished, and stop all running engines.
underneath the machine. By not taking
these measures, you may cause the people
to get injuries or killed. Hill Skirts
When necessary measures are not taken, it
WARNING is dangerous to start the machine on the
skirts of the hills. Ground conditions can be
changed with rain, snow, ice etc. Inspect the
Safety Barricades work area carefully. Drive the machine on
Machines under protection may create the hill area in the first gear, and keep the
danger in the areas open to public. Under attachments (if they are installed). Never
the conditions, when the there is poor stop the engine or shift to neutral as you are
vision, place barricades around the driving downhill.
machine to keep the people away.
Communication
Construction Sites Miscommunication may cause accidents.
Constructions can be dangerous. Inspect Inform the others on what you will be doing.
the work area before you start to work. If you will be working with some people,
Check and see if there are any holes, loose make sure they understand hand signs.
ground, and covered rocks etc. Check if Construction sites can be noisy; do not rely
there are any infrastructure installations on verbal instructions.
such as cables, e.g. electric cables
(underground or aboveground) gas or water
Exercise
pipes etc. Mark the locations of the
If you try to accomplish a duty that you have
underground cables and pipes; Make sure
not done before, you may cause injuries or
there is enough distance between the
fatalities of yourself or others. Do the trial
machine, air power lines, and constructions
work far away from the construction site and
on an open area, make sure there is not
Underground Gas Pipes anyone around. Do not start to work until
you are sure that you can accomplish duties
Before you start to work, contact the local
safely.
gas company to find out if there any gas
pipes under ground. If there is any, obtain
information as to how the work should be
done in that area. Barriers
Some of the modern gas pipes cannot be Heap materials and dikes may collapse. Do
detected by metal detectors. For this not get too close the barriers and dikes that
reason, before starting the work it would be may collapse, and do not work in that area.
the best to have a map showing exact
location of the gas pipes. To determine the
location of the gas pipes, make testing
holes on the ground digging by hand.
WORKING WITH LOADER

Operation Exercise While moving the loaded bucket, back turn it
completely to stop the material from pouring out.
It is necessary to know MST backhoe and
loader and to have the operation capacity to If you are loading heap material, start from the
use it safely. Purpose of this manual is to show bottom, and as it is shown in the drawing, follow
you the controls and teach you how to operate the surface of the heap. Approach the heap by
it safely. However, this is not enough to use keeping the bucket straight and close to the
backhoe/loader properly. If you are not enough ground as if it will touch the ground.
experience related to backhoe/loader then; you
should have training period about the operation Start from the top when you are working with
of MST backhoe/loader. Otherwise; you cannot hard material.
work properly by backhoe/loader or you can
injure yourself. While loading from large heap, leave a bucket
size distance from the bottom of the heap. As
Do not forget that you will be driving the loader the height of the heap gets smaller, start loading
as well as working. Be careful for possible from the bottom.
hazards and people around you. Stay in proper
driving position and fasten your seat belt.
While working with the loader, keep the

backhoe in the back of the machine straight the
way you would be doing before starting the
journey on the road.
Keep the bucket close to the ground during the

journey. This will give you a better vision and
provide a good balance for the machine.
Under possible conditions, while driving

downhill with the loaded bucket, drive in the
reverse gear. Use forward gear, while driving
uphill. Do not go faster than 8 km an hour with
heavily loaded bucket.
Loading the Loader Bucket
WARNING
When you are loading from a high platform
or pile, clean the salient part first. Be careful
sliding. Falling of the salient part of the
material may cover you and the machine.
On the hard surfaces, put the bucket in free

position. As the bucket goes in the heap, lift,
and back turn it at the same time. So that, the
bucket will pick up more material, while
reaching the top of the heap.
As entering a heap, pushing the “hydraulic
speed control” switch, will provide better draw-
power.
By pushing torque transfer switch, you can
transfer more power to the loader and speed
up the work. Half-full buckets are less fruitful.
WORKING WITH LOADER
Loading a Truck Saving the Stuck Machine

0 When the machine is stuck in the heap, use the
Move the truck to the heap approximately 45 .
bucket to get it out, shift the forward/reverse
This will eliminate the unnecessary maneuver.
stick in neutral, and turn the bucket over forward
Leave enough distance to the unloading height,
as shown in the drawing.
so that you will not have to slow down.
Lift up the front wheels by selecting the low
Get the wind behind you, so that you will stop
position of the bucket. After the front wheels
the dust blown to you and the machine.
saved, turning the bucket backward, push the
machine back. When the front wheels touch the
Before unloading the material, come close to
hard surface, shift it in reverse, and drive away
the truck as much as possible.
from the heap.
If the dumper of the truck is as wide as the
bucket, pour the material on the middle of the
bed. If the dumper is as wide as two buckets or
wider, load the front part first.
Do not pour the material with one and sudden

action, turn the bucket over gradually towards
the front. To loosen up the sticky material, use
the control handle to shake the bucket back
and front.
WORKING WITH BACKHOE

Operation Exercise Preparation to Use the Backhoe
While selecting the digging position, if possible,
WARNING refrain from digging downward slope. In possible
situations, unload the load that you dig over the
space on the side of the digging area. These
Before starting to operate the BACKHOE,
measures will stabilize the machine.
you need to turn the machine a safe and
balanced work platform. For details, read
1 When the machine is in the desired position in
the preparation of the backhoe to use the
the construction site, roll the bucket forward
OPERATION section.
and lower the bucket to lighten the weight over
the front wheels.
It is necessary to know the operation capacity
of MST backhoe & loader to use it safely.
Purpose of this manual is to show you the NOTICE
controls and teach you how to operate it Do not roll the bucket completely on the asphalt
safely. However, this is not a schoolbook surfaces. Keep the bottom of the bucket
about the art of loading. If you are a new horizontal on the ground. This will keep the
starting operator, you should have training damage to the surface at the minimum level. If a
about the operation of MST backhoe/loader. If clamshell bucket is installed, do not load weight
you do not have any training, not only you will on the fork carriers.
not be able to accomplish your duties properly,
but also, you will create a hazard for yourself 2 Shift forward/reverse gear in neutral.
and others.
3 Pull emergency brake.
If you will work with a worker, make sure you
understand what each of you will be doing. 4 Turn your seat the way you will face the
Learn common sign language and use it. Do backhoe. Make sure the seat is locked. Later
not shout. He/She will not hear you. on, lower the stabilizer outrigger until the rear
wheels slightly are off the ground. Adjust the
Use appropriate bucket for the work. How to stabilizer position until the machine is leveled,
install and uninstall the bucket is instructed in as shown in the drawing B. On soft surfaces,
the further pages. place strong stabilizer underneath the
outrigger. This will provide the distribution of
In order to spend the fuel the most economical the weight and stop the machine from being
way, while operating the backhoe, try to keep stuck in the ground.
the arrow of the rpm indicator stay in in band,
shown with A.

3 Pass the Digger Arm through the
Uninstalling of Bucket Bucket
1 Adjust the Position of Backhoe Using the controls carefully put the holes on the
connection of dipper and the lever with holes of
Put the Backhoe in straight position in the back the bucket on the same level. Push in the hinge
of the machine. Lean the bucket on the flat pin A. Put the screw B and tighten.
surface as in the drawing. To prevent the motion,
chock it.
WARNING
While pulling out the pins of the hinge, stand

on the side of the bucket and away. After the
pins pulled out it may fall over.
2 Pull out the Pins

Remove screw B and pull out pin A.Repeat this
process for both pins.
3 Pull the Backhoe Arm

Lift the bucket carefully and separate it from the
backhoe by using the control arms.
Installation of the Bucket

1 Adjust the Position of the Bucket
Place the backhoe bucket on a flat surface in a

straight position, using a suitable lifting tool. As
shown in the drawing.
WARNING
If two people will do this, make sure the one

who will use the controls is an experienced
operator. When wrong control bar is moved
or roughly used, the other person either can
be injured or killed.
2 Drive the machine reverse, while lining up

the bucket’s hinge section with end of the
dipper.

BACKHOE
NOTICE
This drawing is showing a typical MST
Backhoe-Loader work machine. However, this
may not be same as your machine.
In order to start digging, bring the backhoe

bucket to the position shown in A, extending
the boom and backhoe arm forward.
Slowly close the bucket and place on the

ground at the same time. While pulling the
bucket, make sure that the angle to the ground
stays same. If necessary, push the boom down
to increase the digging power of the bucket.
When the bucket is full, close it completely, and

at the same time, push the dipper a little
forward as shown in B. This will prevent the
accumulation of the dirt under the machine.
As shown in C, turn the dipper towards where

you will unload the dirt. Unload the dirt as the
dipper approaches the pile. Do not waste time
by piling far away from the digging area. Start
piling on a place close to the place where you
started digging. Taking the dipper back to
digging area, keep on digging.
NOTICE
Do not use the sides of the dug hole to stop the
digger. This may damage the machine.
Backfill the hole, by loading the dipper with dirt,

do not push the dirt with the side of the dipper.
Side sliding the BACKHOE
NOTICE
Before side sliding the digger, clean the turning ways
if they are dirty.
1 To adjust the level the machine using the stabilizer

and fix them bringing the turning 1 shown with A to
upright position.
2 Lean the backhoe dipper on the ground on a level

in the back of the machine, as in the drawing.
3 Open the tightening clamps and push the

tightening lock switch on the indicators panel to
turn it ON. Switch light should be lid.
4 In order to loosen it on the turning rails, move the

boom up and down for few times.
5 Lift the bucket as shown in C and turn to a side of

the machine. Turn it to left when you want it slide
to the right side and turn it to the right, when you
want it to slide to the left side. Lean the dipper
bucket on the ground that it should stay at a 900
angle to the boom.
6 Open the backhoe bucket. As the dipper opens,

turning will be pushed to the back of the machine.
If the turning A is stuck in the middle, slightly lift or
lower the boom to have the turning stay upright on
the rails.
7 When the turning reaches the desired position,

push tightening lock switch shown with B to turn it
OFF to tighten the clamps
NOTICE
The pressure occurring on the backhoe system will
help the clamps to pass through completely. Before
starting the digger, move the control arm of the
digger until it is filled and hold it in this position for at
least five seconds
Use of Telescopic Arm (If installed) WARNING
Telescopic arm, during digging and unloading, At the times when extra digging is not
helps you to reach farther locations. Before required or an attachment besides the dipper
using, telescopic arm lock should be unlocked. is installed, pull the extendable dipper
completely and lock it.
1 Place the digger on the ground and change
the locations of the pins holding the backhoe a Pull the extendable digger back
bucket as in the following: completely.
b Pull out locking latch B.
a Pull out the pin locking latch B.
c Lift the pin until the second locking hole
b Lift the pin until the second locking hole.
d Pass locking pin B through the hole
c Pass the locking latch through the hole
again.
2 Lift the backhoe bucket off the ground,

before you use the telescopic arm.
3 Using the pedal operated by foot shown with

C, take the bucket to the required point and
depth. To unload the bucket, lengthen or
shorten it as in D.
NOTICE
You should take the following measures during
the telescopic arm completely extended. If
these measures are not taken, the machine will
become unbalanced and can be damaged.
I) In maximum extending, make sure the

backhoe does not exceed the working capacity.
II) When the backhoe side slid, be careful for

turning to that direction. To prevent the loss of
the balance of the machine, turn the backhoe
slowly. For the same reason, if possible, refrain
from unloading downhill.
III) During the digging, do not extend or shorten

the arm.
4 When it is not needed, telescopic arm

should be pulled back and locked the way
instructed in the following.

