Maintenance

MaintenanceManual

MAINTENANCEMANUAL

(Detroit S50)

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SANDVIK TAMROCK CORP., TURKU PLANT 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 havebeen given proper training and are authorized to do so should operate the loader. Alloperators should familiarize themselves with themachine and fully understand the contentsof the operator’s manual, maintenance manual, and general safety instructions beforeoperating it.

Read the operator’s manual and “General SafetyInstructions” before starting the work!

This responsibility is particularly pertinent for personnel who work with the loader onlyoccasionally -- e.g., during setup or maintenance.

Continuing research and development of TORO loaders may have caused changes to yourmachine that are not dealt with in this manual.If the machine is equipped with optional equipment -- e.g., a remote control system -- youshould familiarize yourself with the separate instructions in which the equipment’s operationis explained.This manual must always remain available in the cabin for ready accesswhen operating theTORO loader.Always obey the national legislation in force where accident prevention and environmentalprotection are concerned.Generally accepted technical guidelines for safe andprofessionaloperation must also be observed.

For demanding maintenance and repair operations, we recommend that you contact yournearest authorized Sandvik Tamrock Service. Our maintenance personnel have the skillsand special tools required for the most demanding tasks.Through correct use and by following the maintenance instructions, you can expect a highdegree of utilization and long operating life of your loader.

Always obey safety rules!

WARNING

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PREFACE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. GENERAL 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1. Importance of regular maintenance 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2. General safety precautions during operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3. General repair instructions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4. Location of the main components 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. MAINTENANCE AND LUBRICATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1. Maintenance of hydraulics 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2. Electrical system maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3. Battery maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4. Welding 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5. Lubricants 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.1. Engine 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.2. Transmission 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.3. Transfer gearbox (Up--Box) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.4. Hydraulics 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.5. Axles 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.6. Grease nipples 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6. Filling capacities 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7. Special notes 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.1. Cooling system 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.2. Refueling 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8. First servicing 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. MAINTENANCE OPERATIONS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1. Every shift 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2. Every week 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3. Every 125 hours 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4. Every 250 hours 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5. Every 500 hours 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6. Every 1000 hours 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7. Every 1500 hours 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8. Every 2000 hours 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9. Every 4000 hours 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. MAINTENANCE PROGRAM 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL

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1. GENERAL

1.1. Importance of regular maintenance

The TORO 007 is designed for hard work in difficult and demanding mine conditions. Toensure trouble--free and economical operation, it is extremely important to adhere to theschedule for regular maintenance. By following this schedule closely, you can easilydetect possible defects in themachinewhich canbe repaired before they becomeserious.This will ensure low repair costs and minimize production disturbances.

The pages that follow give information on servicing various TORO 007 components andthe corresponding service intervals.Weurge all end users to review theDetroitOperator’sGuide for additional information regarding servicing.

1.2. General safety precautions during operationWe recommend that records be kept on servicingandwearing part replacements.Regularmaintenance procedures at the correct intervals increase productivity, reliability,economy, and the safety of the equipment.

Even maintenance work can be dangerous, unless caution is observed. Everybodyinvolved in maintenance work should understand the possible hazards and use safeworking methods. Before starting any maintenance or repair work, read themanufacturer’s instructions. Be sure to follow them.

The personnel must not wear long, loose hair or loose clothing, nor should they wearjewelry, including rings, because of the risk of injury.

Use personal protection suits and other protective equipment as far as is necessary ormandatory.

Do not perform any modifications, extensions, or rebuilding of the machine that wouldaffect safety. Consult the supplier or manufacturer. This also includes the built--in andadjustment of safety devices and valves, as well as the welding of frame structures.

Spare parts must meet the manufacturer’s technical specifications. Conformity to thesestandards is guaranteed only when genuine spare parts are used.

Notify the location and use of fire extinguishers!

It is absolutely necessary to have suitable specialized workshop equipment to ensurehigh--quality maintenance work.

Any maintenance or repair work on the TORO loader must be performed by properlytrained or instructed personnel only. Work must be performed on electrical appliances byelectricians and on hydraulic appliances by mechanical technicians with knowledge andexperience particular to the work to be done.

Carry out any activity specified in this manual with respect to adjustment, maintenance,and inspection times, in addition to heeding any indications for replacement of parts.

Clean and wash the equipment regularly, and always before and after maintenance andrepair work. Before cleaning the machine with water, or by steam jet or with othercleansers, cover the alternator, connection boxes, and major connections. Remove thecovers after cleaning!

Never attempt to clean, adjust, repair, or lubricate the TORO loader while it is inmotion or the engine is running.

