Merlo p40.7 2009 - advice appreciated

[Case140]

Hi, I have a recently purchased 2009 7k hours Merlo as above from main dealer here in Ireland. (Sold a very old JD4400 with high hours). Deal was done on basis of operators manual, parts book and workshop manual to be supplied. Got first two but am told there is no ws manual for merlo digital or otherwise. Find this hard to believe - Anybody know if im being told porkies? Web search yielded nothing.
Now having a couple of issues which I am not really getting sorted.
Brakes were all done, pads, calipers and they work well. There is a servo on this machine which really works. BUT the system is leaking brake fluid somewhere and I cant find where. There are no tell tale puddles overnight and no visible leaks. calipers look dry, (tiny bit gear oil on one disc - pretty sure it not brake fluid). If you work for couple hours and leave it sit it will empty the fluid. Anybody know how the servo works, could it be leaking across servo?? All oils look ok but wouldnt take much brake fluid to ruin anything.
Second issue (pretty sure not related?) I have an engine managment light yellow light on. Comes on with ignition and stays on. Started couple days ago. Oils/temp ok, new filters throught (Im assured anyway and they look new). Anybody know what systems the management light actually monitors? Wiring/ looms etc look ok, (she is an exceptionally clean machine).
Bit frustrated with service (I have a warantee on main components) but really frustrated I have no workshop manual as working in dark!
Love the machine, beautiful to drive, great vis, lift etc etc
Any advice would be much appreciated, Thanks

 

[texelburger]

Not sure on the Servo leak,sorry.We used to have a Merlo 40.7 and if you had isolated the battery,then turned it back on and started the engine within so many seconds that light wou,d come on.You would need to get a dealer with laptop to reset it.Im not sure about the workshop manual either but may be able to find out.

 

[Case140]

Thanks a mill . Actually that might have happened as I asked a maye to turn isolator and then started . But laptop/serviceman to reset grrttt!
Any idea what systems are actually monitored?

 

[asm]

Your dealer is correct about the workshop manual, engineers get training notes when they attend training courses which are very good,
I would say you have an eprom error on the engine ECU, this happens if you turn the isolator off to quickly,
Deutz say you should wait 120 seconds after shut down before turning the isolator off.
I would guess one of the steel brake lines is starting to leak it will get worse then you'll find it

 

[Case140]

Ok.- an eprom error..(had to google that!)..that is prob what happened. I have been turning off too quickly so. . Be great if I had been told that!! Still think WS manual be a good idea.......but then I wouldnt be calling the service man for silly little problems...(=money for the dealers!). So I now have to get a tech with laptop to reset it
Also do you know how the servo works or where it is located?
Hope you are right about brake line ......whatever about brake fluid going out on the ground I wouldnt like it mixing with hyd oil!!
Thanks a million for imput.

 

[Jim B]

I'm pretty sure that servo brakes didn't come on them until about 2012 and coincided with the newer type digital dash...?

 

[Case140]

Definitely a servo on mine. Push the pedal and feel hydraulics hit and engine labour a bit. Totally different to pushing brake pedal without engine running. Very effective too!

 

[Gone Shooting]

Engine light on ours comes on if started on a slope and stays on for months and months ! just ignore it now.

 

[Case140]

Engine light on ours comes on if started on a slope and stays on for months and months ! just ignore it now.

Ha!! Probably right!!

 

[Bill Turtle]

I think you could have a servo as an option at that time. As for brakes, as already mentioned there is a steel line going from front to back under the cover below the boom. You need to remove the vertical panel on the side of the cab and the lower panel. Often there is so much accumulated debris under that cover that it soaks up any fluid leaks, and rusts out that brake pipe. Check the gearbox oil level while you’re doing all that for piece of mind.

 

[Case140]

I think you could have a servo as an option at that time. As for brakes, as already mentioned there is a steel line going from front to back under the cover below the boom. You need to remove the vertical panel on the side of the cab and the lower panel. Often there is so much accumulated debris under that cover that it soaks up any fluid leaks, and rusts out that brake pipe. Check the gearbox oil level while you’re doing all that for piece of mind.

Thanks a mill...will check later

 

[Case140]

Cant see any leak on that pipe but havnt it bled so not full pressure. Was on my own so will bleed next week when have help.Pretty sure this strange valve is a servo. The brake line is connected to the hydraulic valve shown in photo. Arrow points to brake pipe which is tee d into long brake pipe. ( i presume valve is servo....) My worry is if seal leak in this valve would you get brake fluid in hyd oil

 

[asm]

I think that is a trailer brake valve ( others may know better than me )
The brake booster is behind the brake pedal, the master cylinder bolts to it if I remember correctly

 

[Case140]

I think that is a trailer brake valve ( others may know better than me )
The brake booster is behind the brake pedal, the master cylinder bolts to it if I remember correctly

Never thought of that! Could be right...and maybe (faulty??) that is why i get hydraulic hit and bit engine load when I push brakes. . Could brake fluid escape to hyd system if valve playing up?? Just bit of mystery to me where brake fluid disappearing to.......

 

[asm]

I'm not sure tbh, it's not a fault I've seen.
Try blanking the pipe you have marked and see if the brakes still disappear

 

[Barleycorn]

We are on our 3rd 40.7 Older machine caught fire as the rarely used brake caliper seized, burnt out, so bought another second hand machine to replace it. This caught fire and burnt out recently. The one remaining 40.7 has a fire extinguisher and a 5 gallon container of water on it. Got a new Kramer on order, that has oil immersed brakes! Wouldn't touch another Merlo now, they need to sort out the brakes.

 

[Case140]

We are on our 3rd 40.7 Older machine caught fire as the rarely used brake caliper seized, burnt out, so bought another second hand machine to replace it. This caught fire and burnt out recently. The one remaining 40.7 has a fire extinguisher and a 5 gallon container of water on it. Got a new Kramer on order, that has oil immersed brakes! Wouldn't touch another Merlo now, they need to sort out the brakes.

Thanks for warning! The brakes on mine have been completely overhauled and are working well. I have checked they are not sticking on and are not getting hot (atm!!). My issue is brake fluid loss and cant see where it going

 

[Planttech]

We are on our 3rd 40.7 Older machine caught fire as the rarely used brake caliper seized, burnt out, so bought another second hand machine to replace it. This caught fire and burnt out recently. The one remaining 40.7 has a fire extinguisher and a 5 gallon container of water on it. Got a new Kramer on order, that has oil immersed brakes! Wouldn't touch another Merlo now, they need to sort out the brakes.

The problems you have had are down to poor maintenance and debris around the calipers. Car brakes are similar and don’t catch fire. Personally I think the merlo brakes are simple and cheap to maintain and given the way prices are increasing simplicity is best

 

[deleted user 837354]

We are on our 3rd 40.7 Older machine caught fire as the rarely used brake caliper seized, burnt out, so bought another second hand machine to replace it. This caught fire and burnt out recently. The one remaining 40.7 has a fire extinguisher and a 5 gallon container of water on it. Got a new Kramer on order, that has oil immersed brakes! Wouldn't touch another Merlo now, they need to sort out the brakes.

You just need to use the brakes a bit now and again, take it up and down the road once in a while. At least you can get a Merlo's brakes and clean and inspect them.

 

[Case140]

Thanks guys. Any ideas re brake fluid? Have you come across leak into trailer brake valve? Bit stumped as to where it going!.
Also no ws manuals? Can i get any type on ws info?