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(Detroit S50)
MAINTENANCE MANUAL
2 (64)
04/2004
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PREFACE
Congratulations on your choice of a TORO loader. This manual describes the maintenance of this TORO 007 loader. Only those who have been given proper training and are authorized to do so should operate the loader. All operators should familiarize themselves with the machine and fully understand the contents of the operators manual, maintenance manual, and general safety instructions before operating it. Read the operators manual and General Safety Instructions before starting the work!
WARNING
This responsibility is particularly pertinent for personnel who work with the loader only occasionally -- e.g., during setup or maintenance. Continuing research and development of TORO loaders may have caused changes to your machine that are not dealt with in this manual. If the machine is equipped with optional equipment -- e.g., a remote control system -- you should familiarize yourself with the separate instructions in which the equipments operation is explained. This manual must always remain available in the cabin for ready access when operating the TORO loader. Always obey the national legislation in force where accident prevention and environmental protection are concerned. Generally accepted technical guidelines for safe and professional operation must also be observed. For demanding maintenance and repair operations, we recommend that you contact your nearest authorized Sandvik Tamrock Service. Our maintenance personnel have the skills and special tools required for the most demanding tasks. Through correct use and by following the maintenance instructions, you can expect a high degree of utilization and long operating life of your loader. Always obey safety rules!
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PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. 1.2. 1.3. 1.4. 2. Importance of regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General safety precautions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location of the main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 5 5 5 6 7 10 10 11 12 12 14 14 14 14 14 15 15 15 15 15 16 16 17 17 25 27 29 35 38 42 43 44 45
MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. 2.2. 2.3. 2.4. Maintenance of hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5. Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2. Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.3. Transfer gearbox (Up--Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.4. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.5. Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.6. Grease nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6. Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7. Special notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.1. Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.2. Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8. 3. First servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7. 3.8. 3.9. Every shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 125 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 1500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 4000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.
MAINTENANCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL
1.
GENERAL
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GENERAL
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GENERAL
--
is done. Ensure that all safety systems are tested before the unit is returned to normal work. Pay attention to safety and environmental protection when disposing of process materials and old parts.
3 2 4
1. 2.
3. 4.
Front frame
1. 2. 3. 4. 5.
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GENERAL
Rear frame
7
8 2 5 4 6 1 2
7 3
1. 2. 3. 4.
5. 6. 7. 8.
Battery box Radiator / intercooler / fuel cooler Operators cabin Service hatches
Engine assy
1 6 5 2 4 3
1. 2. 3.
4. 5. 6.
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GENERAL
Power train 1. 2. 3. 4. 5. Front axle Rear axle Transmission / torque converter Transfer gearbox Driveshaft
2.
The TORO 007 is designed for hard work in difficult and demanding mine conditions. To ensure trouble--free and economical operation, it is extremely important to adhere to the service schedule indicated. By paying close attention to the service schedule, you can easily detect possible defects in the machine or other problems that can be addressed before they become serious. This will ensure low repair costs and minimize disturbances to production. The following pages give information for servicing various TORO 007 components and other items for servicing, with their corresponding service intervals. All end users should review the Engine Manuals for additional information regarding servicing.
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Tests Pilot system pressure . Engine at low idle. . Pressure should be 35 bar (3.5 MPa). Steering system pressure . Install the frame locking pin between the front and rear frames. . Engine speed: 1000--1500 rpm. . Turn the machine to full left--hand turn position. . Steering system pressure should be 120 bar (12.0 MPa). Hydraulic pumps pressures . Engine at 1000--1500 rpm. . Lower the boom against the stops and keep the control valve in boom down position. . Pressure should be 250 bar (25.0 MPa).
D D D D
D D
Working on live components D If the component must be live during the work, another worker must be standing by to cut off voltage at the emergency or main switch should an emergency situation occur. Follow electrical safety regulations. D Use a red-and-white safety chain and warning signs to encircle the working area. D Use only insulated tools. D Observe special caution.
2.4. Welding
Before starting to weld, determine the material to be welded and select an appropriate welding method and fillers. Contact SANDVIK TAMROCK Service, if necessary. D Do not repair steering equipment by welding. D Welding must be left to qualified personnel. D Before electrical welding, the main switch must be disconnected. Also, Remote Control equipment (optional) must be disconnected.
