Maintenance Toro 0010

MaintenanceManual

Including automated machines

MAINTENANCEMANUAL

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TKU---C 01241---2 EN 4804

SANDVIK TAMROCK CORP., TURKU PLANT 11/2004

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TKU---C 01241---2 EN 4804

PREFACE

Congratulations on your choice of a TORO loader.This manual describes the maintenance of this TORO 0010 loader. Only those who havebeen given proper training and are authorized to do so should operate the loader. Alloperators should familiarize themselves with the machine and fully understand the contentsof the operators manual, maintenance manual, and general safety instructions beforeoperating it.

Read the operators 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 equipments 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 periodic maintenance 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2. General safety precautions during operations 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

1.5 Locking devices 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. MAINTENANCE AND LUBRICATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1. Maintenance of hydraulics 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2. Electrical system maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3. Battery maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4. Welding 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5. Lubricants 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.1. Engine 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.2. Transmission 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.3. Hydraulics 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.4. Axles 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.5. Grease nipples 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6. Filling capasities 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2.8. First servicing 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. MAINTENANCE OPERATIONS 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1. Every shift 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3.3. Every 125 hours 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4. Every 250 hours 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5. Every 500 hours 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6. Every 1000 hours 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7. Every 1500 hours 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8. Every 2000 hours 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9. Every 4000 hours 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. MAINTENANCE PROGRAM 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL

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1. GENERAL

1.1. Importance of regular maintenance

The TORO 0010 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 0010 components andthe corresponding service intervals.Weurge all end users to review theDetroitOperatorsGuide for additional information regarding servicing.

1.2. General safety precautions during operationWe recommend that records are kept on servicing and wearing part replacements.Regular maintenance 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 themanufacturers 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 manufacturers 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 workwillbe performed.

-- Inform the users of the equipment of the start of maintenance or any special workon the loader.

-- If the equipment or a part of it has been stopped for maintenance or repair, makesure that it cannot be started accidentally.

D Turn main switch off

D Remove ignition key

D Put a DANGER DO NOT START or corresponding warning sign on the mainswitch. 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 levelground and wont move.

-- Pay special attention to the exhaust pipe--work and the exhaust gas cleaningsystem. Ensure sufficient ventilation.

-- Usea lift jack only on level, hard, and firm ground. Before using a jack, always be surethe 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.

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GENERAL

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-- After preventive maintenance and repairs, always tighten fasteners that have beenunscrewed. Reassemble all dismantled safety appliances immediately after theworkis 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 assy4. Power train

Front frame

1. Bucket

2. Swing lever

3. Boom

4. Lift cylinders

5. Tilt cylinder

12

4

5

3 6

5

GENERAL

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Rear frame

5

62

78

3

42

1

885

6

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

5. Battery box6. Radiator / Intercooler / Fuel cooler7. Operators cabin8. Service hatches

Engine assy

51

2

3

6

4

7

1. Alternator2. turbocharger3. Engine oil filters4. Engine coolant filter

5. Fuel filter6. Air filter7. Transmission oil filter

Power train

1. Front axle2. Rear axle3. Transmission4. Torque converter5. Drive shaft6. Parking brake (LCB)

GENERAL

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1.5. Locking devices

Frame locking pin

How to install frame locking pin.1. Remove the pin from its holder on

the frame.2. Insert the pin into the hole on the

frame as shown in attached picture.3. Return to the cabin and turn on the

engine and slowly move thesteering from left to right a little untilthe pin dropps down into thesecond hole.

Note: Observe the pin. When it dropsdown, stop turning.

To remove the locking pin.

1. Climb into the cabin, turn on theengine and turn the unit a little tothe left or to the right until the pin isno--pressured.

2. Then stop the unit step out andremove the pin.

GENERAL

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Boom locking pins

How to install the locking pin.

1. It is recommended that before youinstall the boom locking pins, thatthe center articulation locking pin isfitted in place as described in theprevious page.

2. Ensure the boom is in the haulingposition. Climb up, remove thelocking bars and wing nuts whichkeep the pins in position.

3. Climb into the cabin and raise theboom. Turn off the engine and stepout of the cabin.

4. Climb up onto the wheel guard andremove the pins from their holders.Place the pins correctly into theirholes in to the boom as shown inattached picture.Make sure you dont walk underthe boom under any circumstances.

5. Lower the boom slowly against thestops.

To remove the pins.

1. Walk around the unit and ensureno--one is working on the unit orunder the boom.

2. Sound the horn 3 times and have alook around. When it is safety startthe engine.

3. Raise the boom and then turn offthe engine.

4. Climb up onto the wheel guard andremove the pins. Dont walk underthe boom under any circumstances.

5. Go back into the cabin, sound thehorn again 3 times and turn on theengine, lower the boom slowlyagainst the stops and the bucket tothe ground.

6. Replace the pin locking bars andwing nuts.

MAINTENANCE AND LUBRICATION

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2. MAINTENANCE AND LUBRICATION

The TORO 0010 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 0010 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. Thehigh-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

General

D The hydraulic oil temperature should be 60...80 _C.

D Connect and disconnect pressure gauge(s) only when the circuit is notpressurized.

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 thecabin.


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Tests

Pilot system pressure. Engine at low idle. Pressure should be 25 bar (2,5 MPa)

Steering system pressure. Install the frame locking pin between front and rear frames. Engine revs 1000--1500 rpm. Turn the machine to full left hand turn. Steering system pressure should be 120 bar (12,0 MPa). pressure should be:

0010 120 bar (12,0 MPa). . . . . . .automated 225 bar (22,5 Mpa). .

Bucket hydraulic pressure. Engine at 1000--1500 rpm. Lower the boom against the stops and keep the control valve in boom

down position.. Pressure should be:

0010 210 bar (21,0 MPa). . . . . . .automated 230 bar (23,0 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, SANDVIKTAMROCKs 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.


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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 batterys 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 spotat once with water. Flush the eyes with plenty of 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.Aspark or an open flamecan 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.D If weldingmust be done close to anyof the control modules, disconnect themodule

wiring before beginning welding.D The ground cable of the welding machine must be connected as close as possible

to 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 Operators 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. Hydraulics

Hydraulic oils meeting DIN 51524 HVLP or ISO 6743--4 HV 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 API class CD, or hydraulic oils with wear preventive characteristicscorresponding to those of DIN 51524 HVLP or ISO 6743--4 HV can be used)

2.5.4. Axles

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

Viscosity above -- 25 _C. SAE 80W/140above -- 12 _C SAE 85W/140

2.5.5. Grease nipples

Lithium based greaseswith penetration 265/295 (NLGI 2) and dropping point 180 _Cshouldbe used.


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2.6. Filling capacitiesEngine oil 40 l (with filters)Engine coolant 72 lTransmission 72 lAxles 2 x 61,5 lBucket and steering hydraulics 320 lFuel tank 600 l

2.7. Special notesIf 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 radiators 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 Operators Guide).

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

manufacturers operating and safety requirements.


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

M12 bolts to 85Nm (dry)M20 bolts to 690 Nm (dry)

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

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MAINTENANCE OPERATIONSTKU---C 01241---2 EN 4804

3. MAINTENANCE OPERATIONS

3.1. Every shiftD Check engine oil

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

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

D Check V--belts

Check condition visually, and adjust ifnecessary.

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

D Check engine coolant level

Check before starting the engine.

Coolant level should be seen via the sightglass.

Do not remove the pressure control cap orattemp 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 possible personalinjury (scalding, eye injury, etc.) fromthe hot liquid.

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D 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.

D Check fuel filter element

The filter cover will not fill completelyduring engine operation. It will graduallyfill over time, and the fuel level will rise asthe filter element becomes clogged.

The filter element should be changedevery 250 hours or sooner if the fuel levelhas risen to the top of the element.

D Check intake ducting and connections for leaks

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D Check exhaust ducting and connections for leaks

D Check transmission oil level

Check transmission oil level from dipstickor from gauge glass.

Machine on level ground.Parking brake engagedEngine at low idleGearshift lever in neutral positionTransmission oil in operating temperature

D Check tires and wheel nuts

Check condition

Visually check tire wear and air pressure.

Visually check for loose or missingwheel nuts.

D Check hydraulic oil level

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

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D Check hydraulic tank pressure (automated machines only)Check hydraulic tank pressure from thegauges as shown picture below.

Checking prosedure:--press brake pedal, connect first gearand accelerate the engine running atmax. rpm--check the pressure. It should be 0,3bar.

D Test service and parking brake function

Check for leakage and test brake function.

Brake test (LCB):

Check that the pressure in the brake system is 55--70 bar before testing.

Service brake test (LCB): Press brake pedal, connect first gear and accelerate theengine. The brake should hold 1750 rpm (machine should not move until engine rev.reaches 1750 rpm.)

Parking brake test (LCB): Apply parking brake (push button) and connect second gear.Push parking brake test button and keep the button pressed and accelerate the engine.The brake should hold 1600 rpm.

Brake test (Posi--stop):

Check that the pressure in the brake system is 110--115 bar before testing.

Service & parking brake test (Posi--stop): Press brake pedal, connect first gear andaccelerate the engine. The brake should hold 1890 rpm (machine should not move untilengine rev. reaches 1890 rpm.)

D Check that all the 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.

D Check the emergency steering system (opt.)

Pushing the button (key switch in power on --position,engine not running) should start the emergency steeringpower pack and enable steering the machine.

Note! The machine can not be turned, if the cabin door is open.

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D Check the Brake releasing pump functions (Posi--stop).

Press the button which connects the brake releasingpump. Engine must be stopped and ignition switch onPOWER ON -- position. (Parking brake button has topull fully up before the pump can start.).

D Check major components for oil leaks and mounting

Make sure that the safety locks are removed.Make a general visual inspection of the machine, check for oil leaks and loose hoses,frayed wires or other apparent maintenance needs; if anything looks suspicious call aservice man.

D Check Hand Portable Fire Extinguisher

Gauge pointer in green area

No corrosion

Firmly mounted

Visual seals in place

D Check lights

Front

Rear

Optional lights

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D 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; idling at least 0,35bar, 1800 rpm at least 1,93 bar.

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

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

Transmission oil pressure; should bebetween 12,7 -- 15,4 bar.

D Check display (automated machines only)

Check that the display is functioningproperly.

Checkpressures and temperatures fromthe gauge display.

D Fill fuel tank

Be sure that the machine is correctly parked.

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 systemsuppliers procedures are followed.

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D Check automatic central lubrication system (opt.)

Check the system visually and fill ifneeded.

Check that all lubrication points are wellgreased.

D Grease lift cylinder pins, tilt cylinder pins, lift arm pins and(center mounting, posi--stop only)

Use central lubrication manifold.

(If automatic central lubrication is notinstalled)

D Grease center articulation, steering cylinder pins, oscillating axle and supportbearing for driveshaft

Use central lubrication manifold.

(If automatic central lubrication is notinstalled)

Grease steering cylinders front pinsdirectly through the nipples.

D Grease driveshaft U--joint at center articulation

Grease pins direct through the nippleswith hand grease gun.

D Check remote control system (opt.)

Check the RC--system functioning according to Remote Control system instructions.

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3.2. Every weekD Wash radiator + oil coolers

Open the cooler hatches for proper cleaning

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

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

D Clean cyclone air cleaner bowl

D Check tire pressures

29,5 x 29 L5S Bridgestone

Front 600 Kpa (6,0 bar)

Rear 400 Kpa (4,0 bar)

AA

B

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D Grease dogbone pins

Connect the high pressure grease gunto grease nipple B.Fill the pin with the grease (until the pumpcant pump more).

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

D Fill the automatic central lubrication tank (optional)

Check the system visually and fill ifneeded.

Check that all lubrication points are wellgreased.

D Check dampersVisually check the dampers wear andassembly condition.

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D Test Transmission, bucket-- and steering hydraulics (0010)

The transmission and hydraulics should be at operation temperature during measuring.

A Transmission: Press brake pedal, connect highest gear and accelerate. The engineshould achieve about 2040 -- 2140 rpm stalling speed.

B Bucket hydraulics: Accelerate the engine at maximum engine rpm. Lower the boomdown against the stops, keep the control valve in boom down position. The engineshould achieve about 2050 -- 2150 rpm stalling speed.

S Steering hydraulics: Accelerate the engine at maximum engine rpm. Turn the loaderagainst the stops, keep the control valve in selected positon. The engine should achieveabout 2100 -- 2200 rpm stalling speed.

D Test Transmission, bucket-- and steering hydraulics (automated machines)

The transmission and hydraulics should be at operation temperature during measuring.

A Transmission: Press brake pedal, connect highest gear and accelerate. The engineshould achieve about 2070 -- 2170 rpm stalling speed.

B Bucket hydraulics: Accelerate the engine at maximum engine rpm. Lower the boomdown against the stops, keep the control valve in boom down position. The engineshould achieve about 2090 -- 2190 rpm stalling speed.

S Steering hydraulics: Accelerate the engine at maximum engine rpm. Turn the loaderagainst the stops, keep the control valve in selected positon. The engine should achieveabout 2140 -- 2240 rpm stalling speed.

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3.3. Every 125 hoursD Check wheel nuts tightening torques

410 Nm (dry)

D General cleaning

Operators compartment (do not use highpressure water when cleaning the cabin)

Engine compartmentBefore cleaning the machine with wateror by steam jet or other cleansers, cover the alternator, connection boxes and majorconnections.Do not apply steam or solvent directly to the alternator, starting motor or DDEC electroniccomponents.

Do not apply solvent to hot surfaces.

D Check cabin door and lock condition

Check that cabin door and lock worksproperly.

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D Check junction boxes

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

D Check cables

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

D Check the instrument panel

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

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3.4. Every 250 hoursD Change engine oil and filters

Run engine until operating temperature isreached; then shut down.

Place a suitable container under themachine and drain oil pan , using thedrain valve.

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. Checklube 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.

D 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 bebetween 800...2400 PPM.

Coolant pH between 8,5...10,5

See Detroit Diesel Engine Operators Guide--booklet

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D 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 changedthe safety element must be kept in place.

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

D 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 of the filter in the see--thru cover andclose the drain valve.

Turn collar counter--clockwise and remove.Remove cover, filter spring and coverseal 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 full of 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 engine to purge the air from the system. After air is purged and with the engine stillrunning, loosen the vent cap. The fuel level in the coverwill start falling.When the fuel levelfalls to the top of the collar, tighten the vent cap quickly. Check for leaks.

For further information look the Engine Operators Guide.

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D Change fuel filters (optional)

Turn the handle on the shutoff valve tothe closed position.

Change the primary and secondary fuelfilters.

Fill new filters with clean fuel and coat thegasgets lightly with fuel.

Turn the handle on the shutoff valve to theopen position.

Start the engine and check for leaks.

D Check engine mountings

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

D Check batteries

Electrolyte level

Cable connections

Cleanliness

Always wear eye protection, protectiveoveralls, and protective gloves when servi--cing batteries. The acid in the battery canburn the skin, eats holes in clothing, andcan cause blindness if it gets in the eyes.

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D Check Alternator

Check Alternator terminals for looseconnections and corrosion.

Check mounting

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

D Grease the stationary ends of boom / bucket pins

Use a hand grease gun

D Grease driveshafts

Grease all driveshaft U--joints

D Grease the differential pinion seal

Use hand grease gun

Apply grease until it comes out from thedust shield

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D 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.

D Change brake flushing return filter

Location indicated by arrow in the picture.

D Check center articulation

Check for visual signs of wear

Check that the lubrication works

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D Lubricate operator seat lingages and brake pedal links

Remove the rubber bellow, and lubricatethe seat lingage

D Lubricate door and hatch hinges

Check that all hatch, cabin door andlock works properly

D Check fire suppression system

Check quick check that the system isoperable.

Check that the system has not beentampered with and there is no obviousphysical damage, or condition to preventoperation.

Follow the service recomendations of anylocaly fitted fire suppression system.

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3.5. Every 500 hoursD Check cooling system hoses

Check for signs of deterioration andreplace if necessary

D Drain water from fuel tank

D Check fan shroud

D Check exhaust system fastenings

Check exhaust manifold fastening nuts,exhaust flange, turbo charger 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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D Check axle fastenings visually

D Measure wear to the brake linings

Posi--stop: Apply the parking brake

Push in pin until it contacts reaction plate

If the wear indicator pin reach the samelevel as the outer surface of the nut. Thebrakes are worn out and should beoverhauled.

LCB: Stop the engine.

Release hydraulic tank pressure.

Pressurize service brake to 55--70 bar andhold pressure.

Open the plug and measure lining wear.Compare measurement result to the valuewhich is punched out on the axle.E.g. if the punched out value is 82+5 and the measurement result is bigger than 87, thebrakes are worn out and should be overhauled.

D Check the tightening torques of power train flanges and bolts

Tightening torques (dry)

UNF 3/8 45 Nm. . . . . . . . . . . . . . . . . . .UNF 7/16 72 Nm. . . . . . . . . . . . . . . . . .M12 85 Nm. . . . . . . . . . . . . . . . . . . . . . .M14 150 Nm. . . . . . . . . . . . . . . . . . . . . . .M16 210 Nm. . . . . . . . . . . . . . . . . . . . . . .Wheel nuts 410 Nm. . . . . . . . . . . . . . . . .Axle fastening nuts 2250 Nm. . . . . . . . . .Axle fastening lock nuts 500 Nm. . . . . .

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D Change brake system high pressure oil filter element

D Change steering system high pressure oil filter element

D Change transmission oil filter

Place a suitable container under themachine and open the drain valve.

Change the transmission oil filter.

Close the drain valve.

Start the engine and open the air ventvalve. Vent air until there are coming oilfrom the air vent valve.

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

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D Change return oil filter element for bucket-- and steering hydraulics

D Check breather filter for hydraulic tank (not installed in automated machines)

Visually check.

D Check centre 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 look the workshopmanual.

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D Check oscillating axle tightening torques

Bolt tightness (dry)

M 12 (8.8) bolts 85 Nm. . . .M 20 (12.9) bolts 690 Nm. . .

D Change the control valves filter (automated machines only)Make visual inspection for externalleakage.

Replace the filter.

Check o--rings for damage. Replace ifnecessary.

See Moog Installation and Operationinstructions for further information.

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3.6. Every 1000 hoursD Inspect the cooling system

Pressurize the cooling system and ensure,that there are no leaks.

D Clean engine crankcase breather

The internally mounted (in the enginerocket cover) crankcase breather assemblyshould be removed and the steel mesh padwashed in clean fuel oil.

This cleaning period may be reduced orlenghtened according to the severity ofservice.

D Check engine crankcase pressure

Check and record the crankcase pressure.

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D Grease fan drive bearing fitting

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

Do not overfill housing

D Change transmission oil and filter

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

Change oil filter. See Change transmissionoil filter

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

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

D Check the tightening of axle fastening bolts

Tightening torques (dry) Axle fastening nuts 2250 Nm. . . . . . . . . . . . . . .Axle fastening lock nuts 500 Nm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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D Change oils in front and rear differentials, and in planetary hubs

Remove plug at bottom of axle housing andallow sufficient time for lubricant to drain.Check, if there are metal in the drain plug.Contact SANDVIK TAMROCK Service, ifnecessary.

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 properpositionrefilling wheel ends.

Always ensure, that the arrow is in down position when checking oil level in planetaryhubs. Refer to attached picture.

D Change hydraulic fluid

Clean hydraulic oil tank

If electrical filling pump can be used(option.), the oil tank is also possible tofill by fast coupling

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

D Change breather filter for hydraulic tank (not installed in automatedmachines)

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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 non 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 (0010 / automated)-- Attach a pressure gauge to the

quick--disconnect fitting as shownin the picture.

-- Engine at low idle-- Pressure should be 25 bar

(2,5 MPa)

Steering system pressure (0010)-- Install the frame locking pin between

front and rear frames-- Connect a pressure gauge to quick--

disconnect fitting.-- Engine speed of 1000 --1500 rpm-- Turn the machine to full left hand

turn-- Steering system pressure should be

120 bar (12,0 MPa)

Steering system pressure (automated)-- Install the frame locking pin between

front and rear frames-- Connect a pressure gauge to quick--

disconnect fitting.-- Engine speed of 1000 --1500 rpm-- Turn the machine to full left hand

turn-- Steering system pressure should be

225 bar (22,5 MPa)

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The bucket hydraulic, main relief valve (0010 / automated)-- The main relief valve pressure can

be checked from the quickdisconnect fitting.

-- Engine at 1000 -- 1500 rpm-- Lower the boom down against the

stops and keep the control valve inboom down position.

-- Pressure should be:0010 210 bar (21,0 MPa). . . . . . . .automated 230 bar (23,0 Mpa). . .

D Check pressure accumulators

Pre--charge pressures (nitrogen pressure)-- Brake system accumulators LCB: 30 bar

Posi--stop: 90 bar-- Boom suspension: 20 and 40 bar

D Service fire suppression system

The fire suppression system including alarms, shutdown and associated equipment shallbe thoroughly examined and checked for proper operation by the fire operationmanufacturer, authorized distributor or their designee in accordance with AnsulMaintenance Manual.

NOTE! If system other than Ansul, have system serviced by authorised system supplieror dealer.

Always follow the local regulations.

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3.7. Every 1500 hoursD Check engine tuning

Check valve clearances

Check injector heights

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

3.8. Every 2000 hoursD Change V--belts

Change V--belts.

During replacement, always inspect fanbearings.

D Service hand portable extinquisher

Have the extinquisher serviced by anauthorized supplier or dealer.

Always follow the local regulations.

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3.9. Every 4000 hoursD 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.

D Change thermostats and seals

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MAINTENANCE PROGRAMTKU---C 01241---2 EN 4804

4. MAINTENANCE PROGRAM

Every shift Page Done

Check engine oil 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check V--belts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check engine coolant level 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check air filter indicator and assembly condition 19. . . . . . . . . . . . . . . . . . . . . . . . . .

Check intake ducting 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check exhaust ducting 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check fuel filter element 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check transmission oil 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Check hydraulic oil level 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 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check major components for oil leaks and proper mounting 22. . . . . . . . . . . . . . . .

Check hand fire extinguisher 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check driving/working lights 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check gauges and indicator lights 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check display (automated machines) 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check hydraulic tank pressure (automated machines) 21. . . . . . . . . . . . . . . . . . . . .

Fill fuel tank 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check automatic central lubrication system (option) 24. . . . . . . . . . . . . . . . . . . . . . .

Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* 24. . . . . . . . . . . . . . . . .

Grease center articulation, steering cylinder pins, and oscillating axle* 24. . . . . . .

Grease driveshaft U--joint at center articulation 24. . . . . . . . . . . . . . . . . . . . . . . . . .

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 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check V--belts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check intake and exhaust ducting 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean cyclone air cleaner bowl 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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



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


Check tire pressure 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check dampers 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record = 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record = 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record = 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .









Fill fuel tank 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fill the automatic central lubrication tank (option) 26. . . . . . . . . . . . . . . . . . . . . . . . . .




Grease dogbone pins 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



50 (70)


When completed


Special Notes

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

51 (70)


Every 125 hours 1/2 Page Done

Check engine oil 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check V--belts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .








Check wheel nuts tightening torques 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check dampers 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .









Check junction boxes 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check cables 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .





Check the instrument panel 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Fill fuel tank 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






52 (70)





General cleaning 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check cabin door and lock condition 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


When completed


Special Notes

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

53 (70)


54 (70)



Change engine oil and filters 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check V--belts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measure the coolant nitrite concentration 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service air filter elements 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




Change fuel filter element 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change fuel filters (optional) 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check engine mountings 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check batteries 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check alternator 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check oil level in planetary hubs and differentials 34. . . . . . . . . . . . . . . . . . . . . . . . .


Change brake flushing return filter 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Check dampers 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .










Check cables 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .







55 (70)



Fill fuel tank 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






Grease the stationary ends of boom/bucket pins 33. . . . . . . . . . . . . . . . . . . . . . . . . .

Grease driveshafts 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease the differential pinion seal 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Check center articulation 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricate operator seat linkages 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricate door and hatch hinges 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




Check fire suppression system 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


When completed


Special Notes

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

56 (70)




Check V--belts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




Check exhaust system fastenings 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






Check batteries 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Check cooling system hoses 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check fan shroud 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain water from fuel tank 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change transmission oil filter 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check oil level in planetary hubs and differentials 34. . . . . . . . . . . . . . . . . . . . . . . . .

Check axle fastenings visually 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measure wear to brake linings 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check oscillating axle tightening torques 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the tightening torques of power train flanges and bolts 37. . . . . . . . . . . . . . .


Change brake flushing return filter 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change return oil filter element for bucket and steering hydraulics 39. . . . . . . . . . .

Check breather filter for hydraulic tank 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change brake system high--pressure oil filter element 38. . . . . . . . . . . . . . . . . . . . .

Change steering system high--pressure oil filter element 38. . . . . . . . . . . . . . . . . . .

Change the control valves filter (automated machines) 40. . . . . . . . . . . . . . . . . . . . .


Check dampers 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




57 (70)









Check cables 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .







Fill fuel tank 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






Grease the stationary ends of boom/bucket pins 33. . . . . . . . . . . . . . . . . . . . . . . . . .

Grease driveshafts 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease the differential pinion seal 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Lubricate operator seat linkages 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricate door and hatch hinges 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check center articulation with dial gauge 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Check fire suppression system 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


58 (70)


When completed


Special Notes

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

59 (70)




Check V--belts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Inspect cooling system 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check cooling system hoses 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Check exhaust system fastenings 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






Check batteries 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Check fan shroud 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean engine crankcase breather 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check engine crankcase pressure, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Record = 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain water from fuel tank 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change transmission oil and oil filter 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Change oil in planetary hubs and differentials 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the tightening of axle fastening bolts 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measure wear to brake linings 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check oscillating axle tightening torques 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the tightening torques of power train flanges and bolts 37. . . . . . . . . . . . . . .

Change brake flushing return filter 34. . . . . . .

Maintenance Toro 0010

Documents

Transcript of Maintenance Toro 0010