GENERAL

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1.3. General repair instructions

The person responsible for maintenance and repairs should be clearly identified.-- Do not do any work that you are not authorized to do.-- Secure extensively, as far as necessary, the areawhere themaintenance workwill

be performed.-- Inform the users of the equipment of the start of maintenance or any special work

on the loader.-- If the equipment or a part of it has been stopped for maintenance or repair, make

sure that it cannot be started accidentally.D Turn main switch offD Remove ignition keyD Put a DANGER DO NOT START or corresponding warning sign on the main

switch. The sign must be removed only by a person who is fully aware of thesituation.

-- If required, ensure that suitable and safe ladders or working platforms are availablefor use in repair and maintenance work.

-- Do not use any of the equipment as steps. If maintenance work must be done highup, or in an otherwise dangerous place or position, use the safety devicesnecessary to prevent falling.

-- All platforms, steps, grips, rails, ladders, and other similar parts must be kept cleanof oil, dirt, snow, and ice to prevent accidents.

-- Always use the right tools for the maintenance task.-- Before commencingmaintenance or repair work, ensure that the vehicle is on level

ground and won’t move.-- Pay special attention to the exhaust pipe--work and the exhaust gas cleaning

system. Ensure sufficient ventilation.-- Use a lift jack only on level, hard, and firm ground. Before using a jack, always be sure

the wheels on the other side of the vehicle are blocked. To prevent the possibility ofthe jack slipping, secure the vehicle by using adequate supports and blocksunderneath it.

-- Remove all the air from the tire before loosening the wheel nuts/bolts. Should youforget to do this, a broken rim part under pressure can fly apart and cause seriousinjury.

-- Do not try to repair wheel parts by brazing, welding, or reworking. Be sure to replacethem with new parts of the same size, type, and make.

-- Never transport a fully inflated spare tire mounted on demountable rims. Such tiresshould have just enough air pressure to hold the rim parts firmly in place. Only afterthe tire and rim assembly have been fastened with proper torque applied to all thewheel nuts/bolts should the tire be inflated to the correct operating pressure.

-- In inflating, mounting, or dismounting tires, a safety rack, cage, or some otherprotection should be used

-- During tire inflation, do not stand in front of the assembly. Use an extension hose sothat you can stand to one side.

-- When replacing heavy parts, use correct lifting apparatus and techniques.-- After preventive maintenance and repairs, always tighten fasteners that have been

unscrewed. Reassemble all dismantled safety appliances immediately after thework

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3

2

44

5

GENERAL

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is done. Ensure that all safety systems are tested before the unit is returned tonormal work.

-- Pay attention to safety and environmental protection when disposing of processmaterials and old parts.

1.4. Location of the main components

1

2 4

3

1. Front frame2. Rear frame

3. Engine ass’y4. Power train

Front frame

1. Bucket

2. Swing lever

3. Boom

4. Lift cylinders

5. Tilt cylinder

GENERAL

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Rear frame

5

62

7 88

34

2

1

7

1. Fuel tank2. Oil cooler3. Hydraulic oil level4. Main switch

5. Battery box6. Radiator / intercooler / fuel cooler7. Operator’s cabin8. Service hatches

Engine ass’y

5

1

2

3

6

4

1. Alternator2. Turbocharger3. Engine oil filters

4. Engine coolant filter5. Fuel filter6. Air filter

1 5 5 3 25 4

GENERAL

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Power train

1. Front axle2. Rear axle3. Transmission /

torque converter4. Transfer gearbox5. Driveshaft

MAINTENANCE AND LUBRICATION

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2. MAINTENANCE AND LUBRICATION

The TORO 007 is designed for hard work in difficult and demanding mine conditions. Toensure trouble--free and economical operation, it is extremely important to adhere to theservice schedule indicated. By paying close attention to the service schedule, you caneasily detect possible defects in the machine or other problems that can be addressedbefore they become serious. This will ensure low repair costs and minimize disturbancesto production.

The following pages give information for servicing various TORO 007 components andother items for servicing, with their corresponding service intervals. All end users shouldreview the Engine Manuals for additional information regarding servicing.

2.1. Maintenance of hydraulics

Maintenance, repair, and installation of hydraulic equipment must be carried out only byexperienced hydraulics experts.D Do not attempt any such repairs that you do not fully understand.D Never do any repair work on the hydraulic circuit when the system is pressurized.D Always stop the engine before tightening or repairing a leaking hose connection.D Do not try to locate a leak in a hose or a connection by using your hand. The

high-pressure oil spray from the leak can penetrate the skin and cause seriousinjury. High-pressure oil spray can also start a fire.

D Avoid direct skin contact with oil. Prevent oil from getting into your eyes; use eyeprotection.

D Do not work under a device or component that is held up only by the hydraulics.Use separate supports in conjunction with maintenance and repair.

D Do not remove boom cylinders or their valves unless the boom is properlysupported and the system non--pressurized.

D Pipe connections, hose lengths, and hose types must correspond with thespecifications. When replacing or repairing hoses, use original SANDVIKTAMROCK spare parts or hoses and fittings recommended by the manufacturer.Ensure that the pressure ratings of the hoses and connecting fittings correspondwith the working pressures.

D Any deviations require written authorization from the manufacturer.

Pressure tests

GeneralD The hydraulic oil temperature should be 60...80 _C.D Connect and disconnect pressure gauge(s) only when the circuit is not

pressurized.D Use only special couplings for pressure testing.D Do not over--tighten couplings. When special couplings are used,

finger--tightening is adequate. Over--tightening leads to harmful leakage.D Use hose(s) long enough to read the gauge(s) while the operator is sitting in the

cabin.


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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).

2.2. Electrical system maintenanceD Work on electrical equipment or components is only to be carried out by qualified

electricians or other professionals, or by assistants under their supervision andcontrol, observing electrotechnical regulations.

D Local electrotechnical and electric safety regulations must always be observed.D Always use only original electrical components.D If disturbances in the electricity supply occur, stop the vehicle at once.D Voltage must be cut off from the parts of the equipment or devices that are to be

checked, serviced, or repaired, if regulations so require. Check that thedisconnected parts are dead, and then lock the main switch or arrange groundingfor the work if necessary.

D Do not touch battery terminals, alternator terminals, or wiring while the engine isoperating. Severe electrical shock, which may result in injury, could occur due toimproper shielding of electrical components.

D Check the electrical devices of themachinery regularly. Faults, such as loosewiresand damaged insulation, must be repaired at once.

D When handling high-voltage components, remember that capacitors may becharged even if the voltage is cut off. Discharge the capacitors with a groundingrod.

D Before making any changes concerning the electrical devices, SANDVIKTAMROCK’s electrical engineering department must be consulted and awritten authorization received, to ensure that the operation of the devicedoes not change.


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Working on live componentsD 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 emergencysituation 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.

2.3. Battery maintenance

Always wear eye protection, protective overalls, and protective gloves whenservicing batteries.D Always disconnect the negative (-) pole first, then the positive (+) pole. Always

connect the positive pole (+) first, then the negative (-) pole.D Reversing battery polarity can result in personal injury caused by sudden

discharge of electrolyte from the battery vents and/or the sudden rupture of thebattery case due to explosion of internal hydrogen gas.

D To prevent sparking when connecting a battery charger, disconnect the chargersupply cord or switch the charger off before connecting the charging wires to thebattery terminals. Open the battery’s cell caps slightly during charging to allow thegases generated to escape.

D The acid in the battery can burn the skin, eats holes in clothing, and can causeblindness if it gets in the eyes. If you get battery acid on your skin, flush the areaat once with water. Use sodium bicarbonate to neutralize the acid if it gets in theeyes. Flush the eyes with water, and call a doctor.

D When servicing batteries, remember that lead-acid batteries generate oxygen andhydrogen during charging and discharging, which form a highly explosive mixture.A spark or an open flame can causeanexplosion. If necessary, ventilate thebatterycompartment properly before disconnecting or connecting the cables.

D To prevent explosion, the electrolyte level must be maintained and checkedregularly. Add distilled water, if required, before starting -- and never immediatelyafter use. With a high enough electrolyte level, the cells have less space for gases.

D Use a flashlight when checking electrolyte levels, never an open flame.D The battery terminals should never be shorted, as sparks can cause the battery

to explode.D Do not test electrical devices by making contact with the battery terminal.

2.4. Welding

Before starting to weld, determine the material to be welded and select an appropriatewelding 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 If weldingmust be done close to anyof the control modules, disconnect themodulewiring before beginning welding.

D The ground cable of the welding machinemust be connected as close as possibleto thewelding location. The ground cablemay not be connected so that the currentcan flow through a bearing, joint coupling, sealing surface, lever, or control cable.

D Use a protective mask when welding.D Arrange adequate ventilation.D Arrange protection against fire.


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2.5. Lubricants2.5.1. Engine

Classification API CH--4

Viscosity 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 userequires a shorter oil change interval.Synthetic oilsmaybe used in Detroit Diesel engines, provided that they areAPI licensedandmeet the performance and chemical requirements for non--synthetic oils outlined in thispublication.Product information for synthetic oils should be reviewed carefully. Performance additivesystems often respond differently in synthetic oils. Their use does not permit extension ofrecommended oil change intervals.The use of fuels with sulfur content above 0.5 mass percent will require shorter oil changeintervals and/or the use of a higher TBN oil.See engine Operator’s Guide for more details.

2.5.2. Transmission

Classification Allison C--4 or Caterpillar TO--4

Viscosity --20 _C...+15 _C SAE 10Wabove +0 _C SAE 30

2.5.3. Transfer gearbox (Up--Box)

Oil type: Shell Omala HD 220 or equivalent

ISO Viscosity grade 220Viscosity 40 _C 222.4 cSt

100 _C 25.8 cStViscosity index 148Pour point --48 _CFlash point 245 _C4Ball EP (Weld) 290 kg

2.5.4. Hydraulics

Hydraulic oils meeting DIN 51524 HVLP or ISO 6743--4 HV standards can be used

Viscosityabove --15 _C ISO VG 32 (SAE 10W)above +0 ISO VG 46 (SAE 20)above +5 ISO VG 68 (SAE 30)

Operating temperatures during normal operationabout 45 _C ISO VG 32about 60 _C ISO VG 46about 70 _C ISO VG 68

(Motor oils of API class CD, or hydraulic oils with wear--preventive characteristicscorresponding to the DIN 51524 HVLP or ISO 6743--4 HV standards, can be used)


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2.5.5. Axles

Classification MIL--L--2105 C or API GL--5 + LS (Limited Slip)

Viscosity above --25 _C. SAE 80W/140--25 _C...+15 _C SAE 85W/140

2.5.6. Grease nipples

Lithium--based greases with penetration 265/295 (NLGI 2) and dropping point 180 _Cshould be used.

2.6. Filling capacities

Engine oil 29 L (with filters)Engine coolant 55 LTransmission 72 LTransfer gearbox 9 LAxles 2 x 44 LHydraulic oil tank 250 LFuel tank 310 L

2.7. Special notes

If the machine is fitted with optional equipment such as an automatic central lubricationsystem, please read the instructions for the additional equipment carefully and adhere tothe service schedule given in the maintenance instructions.

2.7.1. Cooling systemD Drain and clean if the engine overheats or solution is dirty.

Note! Overheating indicates a fault. Stop the engine and repair the fault before moreserious damage is caused. Make sure that the engine radiator is not covered and that itis not clogged.

D Whenever draining and refilling the cooling system, always recheck the coolantlevel after the engine reaches its normal operating temperature.

Note! Never open the filler cap when hot.When checking engine coolant level, stop the engine and allow it and the radiator to cooldown. If an overheated engine must be stopped, allow the radiator to cool down beforechecking the coolant level. If there is no time for that, use thick gloves and protectiveclothing when opening the radiator’s filling cap. Stand to the side, turn your face away, andopen the cap a little.Wait until the pressure is released and coolant stops running out, thenopen the cap slowly.

D Adding over 19 liters per minute can cause air pockets in the cooling system.D Operate with a thermostat in the cooling system all year round.D Coolantmust be tested every 250hours to ensure that inhibitor levels remainwithin

the permitted ranges; change the coolant inhibitor filter element if necessary (seeDetroit Diesel Coolant Selections or Engine Operator’s Guide).


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2.7.2. Refueling

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 dangerouswhen 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

manufacturer’s operating and safety requirements.

2.8. First servicing

Check that the lubricants being used meet site--specific operating requirements as perSandvik Tamrock Lubricant Specifications.

The following steps should be carried out during the first week of use (in addition to thenormal, scheduled services):

After the first 50 hours-- Change the transmission oil filter element-- Change transfer gearbox oil-- Change engine oil and filter elements-- Check and tighten the exhaust manifolds’ bolts-- Check that the air filter and air pipes are tight-- Check and tighten bolts of oil sump and engine mountings-- Check/tighten bolts of the axles, wheels, gearbox, and other major components-- Tighten the screws of the oscillating axle

M12 bolts to 80 Nm (dry)M16 bolts to 210--240 Nm (dry)

-- Tighten the screws of driveshafts-- Check V--belts-- Make a visual overall check for leaks and possible damage

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3. MAINTENANCE OPERATIONS

3.1. Every shiftDDDD Check engine oil

Machine on level ground. Measure oillevel with engine stopped (after stopping theengine, allow oil drain to the crankcase forabout 20 minutes before checking the oillevel).

The oil level must be between the LOWand FULL marks on the dipstick.

DDDD Check V--belts

Check condition visually and adjust ifnecessary.

Check belt for worn, grease--coated, oil--soaked, or missing material. Replaceif necessary.

DDDD Check engine coolant level

Check before starting the engine.

Coolant level should be seen via the sightglass.

Do not remove the pressure control cap orattempt to drain the coolant until the enginehas cooled.

Use extreme caution when removing thecap. A sudden pressure release from aheated cooling system can result in aloss of coolant and possibleinjury (scalding, eye injury, etc.) fromthe hot liquid.

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DDDD Check air filter indicator and assembly condition

Consult air restriction indicator; service aircleaner elements as required.

Inspect the entire air system for leaks.Tighten any loose connections.

DDDD Check intake ducting and connections for leaks

DDDD Check exhaust ducting and connections for leaks

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DDDD Check fuel filter element

The filter cover will not fill completely during engineoperation. It will gradually fill over time, and thefuel level will rise as the filter element becomesclogged.

The filter element should be changed every 250hours, or sooner if the fuel level has risen to thetop of the element.

DDDD Check transmission oil level

Machine on level ground.Parking brake engaged.Engine at low idle.Gearshift lever in neutral position.Transmission oil at operating temperature.

DDDD Check transfer gearbox oil level

Machine on level ground.Parking brake engaged.Engine at low idle.Gearshift lever in neutral position.Gearbox oil at operating temperature.

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DDDD Check tires and wheel nuts

Check condition.

Visually check tire wear and air pressure.

Visually check for loose or missingwheel nuts.

DDDD Check hydraulic oil level

Boom in down position and bucket onground. Oil level should be between thesight glasses.

DDDD Check hydraulic tank pressure

It should be 0.3 bar.

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DDDD Test service and parking brake function

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 shouldhold firm at 2000 rpm (machine should not move until engine speed reaches 2000 rpm).

DDDD Check that all controls are functioning correctly

Raise the lift arms, dump the bucket, rollback the bucket, and lower the lift arms withengine at 1000--1500 rpm.

Articulate the machine from left to right.

DDDD Check the emergency steering system (option)

Check the emergency steering system’s 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.

DDDD Brake releasing system function (option).

Check brake releasing pump function. Turnthe switch. The pump should start. (Parkingbrake button has to be pulled fully up beforethe pump can start.)

DDDD Check major components for oil leaks and mounting

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 aservice engineer.

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DDDD Check Hand Portable Fire Extinguisher

Gauge pointer in green area.

No corrosion.

Firmly mounted.

Visually check that seals are in place.

DDDD Check lights

Front

Rear

Optional lights

DDDD Check gauges and indicator lights

DDEC signal lights must go off about 5 secafter the power has been switched on.

Engine temperature should be below 99_C.

Engine oil pressure: at least 0.35bar when idling, at least 1.9 bar when at 1800 rpm.

Brake system oil pressure; warning lightilluminates when pressure drops too low.

Alternator charging voltage; approx. 26--28 V.

Transmission oil pressure; should be16.5 – 21.4 bar.

DDDD Fill fuel tank

Shut off engine before filling.

Insure machine is suitably grounded.

Do not overfill.

Do not fill fuel tank to the top. Fuel expandswhen it becomes warm and can overflow.

If using quick fill, ensure that the systemsupplier’s instructions are followed.

A

A

B

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DDDD Fill automatic central lubrication system (option)

Check the system visually and fill it.

Check that all lubrication points are wellgreased.

DDDD Grease lift cylinder pins, tilt cylinder pins, and lift arm pins

Use central lubrication manifold.

(If automatic central lubrication is notinstalled)

DDDD Grease dogbone pins

Connect the high--pressure grease gunto grease nipple B.Fill the pin with grease (until the pumpcan’t pump more).

Grease the stationary ends (grease nipplesA) with a hand grease gun.

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DDDD Grease ejector cylinder pins (option)

Grease pins directly through the nippleswith a hand grease gun.

DDDD Grease side tipping cylinder pins (option)

Grease pins directly through the nippleswith a hand grease gun.

DDDD Grease center articulation, steering cylinder pins, and oscillating axle

Use central lubrication manifold.

(If automatic central lubrication is notinstalled)

Grease steering cylinders front pinsdirectly through the nipples.

DDDD Check remote control system (option)

Check RC system function according to Remote Control system instructions.

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3.2. Every weekDDDD Wash radiator + oil coolers

Open the cooler hatches for proper cleaning.

WARNINGDo not use high--pressure cleaning units. Itmay result in cooler core damage.

HOT WATER CLEANING WITH SOAP(biodegradable detergent) CAN BE USED,MAX. PRESSURE 82 bar (1200 psi).

DDDD Clean exhaust water scrubber (option)

If the machine is equipped with catalyticexhaust gas purifier, check the purifier afterevery 1000 hours of use.

DDDD Clean cyclone air cleaner bowl (optional)

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DDDD Check tire pressures

18.00 x 25 L5S Bridgestone

Front: 550 kPa (5.5 bar)

Rear: 400 kPa (4.0 bar)

DDDD Test transmission and the bucket and steering hydraulics

The transmission and hydraulics should be at operating temperature duringmeasurement.

A Transmission: Press brake pedal, engage highest gear, and accelerate. The engineshould achieve about a 2060--2160 rpm stalling speed.

BBucket hydraulics: Lower the boom against the stops, keep the control valve in ”boomdown” position, and accelerate. The engine should achieve about a 2100--2200 rpmstalling speed.

S Steering hydraulics: Turn the loader against the stops, keep the control valve in theselected position, and accelerate. The engine should achieve about a 2100--2200 rpmstalling speed.

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3.3. Every 125 hoursDDDD Check wheel nut’s tightening torques

UNF 3/4, 610 Nm (dry)

DDDD General cleaning

Operator’s 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 majorconnections.Do not apply steam or solvent directly to the alternator, starting motor, or DDECelectroniccomponents.

Do not apply solvent to hot surfaces.

DDDD Check cabin door and lock condition.

Check that the cabin door and lock workproperly.

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DDDD Check junction boxes

Open all junction boxes.-- Check that all boxes are dry-- Ensure that the components andjunction boxes are mounted properly-- Visually check for possible loose wiresinside the junction boxes

DDDD Check cables

Visually check the cables for-- Wear-- Sharp bends-- Other possible damage

DDDD Check the instrument panel

Open instrument panel and check-- Mounting of components-- Condition of wiring

DDDD Grease driveshafts

Grease all driveshaft U--joints.

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3.4. Every 250 hoursDDDD Change engine oil and filters

Run engine until operating temperature isreached; then shut down.

Drain oil pan and reinstall drain plug, usinga new gasket if required.

Change oil filters.

Clean the filter adapter.

Fill the new filters with clean lubricating oil,and lightly coat the filter seals with thesame oil.

Add oil as required to bring the oil level tothe FULL mark on the dipstick.

Start engine and run at low idle. Check lube oil pressure gauge reading.

Shut engine down. Wait 20 min.

Recheck oil level and add oil if needed, bringing oil level to FULL mark on the dipstick.

DDDD Change transfer gearbox oil

Drain oil from the bottom of the gearboxand reinstall drain plug, using a new gas--ket if required. Be careful when draininghot oil.

Fill gearbox through filler opening until fluidcomes up to LOW mark on transmissiondipstick.

Run engine for two minutes at idle.Recheck level of fluid in gearbox withengine running at idle.

Add quantity necessary to bring fluid level to LOWmark on dipstick. Recheck with hot oil.

Bring oil level to FULL mark on dipstick.

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DDDD Service the air filter elements

The air filter element must be replacedwhen the service indicator shows red.

Always clean the sealing surface of theoutlet tube and make sure that all contami--nant is removed before the new filter isinserted.

Always clean the inside of the outlet tubecarefully. When the filter element is changed,the safety element must be kept in place.

The safety element must be changed everysecond time the air filter elementis replaced.

DDDD Change fuel filter element

A fuel shutoff valve is installed on thedischarge side of the fuel filter.Turn the handle on the shutoff valve tothe closed position.

Place a suitable container under the filterand open the drain valve at the base of thefuel processor. Drain the fuel until it isbelow the filter in the see--through cover andclose the drain valve.

Turn the collar counter--clockwise andremove. Remove cover, filter spring, andcover 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 ventplug from the top of the cover. Fill the cover with clean fuel by using the hand pump andreinstall 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 enginestill running, loosen the vent cap. The fuel level in the cover will start falling. When the fuellevel falls to the top of the collar, tighten the vent cap quickly. Check for leaks.

For further information, consult Engine Operator’s Guide.

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DDDD Measure the coolant nitrite concentration and change cooling system filter, ifneeded

Never open the filler cap when hot.

Drain and clean if the engine overheatsor solution is contaminated.

Operate with a thermostat in the coolingsystem 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

DDDD Check engine mountings

Check the condition of mounting pads.Tighten and, if necessary, repair.

DDDD Check batteries

Electrolyte level

Cable connections

Cleanliness

Always wear eye protection, protectiveoveralls, and protective gloves whenservicing batteries. The acid in the batterycan burn the skin, eats holes in clothing,and can cause blindness if it gets in theeyes.

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DDDD Check alternator

Check alternator terminals for looseconnections and corrosion.

Check mounting

Check V--belts. Replace if necessary.When replacing, always inspect fanbearings.

DDDD Check oil level in planetary hubs and differentials

Always ensure that the arrow is in downposition when checking oil level in plane--tary hubs. Refer to the picture.

DDDD Change brake flushing return filter

Location indicated by arrow in the picture.

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DDDD Check center articulation

Check for visible signs of wear.

Check that the lubrication works.

DDDD Lubricate operator seat linkages and brake pedal links

Remove the rubber bellows, and lubricatethe seat linkage.

DDDD Lubricate door and hatch hinges.

Check that all hatches, cabin door, andlock work properly.

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DDDD Grease the stationary ends of boom / bucket pins

Use a hand grease gun.

DDDD Check fire suppression system

Check ”quick check” that the system isoperable.

Check that the system has not beentampered with and that there is no obviousphysical damage or problems that wouldprevent operation.

Follow the service recommendations for any locally fitted fire suppression system.

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3.5. Every 500 hoursDDDD Check cooling system hoses

Check for signs of deterioration andreplace if necessary.

DDDD Drain water from fuel tank

DDDD Check fan shroud

DDDD Check exhaust system fastenings

Check exhaust manifold fastening nuts,exhaust flange, turbocharger, and otherconnections for tightness.

Tightening torques

Exhaust manifold bolts 58--73 Nm. . . . . . .Exhaust manifold / turbocharger nuts

58--73 Nm. . . . . . . . . . . . . . . . . . . . . . . . . . .Oil drain line bolts 30--38 Nm. . . . . . . . . . .

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DDDD Check axle fastenings visually

DDDD Measure wear to the brake linings

Apply the parking brake.

Push in pin until it contacts reaction plate.

If the wear indicator pin reaches the samelevel as the outer surface of the nut, thebrakes are worn out and should beoverhauled.

DDDD Check the tightening torques of power train flanges and bolts

Tightening torques (dry)

UNF 3/8 45 Nm. . . . . . . . . . . . . . . . . . .Wheel nuts 610 Nm. . . . . . . . . . . . . . . . .Axle fastening nuts 1000 Nm. . . . . . . . . .Axle fastening lock nuts 500 Nm. . . . . .

DDDD Change brake system high--pressure oil filter element

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DDDD Change transmission oil filter


Add quantity necessary to bring fluid levelto FULL mark on dipstick.

DDDD Change return oil filter element for bucket and steering hydraulics

DDDD Check center articulation with dial gauge

Place a dial gauge with a magnetic standon the upper hinge plate of the front frame.

Press the bucket against theground so that the front framerises from the ground and soyou may observe the readingsof the dial gauge.

The reading should be0.2...0.4 mm.

If the play is smaller or larger, use shims toadjust it.

For further information, consult the workshopmanual.

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DDDD Check oscillating axle tightening torques

Bolt tightness (dry)

M 12 (8.8) bolts 80 Nm. . . .M 16 (8.8) bolts 210--240 Nm. . . .

3.6. Every 1000 hoursDDDD Inspect the cooling system

Pressurize the cooling system and ensurethat there are no leaks.

DDDD Check engine crankcase pressure

Check and record the crankcase pressure.

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DDDD Check catalytic exhaust gas purifiers (optional)

Increased backpressure (2 to 3 incheswater gauge higher from clean purifierwhen at high idle), excessive smoke, orhigh levels of odor or irritation duringoperation of the LHD loader indicatesthat the purifier is not functioningat optimum performance and should becleaned.

Cleaning of the purifier: Dry brush inletface to catalyst, air--clean through outletface of catalyst, soak catalyst in cleaningsolution (1 hour), solvent--air--clean throughoutlet face, and air--clean through outlet face.Do not use solvents containing chlorine, sulfur, metals, or leaded gasoline.

DDDD Grease fan drive bearing fitting

Use a hand grease gun and lubricate thebearings with one shot of lithium--basedmultipurpose grease.

Do not overfill the housing.

DDDD Change transmission oil and filter

Drain oil from the bottom of the transmissionand reinstall drain plug, using a new gas--ket if required. Be careful when draininghot oil.

Change oil filter.


Fill torque converter and transmissionthrough filler opening until fluid comes upto LOW mark on transmission dipstick.

Run engine for two minutes at idle to primetorque converter and hydraulic lines.Recheck level of fluid in transmission with engine running at idle.

Add quantity necessary to bring fluid level to LOWmark on dipstick. Recheck with hot oil.

Bring oil level to FULL mark on dipstick.

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DDDD Check the tightening of axle fastening bolts

Tightening torques (dry) Axle fastening nuts 1000 Nm. . . . . . . . . . . . . . .Axle fastening lock nuts 500 Nm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DDDD Change oil in front and rear differentials, and in planetary hubs

Remove plug at bottom of axle housing andallow sufficient time for lubricant to drain.With planetary wheel ends, rotate wheeluntil filler hole is down. Remove plug andallow sufficient time for draining. Be sureplanet cover oil level hole is in properposition when refilling wheel ends.

Always ensure that the arrow is in down positionwhen checking oil level in planetary hubs.Refer to the picture.

DDDD 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.

Donot 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 inthe picture.

-- Engine at low idle-- Pressure should be 35 bar

(3.5 MPa)

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Steering system pressure-- Install the frame locking pin between front

and rear frames.-- Connect a pressure gauge to the

quick--disconnect fitting after the steeringmain 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).

DDDD Check pressure accumulators

Pre--charge pressures (nitrogen pressure)-- Brake system accumulators: 12 and 90 bar-- Boom suspension: 60 bar-- Emergency steering (option): 60 bar

1

2

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DDDD Service fire suppression system

The fire suppression system, including alarms, shutdown, and associated equipment,shall be thoroughly examined and checked for proper operation by the fire suppressionsystemmanufacturer, authorized distributor, or the designee in accordancewith theAnsulMaintenance Manual.

NOTE! For other than Ansul systems, have the system serviced by an authorized systemsupplier or dealer.

Always follow the local regulations.

DDDD Change hydraulic fluid

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 fastcoupling.

WARNINGAfter filling the hydraulic tank, bleed ALL airfrom the suction towers to avoid pumpcavitation.

3.7. Every 1500 hoursDDDD Check engine tuning

Check valve clearances.

Check injector heights.

See Engine Service Manual,section 12 or contact your nearestDetroit dealer.

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3.8. Every 2000 hoursDDDD Change V--belts

Change V--belts.

During replacement, always inspect fanbearings.

DDDD Service the hand extinguisher

Have the extinguisher serviced by anauthorized supplier or dealer.

Always follow the local regulations.

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3.9. Every 4000 hoursDDDD Drain and replace coolant

Drain the radiator and engine block.

Flush the cooling system.

Install new coolant pre--charge filter.

Fill slowly to avoid air pockets; keep theradiator bleeder screw open.

DDDD Change thermostats and seals

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MAINTENANCE PROGRAMTKU---C 01140---1 EN 0404

4. MAINTENANCE PROGRAM

Every shift 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Every week Page Done

Check engine oil 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check V--belts 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




Wash radiator + oil coolers 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean cyclone air cleaner bowl (option) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean exhaust water scrubber (option) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






Check tires and wheel nuts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check tire pressure 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record = 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record = 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record = 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .







Fill fuel tank 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fill the automatic central lubrication tank (option) 23. . . . . . . . . . . . . . . . . . . . . . . . . .








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When completed


Special Notes

Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Every 125 hours 1/2 Page Done

Check engine oil 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check V--belts 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .













Check wheel nut’s tightening torques 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .












Check the instrument panel 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check cabin door and lock condition 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check junction boxes 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check cables 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fill fuel tank 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .





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Grease driveshafts 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


General cleaning 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


When completed


Special Notes

Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Change engine oil and filters 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check V--belts 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measure the coolant nitrite concentration 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




Service air filter elements 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change fuel filter element 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check engine mountings 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check batteries 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check alternator 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Change transfer gearbox oil 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check oil level in planetary hubs and differentials 32. . . . . . . . . . . . . . . . . . . . . . . . .

Change brake flushing return filter 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

















Check cables 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 (64)



Fill fuel tank 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .








Grease the stationary ends of boom/bucket pins 34. . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricate operator seat linkages 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricate door and hatch hinges 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check center articulation 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




Check fire suppression system 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


When completed


Special Notes

Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 (64)




Check V--belts 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .







Check fan shroud 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check exhaust system fastenings 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Check batteries 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Check cooling system hoses 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change transmission oil filter 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Change return oil filter element for bucket and steering hydraulics 37. . . . . . . . . . .


Change brake system high--pressure oil filter element 36. . . . . . . . . . . . . . . . . . . . .




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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .








53 (64)












Check cables 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fill fuel tank 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .











Check center articulation with dial gauge 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






When completed


Special Notes

Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 (64)




Check V--belts 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Inspect cooling system 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Check engine crankcase pressure, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record = 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check catalytic exhaust gas purifiers (option) 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .





Check fan shroud 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check batteries 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Change transmission oil and filter 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .





Check pressure accumulators 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change hydraulic oil fluid 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Change oil in planetary hubs and differentials 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Check the tightening of axle fastening bolts 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .









55 (64)







Test the hydraulic pressures 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .








Check cables 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fill fuel tank 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Grease fan drive bearing fitting 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .














Service fire suppression system 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


56 (64)


When completed


Special Notes

Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 (64)




Check V--belts 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .







Check fan shroud 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check engine tuning 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check batteries 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Change transmission oil filter 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .










Check axle fastenings visually 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .










58 (64)













Check cables 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fill fuel tank 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

















When completed


Special Notes

Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 (64)




Change V--belts 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .










Check fan shroud 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check batteries 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






















60 (64)















Check cables 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fill fuel tank 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

















Service hand fire extinguisher 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


61 (64)


When completed


Special Notes

Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 (64)




Change V--belts 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain and replace coolant 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change thermostats and seals 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .









Check fan shroud 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check batteries 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .





















63 (64)
















Check cables 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fill fuel tank 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

















Service hand fire extinguisher 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


64 (64)


When completed


Special Notes

Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Documents

Maintenance