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D D
D D D
If welding must be done close to any of the control modules, disconnect the module wiring before beginning welding. The ground cable of the welding machine must be connected as close as possible to the welding location. The ground cable may not be connected so that the current can flow through a bearing, joint coupling, sealing surface, lever, or control cable. Use a protective mask when welding. Arrange adequate ventilation. Arrange protection against fire.
2.5. Lubricants
2.5.1. Engine Classification Viscosity API CH--4 SAE 15W--40
Use oil of API category CH--4. API CF--4 or CG--4 oils may be used when CH--4 oils are not available; however, their use requires a shorter oil change interval. Synthetic oils may be used in Detroit Diesel engines, provided that they are API licensed and meet the performance and chemical requirements for non--synthetic oils outlined in this publication. Product information for synthetic oils should be reviewed carefully. Performance additive systems often respond differently in synthetic oils. Their use does not permit extension of recommended oil change intervals. The use of fuels with sulfur content above 0.5 mass percent will require shorter oil change intervals and/or the use of a higher TBN oil. See engine Operators Guide for more details. 2.5.2. Transmission Allison C--4 or Caterpillar TO--4 --20 _C...+15 _C above +0 _C SAE 10W SAE 30
Classification Viscosity
2.5.3.
Transfer gearbox (Up-Box) 220 222.4 cSt 25.8 cSt 148 --48 _C 245 _C 290 kg
Oil type: Shell Omala HD 220 or equivalent ISO Viscosity grade Viscosity 40 _C 100 _C Viscosity index Pour point Flash point 4Ball EP (Weld) 2.5.4. Hydraulics
Hydraulic oils meeting DIN 51524 HVLP or ISO 6743--4 HV standards can be used Viscosity above --15 _C above +0 above +5 ISO VG 32 ISO VG 46 ISO VG 68 ISO VG 32 ISO VG 46 ISO VG 68 (SAE 10W) (SAE 20) (SAE 30)
(Motor oils of API class CD, or hydraulic oils with wear--preventive characteristics corresponding to the DIN 51524 HVLP or ISO 6743--4 HV standards, can be used)
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2.5.5.
Axles MIL--L--2105 C or API GL--5 + LS (Limited Slip) above --25 _C. --25 _C...+15 _C SAE 80W/140 SAE 85W/140
Classification Viscosity
2.5.6.
Grease nipples
Lithium--based greases with penetration 265/295 (NLGI 2) and dropping point 180 _C should be used.
2 x
Note! Never open the filler cap when hot. When checking engine coolant level, stop the engine and allow it and the radiator to cool down. If an overheated engine must be stopped, allow the radiator to cool down before checking the coolant level. If there is no time for that, use thick gloves and protective clothing when opening the radiators filling cap. Stand to the side, turn your face away, and open the cap a little. Wait until the pressure is released and coolant stops running out, then open the cap slowly. D D D Adding over 19 liters per minute can cause air pockets in the cooling system. Operate with a thermostat in the cooling system all year round. Coolant must be tested every 250 hours to ensure that inhibitor levels remain within the permitted ranges; change the coolant inhibitor filter element if necessary (see Detroit Diesel Coolant Selections or Engine Operators Guide).
The following precautions must be observed when adding fuel: D Do not fill the fuel tank when the engine is running. D Do not overfill. D Take care not to spill fuel on hot surfaces. D Addition of fuel should be done in a well--ventilated space. D Smoking, open flames, and sparks are dangerous when the fuel tank is being filled. D Clean up spilled fuel before starting the engine. D Keep the filling pipe in contact with the fuel tank, or arrange grounding to prevent sparking caused by static electricity. D If fuel quick fill system is to be used, ensure that you are familiar with the system manufacturers operating and safety requirements.
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MAINTENANCE OPERATIONS
3.
D
MAINTENANCE OPERATIONS
Check engine oil
Check V-belts
Check condition visually and adjust if necessary. Check belt for worn, grease--coated, oil-soaked, or missing material. Replace if necessary.
