Merlo TF35.7-115 service schedule
Merlo TurboFarmer telehandlers · 2023– (Stage V; manual dated 02/2023). Used in place of the P32.6, for which no maintenance data was found.
Covers the Merlo TF35.7-115 (TurboFarmer, Stage V).
Every maker's service job for the Merlo TF35.7-115, counted in hours, with the oils, filters and parts each one needs. Add your telehandler to Farmyard Workshop and it works out what's due from your hours and dates, and keeps the service history.
Track your TF35.7-115 for freeVersions: TF35.7-115: Deutz 115 hp (85 kW), Stage V; TF35.7-140 / CS-140 (other engine codes; check your handbook)
Service intervals
| Job | When |
|---|---|
| Hydrostatic transmission oil filter | every 500 hours or every 6 months |
| Hydraulic outlet filter and breather filter | every 500 hours or every 6 months |
| Engine air filter | every 500 hours or every 6 months |
| Boom sliding shoes (wear pads) check | every 500 hours or every 6 months |
| Cab air filter | every 1,000 hours or every year |
| Hydrostatic transmission oil and filter change | every 1,500 hours or every 18 months |
| Hydraulic oil and all hydraulic filters change | every 1,500 hours or every 18 months |
| Gearbox, differential and wheel reducer oil change | every 1,500 hours or every 18 months |
| Brake fluid change | every 1,500 hours or every 18 months |
Service jobs and parts
Hydrostatic transmission oil filter
Transmission · every 500 hours or every 6 months
Merlo lists the hydrostatic transmission oil filter (D150) at the 100-hour running-in service and then every 500 hours or 6 months, more often than the oil (1500 hours). It is also changed with the oil. Merlo says this is workshop maintenance for an authorised Merlo repairer.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Hydrostatic transmission oil filter | 1 | Genuine Merlo number not found; check your handbook | check your handbook |
Step-by-step
- Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
- With the engine off and the key at the on position (or as your handbook says), work the boom and attachment controls a few times to let out trapped hydraulic pressure. Oil at system pressure can pierce skin.
- Clean round the filter, change it with a new seal, run the engine and check for leaks and the oil level.
Tools: Filter wrench, Drain tray, Rags
Hydraulic outlet filter and breather filter
Hydraulics · every 500 hours or every 6 months
Merlo lists the hydraulic outlet filter (D151) at 100 hours and every 500 hours or 6 months, and the tank breather filter (D351) every 500 hours, more often than the oil (1500 hours).
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Hydraulic outlet filter | 1 | Genuine Merlo number not found; check your handbook | check your handbook |
| Hydraulic breather filter | 1 | Genuine Merlo number not found; check your handbook | check your handbook |
Step-by-step
- Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
- With the engine off and the key at the on position (or as your handbook says), work the boom and attachment controls a few times to let out trapped hydraulic pressure. Oil at system pressure can pierce skin.
- Clean round the housings, change both filters with new seals, then check for leaks and the tank level with the boom lowered and retracted.
Tools: Spanners, Drain tray, Lint-free rags, Gloves
Engine air filter
Engine · every 500 hours or every 6 months
Merlo lists the engine air filter (D302) every 500 hours or 6 months, and says to shorten intervals in dust or wood chips. The extracted schedule does not show the action symbol, so whether this is a check or a change is read from how the item codes repeat; check your handbook.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Engine air filter element | 1 | Genuine Merlo number not found; check your handbook | check your handbook |
Step-by-step
- Stop the engine and take the key out. Never run it with the filter out.
- Take out the element without spilling dust, wipe the housing and fit the new or cleaned element as your handbook says.
Tools: Torch, Damp lint-free cloth
Boom sliding shoes (wear pads) check
Boom · every 500 hours or every 6 months
Merlo lists the internal boom sliding shoes (D306) every 500 hours and the external sliding shoes (D205) at 100 hours and every 1000 hours. The extracted schedule does not show the action symbol, so whether this is a check or a change is read from how the item codes repeat; check your handbook.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Sliding shoes or shims (if worn) | 1 | Genuine Merlo number not found; check your handbook | check your handbook |
Step-by-step
- Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
- Never work under a raised boom or attachment unless it is held up with a proper safety prop. The hydraulics alone are not safe to work under.
- Look at the shoes for wear and play, and get them adjusted or changed by a Merlo dealer if they are worn.
Tools: Torch, Feeler gauges, Grease gun
Cab air filter
Cab · every 1,000 hours or every year
Merlo lists the cab air filter (D403) every 1000 hours or 12 months. The extracted schedule does not show the action symbol, so whether this is a check or a change is read from how the item codes repeat; check your handbook.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Cab air filter | 1 | Genuine Merlo number not found; check your handbook | check your handbook |
Step-by-step
- Stop the engine and take the key out.
- Take out the filter, clean the housing and fit the new filter the right way round.
Tools: Screwdriver, Vacuum cleaner
Hydrostatic transmission oil and filter change
Transmission · every 1,500 hours or every 18 months
Merlo lists the hydrostatic transmission oil (D503) every 1500 hours or 18 months. The filter is changed at the same time.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Hydrostatic transmission oil | 1 | check your handbook | check your handbook |
| Hydrostatic transmission oil filter | 1 | Genuine Merlo number not found; check your handbook | check your handbook |
Step-by-step
- Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
- With the engine off and the key at the on position (or as your handbook says), work the boom and attachment controls a few times to let out trapped hydraulic pressure. Oil at system pressure can pierce skin.
- Let hot oil cool until it is warm, not scalding. Wear gloves and wash used oil off your skin promptly.
- Drain the oil, change the filter, refill with the oil your handbook lists and check the level after a short run.
Tools: Large drain tray, Spanners, Filter wrench, Gloves
Hydraulic oil and all hydraulic filters change
Hydraulics · every 1,500 hours or every 18 months
Merlo lists the hydraulic oil (D502) and the hydraulic inlet filter (D501) every 1500 hours or 18 months. The outlet and breather filters are changed at the same time.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Hydraulic oil | 1 | ISO 46 for -15 to +30 °C (other grades for colder or hotter climates); capacity: check your handbook. Aztec Oils match: HYDRATEC HM 46 | check your handbook |
| Hydraulic inlet filter | 1 | Genuine Merlo number not found; check your handbook | check your handbook |
| Hydraulic outlet filter | 1 | Genuine Merlo number not found; check your handbook | check your handbook |
| Hydraulic breather filter | 1 | Genuine Merlo number not found; check your handbook | check your handbook |
Step-by-step
- Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
- With the engine off and the key at the on position (or as your handbook says), work the boom and attachment controls a few times to let out trapped hydraulic pressure. Oil at system pressure can pierce skin.
- Never work under a raised boom or attachment unless it is held up with a proper safety prop. The hydraulics alone are not safe to work under.
- Drain the tank, change all three filters, refill with clean oil of the grade for your climate and check the level with the boom lowered and retracted.
Tools: Large container, Spanners, Clean funnel, Gloves
Gearbox, differential and wheel reducer oil change
Axles · every 1,500 hours or every 18 months
Merlo checks the gearbox (D353), differential (D354) and wheel reducer (D355) oils every 500 hours and lists them under new codes (D553, D554, D555) at 1500 hours or 18 months, which reads as the change. The extracted schedule does not show the action symbol, so whether this is a check or a change is read from how the item codes repeat; check your handbook.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Gearbox, axle and hub oil | 1 | Roloil TIV Merlo is listed in the lubricant table; capacities: check your handbook | check your handbook |
Step-by-step
- Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
- Chock the wheels. Drain while warm.
- Drain each unit, refill to the level plug, refit plugs to the torque in your handbook and check for leaks.
Tools: Drain tray, Spanners, Oil pump or squeeze bottle
Brake fluid change
Brakes · every 1,500 hours or every 18 months
Merlo lists the brake fluid (D504) every 1500 hours or 18 months. Brake fluid takes up water over time.
| Part | Qty | Notes | Part number |
|---|---|---|---|
| Brake fluid | 1 | DOT 4. Q8 Brake Fluid DOT 4; amount: check your handbook. Aztec Oils match: HYDRATEC DOT 4 BF | check your handbook |
Step-by-step
- Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
- Chock the wheels.
- Replace and bleed the fluid as your handbook or dealer describes, keeping the reservoir topped up so no air gets in.
- Test the brakes at low speed before work.
Tools: Bleed kit, Clear tube and bottle, Spanner
Oils, fluids and capacities
| System | Oil or spec | Capacity |
|---|---|---|
| Engine | Deutz 4-cylinder turbo diesel, 115 hp (85 kW) at 2,300 rpm, Stage V with AdBlue (model not named in the operator's manual) | |
| Engine oil | See the separate Deutz engine manual: check your handbook | |
| Coolant | Glysantin G30 mixed with water (capacity: check your handbook) | |
| Engine oil | See the Deutz engine manual: check your handbook | |
| Hydraulic system | ISO 46 hydraulic oil for -15 to +30 °C (Q8 Handel 46, Total Equivis E46, Panolin Synth 46 and others listed); ISO 22 (Roloil LI/22-HIV) for -30 to +10 °C; ISO 68 (Esso Univis N68) for +20 to +60 °C | check your handbook |
| Hydrostatic transmission | Shares the hydraulic oil list in the table (check your handbook) | check your handbook |
| Gearbox, axles and wheel reducers | Roloil TIV Merlo (listed in the lubricant table; check your handbook for which units) | check your handbook |
| Brakes | Q8 Brake Fluid DOT 4 | check your handbook |
| Coolant | Glysantin G30 | check your handbook |
| Fuel tank | Diesel | ≈85 L (80 L on some engine versions) |
| AdBlue tank | AdBlue (urea) | ≈12 L |
Specifications
| Engine power | 115 hp (85 kW) at 2,300 rpm, Stage V |
| Lift height | 6.6 m |
| Maximum forward reach | 3.5 m |
| Top speed | 40 km/h |
| Weight | ≈6,800 kg (Stage V version; read from a garbled table) |
| Drive | Hydrostatic transmission with gearbox |
Known problems
Engine service is in a separate manual
The Merlo manual does not give the engine oil, fuel filter or coolant intervals; they are in the Deutz engine manual. Get that manual before servicing the engine.
Running-in service at 100 hours
Merlo wants the transmission and hydraulic filters, external boom shoes and the axle, wheel and steering bolts seen to at 100 hours or 1 month.
Service reminder light
The dash reminds you at 100 hours and every 500 hours. If you mute it without doing the service, the yellow warning light comes on.
Hard work shortens intervals
Merlo says shorten the intervals in dust, wood chips and other harsh work.
Hydraulic oil grade by climate
Merlo lists different hydraulic oil grades for cold, mild and hot climates. Use the one for your temperature range.
Repair guides
- 100-hour first service, service reminder light and the separate Deutz engine manual (Moderate, 2–3 hours for the 100-hour service): Yellow service warning light on, reminder muted but service not done, unsure of engine oil grade or filter intervals.
- Hydraulic oil grade for your climate and shorter intervals in harsh work (Easy, 30 minutes to check; longer for an oil change): Slow, noisy hydraulics in frost; oil thin and hot in summer; filters blocking early in dust or wood chip work.
- Boom sliding shoes: inspection, greasing and using the safety stop (Moderate, 1 hour): Grooves, burrs or chips on the boom where the shoes run, boom knocks or judders when extending, boom side play.
- Brake fluid, brake wear limits and wheel bolts (Moderate, 30 minutes to check; dealer for internal brake work): Brake fluid warning light [46], soft pedal, poor stopping, loose wheel, brake noise.
- Steering mode faults and rear wheel alignment (Easy, 10 minutes): Rear wheels out of line, alignment light [241] flashing, crab steer light [55] on unexpectedly, steering mode won't change.
- Load control system warnings (never bypass it) (Easy, Minutes): Yellow or red load indicator, beeper, boom movements blocked, total block light [54] on.
The full step-by-step guides are in Farmyard Workshop once you add your telehandler.
Sources
- Maintenance programme, intervals and item codes (TF35.7-115 instruction manual, 02/2023)
- Every 500 hours or 6 months schedule
- Every 1000 hours or 12 months schedule
- Every 1500 hours or 18 months schedule
- Technical data: engine, lift height, reach, speed, fuel and AdBlue tanks
- Lubricant table: hydraulic grades, coolant, brake fluid, transmission oil
More from Merlo.