1 Bring the machine into the right position; see
Lifting with Backhoe Preparation to Use Backhoe section.
Machine owner and/or operator should be sure 2 Fix the lifting chains on the hook A. Make the
that they realize the related laws and chain as short as possible to prevent
regulations about the usage of MST as swinging. Start lifting with the backhoe bucket
backhoe and loader for excavation or crane is closed. Bring the backhoe arm close to the
work for more information, contact the dealer. boom.
If your machine is not attached with lifting point 3 By opening the backhoe bucket slowly, lift the
such as a certified hook, it should not be used load and move it forward. Push the backhoe
as a crane. You only should use it for arm, lift the load. In order to determine the
excavations. exact height, open the backhoe bucket
If your machine is attached with a certified .

lifting a hook or a ring and tested for safe 4 Take the load down by pulling the backhoe
weight operation, documented and registered, arm.
complying with all regulations, then it can be
used as a crane.
Read The Following Before Lifting

Load With The Backhoe
Always use a sufficiently strong and in a good
condition lifting system. When selecting, check
the lifting weight of chains.
In order to lift with the digger, a backhoe bucket
should be installed. Make sure that the load of
the backhoe bucket does not exceed the safe
working weight.
Tie a securing cable on the load. Make sure

that the individual who will hold the cable stay
away from the machine. Lift the load 25-30mm
off the ground and test it by moving the load,
using the controls, above the ground slowly.
When the load is on the digger, make sure that

there is not any body around the machine.
The moment you feel that either the load or the

machine becomes unbalanced, put the load on
the ground.
If you do not care of these warnings then

there will be death or injuries.
For more information that is detailed, read

Lifting (Using Crane) Instructions and safe
working loads in SPECIFICATIONS section.
OPERATION IN COLD AND HOT AIR

Cold Weather
Take the following measures while working in
cold weather conditions. These measures will
maintain the machine work easier and prevent
the possible damage.
1 Use the engine oil with suitable viscosity.
2 If possible, use low temperature diesel fuel.
3 Use the right coolant.
4 Keep the battery fully charged.
5 Refill the fuel tank after each working period.

This will help to prevent the tank walls from
becoming dense.
Hot Weather
6 When not in use, park the machine in a
building or cover it with a waterproof tarp. Taking the following measures while working in
hot weather conditions, you can prevent the
7 In cold weather, use engine-starting aid. In machine from damaging possibility
very cold weather, for example at -180C
lower temperatures, it may be necessary to 1 Use the proper viscosity engine oil.
start using auxiliaries such as fuel, oil, and
coolant heaters. For more information, 2 Use the right coolant
contact your dealer.
3 Check the cooling system periodically. Keep
8 Before starting the engine, clean the snow the radiator fluid level. Make sure that there
off the hood and ventilation holes shown is not any leakage.
with a, otherwise snow can go in air cleaner.
4 Keep the radiator clean. Periodically clean
the dirt and waste off the radiator and the
WARNING engine.
Do not attempt to start to work with the 5 Check the fan belt periodically.
machine immediately in the cold weather.
Machine may not respond right to the
control actions. While the engine is running
with half way acceleration, let the engine
run for at least 10 minutes to heat up. To
heat the hydraulic fluid, move the arm and
backhoe bucket.
RELOCATION OF A DEFECTIVE MACHINE
Preparation for Towing WARNING
Tow the machine only when there is no other Blockade the loading arms, before tying the
choice. Do not forget you can put more tow bar.
damage to the machine by towing. If possible,
try to repair the machine where it is. If it is
definitely supposed to be towed, read the Now, machine is ready to be towed. Make sure
WARNING notes and go by the instructed you understand what the driver of the towing
procedure. vehicle will be doing. Comply with the
instructions given by him and related
WARNING regulations.
Also, do not forget that you will have to spend
more effort to turn the steering wheel, since the
Towing for too far or too fast may damage engine will not be running.
the transmission. Tow the machine
maximum 1.5 kilometer away. When the
machine is needed to be towed, prepare it
the way it is instructed in the following and
do not exceed the speed of 25 kilometer per
hour. If you do not apply the instructions,
fluid will be short and transmission will be
damaged.
Use a strong tow bar. If towing chain has to

be used, use two vehicles for towing. One
of the towing vehicles should be tied to the
machine in front of defective machine;
second vehicle should be tied to the
machine in the back to serve for braking.
Towing vehicle should have enough power

move and to stop the machine.
1 Engage parking brake.
2 Put forward/reverse gear stick into neutral.
3 Prepare the machine for the road. If the

engine cannot be started, backhoe bucket,
and pedestals should be put in transport
position and secured.
4 How this procedure will be done depends on

the conditions of the machine and hydraulic
system.
Because of this reason, before you start the

preparation, you should contact the dealer
and receive their assistance and advice.
5 Tie the tow bar to a suitable place.

RELOCATION OF THE MACHINE

“This product will be relocated as it is instructed in the following “
WARNING a Make sure that ramps are on the right
locations and secured.
b Preparation of the loading bucket and the
During the transportation of the load, backhoe for transportation as it is
transportation company and the driver are instructed in (Operation Section)
responsible for safety. Any part of the c Drive the machine carefully over the rails.
machinery, attachment or parts that may d Engage the parking brake and shift it to
move during the transportation should be neutral.
secured properly. e When the machine is safely place, unlock
the boom lock. Lower the loading bucket
and the backhoe. For side sliding
Before you relocate the machine, make sure machines, lower the stabilizers down. For
that it will be legally appropriate for the laws centrally supported machines, secure the
and rules of the all areas that it will go through. stabilizers during the transportation to
See the section (Technical Specifications) to prevent the movement.
make sure the length of the relocation vehicle, f Place the revolving lock.
weight of the vehicle and dimensions are g Make sure the overall height of the load is
appropriate. within the regulations. If needed, adjust it.
h Stop the engine.
i Secure the cab.
WARNING
j Cover the exhaust pipe.
Before you load the machine onto the

trailer, make sure that the ramp does not NOTICE
contain oil, grease, and ice. Wipe off oil, If revolving cannot be installed for any reason,
grease, and ice on the tires of the machine. bucket should be safely tied to the bed of the
Make sure the machine will be able to be trailer. If bucket could not be placed, tie the
loaded over the ramp/trailer meeting point edge of the Backhoe tightly to the trailer bed.
without being stuck on anything. See 4 Chain the Machine
TECHNICAL SPECIFICATIONS section for Put blockers in front and rear of all four tires.
the distance between the machine and the Chain the machine to the trailer. Chaining
ground, locations are shown with X.
1 Block the Tires of Transporting Vehicle 5 Measure the Height of the Machine
2 Block front and rear tires of the trailer Measure the maximum height of the
3 Move The Machine Onto The Ramp machine. Make sure the driver knows that
height.
75 MAINTENANCE
OILS – HEALTH AND SAFETY
It is so significant to read and understand the given information and the publications are attributed here.
Let all of your colleagues, who deal with oils, read this information.
Cleaning 3 Pay attention to the following points while

cleaning the engine oil that smeared on your
The existing oil existing in the hydraulic system do not skin:
cause any risk for health if they used by correct
purposes. a Wash your skin with soap and plenty of
water.
In addition, frequent or excessive contact of your skin b Use a nailbrush.
with the oil may result in loss of natural fats in your c Use special cleaning products to clean
skin, and accordingly, dryness and irritation. your hands.
d Do not use gasoline, fuel oil or paraffin to
Low viscosity oil can cause such risks; therefore, be clean your skin.
careful when working with the dirty and used oil that
might be smeared with fuel. 4 Be careful of smeared clothes which contact with
your skin.
While working with petroleum products, you should be
more carefull of application of cleaning standards on 5 Do not put oiled parts in your pocket.
personal and workplace area as well. In addition you
should follow the publications of the regional health 6 Wash your dirty clothes before wearing again.
institutes in order to obtain such precautions in detail.
7 Dispose the shoes that absorbed oil.
Storage
Keep oil away from the reach of the children. First Aid (Oil)
Never place the oil in open or unlabeled containers. Eyes

In case, If any contact occurs with eyes, wash your
Waste-disposal eyes with plenty of water for 15 minutes. See a
doctor if the irritation continues.
All detrimental waste should be disposed in
accordance with the related directives. Swallowing
If you swallow oil, do not try to vomit. See a doctor.
Discharge and disposal applications should be
performed according to local directives. Never dispose Skin
used engine oil into the canalization or gutters. In case of excessive contact with the skin, wash
with soap and water.
Usage
Spilling
New Oils
No special precaution for using or working with new oil Use sand or approved absorbent granules for oil.
except for normal care and cleaning procedures. Then sweep and take to chemical substance
disposal area.
Used Oils
You should follow precautions when you contact with Fire
used oil in order to protect your health Extinguish with dry chemicals or foam. The people
who extinguish the fire should use external
1 Prevent repetitive contact from used oil with your respiration device and mask.
skin.
2 Apply protective cream on your hands when you

touch with the used engine oil.
76 MAINTENANCE
SERVICE REQUIREMENTS
Introduction Support for the Owner/Operator
The machine is designed and manufactured in order MST aims to let you satisfy with your new MST
to give the highest performance. It can be used easily vehicle. However, when you meet any problem,
and economically in various work conditions. It was please contact with the Service Department of the
controlled in the factory and in the distributor before Distributor who wants to help you.
delivery with respect to the guarantee of the best When you buy your vehicle, the vendor shall give the
condition. In order to procure its good position and its list of all Service Departments.
operation facility without facing any difficulty, it should
be serviced by authorized MST vendor at regular In order to benefit from the Service completely,
intervals as mentioned in this Manual. please present them following details.
Maintenance 1 Your name, address and telephone number.