Check before starting the engine. Coolant level should be seen via the sight glass. Do not remove the pressure control cap or attempt to drain the coolant until the engine has cooled. Use extreme caution when removing the cap. A sudden pressure release from a heated cooling system can result in a loss of coolant and possible injury (scalding, eye injury, etc.) from the hot liquid.
Consult air restriction indicator; service air cleaner elements as required. Inspect the entire air system for leaks. Tighten any loose connections.
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MAINTENANCE OPERATIONS
The filter cover will not fill completely during engine operation. It will gradually fill over time, and the fuel level will rise as the filter element becomes clogged. The filter element should be changed every 250 hours, or sooner if the fuel level has risen to the top of the element.
Machine on level ground. Parking brake engaged. Engine at low idle. Gearshift lever in neutral position. Transmission oil at operating temperature.
Machine on level ground. Parking brake engaged. Engine at low idle. Gearshift lever in neutral position. Gearbox oil at operating temperature.
Check condition. Visually check tire wear and air pressure. Visually check for loose or missing wheel nuts.
Boom in down position and bucket on ground. Oil level should be between the sight glasses.
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MAINTENANCE OPERATIONS
Check for leakage and test brake function. Brake test: Check that the pressure in the brake system is 150--185 bar before testing. Brake test: Press brake pedal, engage first gear, and rev the engine. The brake should hold firm at 2000 rpm (machine should not move until engine speed reaches 2000 rpm). D Check that all controls are functioning correctly
Raise the lift arms, dump the bucket, roll back the bucket, and lower the lift arms with engine at 1000--1500 rpm. Articulate the machine from left to right.
Check the emergency steering systems function (option). Turn the ignition key to the 0 position to turn off the engine. When the engine has stopped, turn the ignition key to the 1 position. Turn the steering lever; the machine should turn. Note! The machine cannot be turned if the cabin door is open.
Check brake releasing pump function. Turn the switch. The pump should start. (Parking brake button has to be pulled fully up before the pump can start.)
Make sure that the safety locks are removed. Make a general visual inspection of the machine, and check for oil leaks and loose hoses, frayed wires, or other apparent maintenance needs; if anything looks suspicious, call a service engineer.
Gauge pointer in green area. No corrosion. Firmly mounted. Visually check that seals are in place.
Check lights
DDEC signal lights must go off about 5 sec after the power has been switched on. Engine temperature should be below 99_C. Engine oil pressure: at least 0.35 bar when idling, at least 1.9 bar when at 1800 rpm. Brake system oil pressure; warning light illuminates when pressure drops too low. Alternator charging voltage; approx. 26--28 V. Transmission oil pressure; should be 16.5 21.4 bar.
Shut off engine before filling. Insure machine is suitably grounded. Do not overfill. Do not fill fuel tank to the top. Fuel expands when it becomes warm and can overflow. If using quick fill, ensure that the system suppliers instructions are followed.
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MAINTENANCE OPERATIONS
Check the system visually and fill it. Check that all lubrication points are well greased.
Grease lift cylinder pins, tilt cylinder pins, and lift arm pins
Use central lubrication manifold. (If automatic central lubrication is not installed)
Connect the high--pressure grease gun to grease nipple B. Fill the pin with grease (until the pump cant pump more). Grease the stationary ends (grease nipples A) with a hand grease gun.
A
Grease pins directly through the nipples with a hand grease gun.
Grease pins directly through the nipples with a hand grease gun.
Use central lubrication manifold. (If automatic central lubrication is not installed) Grease steering cylinders front pins directly through the nipples.
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MAINTENANCE OPERATIONS
If the machine is equipped with catalytic exhaust gas purifier, check the purifier after every 1000 hours of use.
18.00 x 25 L5S Bridgestone Front: 550 kPa (5.5 bar) Rear: 400 kPa (4.0 bar)
The transmission and hydraulics should be at operating temperature during measurement. A Transmission: Press brake pedal, engage highest gear, and accelerate. The engine should achieve about a 2060--2160 rpm stalling speed. B Bucket hydraulics: Lower the boom against the stops, keep the control valve in boom down position, and accelerate. The engine should achieve about a 2100--2200 rpm stalling speed. S Steering hydraulics: Turn the loader against the stops, keep the control valve in the selected position, and accelerate. The engine should achieve about a 2100--2200 rpm stalling speed.
