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1857 768 M1

1-5

MF9205

Workshop Manual

FOREWORD CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hydraulic System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Spark Arrestor Exhaust System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fire Extinguishers   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Telescopic Handler Serial Number  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Engine Serial Number   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Other Serial Numbers   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

MASSEY FERGUSON TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . 1-14

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Summary of Contents for MF 9205

Page 1: ...05 Serial Number AC1911000 EN AGCO Ltd Abbey Park Stoneleigh Kenilworth England CV8 2TQ MASSEY FERGUSON is a wholly owned subsidiary of AGCO Corporation September 2011 1857768M1 Issue 1a MF9205 EAME English AGCO Limited 2011 Workshop Manual ...

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Page 3: ...nd clothing away from moving parts electrical contact hot parts and exhaust Wear eye protection to guard from battery acid compressed springs fluids under pressure and flying debris when engines are running or tools are used Use eye protection approved for type of welding Never work on Telescopic Handler with boom up unless boom is held by an approved boom stop Replace if damaged Never modify equi...

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Page 5: ...ONTENTS SAFETY AND MAINTENANCE 10 HYDRAULIC SYSTEM 20 HYDROSTATIC SYSTEM 30 DRIVE SYSTEM 40 MAIN FRAME 50 ELECTRICAL SYSTEM AND ANALYSIS 60 ENGINE SERVICE 70 HEATING VENTILATION AIR CONDITIONING 80 SPECIFICATIONS SPEC ALPHABETICAL INDEX INDEX ...

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Page 7: ...10 Electrical 1 10 Hydraulic System 1 11 Fueling 1 11 Starting 1 11 Spark Arrestor Exhaust System 1 11 Welding And Grinding 1 11 Fire Extinguishers 1 11 SERIAL NUMBER LOCATION 1 12 Telescopic Handler Serial Number 1 12 Engine Serial Number 1 12 Other Serial Numbers 1 12 DELIVERY REPORT 1 13 MASSEY FERGUSON TELESCOPIC HANDLER IDENTIFICATION 1 14 ...

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Page 9: ...rectly 2 Check that ROPS mounting hardware is tightened and is Massey Ferguson approved 9 Enclosure door latches must open and close freely 3 The seat belt must be correctly installed functional and in good condition 10 Attachment locking pins must function correctly and be in good condition Bob Tach wedges and linkages if equipped must function correctly and be in good condition 4 Check boom stop...

Page 10: ...aner for damage or leaks Check the condition of the element 22 Operate the machine and check all functions 18 Check the electrical charging system 23 Check function or condition of all equipped options and accessories examples back up alarm fire extinguisher rotating beacon front stabilizers etc 19 Check tires for wear and pressure Use only approved tires 24 Recommend to the owner that all necessa...

Page 11: ...of the machine and can be stored in a container provided on the machine Replacement Operation Maintenance Manuals can be ordered from your Massey Ferguson dealer Machine signs decals instruct on the safe operation and care of your Massey Ferguson machine or attachment The signs and their locations are shown in the Operation Maintenance Manual Replacement signs are available from your Massey Fergus...

Page 12: ...e operator s area engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating All fuels most lubricants and some coolants mixtures are flammable Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire Operation Do not use the machine where exhaust arcs sparks or hot c...

Page 13: ...of hot particles from the engine and exhaust system but the muffler and the exhaust gases are still hot Check the spark arrestor exhaust system regularly to make sure it is maintained and working properly Use the procedure in the Operation Maintenance Manual for cleaning the spark arrestor muffler if equipped Welding And Grinding Always clean the machine and attachment disconnect the battery and d...

Page 14: ...ement parts Other Serial Numbers Other components may also have serial numbers and an identification plate Always use these serial numbers when ordering parts DELIVERY REPORT Figure 1 3 The delivery report must be completed by the dealer and signed by the owner or operator when the Massey Ferguson telescopic handler is delivered An explanation of the form must be given to the owner Make sure it is...

Page 15: ... MIRROR FRONTWORK LIGHTS ENGINE COVER SEAT BELT BOOM STOP 2 OPERATOR CAB ROPS FOPS LOAD CAPACITY CHARTS MIRROR BOOM TELESCOPING BOOM 1 BUCKET 3 TYRES Use only approved tyres at correct pressure EM6244 EM6345 PARKING BRAKE REAR WORK LIGHT HYDRAULIC COUPLERS BOB TACH REAR LIGHTS FRONT LIGHTS ...