2 Model and serial number of your vehicle.
In this part of the Manual, all service requirements are 3 Date of delivery, and operating hours.
mentioned in details in order to warrant full efficiency 4 The details of the problem.
of your MST vehicle.
Remember that the MST Service has various
In order to maintain the performance of your vehicle, resources to help you for your problem.
the first service and audit should be performed after
one month or after completing the initial 100 hours of Service & Maintenance Contracts
duty (whichever occurs first). Inform your service
previously in order to make necessary arrangements. We recommend you to benefit from Service and
Maintenance Contracts offered by your Service that
As it will be detailed in the following pages under will help you to plan your maintenance costs and to
“Service Periods” title, most of the required service spread the manufacture and service expenses of
controls should be carried out only by a competent your vehicle into equal periods. Such Contracts can
MST technician. Only the trained MST Service be specially laid out according to your working
Technicians are equipped with special tools and conditions and your suitable time.
control devices in order to fulfill such duties Please contact your authorized MST Service for
completely, reliably, correctly and sufficiently. detailed information on this matter.
MST Service Staff are regularly informed about new

product improvements, and the modifications in the
features and applications of the products. Therefore,
only the authorized MST Service Staff can perform
maintenance and service of your Machine completely.
The Service Enrolment Form enclosed to this Manual

will help you to arrange your service requirements and
to record your services. This record should be sealed
and signed by our staff and written down the date
after each services.
Do not forget that regular and complete services will

maintain the reliability of your vehicle as well as
keeping its value when you consider selling it.
77 MAINTENANCE
CLEANING
Park your machine on a flatness ground, lift the hand
brake and release the gear. Lower the riggers on the
ground and shut down the engine.
Clean the machine with water and/or steam. Prevent

piling up of mud, dirt (etc.) on the machine and
especially pay attention to the following points:
1 Excavation hoses installed on the main chassis

2 Return pistons
3 Kingpost sliding rails
4 Kingpost hose tray and the lower “shelf”
5 Return pistons and the kingpost casting
The cavities of the stabilizers can be plugged while

working on soft/wet ground conditions. Remove any
dirt and clean it.
Do not allow piling up of mud at the engine and

gearbox. Be careful of plugging of the radiator grid.
ATTENTION
Do not allow light, flying and combustible

materials such as straw, grass, sawdust, etc. to
be piled up in the engine compartment or inside
the prop-shaft protectors. Check these parts
frequently and clean before starting work each
time or more frequently if required. Ensure that
there is no dirt on the engine lid before opening
it.
Do not use detergent alone.Dilute it according to the

recommendations of the Manufacturer. Otherwise,
the paint of your vehicle can be damaged.
Remember that washing with high-pressure water

may harm the felts and bearings. During regular
washings, do not expose pressure water directly on
the oil felts and articulations.
Note: The vehicle should be greased every time after

being washed by pressure water or steam cleaning.
Always follow the local applications for disposing

wastes that remain after cleaning the machine.
Some parts should be cleaned completely that are

displayed in the figures.
78 MAINTENANCE
DAMAGE CONTROL
Check whether steel parts are damaged or not. Check all ladle nails for any damages.
Check whether the paints are damaged to be able to
repair in the future or not. Check whether the lamp glasses are damaged or not.
Check whether the articulation pins are placed at the Check whether the tires are damaged, or any sharp
correct position and are secured with the locking objects thrust or not.
mechanisms.
Check whether all safety labels are at the right places
Check whether the steps and banisters are damaged and are not damaged. Stick new labels/stickers if
or not. required.
Check whether are there any break or crack on the

windows or not. Replace the broken window.
SPARE PARTS SUPPLY

We recommend you to use only original MST spare
parts. The Excavator-Loader Spare Part Catalogue will
help you to determine parts and order from your
authorized MST Vendor.
The Vendor will ask for the certain model, manufacture

and serial numbers of your Machine. The Serial Number
of the Machine is written on a plate placed at the left part
of the machine.
The plate also indicates serial numbers of the engine,

gearbox and axles. However, if any of these units is
replaced, the number on the plate will be wrong.
Therefore, directly look at the serial number written on
the replaced unit.
ATTENTION
There are Warning Labels on some parts of your

machine. Ensure that the Warning Label to be stuck
on the replaced unit is attached correctly. See
Safety Labels Section in the INTRODUCTION Part. If
there is no label, then apply to your authorized
Service.
79 MAINTENANCE
SERVICE PERIODS
Maintenance application is very important because of The Maintenance applications should be arranged at
the risk both for the operator and the other staffs. operation time of the machine considerably except for
Please perform regular maintenance and greasing the daily maintenance applications. Check the
applications at the suggested service periods in order operation timetable frequently in order to follow the
to allow safe and regular operation of your machine. service periods. Do not operate the machine that
ATTENTION requires service. Repair the defects which have seen
during the regular maintenance applications
Maintenance should be carried out by the immediately.
authorized MST service staffs. Before starting any
maintenance application, check whether the Calendar Equivalence
machine is secure. Park the machine on a smooth 10 Hours: Daily
surface. If it is required to work as the loader 50 Hours: Weekly
handles are lifted, insert the safety prop in its 500 Hours: Six Months
place as mentioned in Loader Handle Safety Prop 1000 Hours: Annual
Section (MAINTENANCE Part). 2000 Hours: 2 Years
Pre-Operation Cold Checks Operation 10 H 50 H 100 H 500 H 1000 H 2000 H

Service Points and Liquid Levels
MOTOR
Oil Level Control ● ●
Oil and Filter Replace ● ● ● ●
Air Filter (Internal and External Element) Replace ● ●
Fuel Filter Replace ● ● ● ●
Fuel Filter Discharge ●
Cooling Quality/Level Control ● ● ● ● ● ●
Fuel Precipitator Discharge and Clean ● ● ● ● ●
Ventilator Strap Tension/State Control ● ● ● ● ●
Engine Connection Bolts–Squeezing Control ● ● ● ●
Radiator Clean ● ● ●
All Hoses – State Control ● ● ● ●
GEARBOX, AXLES and STEERING

Gearbox Oil Level Control ● ● ● ●
Gearbox Oil Replace ● ● ●
Gearbox Filter Replace ● ● ● ●
Gearbox Filter Clean ● ●
Axle Oil Level Control ● ●
Axle Pulling Heads Oil Level Control
Front Axle Oil (M544 / M542) Replace ● ● ●
Back Axle Oil (M542) Replace ● ● ●
Back Axle Oil (M544) Replace ● ● ●
Rubber Pressures Lug nut Nuts/State Control ● ● ● ● ● ●
Front Rim Bearings Control ● ● ● ●
Prop Shafts Secure/Grease ● ● ● ●
Steering Axle Motion /Rolling Control ● ● ● ●
Axle Pivots and Connections Grease ● ● ● ●
Front Axle Main Pivot Grease ● ● ● ● ● ●
HYDRAULIC SYSTEM
Oil Level Control ● ● ● ● ●
Oil Replace ●
Oil Filter (Turning) Replace ● ● ● ●
Oil Filter (Absorption) Replace ● ● ● ●
Pistons Chrome State Control ● ● ● ●
Hydraulic Oil Cooler Control / Clean ● ● ●
Hydraulic Pump Prop Shaft Control / Grease
BRAKES
Brake System Control ● ● ● ● ● ●
Hand Brake Control and Adjust ● ● ● ●
ELECTRIC SYSTEM
Battery Electrolyte Level (if required) Control ● ● ●
Battery Poles State and Tightness Control ● ● ● ●
80 MAINTENANCE
SERVICE PERIODS
(Continued)
Pre-Operation Cold Checks Operation 10 St 50 St 100 St 500 St 1000 St 2000 St
Service Points and Liquid Levels
CAROUSER and CABIN

Pins and Bearings Control / Grease ● ● ● ● ● ●
Door/Window Hinges Grease ● ● ●
All Cables Control ● ● ●
Telescopic Handle Adjust / Grease ● ● ● ● ●
Kingpost Pistons Control and Adjust ● ● ● ●
Door – Soundness and Locks Control ● ● ● ●
Cabin Seat – Functions Control ● ● ● ●
Front Fender (M544) Control ● ●
Front Window Sprayer Liquid Level Control ● ● ● ● ● ●
Installation of Bom Lock Control ● ● ● ● ● ●
Paint State Control ● ● ● ●
Leaks and/or General State of Machine Control / Clean ● ● ● ● ● ●
RIGGINGS
Self opening-closing Cauldron Grease ● ● ● ● ● ●
Function Test and Final Inspections Operation 10 St 50 St 100 St 500 St 1000 St 2000 St
MOTOR
Release Cycle Control / Adjust ● ● ● ●
Fall Cycle Control ● ● ● ●
Maximum Load-free Speed Control / Adjust ● ● ● ●
Exhaust Fume (excessive) Control ● ● ● ● ●
Exhaust System Safety Control ● ● ● ●
Air Input System Safety Control ● ● ● ●
Gas system and Control Cable Control ● ● ● ●
GEARBOX, AXLES and STEERING