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MAINTENANCE OPERATIONS
General cleaning
Operators compartment (do not use high-pressure water when cleaning the cabin). Engine compartment: Before cleaning the machine with water, or by steam jet or via other cleansers, cover the alternator, connection boxes, and major connections. Do not apply steam or solvent directly to the alternator, starting motor, or DDEC electronic components. Do not apply solvent to hot surfaces.
Open all junction boxes. -- Check that all boxes are dry -- Ensure that the components and junction boxes are mounted properly -- Visually check for possible loose wires inside the junction boxes
Check cables
Visually check the cables for -- Wear -- Sharp bends -- Other possible damage
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MAINTENANCE OPERATIONS
Drain oil from the bottom of the gearbox and reinstall drain plug, using a new gas-ket if required. Be careful when draining hot oil. Fill gearbox through filler opening until fluid comes up to LOW mark on transmission dipstick. Run engine for two minutes at idle. Recheck level of fluid in gearbox with engine running at idle. Add quantity necessary to bring fluid level to LOW mark on dipstick. Recheck with hot oil. Bring oil level to FULL mark on dipstick.
The air filter element must be replaced when the service indicator shows red. Always clean the sealing surface of the outlet tube and make sure that all contami-nant is removed before the new filter is inserted. Always clean the inside of the outlet tube carefully. When the filter element is changed, the safety element must be kept in place. The safety element must be changed every second time the air filter element is replaced.
A fuel shutoff valve is installed on the discharge side of the fuel filter. Turn the handle on the shutoff valve to the closed position. Place a suitable container under the filter and open the drain valve at the base of the fuel processor. Drain the fuel until it is below the filter in the see--through cover and close the drain valve. Turn the collar counter--clockwise and remove. Remove cover, filter spring, and cover seal ring by lifting straight up and over the filter element. Replace filter element and grommet. Assemble cover (check spring and seal). Tighten the collar by hand only. Remove the vent plug from the top of the cover. Fill the cover with clean fuel by using the hand pump and reinstall the plug (check the plug O--ring) and tighten by hand only. Turn the handle on the shutoff valve to the open position. Start the engine, to purge the air from the system. After air is purged and with the engine still running, loosen the vent cap. The fuel level in the cover will start falling. When the fuel level falls to the top of the collar, tighten the vent cap quickly. Check for leaks. For further information, consult Engine Operators Guide.
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MAINTENANCE OPERATIONS
Measure the coolant nitrite concentration and change cooling system filter, if needed
Never open the filler cap when hot. Drain and clean if the engine overheats or solution is contaminated. Operate with a thermostat in the cooling system all year round. The nitrite (NO2) concentration must be between 800 and 2400 ppm. Coolant pH should be between 8.5 and 10.5. See Detroit Diesel Engine Operators Guide booklet Check engine mountings
Check batteries
Electrolyte level Cable connections Cleanliness Always wear eye protection, protective overalls, and protective gloves when servicing batteries. The acid in the battery can burn the skin, eats holes in clothing, and can cause blindness if it gets in the eyes.
Check alternator terminals for loose connections and corrosion. Check mounting Check V--belts. Replace if necessary. When replacing, always inspect fan bearings.
Always ensure that the arrow is in down position when checking oil level in plane-tary hubs. Refer to the picture.
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MAINTENANCE OPERATIONS
Check for visible signs of wear. Check that the lubrication works.
Check that all hatches, cabin door, and lock work properly.
Check quick check that the system is operable. Check that the system has not been tampered with and that there is no obvious physical damage or problems that would prevent operation. Follow the service recommendations for any locally fitted fire suppression system.