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Page 17: ...g The Filter Element 10 60 1 ENGINE COOLING SYSTEM 10 70 1 Cleaning 10 70 1 Removing And Replacing The Coolant 10 70 2 Checking Level 10 70 3 FUEL SYSTEM 10 80 1 Fuel Specifications 10 80 1 Filling The Fuel Tank 10 80 1 Fuel Filter 10 80 2 ENGINE LUBRICATION SYSTEM 10 90 1 Checking Engine Oil 10 90 1 Oil Chart 10 90 1 Replacing Oil And Filter 10 90 1 HYDRAULIC HYDROSTATIC SYSTEM 10 100 1 Checking ...

Page 18: ...ure 10 150 1 APPROVED BOOM STOP IF EQUIPPED 10 160 1 Installing The Approved Boom Stop 10 160 1 Removing The Approved Boom Stop 10 160 1 ENGINE COVER 10 170 1 Opening And Closing The Engine Cover 10 170 1 REMOTE START 10 180 1 Connecting to the Telescopic Handler 10 180 1 Remote Start Procedure For Tools MEL1563 and MEL1565 10 180 3 Remote Start Procedure For Tool Kit P N 6689779 10 180 4 TELESCOP...

Page 19: ...jackstands can allow the machine to fall or move and cause injury or death W 2017 0286 Figure 10 10 1 Always park the machine on a level surface STOP the engine Put the floor jack under the center of the front axle Lift the Telescopic Handler and install jackstands Figure 10 10 1 Figure 10 10 2 Put the floor jack under the center of the rear axle Lift the Telescopic Handler and install jackstands ...

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Page 21: ... Falling Object Protective Structure per SAE J1043 and ISO 3449 WARNING Never modify operator cab by welding grinding drilling holes or adding attachments unless instructed to do so by Masey Ferguson Do not operate without right window Changes to the cab can cause loss of operator protection from rollover and falling objects and result in serious injury or death W 2906 0211 Emergency Exit Figure 1...

Page 22: ... of the cab using the latch Item 2 Figure 10 20 3 and from the inside of the cab by squeezing the latch Item 1 Figure 10 20 4 as shown Cab Door Window Figure 10 20 5 Turn the handle Item 1 Figure 10 20 5 as shown Push the window open fully until it latches against the cab Figure 10 20 6 Pull up the lever Item 1 Figure 10 20 6 inside the cab to disengage the latch and close the window S6522 2 1 P 4...

Page 23: ...f telescopic handler see Performance on page 2 WARNING AVOID SERIOUS INJURY OR DEATH Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle Wood ramps can break and cause personal injury W 2058 0807 Fastening Figure 10 30 2 Fasten the telescopic handler to the transport vehicle to prevent if from moving during sudden s...

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Page 25: ...lease the brakes or there is no hydraulic pressure Only the front axle has brakes The following procedure describes how to release the brakes Figure 10 40 1 Loosen the four bolts Item 1 until the slotted spacers Item 2 Figure 10 40 1 can be removed from under the bolt heads the bolts and spacers are located on both the front and rear side of the front axle Remove the spacers Item 2 Figure 10 40 1 ...

Page 26: ...s to the OPERATING POSITION NOTE If the tow valve is not returned to the operating position the machine will not be able to be driven forward or backward Engaging The Brake Discs Figure 10 40 4 Loosen the four bolts Item 1 until the spacers Item 2 Figure 10 40 4 can be installed under the bolt heads the bolts and washers are located on both the front and rear side of front axle Figure 10 40 5 Even...

Page 27: ...based grease Rear Axle Pivots Lubricate with multipurpose lithium based grease Boom and Cylinder Pivots Lubricate with multipurpose lithium based grease Hydraulic Hoses Tubelines and Connections Check for damage and leaks Repair or replace as needed Universal Joints and Slip Yoke on Drive Shaft Lubricate with multipurpose lithium based grease Cab Filter Clean dust out of the cab filter Replace eve...

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Page 29: ...r filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced Figure 10 60 2 Loosen the filter housing clamps Item 1 Figure 10 60 2 Release the fastener and remove the cover Item 2 Figure 10 60 2 Figure 10 60 3 Pull the element straight out Figure 10 60 3 NOTE Make sure all sealing surfaces are free of dirt ...

Page 30: ... all sealing surfaces are free of dirt and debris Do not use compressed air to remove dirt or debris Figure 10 60 5 Remove the inner filter Item 1 Figure 10 60 5 and install a new element Install the outer element Figure 10 60 6 Install the dust cover Item 1 Figure 10 60 6 and fasten Connect the filter housing clamps Item 2 Figure 10 60 6 S3273 1 S3271 2 2 1 ...

Page 31: ...aterial is present Engine is running Tools are being used W 2019 0907 Cleaning Figure 10 70 1 Open the engine cover Item 1 Figure 10 70 1 Figure 10 70 2 Loosen the knob Item 1 Figure 10 70 2 and tilt the condenser if equipped forward Loosen the knob Item 2 Figure 10 70 2 and tilt the oil cooler forward Use low air pressure or water pressure to clean the condenser if equipped oil cooler and radiato...

Page 32: ... may cause serious premature engine damage Too little antifreeze reduces the additives which protect the internal engine components reduces the boiling point and freeze protection of the system Always add a premixed solution Adding full strength concentrated coolant can cause serious premature engine damage I 2124 0497 Figure 10 70 4 Remove the radiator cap Item 1 Figure 10 70 4 Figure 10 70 5 Ope...

Page 33: ...diator cap Add coolant to the overflow bottle as needed Run the engine until it is at operating temperature Stop the engine Check the coolant level when the engine is cold and add coolant as needed until it is at the mark Item 1 Figure 10 70 3 on the overflow bottle IMPORTANT AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze Too much antifreeze reduces cooling system efficien...

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Page 35: ...ive percent biodiesel mixed with low sulfur or ultra low sulfur petroleum based diesel This is commonly marketed as B5 blended diesel fuel Filling The Fuel Tank WARNING AVOID INJURY OR DEATH Stop and cool the engine before adding fuel NO SMOKING Failure to obey warnings can cause an explosion or fire W 2063 0807 Figure 10 80 1 Remove the fuel fill cap Item 1 Figure 10 80 1 Use a clean approved saf...

Page 36: ...to remove water from the filter Remove the filter element Item 2 Figure 10 80 2 Clean the area around the filter housing Put clean oil on the seal of the new filter element Install the fuel filter and hand tighten WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil Keep heat flames sparks or lighted tobacco away from fuel and oil Failure to use care around combustibles can cause expl...

Page 37: ...and filter See SERVICE SCHEDULE on Page 10 50 1 Run the engine until it is at operating temperature Stop the engine Figure 10 90 3 Remove the oil plug Item 1 Figure 10 90 3 at the bottom of the engine compartment Drain the oil into a container and recycle or dispose of used oil in an environmentally safe manner NOTE Oil at engine operating temperature is extremely hot Take all necessary precaution...

Page 38: ...90 6 Remove the fill cap Item 1 Figure 10 90 6 Put oil in the engine See Fluid Capacities on Page SPEC 10 4 See Oil Chart on Page 10 90 1 Install the fill cap start the engine and let it run for several minutes Stop the engine and check for leaks at the oil filter Let the engine cool Figure 10 90 7 Remove the dipstick Item 1 Figure 10 90 7 and check the oil level Add oil as needed if it is not at ...

Page 39: ...cing The Hydraulic Hydrostatic Filters For the correct service interval for replacing the hydraulic hydrostatic filters See SERVICE SCHEDULE on Page 10 50 1 Figure 10 100 3 Stop the engine and open the engine cover Remove the two filter elements Items 1 2 Figure 10 100 3 Clean the surface of the filter housings where the filter seals contacts the housings Put clean oil on the seals of the new filt...

Page 40: ...piece of cardboard or wood to find leaks Do not use your bare hand Wear safety goggles If fluid enters skin or eyes get immediate medical attention from a physician familiar with this injury W 2072 0807 WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil Keep heat flames sparks or lighted tobacco away from fuel and oil Failure to use care around combustibles can cause explosion or fi...

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