Drawing Modes – Running/Phasing Control ● ● ● ● ● ●
2TD/4TD Selection Control ● ● ● ●
Wheel Nuts Torque Control ● ● ● ● ● ●
Forward/Backward and gear changing - Operation Control ● ● ● ●
Steering Circuit Pressure Control ● ● ● ●
Gearbox Main Line Pressure Control ● ● ●
Gearbox Discharge Operation Control ● ● ● ●
Marching at the Release gear Control ● ● ● ● ●
Brake lining Group Pressures Control ● ● ● ●
HYDRAULIC SYSTEM
MRV Pressure Control / Adjust ● ● ● ●
Operation of All Services Control ● ● ● ● ●
Hose Puncture Protection Valves (if available) Control ● ● ● ●
Discharge Valve Pressure Control / Adjust ● ● ● ●
Auxiliary Circuit & Pressures Control / Adjust ● ● ● ●
BRAKES Control ● ● ● ●
Foot Brake – Operation Control ● ● ● ● ● ●
Hand Brake – Operation
ELECTRIC SYSTEM
March Engine Control ● ● ● ●
Alternator – Output Control ● ● ● ●
Operation of all Electrical Devices (e.g. warning Control
● ● ● ● ● ●
lamps, flashes, alarms, horn, wipers, etc.)
Engine Shut down Solenoid/E.S.O.S. Control ● ● ● ● ● ●
CAROUSER and CABIN Control
Nails and Side Nails Control ● ● ● ●
Doors and Windows – Riggings/Leaks Control ● ● ● ●
Seat/Seat Belt Control ● ● ● ●
81 MAINTENANCE
SERVICE PERIODS
(Continued)
⌧ Note : The initial service of 100 hours should be performed only by authorized MST Service.
Note : Check leaks for each 50 hours. If there is leakage, then check the level.
Note : Check Hydraulic liquid level when the loader and backhoe are at the movement motion position.
Note : The applications that are marked with sign should be carried out by a competent technician.
Note : If you work under hard conditions, replace the engine oil and the filter for each 250 hours.
Note : Check all systems such as hydraulic, engine (cooler, fuel and oil), gearbox, brakes, axles, etc. for
general leaks. If there is a leakage, find out its source and repair if possible. After repair, fill liquid into the system
at the sufficient level. Some of the common following defects can occur on the machine: paint, flooring, window
wicks; repair such defects in the required way and time. If any repair and liquid filling operations are not referred in
this Maintenance Manual, apply to the authorized MST Service for detailed information.
Note : If the machine is operated under dusty conditions. Clean the cabin heater more often.
Note : Axles and movement pivot were greased with high performance grease at the factory. If the standard
application is applied during the Service, then the service period would reduce to 50 hours. Apply to MST vendor
for information.
Note : After a gearbox repair, the new oil should be poured at the operation temperature, and the poured oil
should be replaced again in order to clean any dirt that might have entered during repairing application. If the oil is
polluted due to or after any defect (e.g. water leakage), then replace the oil and filter following 100 hours again.
Note : After the repair of the rim, the new oil should be flown at the operation temperature, and it should be
replaced again in order to clean any dirt that might have entered during repairs. Replace the oil following 100
hours and clean the precipitated abrasions. If the brake linings are replaced, this point is especially significant.
82 MAINTENANCE
LOADER HANDLE SAFETY PROP
INSTALLATION
Before working under the loader handles at the lifted

position, install the loader handle safety prop as
mentioned below.
ATTENTION
The loading handles, are at the lifted position,

may suddenly fall down and cause serious
injuries. Before working under the loader handles
at the lifted position, install the loader handle
safety prop.
1 Empty the ladle and lift the Loader Handles

completely.
2 Shut down the Engine.

(Take out the contact key.)
ATTENTION
If the loading control runs by accident, you may
die or be injured. While releasing the safety prop,
make sure that nobody is around the machine.
3. Remove the prop

4. Install the prop
5. Bring down the prop on the roller
You should bring down loading handles on

the safety
prop carefully, as shown in the figure, in
order to
eliminate the possibility of slipping of the
loading
handles and compress your fingers.
Note : Operate the control stick carefully while

bringing down the Loader. Operate the stick with little
motions in order to bring down the Loader very
slowly.
Removal
1. Lift up the Loading Handles completely
In order to remove the weight on the safety prop
2. Shut down the Engine.
(Take out the contact key.
3 Remove the prop

4 Lift the prop
83 MAINTENANCE
ENGINE HOOD
Opening and Closing the engine hood
ATTENTION
Before dismantling the engine hood, the loader

handles should be lifted or locked. Keep the
handles locked until reinstalling the hood. If you
do not lock the Loader handles, the ladle may fall
down and cause injuries. See Loader Handle
Safety Prop Section in MAINTENANCE Part.
ATTENTION
Do not open the engine hood while the engine is

running.
1 Lift Loader handles and install the safety prop.

See Loader Handle Safety Prop Section
(MAINTENANCE Part).
2 Shut down the Engine and remove the contact

key.
3 Unlock the handle B with its key and pull the

engine hood upwards.
4 Close again the hood carefully and insert into

its place. Lock the handle.
In the daily controls, it is possible to reach the

engine from the left side of the machine by using the
steps as shown in the figure C. Do not step on
thefuel tank.
ATTENTION
Your leg might squeeze between the lifting stand

and the machine. Use existing steps to prevent
such a risk. If you do not use the steps the other
staff may be injured.
84 MAINTENANCE
SAFETY BELT
Checking the State and Reliability of the Safety Belt
ATTENTION
If the safety belt is damaged, if its fabric worn out, or if the machine had an accident before, then replace
the safety belt. Replace the safety belt once in three years.
Check whether there are wearing out and tension indications at your safety belt. Its appearance has to be safe
by the seam of the belt and also any damage. Check whether the belt lock is robust and work regularly or not.
Check whether the belt montage bolts are robust, installed and is tightened correctly or not.
85 MAINTENANCE
GREASING
In order to have efficient operation of your machine, Greasing should be applied with a greasing pistol.
you should grease it regularly. Regular greasing will Normally two sprays with the pistol are enough.
also extend the operation life of the machine as well. When you see new grease on the seal, stop
greasing.
The vehicle should be greased after each washing by
pressure or steam cleaning. The points to be greased are numerated in the
following figures. Follow this order while performing
greasing. After finishing greasing, reinstall the dust
lids.
ATTENTION
If you will work near the machine while Loading Arm

performing these aplications, bring down the
attachments if possible. Remove the contact key Each point to be greased should have a counterpart
and dismantle the connections of the battery. at the other side of the machine.
This will prevent running of the engine. Make
sure that you have pulled the hand brake.
Before lying under the machine, place a stopper

at each wheel.
86 MAINTENANCE
GREASING
(Continued)
Backhoe
Total points to be greased: 13
Note: A typical bom and backhoe arrangement is shown in the Figure.

87 MAINTENANCE
GREASING
(Continued)
Front Axle (M542)

Note: The greasing point number 5 is mounted at the side of the main chassis, is a remoted greasing point
Front Axle (M544)

Note: The greasing point number 5 is mounted at the main chassis behind the battery, is a remoted greasing point.
Rear Axle (M544 )

Note: Steering piston exists at the rear axle of M544 backhoe loader. M542 rear axles don’t need greasing
88 MAINTENANCE
GREASING
(Continued)
Telescopic Dipper Shafts
Extend the telescopic dipper. Grease the sledges as
shown in the Figure. Front Shafts
Back Shafts
89 MAINTENANCE
GREASING
(Continued)
Clam Shovel Kingpost
3 points to be greased at each side. Total points to be greased: 10

90 MAINTENANCE
TIRES AND WHEELS

Inflating Tires Torque Control of the Lug nut
These instructions are about pumping air to an
already inflated tire. If the entire air of the tire is run Check the torque settings of the rim nuts every two
out, you should apply to a competent tire technician. hours for the new machines whenever one of the
The technician should use a tire inflating cage and wheels is replaced.
appropriate apparatus for the work.
Check the tightness of the rim nuts before starting
work every day.
ATTENTION
Correct torque settings are shown in the table below.
A split tire may cause death. Inflatable tires can
also be split when they are heated excessively.
Do not cut the rims and do not perform welding Front – (544) Nm (542) Nm
on the rim. Make all repair works by a competent 680 370
tire/wheel master.
Back – Nm
1 Prepare the Tire 680
Before pumping air into the tire, make sure that
it is adequately placed on the machine or it is ATTENTION
placed in a tire- inflating cage.
2 Prepare Equipment No matter what the reason is, when you replace
Absolutely use an air pump system that has a one of the wheel pim; you should replace set of
pressure regulator. Adjust the regulator so that it them because if one of them is defected, the
shall not exceed the 2,38 bar pressure others might be defected too.
suggested for a tire. See Tire Dimensions and
Pressures Section (FEATURES Chapter) for
the tires and pressures suggested for your
machine.
Use an air hose that can be closed with a

remote control, and the self-locked joint
connection.
3 Pump Air
Let the air hose link to the tire valve correctly.
Let everybody go away from there. Stand behind
the tire base while pumping air.
Inflate the tire at the suggested pressure. Do not

inflate more than it is suggested.
91 MAINTENANCE
BRAKES
Using of Hand Brake
1 Push B button and don’t release it.
2 Pull A handle uprights until its comming to end .
3 Release B button.
4 Push again B button and A handle downwards

until its end position.
Carraro-Safim Brake system diagram

92 MAINTENANCE
ENGINE AIR FILTER

Replacement of Filter Components 4 Open A clips and remove external filter B.
5 Clean inside of the bucket with a piece of

WARNING
damp cloth without letting dust into the
system. Clean the dust of C valve.
When the light of the air filter turns on the
display panel the internal and external filter 6 Remove D internal element.
elements should be replaced.
7 Place new D element.
Note: Do not attempt to wash or clean the
components. Just replace them. 8 Place new B element and squeeze A clips.
1 Shut down the engine. 9 Reinstall H reduction hose. Ensure that the
display sensor is installed.
2 Open the engine hood.
3 While replacing the inner part, close the head of

the hose to prevent rains and dirt into the
engine.
93 MAINTENANCE
ENGINE OIL AND FILTER

Oil Level Control
1 Park the machine on a flat ground, pull the hand

brake and release the gear. Raise the loader
lever and block. Lower the loader lever and the
backhoe on the ground, let the engine to the
OFF mode, and remove the contact key.
2 Open the hood.
3 Check whether C Oil level is between two

notches on the C stick.
4 Fill oil from the D lid. Ensure that the oil stick
and the lid are placed and tightened well.
94 MAINTENANCE
ENGINE OIL AND FILTER

(Continued)
Replacement of Oil and Filter
Empty the oil when the engine is warm, as the 6 Fill the engine with oil up to the Max sign on the
smeared substances in the suspension will discharge control stick. See the chart at the end of the
together with the oil. Park the machine on a sound MAINTENANCE Chapter for recommended oil.
ground. Clean any spilled or splashed oil. Check whether
there is any leakage or not. Place the depot lid
1 Park the machine on a sound ground. Make sure correctly.
that the hand brake is pulled and the gear is
released. 7 Being sure that the engine will not run, turn the
contact key so that it just runs the march engine,
and wait until the oil pressure LED indicator shuts
2 Open the hood. down. (Remove the solenoid engine switch off fuse
ATTENTION in order to prevent running of the engine)
8 Reinsert the solenoid engine switch off fuse and

Make sure that it is safe to underlie the machine. start the engine. Check for any leakage. Check oil
Bring down the attachments, pull the hand brake level when the engine cools down.
and remove the contact key.
3 Remove the front shutter. Remove the safety
prop, bring down the loader lever and the
backhoe, shut down the engine at the OFF
position and remove the contact key. Dismantle
the battery connections.
4 Empty oil.
WARNING
The oil will flush out suddenly when you open the
discharge lid. Hot oil and engine parts may cause
injuries. Get a side when you open the lid.
a. Place a plate at suitable size under the

discharge valve.
b. Remove O-ring with the discharge plug

displayed with C. Empty oil, clean the
discharge plug and replace with a new O-ring.
Squeeze at 34 Nm.
5 Replace the filter.
A Dismantle the D filter vessel. Remember that it

will be filled with oil.
B Check whether the G adapter is undamaged and

at its place.
C Clean F filter head.
D Add clean engine oil into the new filter vessel.

Allow sufficient time for the filtration of the oil on the
filter element.
E Daub E felt on the new filter with oil. Insert the new
filter vessel into its place. Just squeeze by hand.
95 MAINTENANCE
ENGINE COOLING SYSTEM
Controlling the Coolant Level

ATTENTION
When the cooler is hot, that means there is

pressure in the cooling system. A hot cooler
mixing may cause body injuries. Ensure that the
engine is cooled down before checking the
coolant level or discharging the system.
1 Park the machine on a flat ground. Pull the hand
brake and release the gear. Bring down the
loader levers and the backhoe on the ground,
shut down the engine and remove the contact
key.
2 Open the bonnet.
3 The coolant level should be between COLD/MIN
and HOT/MAX on the coolant vessel B. Fill with
water/antifreeze mixture if required. Keep your face a side from the discharge outlet
while pulling out the discharge plug.
4 Remove D discharge plug and let the oil emptied.
Ensure that the discharge outlet is not plugged.
5 Remove D discharge plug and empty the coolant.
Wash the system with clean water.
Replacement of Coolant
ATTENTION
When the cooler is hot, that means there is 6 Clean D plug and reinstall. Ensure that it is at the
pressure in the cooling system. A hot cooler security mode. Connect the radiator hose.
mixing may cause body injuries. Ensure that the 7 Mix and use the water and antifreeze. See Coolant
engine is cooled down before checking the Mixtures Section (MAINTENANCE Chapter). Fill it
coolant level or discharging the system. up to COLD/MIN level on the B coolant vessel.
1 Park the machine on a flat ground. Pull the hand 8 Start the engine and leave working in order to allow
brake and release the gear. Bring down the loader circulation of the coolant, and add some coolant if
levers and the excavator on the ground, shut required.
down the engine and remove the contact key. 9 Reinstall the depot lid. Ensure to tighten well.
2 Open the bonnet. 10 Shut down the engine in order to set the cooler at
3 Loosen the B lid carefully. Allow release of the the operation temperature and pressure. Check for
existing pressure. Remove the lid. any leakage.
Note: Ensure to leave the cabin air-conditioner at the

heating mode. This will lead the coolant mixture
circulate in the entire system.
96 MAINTENANCE
ENGINE COOLING SYSTEM

(Continued)
Ventilator Strap Alignment
ATTENTION
Ensure that the machine cannot run. Dismantle

the battery connections before performing this
alignment.
1 Park the machine on a flat ground. Pull the hand

brake and release the gear. Bring down the
loader levers and the excavator on the ground,
and shut down the engine.
2 Loosen A and B articulation fixing screws.

Loosen articulation-fixing screws of C and D
alignment connection.
3 The Alternator should be positioned to allow 10

mm flexibility at the X point.
4 Squeeze C and D screws. Then tighten A and B

screws.
Note: If you replaced the strap recently, the strap

tension should be checked following initial 20 hours
of operating time.
97 MAINTENANCE
FUEL SYSTEM
Fuel Types Fuels that are Used in Cold Weathers
Use quality diesel fuel in order to obtain sufficient It is possible to find special fuels produced for winter
power and performance from your engine. The conditions at the temperatures under zero. The
features of the fuel suggested for the engines are viscosity of such fuels is less. They also restrict
mentioned below: waxing in the fuel in cold weathers (the waxing can
be prevented by filtering the fuel).
Setan Rate : 45 (min.)
Viscosity : 2,5/4,5 at 40°C Additives that increase fluidity can be obtained.
Density : 0,835/0,855 kg/lit. Such additives can be mixed into the fuel in order to
Sulfur : 0,5% of the mass (max.) decrease waxing.
Distillation : 85% at 350°C
Gasoline
Setan Rate (Number)
ATTENTION
It indicates the ignition performance. The Setan rate
may result in engine start up problems at low fuel and
in cold weathers, and may affect ignition Do not use gasoline in this machine. Do not
confuse diesel oil and gasoline; gasoline will
Viscosity come out of the surface from the barrel depot
It indicates the fluidity resistance. The performance of and produce steam.
the engine can be affected if it is not within the
suggested limits. Information
If you are obliged to use non-standard fuels, apply to
Density your authorized MST Service to have information on
Low density decreases the engine power. High engine modifications and oil replacement periods.
density increases engine power together with the
amount of exhaust fumes.
ATTENTION
Sulfur
High amounts of sulfur in the fuel may result in
abrasion in the engine. If you are obliged to use fuels Diesel fuel is flammable. Do not approach to the
with high sulfur rate, you should use high alkali machine with fire. Do not smoke while working
engine oil, or replace the normal oil more often. on the machine or filling fuel. Do not fill fuel
while engine is running. If you do not take these
If you are obliged to use fuels with low sulfur rate, we precautions, you may cause fire or injuries.
advise you to use an oil additive suggested by your
petrol station.
Distillation
It indicates mixture of different hydrocarbons in the
fuel. Existence of light hydrocarbons at high rates may
affect ignition characteristics.
Fuel Standards
Apply to your authorized MST Service or Fuel Dealer
to have more information on the fuels that you
hesitate.
98 MAINTENANCE
FUEL SYSTEM
(Continued)
Filling Depot
ATTENTION
Before filling the depot, bring down the loader

levers on the ground, and shut down the
engine. Do not permit to budge with the
machine controls while supplying fuel.
Fill the depot with appropriate fuel at the end of

each workday. This will prevent precipitation of
water inside the fuel during the night time.
Keep the A fuel depot lid always closed.
Closing the lid

The key turns on the lid of the depot. In order to
remove the lid from the depot, you should insert
the key and turn on the lock.
Note: It is COMPULSORY to insert the key into

the lid in plug in and out operations.
99 MAINTENANCE
FUEL SYSTEM
(Continued)
Emptying the Filter
1 Park the machine on a sound ground, pull the

hand brake and release the gear. Raise the
loader lever and block. Lower the loader lever
and the excavator on the ground, let the engine
to the OFF mode, and remove the contact key.
2 Open hood.
3 Turn D tap and empty the remaining water

inside C filter vessel.
4 Ensure that D tap is closed and completely fit in

its place. Insert the engine side maintenance
lid.
5 Discharge the system.
6 Remove the safety prop and bring down the

loader lever on the ground.
100 MAINTENANCE
FUEL SYSTEM
(Continued)
Replacement of Filter Element
1 Park the machine on a sound ground, pull the hand

brake and release the gear. Raise the loader lever
and insert the safety prop. Bring down the back
excavator on the ground and shut down the engine.
ATTENTION
An electric pump fed by the ignition circuit of the

machine is included in the fuel system. Ensure
that the engine is in the OFF mode whenever you
work on the fuel system. Otherwise it may cause
fire or injury.
2 Open engine hood.
3 Hold A filter vessel, pull out from the B filter. The

filter would be full of fuel.
4 In order to remove the element from the cabin,

push the part down and turn a quarter tour to
reverse clockwise. Then you can lift the element
and remove from the vessel.
5 Wash the vessel with clean fuel.
6 Replace C vessel leak-free ring. (A new leak-free

ring should be inserted each time you dismantle the
vessel from the filter compartment).
7 Insert a new element into the vessel. Turn it until it

is secured to its place. (When the filter is placed on
its compartment, it would not be possible to turn it
with a soft move). Push the element downside, and
turn a quarter tour clockwise, as in D. (The filter
should have placed on the vessel tightly).
8 Slightly wet the filter vessel C. Screw the filter

vessel into its compartment back. Squeeze the
filter vessel just by hand.
Note: The cog that stabilizes the filter element and the
vessel into the compartment is chipped through the
element’s material. Excessive squeezing may damage
this cog.
9 Discharge the system.

101 MAINTENANCE
FUEL SYSTEM
(Continued)
Emptying Sediment Vessel
1 Park the machine on a sound ground, pull the

hand brake and release the gear. Raise the
loader lever and insert the safety prop. Bring
down the back excavator on the ground and shut
down the engine
ATTENTION
An electric pump fed by the ignition circuit of the
machine is included in the fuel system. Ensure
that the engine is in the OFF mode whenever you
work on the fuel system. Otherwise it may cause
fire or injury.
2 Look behind the fuel tank to the A vessel. If you

see dregs inside the vessel, perform stages 4 –
6. If there is no sediment but water, open B plug
and empty water. Ensure that the B plug is
closed and secured.
3 Hold A vessel and dismantle C nut. Remove the

vessel.
4 Use clean fuel to wash the vessel.
5 Place the vessel back. Ensure that the seals are

placed securely.
6 Discharge the air of the system.
Discharge the air of the system
Running the engine while air existing inside the

system may damage fuel injection pump. After
applying maintenance, discharge the air of the
system as follows:
An electrical ignition pump is included in the machine.

If the fuel system is defected, the system will require
ignition.
1 Ensure that there is enough fuel in the fuel tank.
2 In order to ignite the fuel system, let the contact

button on “IGN” sign and wait for three minutes.
Note: Do not operate electrical ignition pump without

fuel for a long time.
After running, do not force the engine for at least two

minutes in order to let the air pockets release away.
102 MAINTENANCE
AUTO POWER SHIFT TRANSMISSION

Checking Oil Level Replacement of Oil and the Filter
1 Ensure that the hand brake is pulled and it is out The gearbox oil should be discharged by letting flow
of gear. Bring down the loader levers and the from the space of the absorber filter, instead of
excavator on the ground. Shut down the engine discharge lid. Accordingly, the pieces falling over
and remove the contact key. the filter will be cleaned while pulling it out.
2 Open the bonnet.
3 Shut down the engine and remove the contact 1 Park the machine on a smooth surface. Pull the
key. Fill gearbox oil up to maximum point of the park brake. Bring down the attachments on the
indicator stick. ground. Shut down the engine. Remove the
4 Run the engine for a period not exceeding 5 contact key. Disconnect the battery
minutes and then operate quietly. This operation connections.
will enable the filter, pump, torque converter, oil
cooler and the hoses to be filled with oil. 2 Ope the engine hood.
5 Shut down the engine, remove the contact key
and wait for 20 minutes. Check the oil level and ATTENTION
fill it up to stick level if required.
Ensure that it is safe to underlie the machine.
Bring down the attachments; pull the park
brake; remove the contact key, and unplug the
battery cable.
3 Place a suitable size vessel under the

absorption filter. Remove D nuts. Remove E
filter and F seal. Wait for emptying of the oil
into the vessel. Be careful that the oil can be
hot.
ATTENTION
The oil may flush when the filter is removed.
Keep aside while removing the filter.
4 Clean the filter with an adequate solvent.

Follow the instructions of the solvent’s
Manufacturer for your safety.
5 Place E filter and a new F seal. Apply the liquid

seal before placing and squeezing D bolts.
Squeeze the bolts at a torque of 10 Nm.
6 Pull out and remove B filter. Replace the new

filter:
a Daub C felt with the gearbox oil.
b Insert the filter so that it contacts with the
filter head.
c Turn the filter for ¾ tours more.
7 Fill new oil into the system from the A oil level
stick/filling pipe. Do not exceed the maximum
level on the oil stick.
Note: Use only original MST filters, otherwise

damage may occur in the system due to pollution.
103 MAINTENANCE
HYDRAULIC SYSTEM
Checking Oil Level Hydraulic Oil Level and
ATTENTION Temperature Indicators
The fine hydraulic oil may blow out with high Hydraulic Oil Level and Temperature
pressure and penetrate into the skin. Do not Indicators are on the oil tank.
check hydraulic oil leaks with your fingers. Do
not approach your face to the parts that
suspect of leakage. Use a piece of paper to ATTENTION
learn whether there is any leakage or not. If the
hydraulic oil pierces your skin, immediately Oil level should be at the half level of the
apply for a medical aid. indicator normally. If there is oil in the
1 Park the machine on a smooth surface. hydraulic pistons, the level seems less
Bring down the loader ladle on the ground. than the half level.
If it is affixed, pull back the telescopic
handle. Lift the bom, get back the lever The hydraulic system has an oil cooler The oil
and close the ladle. Shut down the engine. cooler holds the oil temperature between
Remove the contact key. 55-65 OC.Hydraulic oil were cooled by engine
2 Check liquid level from A oil indicator. The fan automatically.
level should be above the half of the level
indicator.
3 If the oil level is low, remove B filling lid
and fill with hydraulic oil at the required
amount.
O O
B
F C
200
80
A
150
60
ATTENTION
During the maintenance of the machine bring
down the loader lever
and the back excavator body on the ground. It
is recommended to get 40
100
the back excavator at the position shown in C
(ladle open completely,
bom and ladle rake extended completely). 20
There is no pressure in the hydraulic system in
this position. 50
0
104 MAINTENANCE
HYDRAULIC SYSTEM
(Continued)
Replacement of Return Filter Replacement of Suction Filter
Elements Elements
ATTENTION
ATTENTION
The fine hydraulic oil may blow out with Ensure that it is safe to underlie the
high pressure and penetrate into the skin. machine. Bring down the attachments; pull
Do not check hydraulic oil leaks with your the park brake; remove the contact key, and
fingers. Do not approach your face to the unplug the battery cable.
parts that suspect of leakage. Use a piece
of paper to learn whether there is any 1 Park the machine on a smooth surface.
leakage or not. If the hydraulic oil pierces Lean aside the loader bringing down its
your skin, immediately apply for a medical ladle front. If it is affixed, pull back the
aid. telescopic handle. Close the excavator
ladle. Pull the deeper. Release the bom
1 Park the machine on a smooth surface. until the ladle leans on the ground.
Lean aside the loader bringing down its Stabilize the stands on the ground. Shut
ladle front. If it is affixed, pull back the down the engine. Remove the contact
telescopic handle. Close the excavator key.
ladle. Pull the deeper. Release the bom
until the ladle leans on the ground. 2 Remove the hydraulic depot cover.
Stabilize the stands on the ground. Shut
down the engine. Remove the contact
key. 3 Put a vessel under the hydraulic depot to
contain the oil. Remove the discharge
2 Dismantle element fitting plug C under the depot and empty the
hydraulic oil. The cabin should be large
3 Remove the hydraulic depot cover enough to contain the components inside
the depot. See Service Capacities and
a Remove the A screws. Remove E Oils Part for detailed information.
banjo screw,F pipe and G lid plate.
4 Dismantle the element fitting.
b Remove spring.
a Remove A screws. Remove B lid
4 Pull out the H filter element from its plate.
compartment. b Remove D suction filter by using 65
mm wrench and dispose them.
5 Insert the new element.
Replace D suction filter, and squeeze by
a Push the element H into its turning at 15-20 Nm.
compartment.
5 Reinstall the lid plate and squeeze by
b Insert spring and new o-ring seal. turning at 10 Nm.
c Squeeze the lid plate G and A screws 6 Re-fill the Hydraulic depot.
up to 21 Nm.
d Check oil level and fill by filtering, if

required.
105 MAINTENANCE
HYDRAULIC SYSTEM
(Continued)
106 MAINTENANCE
HYDRAULIC SYSTEM
(Continued)
M544 Standart Arm hydraulic scheme
107 MAINTENANCE
HYDRAULIC SYSTEM
(Continued)
M544 Standart Arm with Breaker valve hydraulic scheme
108 MAINTENANCE
HYDRAULIC SYSTEM
(Continued)
M544 Extendet Arm with Breaker valve hydraulic scheme
109 MAINTENANCE
HYDRAULIC SYSTEM
(Continued)
M542 Standart Arm hydraulic scheme
110 MAINTENANCE
HYDRAULIC SYSTEM
(Continued)
M542 Standart Arm with Breaker valve hydraulic scheme
111 MAINTENANCE
HYDRAULIC SYSTEM
(Continued)
M542 Extendet Arm with Breaker valve hydraulic scheme
112 MAINTENANCE
FRONT AND REAR AXLES

(M544 4 Wheel, Steering, Machine)
Checking Differential Oil Level Replacement of Differential Oil
ATTENTION ATTENTION
Ensure that it is safe to underlie the Ensure that it is safe to underlie the
machine. Bring down the attachments; pull machine. Bring down the attachments; pull
the park brake; remove the contact key, and the park brake; remove the contact key, and
unplug the battery cable. unplug the battery cable.
WARNING
1 Park the machine on a sound surface. Pull
The oil level of the axle should be checked the park brake. Let the machine out of
when the machine is on a smooth surface, gear. Bring down the attachments on the
otherwise the oil level of the axle will be ground. Shut down the engine. Remove
measured incorrectly. the contact key.
2 Put a suitable size vessel under the B

1 Park the machine on a sound surface. Pull plug to contain the oil. Remove the B plug
the park brake. Let the machine out of and the washer. Discharge oil. The
gear. Bring down the attachments on the discharge plug is magnetic. Clean it by
ground. Shut down the engine. Remove wiping. (metal pieces should be cleaned
the contact key. carefully). Reinsert B plug and seal.
Squeeze at 60 NM torque.
2 Clean around the filling/level plug A, and
then remove the plug and the washer. The 3 Fill suggested oil into filling/level A hole.
oil level should be at the deep of the hole. Clean A plug and seal, and insert into the
Fill with the suggested oil if required. places. Squeeze at 60 NM torque.
3 Clean the plug and roundel, and reinsert.

113 MAINTENANCE

(Continued)
Front Axle
Rear Axle
114 MAINTENANCE

(Continued)
Checking Hub Oil Levels Replacement of Hub Oil
Check each hub separately. Axle oil is used to oil brake components and
cool down the brake linings.
1 Park the machine on a sound surface
when the OIL LEVEL sign is at the It is significant to replace the oil regularly as
horizontal position. 5 mm distance is mentioned in the service schedule. The
tolerated at the upper or lower part of the efficiency of the oil will reduce when the brakes
horizontal line. become worn out.
2 Pull the park brake. Let the machine out of Apply to the authorized MST service if
gear. Bring down the attachments on the required.
ground. Shut down the engine. Remove
the contact key. Replace the oil in each hub separately.
3 Clean around the filling/level plug C. 1 Park the machine on a smooth surface so
Remove the plug. The oil level should be that the tires stay just upside the surface.
at the deep of the hole. Fill with the Turn the wheels by hand until the OIL
suggested oil if required. Clean the plug LEVEL sign on the hub comes to vertical
before reinserting. position. C filling/level plugs should remain
at the bottom.
2 a Put a suitable size vessel under the C

plug to contain the oil.
b Remove C filling/level plugs. Allow time

for the flowing of oil.
3 a Let OIL LEVEL sign have horizontal

position. 5 mm distance is tolerated at the
upper or lower part of the horizontal line.
b Fill the plugs from C filling/level holes

with the suggested axle oil. The oil should
be at the same level with the filling/level
hole.
115 MAINTENANCE

Front axle applications are the same with the 1 Park the machine on a smooth surface so
definitions in the previous pages (whole wheel, that the OIL LEVEL sign on the hub
steering, machine). Read the following steps comes to down position. Pull the park
to check the rear axle and replace its oil. brake. Let the machine out of gear. Bring
down the attachments on the ground. Shut
Checking Oil Level down the engine. Remove the contact
key.
WARNING 2 Put a suitable size vessel under the C

plug to contain the oil. Remove C
The oil level of the axle should be checked filling/level plug from the hub. Discharge
when the machine is on a smooth surface, oil. The discharge plug is magnetic. Clean
otherwise the oil level of the axle will be it by wiping. (metal pieces should be
measured incorrectly. cleaned carefully). Clean C filling/level
plug and reinstall.
1 Park the machine on a smooth surface.