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MAINTENANCE OPERATIONS
Check exhaust manifold fastening nuts, exhaust flange, turbocharger, and other connections for tightness. Tightening torques Exhaust manifold bolts . . . . . . . 58--73 Nm Exhaust manifold / turbocharger nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 58--73 Nm Oil drain line bolts . . . . . . . . . . . 30--38 Nm
Apply the parking brake. Push in pin until it contacts reaction plate. If the wear indicator pin reaches the same level as the outer surface of the nut, the brakes are worn out and should be overhauled.
UNF 3/8 . . . . . . . . . . . . . . . . . . . Wheel nuts . . . . . . . . . . . . . . . . . Axle fastening nuts . . . . . . . . . . Axle fastening lock nuts . . . . . .
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MAINTENANCE OPERATIONS
Clean the filter adapter. Add quantity necessary to bring fluid level to FULL mark on dipstick.
Change return oil filter element for bucket and steering hydraulics
Place a dial gauge with a magnetic stand on the upper hinge plate of the front frame. Press the bucket against the ground so that the front frame rises from the ground and so you may observe the readings of the dial gauge. The reading should be 0.2...0.4 mm. If the play is smaller or larger, use shims to adjust it. For further information, consult the workshop manual.
MAINTENANCE OPERATIONS
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MAINTENANCE OPERATIONS
Increased backpressure (2 to 3 inches water gauge higher from clean purifier when at high idle), excessive smoke, or high levels of odor or irritation during operation of the LHD loader indicates that the purifier is not functioning at optimum performance and should be cleaned. Cleaning of the purifier: Dry brush inlet face to catalyst, air--clean through outlet face of catalyst, soak catalyst in cleaning solution (1 hour), solvent--air--clean through outlet face, and air--clean through outlet face. Do not use solvents containing chlorine, sulfur, metals, or leaded gasoline.
Use a hand grease gun and lubricate the bearings with one shot of lithium--based multipurpose grease. Do not overfill the housing.
Drain oil from the bottom of the transmission and reinstall drain plug, using a new gas-ket if required. Be careful when draining hot oil. Change oil filter. Clean the filter adapter. Fill torque converter and transmission through filler opening until fluid comes up to LOW mark on transmission dipstick. Run engine for two minutes at idle to prime torque converter and hydraulic lines. Recheck level of fluid in transmission with engine running at idle. Add quantity necessary to bring fluid level to LOW mark on dipstick. Recheck with hot oil. Bring oil level to FULL mark on dipstick.
Tightening torques (dry) . . . . . Axle fastening nuts . . . . . . . . . . 1000 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle fastening lock nuts . . . . . 500 Nm
Remove plug at bottom of axle housing and allow sufficient time for lubricant to drain. With planetary wheel ends, rotate wheel until filler hole is down. Remove plug and allow sufficient time for draining. Be sure planet cover oil level hole is in proper position when refilling wheel ends. Always ensure that the arrow is in down position when checking oil level in planetary hubs. Refer to the picture. D Test the hydraulic pressures
The hydraulic oil temperature should be 60...80 _C. Connect and disconnect pressure gauge(s) only when the circuit is not pressurized. Use only special couplings for pressure testing. Do not over--tighten couplings. When special couplings are used, finger--tight is adequate. Over--tightening causes harmful leakage. Use hose(s) long enough that the gauge(s) can be read while one is sitting in the cabin. Pilot system pressure -- Attach a pressure gauge to the quick--disconnect fitting as shown in the picture. -- Engine at low idle -- Pressure should be 35 bar (3.5 MPa)
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MAINTENANCE OPERATIONS
Steering system pressure -- Install the frame locking pin between front and rear frames. -- Connect a pressure gauge to the quick--disconnect fitting after the steering main valve. -- Engine speed of 1000 --1500 rpm. -- Turn the machine to full left--hand turn. -- Steering system pressure should be 120 bar (12.0 MPa).
Hydraulic pumps pressures -- The hydraulic pumps pressures can be checked from the quick--disconnect fittings. -- Engine at 1000--1500 rpm. -- Lower the boom against the stops and keep the control valve in boom down position. -- Pressure should be 250 bar (25.0 MPa) (points 1 and 2). --Standby pressure for steering pump: 40 bar (4.0 MPa) (point 1). Standby pressure for bucket pump: 20 bar (2.0 MPa) (point 2).
Pre--charge pressures (nitrogen pressure) -- Brake system accumulators: 12 and 90 bar -- Boom suspension: 60 bar -- Emergency steering (option): 60 bar
The fire suppression system, including alarms, shutdown, and associated equipment, shall be thoroughly examined and checked for proper operation by the fire suppression system manufacturer, authorized distributor, or the designee in accordance with the Ansul Maintenance Manual. NOTE! For other than Ansul systems, have the system serviced by an authorized system supplier or dealer. Always follow the local regulations.
Clean hydraulic oil tank. Check for correct positive tank pressure, 0.3 bar at operating temperature. If electrical filling pump can be used (option), the oil tank can also be filled by fast coupling. WARNING After filling the hydraulic tank, bleed ALL air from the suction towers to avoid pump cavitation.
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MAINTENANCE OPERATIONS
Have the extinguisher serviced by an authorized supplier or dealer. Always follow the local regulations.
MAINTENANCE OPERATIONS
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MAINTENANCE PROGRAM
4.
MAINTENANCE PROGRAM
Page
Done
Every shift
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Check engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Check air filter indicator and assembly condition . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Check fuel filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Check transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Check transfer gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Check tires and wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check hydraulic oil tank pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check that all controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check the emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check brake releasing pump function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check major components for oil leaks and proper mounting . . . . . . . . . . . . . . . . 21 Check hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check driving/working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill the automatic central lubrication system (option) . . . . . . . . . . . . . . . . . . . . . . . 23 Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* . . . . . . . . . . . . . . . . . 23 Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease side tipping cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease center articulation, steering cylinder pins, and oscillating axle* . . . . . . . 24 Grease dogbone pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 * if automatic central lubrication is not installed When completed Date . . . . . . . . . . . . . . . . . . . . . . . Engine hours . . . . . . . . . . . . . . . . Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
Done
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Check engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Check air filter indicator and assembly condition . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Wash radiator + oil coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clean cyclone air cleaner bowl (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clean exhaust water scrubber (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Check fuel filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Check transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Check transfer gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Check hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check hydraulic oil tank pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check tires and wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check that all controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check the emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check brake releasing pump function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check major components for oil leaks and proper mounting . . . . . . . . . . . . . . . . 21 Check hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check driving/working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill the automatic central lubrication tank (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* . . . . . . . . . . . . . . . . . 23 Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease side tipping cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease center articulation, steering cylinder pins, and oscillating axle* . . . . . . . 23 Grease dogbone pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 * if automatic central lubrication is not installed
47 (64)
MAINTENANCE PROGRAM
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
Done
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Check engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Check air filter indicator and assembly condition . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Wash radiator + oil coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clean cyclone air cleaner bowl (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clean exhaust water scrubber (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Check fuel filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Check transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Check transfer gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Check hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check hydraulic oil tank pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check wheel nuts tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check that all controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check the emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check brake releasing pump function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check major components for oil leaks and proper mounting . . . . . . . . . . . . . . . . 21 Check hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check driving/working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cabin door and lock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check junction boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill the automatic central lubrication tank (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* . . . . . . . . . . . . . . . . . 23 Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease side tipping cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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MAINTENANCE PROGRAM
Page
Done
Grease center articulation, steering cylinder pins, and oscillating axle* . . . . . . . 24 Grease dogbone pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 General cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 * if automatic central lubrication is not installed
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
Done
Change engine oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Measure the coolant nitrite concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Clean exhaust water scrubber (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clean cyclone air cleaner bowl (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Service air filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Change fuel filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Check engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Check transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Change transfer gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Check hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check hydraulic oil tank pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check oil level in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . 32 Change brake flushing return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check wheel nuts tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check that all controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check the emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check brake releasing pump function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check major components for oil leaks and proper mounting . . . . . . . . . . . . . . . . 21 Check hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check driving/working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cabin door and lock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check junction boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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MAINTENANCE PROGRAM
Page
Done
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill the automatic central lubrication tank (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* . . . . . . . . . . . . . . . . . 23 Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease side tipping cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease center articulation, steering cylinder pins, and oscillating axle* . . . . . . . 24 Grease dogbone pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Grease the stationary ends of boom/bucket pins . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lubricate operator seat linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Lubricate door and hatch hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Check center articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Wash radiator + oil coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Check fire suppression system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 * if automatic central lubrication is not installed
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
Done