Pull the park brake. Let the machine out of 3 Align the other wheel of the same axles so
gear. Bring down the attachments on the that the OIL LEVEL sign come to the
ground. Shut down the engine. Remove down position. Follow the second stage
the contact key. again.
2 Clean around the filling/level plug A, and 4 Put a suitable size vessel under the B
remove the plug and the insulation seal. discharge plug to contain the oil.
The oil level should be at the deep of the
hole. Fill with the suggested oil if required.
WARNING
3 Clean the plug and the washer and
reinstall. Oil may flush when you remove the
discharge plug. Therefore, stand aside when
you remove the plug.
Replacement of Oil
Remove B filling/level plug. Discharge oil.
The discharge plug is magnetic. Clean it
Axle oil is used to oil brake components and by wiping. (metal pieces should be
cool down the brake linings. cleaned carefully). Clean B discharge plug
and reinstall.
It is significant to replace the oil regularly as
mentioned in the service schedule. The 5 Remove A filling/level plug. Fill the axle
efficiency of the oil will reduce when the brakes with the suggested oil type and at the
become worn out. required quantity. Clean A discharge plug
and reinstall.
Apply to the authorized MST service if
required.
116 MAINTENANCE

(Continued)
Front Axle
Rear Axle
117 MAINTENANCE
ELECTRIC SYSTEM
Fuse Description
WARNING
Replace the blown fuses usually with the correct ampere fuses in order to avoid damages to
the Electric System.
The fuses are placed on the side console.
If any fuse is blown, try to find out its reason and repair the defect before replacing the fuse.
WARNING
When you see any broken wire on

the fuse, replace it with the new one.
118 MAINTENANCE
ELECTRIC SYSTEM
(Continued)
M544 FRONT DASHBOARD
M542 FRONT DASHBOARD

119 MAINTENANCE
ELECTRIC SYSTEM
(Continued)
M544 SIDE DASHBOARD
120 MAINTENANCE
ELECTRIC SYSTEM
(Continued)
M542 SIDE DASHBOARD
121 MAINTENANCE
ELECTRIC SYSTEM
(Continued)
M544 MAIN WIRING DIAGRAM 1
122 MAINTENANCE
ELECTRIC SYSTEM
(Continued)
123 MAINTENANCE
ELECTRIC SYSTEM
(Continued)
124 MAINTENANCE
ELECTRIC SYSTEM
(Continued)
125 MAINTENANCE
BATTERY
Warning Signs
WARNING
Following warning signs should be available
on the battery.
Do not pull out the battery while the engine
is running, otherwise electrical circuits can
Sign Description be damaged.
ATTENTION
Keep away from the children.
While installing or removing any electrical
component, ensure that you know the
electrical circuit exactly. Any incorrect
connection may cause injury and/or
Protect your eyes. damages.
DANGER
Do not smoke, approach with Battery electrolyte is both poisonous and

fire, or make sparkle. burning. Do not inhale the gasses coming
out of the battery. Keep the electrolyte away
from your clothes, skin, mouth and eyes.
Put on protective eyeglasses.
WARNING
Explosive gas.
Damaged and consumed batteries and the
ones remaining from any fire or leakage
should be stored in acid free and closed
containers. Besides, they should be
Battery acid. disposed according to local waste
directives.
ATTENTION
Note instructions. The gasses coming out of the batteries are

sparkling. Keep the battery away from the
fire and sparks. Do not smoke around the
battery. Ensure that the closed areas where
batteries are used and charged are well
ventilated. Do not check whether the battery
charges by touching at the poles; use
hydrometer or voltmeter for this.
126 MAINTENANCE
BATTERY
(Continued)
ATTENTION CONTACTS WITH SKIN

Wash with water, put off smeared clothes, wrap
The gasses coming out of the batteries are burnt parts with sterilized bandage, and
sparkling. Do not smoke while handling or immediately apply to medical aid.
around the battery. Keep the battery away
from fire and sparks.
Checking Battery Acid Level
The battery acid contains sulfur acid. It may
cause serious injuries if contacts with your skin There is no need to make addition to the
and eyes. Wear protective eyeglasses. Handle batteries that do not require maintenance
the battery carefully in order to prevent flushes. under normal warm climates. However, the
Do not approach metal objects (watch, ring, electrolyte level should be checked as follows
fastener, etc.) to the battery poles. Such in some conditions (e.g. operation at tropical
objects may result in short circuits and cause temperatures for a long time, or when the
burns. alternator overcharges).
While plugging or unplugging the battery, let all
buttons in the cabin turn to OFF mode. When ATTENTION
you remove the battery, firstly dismantle the
grounding (-) connection. Do not add acid into the battery. Otherwise
the battery acid may froth and overflow, and
When you reinstall it, connect (+) cable at first. may cause burns.
Charge the battery in a well-ventilated place
and away from the machine. 1 Park the machine on a sound surface. Pull
Switch off the charge circuit before installing or the park brake, and let it out of gear. Bring
dismantling the battery. down the loader levers and the excavator
Wait 5 minutes before making connections on the ground. Shut down the engine and
when you install the battery on the machine. remove the contact key.
First Aid - Battery Acid 2 Remove the radiator shutter.
If the electrolyte; 3 Remove shelf covers of the battery. Check

the level at each shelf. The battery plates
CONTACTS WITH EYES should be over 6 mm. Reinforce with pure
water or ion-free water, if required.
Immediately wash your eyes with water for 15
minutes and apply for medical aid.
SWALLOWED
Do not try to vomit. Drink plenty of water or
milk. Then drink magnesium, milk, egg or
vegetable oil. Immediately apply to medical aid.
127 MAINTENANCE
BATTERY
(Continued)
Battery Isolator
In order to cut off the battery connection from
the electrical system of the machine, a battery
isolator is included.
Do not use the battery isolator to let the engine

OFF mode except urgent positions. If you do
not obey this rule, you may cause damage to
the electrical circuits.
At the end of the work period or when the

machine is left alone, the battery should be
isolated if the lights are not required to be on.
Before operating the engine or using machine
electrical system, the battery isolator key
should be inserted and operated.
WARNING
Before performing arc welding on the

machine, dismantle the battery and the
alternator in order to protect the circuits
and components.
The battery should be dismantled although

the battery isolator is installed.
128 MAINTENANCE
TELESCOPIC DIPPER WORN-OUT TAMPONS
Telescopic handle worn-out tampons are Control of Upper Worn-out Tampons

replaceable parts that can be installed by
screwing. Such tampons support internal part 1 Park machine on a smooth surface. Pull
of the Telescopic Handle when they are the park brake, and let it be out of gear.
extended or shortened, and they function as a Let the Bom and Telescopic Handle at the
guide. It is explained how to control and align position displayed in C. Draw back the
the tampons below. Telescopic Handle displayed in D. The
ladle should be distant from the ground
There are two sets of tampons: front and back. sufficiently; the Telescopic Handle should
Both sets are also formed by upper worn-out be supported.
tampons displayed with A, and lower worn-out
tampons displayed with B. 2 Shut down the engine and remove the
contact key.
The three worn-out tampons displayed with A
cannot be adjusted, and should be replaced 3 Replace the worn-out tampons as
with the new ones when they are worn out. See displayed in E, until they are worn-out up
Control of Upper Worn-out Tampons to the depth of the groove, or before they
Section. are worn-out completely. If the cushions
are worn out almost completely, they
However, lower worn-out tampons displayed should be controlled more often than
with B can be adjusted; these eliminate mentioned in the Service Schedule. In
abrasion both on the upper and lower fibers. order to prevent the worn-out cushions or
Lower fibers should also be replaced with the ladle for any damages, the cushions
new ones when they are worn out. See Lower should be installed as indicated at J.
Worn-out Tampons Adjustment Section
(MAINTENANCE Chapter).
A and B worn-out tampons should be replaced

as set and they should be replaced by a
competent service technician.
129 MAINTENANCE
TELESCOPIC DIPPER WORN-OUT TAMPONS

(Continued)
Control of Lower Worn-out Tampons

1 Park machine on a smooth surface. Pull the park brake, and let it be out of gear. Support the
Bom and Telescopic Handle as displayed in C. Shut down the engine.
2 Clean slippery surfaces of the internal telescopic handle by using an adequate solvent.
3 Start the engine. Draw back the Telescopic Handle displayed in D. The ladle should be distant
from the ground sufficiently. The Telescopic Handle should be supported. Shut down the engine.
4 After removing any grease, mud, etc. from the slippery surfaces, check by looking down the
space G between the Telescopic Handle and upper worn-out tampon A. This space should not
be more than 1.5 mm.
5 If the space is more than 1.5 mm, then adjust as mentioned below:
a Remove H adjustment bolt and dispose J washer. Reinsert H bolt and tighten.
b Repeat this operation for the three adjustment bolts displayed by H at the same part.
c Re-check the space displayed with G and control whether it is more than 1.5 mm. Apply the
instruction mentioned in 5a and 5b to four bolts H on the other side, if required.
d Make sure to place the Telescopic Handle inside box at the center position compared to the
frames of Telescopic Handle outside box.
Note: Do not forget to perform application at separate sides in each adjustment. If the space is still
more than 1.5 mm after removing all adjustment washers displayed with J, then replace A and B
worn-out tampons as a set, and they should be replaced by the authorized service technician
6 Grease slippery surfaces of the internal Telescopic Handle when the adjustments are completed.
130 MAINTENANCE
HYDRAULIC / TRANSMISSION OIL COOLER
Cleaning the Pipes/Winglets

Hydraulic/Gearbox oil cooler engine is at the
front part of the water radiator. If the
pipes/winglets of the Hydraulic/Gearbox oil
cooler are plugged (due to dirt, flies, etc.), the
radiator and cooler shall get less efficient.
1 Park the machine on a sound surface.

Pull the park brake, and let it out of gear.
Lift and block the loader levers. Bring
down the back excavator on the ground.
Shut down the engine.
2 Remove A bolts. Lift the radiator shutter

and remove it.
3 Clean with a brush all dirt remaining on

the cooler pipes and winglets. Ensure
that the dirt removed by the brush do not
get into the cooler section.
4 Reinsert the radiator shutter. Install A

bolts tightening each equally.
WINDOW CLEANING LIQUID
1 Park the machine on a sound surface. Pull

the park brake, and let it out of gear. Lift
and block the loader levers. Bring down
the back excavator on the ground. Shut
down the engine.
2 Fill adequate liquid into the window-

washing bottle B. Add a special liquid that
prevents freezing and ice formation. Do
not use engine cooling antifreeze.
131 MAINTENANCE
STABILIZER (BALANCE) STANDS
Worn-out Tampons Worn-out Tampon Adjustment

Worn-out tampons support and orient internal
leg section. They allow the internal leg to Note: It is significant to adjust the worn-out
remain on the center and prevent its “swim” as pads at the right service intervals, because
much as possible while extension and they may contact with the internal leg and
shortening of the internal leg. cause abrasion. Abrasion will decrease the
life of the pads substantially.
When B tampons wear-out up to the minimum
thickness of 0,5 mm, they should be replaced Clean all dirt remaining in the stabilizer spaces.
with the new ones. The stabilizer’s internal leg
should be removed in order to replace the Approximately 1 mm space is required
tampons. (Apply to authorized MST Service). between the internal and external legs of the
stabilizer for rotation.
It is significant to know that B lower tampons
were designed to compensate much of the load Before adjusting this space, ensure that the leg
in the stabilizer stand operation. Therefore, in is lifted from the ground completely and it is
order to determine the wear-outs in these drawn back completely.
tampons, they should be controlled regularly.
In order to adjust the interval, tighten A screws
so that the C tampon contacts with the internal
leg, and draw back the screws for one quarter
turning.
Note: Squeezing adjustable A screws

excessively will lock the tampon on the position
and it would not be possible to draw it back. If
this happens, run the stabilizer leg normally,
but consider that the C and B tampons will
wear-out more quickly.
132 MAINTENANCE
M542 – M544 SERVICE CAPACITIES AND LUBRICATIONS
PART OIL / LIQUID AND CODES CAPACITY - Liter

Engine (Oil) Shell Rimula 15W40 8
Engine (Cooler) Water + Antifreeze Mixture 26 (13 + 13)
Gearbox Shell Donax TA ATF 19,5
Front Axle (M542) Shell Spirax HD 80/90 6,5
Hub (M542) Shell Spirax HD 80/90 0,8x2
Rear Axle (M542) Mobil Fluid 424 14±0.5
Hub (M542) Mobil Fluid 424 1,5 x2
Front Axle (M544) Shell Spirax HD 80/90 8,5±0,5
Hub (M544) Shell Spirax HP / 140 1,5x2
Rear Axle (M544) Mobil Fluid 424 13
Hub (M544) Shell Spirax HP / 140 1,5x4
Hydraulic System Shell Tellus T-32 (Winter) veya T-46 (Summer) 152
Greasing Part Shell Retinax HDX2 -
Fuel Tank Without dregs and Filtered Diesel 105
Coolant Mixtures
ATTENTION
Antifreeze can be harmful. Follow the instructions of the manufacturer while using pure or diluted
antifreeze.
Ensure that there is corrosion preventive in the antifreeze. Do not use mixtures more than 60% and less
than 60%, otherwise the cooling system can be damaged.
55% Solution – Keeps circulation up to - 36°C, and prevents damages up to - 41°C.
The efficiency of the antifreeze solution should be checked at least once a year, preferably in the beginning
of the cold season. It is useful to exist antifreeze throughout the year as it allows continual protection against
rots. Usually replace the antifreeze once in two years. Even if there is no need to use antifreeze against
freezing, 50% antifreeze mixture should be used. This will allow protection against rotting, and increase the
boiling point of the cooler.
Do not forget that serious damages may occur in the cooling system unless anti-corrosives are used.
133 MAINTENANCE
PROBLEM – REASON – SOLUTION

Determining Defects
The Operator should study on the following problems and solutions in order to perform required operation
on time against possible defects that might happen in MST Serial Excavator – Loader Work Machines, and
to apply to authorized MST Service when he meets problems that he cannot overcome.
CAUSES
PROBLEM
OPERATOR’S CONTROL AUTHORIZED SERVICE CONTROL
Starter engine turns slowly 1,2,3,4 -
Engine does not work 5,6,7,8,9,10,12,13,14,15,17 34,35,36,37,38,42,43,44
5,7,8,9,10,11,12,13,1,4,15,16,
Engine works hardly 34,36,37,38,40,42,43,44
17,19
8,9,10,11,12,13,16,17,18,19,2
Weak engine power 34,36,37,38,39,42,43,44,61,63, 64
0,21
Engine does not make ignition 8,9,10,12,13,15,20,22 34,36,37,38,39,40,41,43
Excessive fuel consumption 11,13,15,17,18,19,21,22 34,36,37,38,39,40,42,43,44,63
Dark exhaust fumes 11,13,15,17,19,21,22 34,36,37,38,39,40,42,43,44,61,63,
Blue and white exhaust fumes 4,15,21,23 36,37,38,39,42,44,45,52,58,62
Low Greasing oil Pressure 4,24,25,26 46,47,48,50,51,59
Strike at the engine 9,13,15,17,20,22,23 36,37,40,42,44,46,52,53,60
7,8,9,10,11,12,13,15,16,18,20,
Engine runs irregularly 34,38,40,41,44,52,60
22,23
There is vibration 13,18,20,27,28 34,38,39,40,41,44,52,54
High Greasing oil Pressure 4,25 49
Engine temperature very high 11,13,15,19,27,29,30,32 34,36,37,39,52,55,56,57,64
Carter pressure 31,33 39,42,44,45,52
Compression weak 11,22 37,39,40,42,43,44,45,53,60
Engine runs and stops 10,11,12 -

134 MAINTENANCE
PROBLEM – REASON – SOLUTION

(Continued)
POSSIBLE REASONS
1. Low battery 33. Vacuum pipe leaking or ventilation error
2. Ill electrical connections 34. Error in fuel injection pump
3. March engine defected 35. Fuel pump not compressing
4. Inadequate oil thickness 36. Fuel pump timing faulty
5. March engine turns weakly 37. Ignition time faulty
6. Fuel tank empty 38. Low compression
7. Stop control defect 39. Roller head seal run away
8. Plugging in the fuel pipes 40. Valves not free
9. Fuel absorption pipe defect 41. Incorrect high pressure pipe
10. Dirty filter element 42. Rollers worn-out
11. Plugging in the air filter, cleaning or absorption 43. Leakage between valves and valve
system compartments
12. Air in the fuel system 44. Segments do not move free; worn out, or broken
13. Injector defect or unfit injector 45. Valve handle and/or gaits worn out
14. Incorrect use of cold operation system 46. Crank axle bearings worn-out or broken
15. Cold operation system defect 47. Oil pump worn-out
16. Plugging in fuel tank ventilation 48. By-pass valve does not close
17. Incorrect fuel usage 49. By-pass valve does not open
18. Restriction of engine speed control movement 50. By-pass valve spring broken
19. Plugging in the exhaust pipe 51. Oil pump absorption pipe plugged or leaks air
20. Engine running very high 52. Piston damaged
21. Engine running very low 53. Piston height wrong
54. Steering head or steering head casing
22. Incorrect valve adjustment
centralization incorrect
23. Excessive or inadequate oil usage at wet-type air
55. Thermostat faulty or incorrect thermostat type
filter
24. Lack of greasing oil in the oil tank 56. Plugging in the cooling circuit
25. Pressure clock defected 57. Recycle pump defected
26. Oil filter element dirtied 58. Valve handle seal defected (if available)
27. Propeller damage 59. Plugging in oil tank filter
28. Engine pegs or steering casings defected 60. Valve string broken
29. Excessive oil in the oil tank 61. Turbo-charge wings dirty or broken
30. Radiator water canals plugged 62. Turbo-charge greasing oil seal leaks
31. Oil tank ventilation pipe plugged 63. Absorption system leaks
32. Lack of cooling water 64. Turbo-charge discharge system runs incorrectly

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34 OPERATION INSTRUCTIONS

ENGINE AND DRIVING COMMANDS, SWITCHES AND GAUGES (INSTRUMENT PANEL)

To re-set the Steering System Ignition Key Hole

I- When the ignition key is in this position, it gives

2 Run the engine until the rear wheels get

3 Select 4-wheel drive mode again.

ENGINE AND DRIVING COMMANDS, SWITCHES AND GAUGES (INSTRUMENT PANEL)

Steering Wheel Tilting Adjustment Interior light of the Cab

Adjust the steering wheel’s position. Tighten the

NOTE: Locking position of arm B can be changed.

ENGINE AND DRIVING COMMANDS, SWITCHES AND GAUGES (INSTRUMENT PANEL)

2-a Engine Speed Gauge

It shows the engine speed in revolution per

On the instrument panel ,Rearwindow

ENGINE AND DRIVING COMMANDS, SWITCHES AND GAUGES (INSTRUMENT PANEL)

Front instrument panel

Note: If any of the following lights on during operation,

7- Battery charge lamp

9- Parking brake lamp

5- Engine Oil Level is Low.

8- Transmission Fluid Pressure is Low.

4- Water Temperature is High

Heating system is controlled by the switches below.

A- 2-speed fan switch

Heater Fan (Two-Speed)

Standard Bucket Hydraulic Speed Control

Loader’s speed depends on how fast you move the

On the top of the control lever, it is described with

Loader Bucket Forward Overturning

Lifting To tilt the bucket forward as shown in C, push the

To lower the bucket as shown in B, push the stick

Loading Bucket (Continued) 6 Purposed Opening/Closing Bucket

Releasing In the machines installed with a 6-purposed

Bucket Leveling Position

While running the stabilizer controls, you should

Do not run the stabilizers from outside the

Before you start to run the backhoe, stabilizers

In order to level up the machine and to lighten the

Before you start moving, lift up both stabilizing

In order to lift up the stabilizers, pull the lever towards

To let the stabilizers down, push the levers towards

When the machine is on the slope, to stabilize the

MST Plus (‘+’) Signed Control Lifting Boom

For each motion of dipper, both arms should be

In order to have more productive work, both levers

It is indicated on the sticky label that what motions

MST Plus (‘+’) Signed Control Lowering the Dipperstick

Closing Bucket Some models have breaker and telescopic-arm-motion

Kingpost (Tightening) Clamps

Before starting any excavation work, kingpost should

Releasing the Clamps

To unlock the clamps, push the button on the

In order to tighten the clamps,open the rear bucket until

BOOM AND ROTATION LOCKS

Every day, make sure that boom lock completely

If you operate control handles from outside, you

It is recommended that rotation lock be fastened

Locking the Boom

1 Place the DIGGER exactly in the back of the

2 Make sure the boom lock A is in completely