Change engine oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Measure the coolant nitrite concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Clean exhaust water scrubber (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clean cyclone air cleaner bowl (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Service air filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Change fuel filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Check fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check exhaust system fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Check cooling system hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Change transmission oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Check transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Change transfer gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Change return oil filter element for bucket and steering hydraulics . . . . . . . . . . . 37 Change brake flushing return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Change brake system high--pressure oil filter element . . . . . . . . . . . . . . . . . . . . . 36 Check hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check hydraulic oil tank pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check oil level in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . 32 Measure wear to brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Check axle fastenings visually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Check oscillating axle tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check the tightening torques of power train flanges and bolts . . . . . . . . . . . . . . . 36 Drain water from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check wheel nuts tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check that all controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Done
Check the emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check brake releasing pump function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check major components for oil leaks and proper mounting . . . . . . . . . . . . . . . . 21 Check hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check driving/working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cabin door and lock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check junction boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill the automatic central lubrication tank (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* . . . . . . . . . . . . . . . . . 23 Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease side tipping cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease center articulation, steering cylinder pins, and oscillating axle* . . . . . . . 24 Grease dogbone pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Grease the stationary ends of boom/bucket pins . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lubricate operator seat linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Lubricate door and hatch hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Check center articulation with dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Wash radiator + oil coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Check fire suppression system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 * if automatic central lubrication is not installed When completed Date . . . . . . . . . . . . . . . . . . . . . . . Engine hours . . . . . . . . . . . . . . . . Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
Done
Change engine oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Measure the coolant nitrite concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Inspect cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Check engine crankcase pressure, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check catalytic exhaust gas purifiers (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Clean exhaust water scrubber (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clean cyclone air cleaner bowl (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Service air filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Change fuel filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Check fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check exhaust system fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Check cooling system hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Change transmission oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Change transfer gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Change return oil filter element for bucket and steering hydraulics . . . . . . . . . . . 37 Change brake flushing return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Change brake system high--pressure oil filter element . . . . . . . . . . . . . . . . . . . . . 36 Check pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Change hydraulic oil fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Check hydraulic oil tank pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Change oil in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Measure wear to brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Check the tightening of axle fastening bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Check oscillating axle tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check the tightening torques of power train flanges and bolts . . . . . . . . . . . . . . . 36 Drain water from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check wheel nuts tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check that all controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check the emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check brake releasing pump function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Test the hydraulic pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Check major components for oil leaks and proper mounting . . . . . . . . . . . . . . . . 21 Check hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check driving/working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cabin door and lock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check junction boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill the automatic central lubrication tank (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease fan drive bearing fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* . . . . . . . . . . . . . . . . . 23 Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease side tipping cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease center articulation, steering cylinder pins, and oscillating axle* . . . . . . . 24 Grease dogbone pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Grease the stationary ends of boom/bucket pins . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lubricate operator seat linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Lubricate door and hatch hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Check center articulation with dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Wash radiator + oil coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Service fire suppression system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 * if automatic central lubrication is not installed
MAINTENANCE PROGRAM
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Page
Done
Change engine oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Measure the coolant nitrite concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Clean exhaust water scrubber (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clean cyclone air cleaner bowl (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Service air filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Change fuel filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Check fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check engine tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Check exhaust system fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Check cooling system hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Change transmission oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Check transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Change transfer gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Change return oil filter element for bucket and steering hydraulics . . . . . . . . . . . 37 Change brake flushing return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Change brake system high--pressure oil filter element . . . . . . . . . . . . . . . . . . . . . 36 Check hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check hydraulic oil tank pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check oil level in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . 32 Measure wear to brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Check axle fastenings visually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Check oscillating axle tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check the tightening torques of power train flanges and bolts . . . . . . . . . . . . . . . 36 Drain water from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check wheel nuts tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check that all controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Page
Done
Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check the emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check brake releasing pump function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check major components for oil leaks and proper mounting . . . . . . . . . . . . . . . . 21 Check hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check driving/working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cabin door and lock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check junction boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill the automatic central lubrication tank (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* . . . . . . . . . . . . . . . . . 23 Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease side tipping cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease center articulation, steering cylinder pins, and oscillating axle* . . . . . . . 24 Grease dogbone pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Grease the stationary ends of boom/bucket pins . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lubricate operator seat linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Lubricate door and hatch hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Check center articulation with dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Wash radiator + oil coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Check fire suppression system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 * if automatic central lubrication is not installed When completed Date . . . . . . . . . . . . . . . . . . . . . . . Engine hours . . . . . . . . . . . . . . . . Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59 (64)
MAINTENANCE PROGRAM
Page
Done
Change engine oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Change V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Measure the coolant nitrite concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Inspect cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Check engine crankcase pressure, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check catalytic exhaust gas purifiers (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Clean exhaust water scrubber (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clean cyclone air cleaner bowl (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Service air filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Change fuel filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Check fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check exhaust system fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Check cooling system hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Change transmission oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Change transfer gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Change return oil filter element for bucket and steering hydraulics . . . . . . . . . . . 37 Change brake flushing return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Change brake system high--pressure oil filter element . . . . . . . . . . . . . . . . . . . . . 36 Check pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Change hydraulic oil fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Check hydraulic oil tank pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Change oil in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Measure wear to brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Check the tightening of axle fastening bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Check oscillating axle tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check the tightening torques of power train flanges and bolts . . . . . . . . . . . . . . . 36 Drain water from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check wheel nuts tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check that all controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Page
Done
Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check the emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check brake releasing pump function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Test the hydraulic pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Check major components for oil leaks and proper mounting . . . . . . . . . . . . . . . . 21 Check hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check driving/working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cabin door and lock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check junction boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill the automatic central lubrication tank (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease fan drive bearing fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* . . . . . . . . . . . . . . . . . 23 Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease side tipping cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease center articulation, steering cylinder pins, and oscillating axle* . . . . . . . 24 Grease dogbone pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Grease the stationary ends of boom/bucket pins . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lubricate operator seat linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Lubricate door and hatch hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Check center articulation with dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Wash radiator + oil coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Service fire suppression system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Service hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 * if automatic central lubrication is not installed
61 (64)
MAINTENANCE PROGRAM
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
Done
Change engine oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Change V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Drain and replace coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Change thermostats and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Inspect cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Check engine crankcase pressure, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check catalytic exhaust gas purifiers (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Clean exhaust water scrubber (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Clean cyclone air cleaner bowl (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Service air filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Change fuel filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Check fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check exhaust system fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Check cooling system hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Change transmission oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Change transfer gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Change return oil filter element for bucket and steering hydraulics . . . . . . . . . . . 37 Change brake flushing return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Change brake system high--pressure oil filter element . . . . . . . . . . . . . . . . . . . . . 36 Check pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Change hydraulic oil fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Check hydraulic oil tank pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Change oil in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Measure wear to brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Check the tightening of axle fastening bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Check oscillating axle tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check the tightening torques of power train flanges and bolts . . . . . . . . . . . . . . . 36 Drain water from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check wheel nuts tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check that all controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
63 (64)
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Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check the emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check brake releasing pump function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Test the hydraulic pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Check major components for oil leaks and proper mounting . . . . . . . . . . . . . . . . 21 Check hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check driving/working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Check the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cabin door and lock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check junction boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fill the automatic central lubrication tank (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease fan drive bearing fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* . . . . . . . . . . . . . . . . . 23 Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease side tipping cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Grease center articulation, steering cylinder pins, and oscillating axle* . . . . . . . 24 Grease dogbone pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grease driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Grease the stationary ends of boom/bucket pins . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lubricate operator seat linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Lubricate door and hatch hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Check center articulation with dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Wash radiator + oil coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Service fire suppression system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Service hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
MAINTENANCE PROGRAM
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .