Maintenance Manual

Maintenance
Manual
(Detroit S50)
MAINTENANCE
MANUAL
2 (64)
TKU C 01140--- 1 EN 0404
SANDVIK TAMROCK CORP., TURKU PLANT
04/2004
3 (64)
TKU C 01140--- 1 EN 0404
PREFACE
Congratulations on your choice of a TORO loader.
This manual describes the maintenance of this TORO 007 loader. Only those who have
been given proper training and are authorized to do so should operate the loader. All
operators should familiarize themselves with the machine and fully understand the contents
of the operators manual, maintenance manual, and general safety instructions before
operating it.
Read the operators manual and General Safety
Instructions before starting the work!
WARNING
This responsibility is particularly pertinent for personnel who work with the loader only
occasionally -- e.g., during setup or maintenance.
Continuing research and development of TORO loaders may have caused changes to your
machine that are not dealt with in this manual.
If the machine is equipped with optional equipment -- e.g., a remote control system -- you
should familiarize yourself with the separate instructions in which the equipments operation
is explained.
This manual must always remain available in the cabin for ready access when operating the
TORO loader.
Always obey the national legislation in force where accident prevention and environmental
protection are concerned. Generally accepted technical guidelines for safe and professional
operation must also be observed.
For demanding maintenance and repair operations, we recommend that you contact your
nearest authorized Sandvik Tamrock Service. Our maintenance personnel have the skills
and special tools required for the most demanding tasks.
Through correct use and by following the maintenance instructions, you can expect a high
degree of utilization and long operating life of your loader.
Always obey safety rules!
4 (64)
TKU C 01140--- 1 EN 0404
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.
2.
3.
4.
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.
Importance of regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.
General safety precautions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.
General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.
Location of the main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.1.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.2.
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.3.
Transfer gearbox (Up--Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.4.
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.5.
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.6.
Grease nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14
14
14
14
15
15
2.6.
Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
2.7.
Special notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1.
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.2.
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
16
2.8.
First servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
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
MAINTENANCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
5 (64)
TKU C 01140--- 1 EN 0404
1.
GENERAL
GENERAL
1.1. Importance of regular maintenance

The TORO 007 is designed for hard work in difficult and demanding mine conditions. To
ensure trouble--free and economical operation, it is extremely important to adhere to the
schedule for regular maintenance. By following this schedule closely, you can easily
detect possible defects in the machine which can be repaired before they become serious.
This will ensure low repair costs and minimize production disturbances.
The pages that follow give information on servicing various TORO 007 components and
the corresponding service intervals. We urge all end users to review the Detroit Operators
Guide for additional information regarding servicing.
1.2. General safety precautions during operation

We recommend that records be 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. Everybody
involved in maintenance work should understand the possible hazards and use safe
working methods. Before starting any maintenance or repair work, read the
manufacturers instructions. Be sure to follow them.
The personnel must not wear long, loose hair or loose clothing, nor should they wear
jewelry, including rings, because of the risk of injury.
Use personal protection suits and other protective equipment as far as is necessary or
mandatory.
Do not perform any modifications, extensions, or rebuilding of the machine that would
affect safety. Consult the supplier or manufacturer. This also includes the built--in and
adjustment of safety devices and valves, as well as the welding of frame structures.
Spare parts must meet the manufacturers technical specifications. Conformity to these
standards 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 ensure
high--quality maintenance work.
Any maintenance or repair work on the TORO loader must be performed by properly
trained or instructed personnel only. Work must be performed on electrical appliances by
electricians and on hydraulic appliances by mechanical technicians with knowledge and
experience 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 and
repair work. Before cleaning the machine with water, or by steam jet or with other
cleansers, cover the alternator, connection boxes, and major connections. Remove the
covers after cleaning!
Never attempt to clean, adjust, repair, or lubricate the TORO loader while it is in
motion or the engine is running.
6 (64)
GENERAL
TKU C 01140--- 1 EN 0404
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 area where the maintenance work will
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 off
D Remove ignition key
D 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 the
situation.
-- If required, ensure that suitable and safe ladders or working platforms are available
for use in repair and maintenance work.
-- Do not use any of the equipment as steps. If maintenance work must be done high
up, or in an otherwise dangerous place or position, use the safety devices
necessary to prevent falling.
-- All platforms, steps, grips, rails, ladders, and other similar parts must be kept clean
of oil, dirt, snow, and ice to prevent accidents.
-- Always use the right tools for the maintenance task.
-- Before commencing maintenance or repair work, ensure that the vehicle is on level
ground and wont 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 of
the jack slipping, secure the vehicle by using adequate supports and blocks
underneath it.
-- Remove all the air from the tire before loosening the wheel nuts/bolts. Should you
forget to do this, a broken rim part under pressure can fly apart and cause serious
injury.
-- Do not try to repair wheel parts by brazing, welding, or reworking. Be sure to replace
them with new parts of the same size, type, and make.
-- Never transport a fully inflated spare tire mounted on demountable rims. Such tires
should have just enough air pressure to hold the rim parts firmly in place. Only after
the tire and rim assembly have been fastened with proper torque applied to all the
wheel nuts/bolts should the tire be inflated to the correct operating pressure.
-- In inflating, mounting, or dismounting tires, a safety rack, cage, or some other
protection should be used
-- During tire inflation, do not stand in front of the assembly. Use an extension hose so
that 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 the work
7 (64)
TKU C 01140--- 1 EN 0404
--
GENERAL
is done. Ensure that all safety systems are tested before the unit is returned to
normal work.
Pay attention to safety and environmental protection when disposing of process
materials and old parts.
1.4. Location of the main components
3
2
1.
2.
Front frame
Rear frame
3.
4.
Engine assy
Power train
Front frame
1.
Bucket
2.
Swing lever
3.
Boom
4.
Lift cylinders
5.
Tilt cylinder
2
3
8 (64)
TKU C 01140--- 1 EN 0404
GENERAL
Rear frame
7
8
6
2
5
1.
2.
3.
4.
Fuel tank
Oil cooler
Hydraulic oil level
Main switch
5.
6.
7.
8.
Battery box
Radiator / intercooler / fuel cooler
Operators cabin
Service hatches
Engine assy
1
6
2
4
3
1.
2.
3.
Alternator
Turbocharger
Engine oil filters
4.
5.
6.
Engine coolant filter

Fuel filter
Air filter
9 (64)
TKU C 01140--- 1 EN 0404
GENERAL
Power train
1.
2.
3.
4.
5.
Front axle
Rear axle
Transmission /
torque converter
Transfer gearbox
Driveshaft
10 (64)
MAINTENANCE AND LUBRICATION
2.
TKU--- C 01140--- 1 EN 0404
The TORO 007 is designed for hard work in difficult and demanding mine conditions. To
ensure trouble--free and economical operation, it is extremely important to adhere to the
service schedule indicated. By paying close attention to the service schedule, you can
easily detect possible defects in the machine or other problems that can be addressed
before they become serious. This will ensure low repair costs and minimize disturbances
to production.
The following pages give information for servicing various TORO 007 components and
other items for servicing, with their corresponding service intervals. All end users should
review the Engine Manuals for additional information regarding servicing.
2.1. Maintenance of hydraulics

Maintenance, repair, and installation of hydraulic equipment must be carried out only by
experienced 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 serious
injury. High-pressure oil spray can also start a fire.
D Avoid direct skin contact with oil. Prevent oil from getting into your eyes; use eye
protection.
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 properly
supported and the system non--pressurized.
D Pipe connections, hose lengths, and hose types must correspond with the
specifications. When replacing or repairing hoses, use original SANDVIK
TAMROCK spare parts or hoses and fittings recommended by the manufacturer.
Ensure that the pressure ratings of the hoses and connecting fittings correspond
with the working pressures.
D Any deviations require written authorization from the manufacturer.
Pressure tests
General
D
D
D
D
D
The hydraulic oil temperature should be 60...80 _C.

Connect and disconnect pressure gauge(s) only when the circuit is not
pressurized.
Use only special couplings for pressure testing.
Do not over--tighten couplings. When special couplings are used,
finger--tightening is adequate. Over--tightening leads to harmful leakage.
Use hose(s) long enough to read the gauge(s) while the operator is sitting in the
cabin.
11 (64)
TKU--- C 01140--- 1 EN 0404
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 maintenance

D
D
D
D
D
D
D
Work on electrical equipment or components is only to be carried out by qualified

electricians or other professionals, or by assistants under their supervision and
control, observing electrotechnical regulations.
Local electrotechnical and electric safety regulations must always be observed.
Always use only original electrical components.
If disturbances in the electricity supply occur, stop the vehicle at once.
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 the
disconnected parts are dead, and then lock the main switch or arrange grounding
for the work if necessary.
Do not touch battery terminals, alternator terminals, or wiring while the engine is
operating. Severe electrical shock, which may result in injury, could occur due to
improper shielding of electrical components.
Check the electrical devices of the machinery regularly. Faults, such as loose wires
and damaged insulation, must be repaired at once.
When handling high-voltage components, remember that capacitors may be
charged even if the voltage is cut off. Discharge the capacitors with a grounding
rod.
Before making any changes concerning the electrical devices, SANDVIK
TAMROCKs electrical engineering department must be consulted and a
written authorization received, to ensure that the operation of the device
does not change.
12 (64)
TKU--- C 01140--- 1 EN 0404
Working on live components

D If the component must be live during the work, another worker must be standing
by to cut off voltage at the emergency or main switch should an emergency
situation occur. Follow electrical safety regulations.
D Use a red-and-white safety chain and warning signs to encircle the working area.
D Use only insulated tools.
D Observe special caution.
2.3. Battery maintenance

Always wear eye protection, protective overalls, and protective gloves when
servicing 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 the
battery case due to explosion of internal hydrogen gas.
D To prevent sparking when connecting a battery charger, disconnect the charger
supply cord or switch the charger off before connecting the charging wires to the
battery terminals. Open the batterys cell caps slightly during charging to allow the
gases generated to escape.
D The acid in the battery can burn the skin, eats holes in clothing, and can cause
blindness if it gets in the eyes. If you get battery acid on your skin, flush the area
at once with water. Use sodium bicarbonate to neutralize the acid if it gets in the
eyes. Flush the eyes with water, and call a doctor.
D When servicing batteries, remember that lead-acid batteries generate oxygen and
hydrogen during charging and discharging, which form a highly explosive mixture.
A spark or an open flame can cause an explosion. If necessary, ventilate the battery
compartment properly before disconnecting or connecting the cables.
D To prevent explosion, the electrolyte level must be maintained and checked
regularly. Add distilled water, if required, before starting -- and never immediately
after 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 appropriate
welding method and fillers. Contact SANDVIK TAMROCK Service, if necessary.
D Do not repair steering equipment by welding.
D Welding must be left to qualified personnel.
D Before electrical welding, the main switch must be disconnected. Also, Remote
Control equipment (optional) must be disconnected.
13 (64)
TKU--- C 01140--- 1 EN 0404
D
D
D
D
D
If welding must be done close to any of the control modules, disconnect the module
wiring before beginning welding.
The ground cable of the welding machine must be connected as close as possible
to the welding location. The ground cable may not be connected so that the current
can flow through a bearing, joint coupling, sealing surface, lever, or control cable.
Use a protective mask when welding.
Arrange adequate ventilation.
Arrange protection against fire.
14 (64)
TKU--- C 01140--- 1 EN 0404
2.5. Lubricants
2.5.1.
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 use
requires a shorter oil change interval.
Synthetic oils may be used in Detroit Diesel engines, provided that they are API licensed and
meet the performance and chemical requirements for non--synthetic oils outlined in this
publication.
Product information for synthetic oils should be reviewed carefully. Performance additive
systems often respond differently in synthetic oils. Their use does not permit extension of
recommended oil change intervals.
The use of fuels with sulfur content above 0.5 mass percent will require shorter oil change
intervals and/or the use of a higher TBN oil.
See engine Operators Guide for more details.
2.5.2.
Transmission
Classification
Allison C--4 or Caterpillar TO--4
Viscosity
--20 _C...+15 _C
above +0 _C
2.5.3.
SAE 10W
SAE 30
Transfer gearbox (Up--Box)
Oil type: Shell Omala HD 220 or equivalent

ISO Viscosity grade
Viscosity
40 _C
100 _C
Viscosity index
Pour point
Flash point
4Ball EP (Weld)
2.5.4.
220
222.4 cSt
25.8 cSt
148
--48 _C
245 _C
290 kg
Hydraulics
Hydraulic oils meeting DIN 51524 HVLP or ISO 6743--4 HV standards can be used
Viscosity
above --15 _C
above +0
above +5
Operating temperatures during normal operation

about 45 _C
about 60 _C
about 70 _C
ISO VG 32
ISO VG 46
ISO VG 68
(SAE 10W)
(SAE 20)
(SAE 30)
ISO VG 32
ISO VG 46
ISO VG 68
(Motor oils of API class CD, or hydraulic oils with wear--preventive characteristics
corresponding to the DIN 51524 HVLP or ISO 6743--4 HV standards, can be used)
15 (64)
TKU--- C 01140--- 1 EN 0404
2.5.5.
Axles
Classification
MIL--L--2105 C or API GL--5 + LS (Limited Slip)
Viscosity
above --25 _C.

--25 _C...+15 _C
2.5.6.
SAE 80W/140
SAE 85W/140
Grease nipples
Lithium--based greases with penetration 265/295 (NLGI 2) and dropping point 180 _C
should be used.
2.6. Filling capacities

Engine oil
Engine coolant
Transmission
Transfer gearbox
Axles
Hydraulic oil tank
Fuel tank
2 x
29 L (with filters)
55 L
72 L
9L
44 L
250 L
310 L
2.7. Special notes

If the machine is fitted with optional equipment such as an automatic central lubrication
system, please read the instructions for the additional equipment carefully and adhere to
the service schedule given in the maintenance instructions.
2.7.1. Cooling system
D Drain and clean if the engine overheats or solution is dirty.
Note! Overheating indicates a fault. Stop the engine and repair the fault before more
serious damage is caused. Make sure that the engine radiator is not covered and that it
is not clogged.
D
Whenever draining and refilling the cooling system, always recheck the coolant
level 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 cool
down. If an overheated engine must be stopped, allow the radiator to cool down before
checking the coolant level. If there is no time for that, use thick gloves and protective
clothing when opening the radiators filling cap. Stand to the side, turn your face away, and
open the cap a little. Wait until the pressure is released and coolant stops running out, then
open the cap slowly.
D
D
D
Adding over 19 liters per minute can cause air pockets in the cooling system.
Operate with a thermostat in the cooling system all year round.
Coolant must be tested every 250 hours to ensure that inhibitor levels remain within
the permitted ranges; change the coolant inhibitor filter element if necessary (see
Detroit Diesel Coolant Selections or Engine Operators Guide).
16 (64)

2.7.2.
TKU--- C 01140--- 1 EN 0404
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 dangerous when the fuel tank is being filled.
D Clean up spilled fuel before starting the engine.
D Keep the filling pipe in contact with the fuel tank, or arrange grounding to prevent
sparking caused by static electricity.
D If fuel quick fill system is to be used, ensure that you are familiar with the system
manufacturers operating and safety requirements.
2.8. First servicing

Check that the lubricants being used meet site--specific operating requirements as per
Sandvik Tamrock Lubricant Specifications.
The following steps should be carried out during the first week of use (in addition to the
normal, 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
17 (64)
TKU--- C 01140--- 1 EN 0404
3.
MAINTENANCE OPERATIONS
3.1. Every shift

D
Check engine oil
Machine on level ground. Measure oil

level with engine stopped (after stopping the
engine, allow oil drain to the crankcase for
about 20 minutes before checking the oil
level).
The oil level must be between the LOW
and FULL marks on the dipstick.
Check V--belts
Check condition visually and adjust if

necessary.
Check belt for worn, grease--coated, oil-soaked, or missing material. Replace
if necessary.
Check engine coolant level
Check before starting the engine.

Coolant level should be seen via the sight
glass.
Do not remove the pressure control cap or
attempt to drain the coolant until the engine
has cooled.
Use extreme caution when removing the
cap. A sudden pressure release from a
heated cooling system can result in a
loss of coolant and possible
injury (scalding, eye injury, etc.) from
the hot liquid.
18 (64)
Check air filter indicator and assembly condition
Consult air restriction indicator; service air

cleaner elements as required.
Inspect the entire air system for leaks.
Tighten any loose connections.
Check intake ducting and connections for leaks
Check exhaust ducting and connections for leaks
TKU--- C 01140--- 1 EN 0404
19 (64)
TKU--- C 01140--- 1 EN 0404
Check fuel filter element
The filter cover will not fill completely during engine

operation. It will gradually fill over time, and the
fuel level will rise as the filter element becomes
clogged.
The filter element should be changed every 250
hours, or sooner if the fuel level has risen to the
top of the element.
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.
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.
20 (64)
Check tires and wheel nuts
Check condition.
Visually check tire wear and air pressure.
Visually check for loose or missing
wheel nuts.
Check hydraulic oil level
Boom in down position and bucket on

ground. Oil level should be between the
sight glasses.
Check hydraulic tank pressure
It should be 0.3 bar.
TKU--- C 01140--- 1 EN 0404
21 (64)
TKU--- C 01140--- 1 EN 0404
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 should
hold firm at 2000 rpm (machine should not move until engine speed reaches 2000 rpm).
D
Check that all controls are functioning correctly
Raise the lift arms, dump the bucket, roll

back the bucket, and lower the lift arms with
engine at 1000--1500 rpm.
Articulate the machine from left to right.
Check the emergency steering system (option)
Check the emergency steering systems function (option). Turn the ignition key to the 0
position to turn off the engine. When the engine has stopped, turn the ignition key to the
1 position. Turn the steering lever; the machine should turn.
Note! The machine cannot be turned if the cabin door is open.
Brake releasing system function (option).
Check brake releasing pump function. Turn

the switch. The pump should start. (Parking
brake button has to be pulled fully up before
the pump can start.)
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 a
service engineer.
22 (64)
Check Hand Portable Fire Extinguisher
Gauge pointer in green area.

No corrosion.
Firmly mounted.
Visually check that seals are in place.
Check lights
Front
Rear
Optional lights
Check gauges and indicator lights
DDEC signal lights must go off about 5 sec

after the power has been switched on.
Engine temperature should be below 99_C.
Engine oil pressure: at least 0.35
bar when idling, at least 1.9 bar when at 1800 rpm.
Brake system oil pressure; warning light
illuminates when pressure drops too low.
Alternator charging voltage; approx. 26--28 V.
Transmission oil pressure; should be
16.5 21.4 bar.
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 expands
when it becomes warm and can overflow.
If using quick fill, ensure that the system
suppliers instructions are followed.
TKU--- C 01140--- 1 EN 0404
23 (64)
TKU--- C 01140--- 1 EN 0404
Fill automatic central lubrication system (option)
Check the system visually and fill it.

Check that all lubrication points are well
greased.
Grease lift cylinder pins, tilt cylinder pins, and lift arm pins
Use central lubrication manifold.

(If automatic central lubrication is not
installed)
Grease dogbone pins
Connect the high--pressure grease gun

to grease nipple B.
Fill the pin with grease (until the pump
cant pump more).
Grease the stationary ends (grease nipples
A) with a hand grease gun.
A
24 (64)
TKU--- C 01140--- 1 EN 0404
Grease ejector cylinder pins (option)
Grease pins directly through the nipples

with a hand grease gun.
Grease side tipping cylinder pins (option)
Grease pins directly through the nipples

with a hand grease gun.
Grease center articulation, steering cylinder pins, and oscillating axle
Use central lubrication manifold.

(If automatic central lubrication is not
installed)
Grease steering cylinders front pins
directly through the nipples.
Check remote control system (option)
Check RC system function according to Remote Control system instructions.
25 (64)
TKU--- C 01140--- 1 EN 0404
3.2. Every week

D
Wash radiator + oil coolers
Open the cooler hatches for proper cleaning.

WARNING
Do not use high--pressure cleaning units. It
may result in cooler core damage.
HOT WATER CLEANING WITH SOAP
(biodegradable detergent) CAN BE USED,
MAX. PRESSURE 82 bar (1200 psi).
Clean exhaust water scrubber (option)
If the machine is equipped with catalytic

exhaust gas purifier, check the purifier after
every 1000 hours of use.
Clean cyclone air cleaner bowl (optional)
26 (64)
TKU--- C 01140--- 1 EN 0404
Check tire pressures
18.00 x 25 L5S Bridgestone

Front: 550 kPa (5.5 bar)
Rear: 400 kPa (4.0 bar)
Test transmission and the bucket and steering hydraulics
The transmission and hydraulics should be at operating temperature during

measurement.
A Transmission: Press brake pedal, engage highest gear, and accelerate. The engine
should achieve about a 2060--2160 rpm stalling speed.
B Bucket hydraulics: Lower the boom against the stops, keep the control valve in boom
down position, and accelerate. The engine should achieve about a 2100--2200 rpm
stalling speed.
S Steering hydraulics: Turn the loader against the stops, keep the control valve in the
selected position, and accelerate. The engine should achieve about a 2100--2200 rpm
stalling speed.
27 (64)
TKU--- C 01140--- 1 EN 0404
3.3. Every 125 hours

D
Check wheel nuts tightening torques
UNF 3/4, 610 Nm (dry)
General cleaning
Operators compartment (do not use high-pressure water when cleaning the cabin).
Engine compartment:
Before cleaning the machine with water,
or by steam jet or via other cleansers, cover the alternator, connection boxes, and major
connections.
Do not apply steam or solvent directly to the alternator, starting motor, or DDEC electronic
components.
Do not apply solvent to hot surfaces.
Check cabin door and lock condition.
Check that the cabin door and lock work

properly.
28 (64)
Check junction boxes
Open all junction boxes.

-- Check that all boxes are dry
-- Ensure that the components and
junction boxes are mounted properly
-- Visually check for possible loose wires
inside the junction boxes
Check cables
Visually check the cables for

-- Wear
-- Sharp bends
-- Other possible damage
Check the instrument panel
Open instrument panel and check

-- Mounting of components
-- Condition of wiring
D Grease driveshafts
Grease all driveshaft U--joints.
TKU--- C 01140--- 1 EN 0404
29 (64)
TKU--- C 01140--- 1 EN 0404

D
Change engine oil and filters
Run engine until operating temperature is

reached; then shut down.
Drain oil pan and reinstall drain plug, using
a 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 the
same oil.
Add oil as required to bring the oil level to
the 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.
Change transfer gearbox oil
Drain oil from the bottom of the gearbox

and reinstall drain plug, using a new gas-ket if required. Be careful when draining
hot oil.
Fill gearbox through filler opening until fluid
comes up to LOW mark on transmission
dipstick.
Run engine for two minutes at idle.
Recheck level of fluid in gearbox with
engine running at idle.
Add quantity necessary to bring fluid level to LOW mark on dipstick. Recheck with hot oil.
Bring oil level to FULL mark on dipstick.
30 (64)
TKU--- C 01140--- 1 EN 0404
Service the air filter elements
The air filter element must be replaced

when the service indicator shows red.
Always clean the sealing surface of the
outlet tube and make sure that all contami-nant is removed before the new filter is
inserted.
Always clean the inside of the outlet tube
carefully. When the filter element is changed,
the safety element must be kept in place.
The safety element must be changed every
second time the air filter element
is replaced.
Change fuel filter element
A fuel shutoff valve is installed on the

discharge side of the fuel filter.
Turn the handle on the shutoff valve to
the closed position.
Place a suitable container under the filter
and open the drain valve at the base of the
fuel processor. Drain the fuel until it is
below the filter in the see--through cover and
close the drain valve.
Turn the collar counter--clockwise and
remove. Remove cover, filter spring, and
cover seal ring by lifting straight up and over the filter element.
Replace filter element and grommet.
Assemble cover (check spring and seal). Tighten the collar by hand only. Remove the vent
plug from the top of the cover. Fill the cover with clean fuel by using the hand pump and
reinstall the plug (check the plug O--ring) and tighten by hand only.
Turn the handle on the shutoff valve to the open position.
Start the engine, to purge the air from the system. After air is purged and with the engine
still running, loosen the vent cap. The fuel level in the cover will start falling. When the fuel
level falls to the top of the collar, tighten the vent cap quickly. Check for leaks.
For further information, consult Engine Operators Guide.
31 (64)
TKU--- C 01140--- 1 EN 0404
Measure the coolant nitrite concentration and change cooling system filter, if
needed
Never open the filler cap when hot.

Drain and clean if the engine overheats
or solution is contaminated.
Operate with a thermostat in the cooling
system all year round.
The nitrite (NO2) concentration must be between 800 and 2400 ppm.
Coolant pH should be between 8.5 and 10.5.
See Detroit Diesel Engine Operators Guide booklet
Check engine mountings
Check the condition of mounting pads.

Tighten and, if necessary, repair.
Check batteries
Electrolyte level
Cable connections
Cleanliness
Always wear eye protection, protective
overalls, and protective gloves when
servicing batteries. The acid in the battery
can burn the skin, eats holes in clothing,
and can cause blindness if it gets in the
eyes.
32 (64)
Check alternator
Check alternator terminals for loose

connections and corrosion.
Check mounting
Check V--belts. Replace if necessary.
When replacing, always inspect fan
bearings.
Check oil level in planetary hubs and differentials
Always ensure that the arrow is in down

position when checking oil level in plane-tary hubs. Refer to the picture.
Change brake flushing return filter
Location indicated by arrow in the picture.
TKU--- C 01140--- 1 EN 0404
33 (64)
TKU--- C 01140--- 1 EN 0404
Check center articulation
Check for visible signs of wear.

Check that the lubrication works.
Lubricate operator seat linkages and brake pedal links
Remove the rubber bellows, and lubricate

the seat linkage.
Lubricate door and hatch hinges.
Check that all hatches, cabin door, and

lock work properly.
34 (64)
TKU--- C 01140--- 1 EN 0404
Grease the stationary ends of boom / bucket pins
Use a hand grease gun.
Check fire suppression system
Check quick check that the system is

operable.
Check that the system has not been
tampered with and that there is no obvious
physical damage or problems that would
prevent operation.
Follow the service recommendations for any locally fitted fire suppression system.
35 (64)
TKU--- C 01140--- 1 EN 0404

D
Check cooling system hoses
Check for signs of deterioration and

replace if necessary.
Drain water from fuel tank
Check fan shroud
Check exhaust system fastenings
Check exhaust manifold fastening nuts,

exhaust flange, turbocharger, and other
connections for tightness.
Tightening torques
Exhaust manifold bolts . . . . . . . 58--73 Nm
Exhaust manifold / turbocharger nuts
. . . . . . . . . . . . . . . . . . . . . . . . . . . 58--73 Nm
Oil drain line bolts . . . . . . . . . . . 30--38 Nm
36 (64)
Check axle fastenings visually
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 same
level as the outer surface of the nut, the
brakes are worn out and should be
overhauled.
Check the tightening torques of power train flanges and bolts
Tightening torques (dry)
UNF 3/8 . . . . . . . . . . . . . . . . . . .
Wheel nuts . . . . . . . . . . . . . . . . .
Axle fastening nuts . . . . . . . . . .
Axle fastening lock nuts . . . . . .
45 Nm
610 Nm
1000 Nm
500 Nm
Change brake system high--pressure oil filter element
TKU--- C 01140--- 1 EN 0404
37 (64)
TKU--- C 01140--- 1 EN 0404
Change transmission oil filter

Add quantity necessary to bring fluid level
to FULL mark on dipstick.
Change return oil filter element for bucket and steering hydraulics
Check center articulation with dial gauge
Place a dial gauge with a magnetic stand

on the upper hinge plate of the front frame.
Press the bucket against the
ground so that the front frame
rises from the ground and so
you may observe the readings
of the dial gauge.
The reading should be
0.2...0.4 mm.
If the play is smaller or larger, use shims to
adjust it.
For further information, consult the workshop
manual.
38 (64)
Check oscillating axle tightening torques
Bolt tightness (dry)

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

D
Inspect the cooling system
Pressurize the cooling system and ensure

that there are no leaks.
Check engine crankcase pressure
Check and record the crankcase pressure.
TKU--- C 01140--- 1 EN 0404
39 (64)
TKU--- C 01140--- 1 EN 0404
Check catalytic exhaust gas purifiers (optional)
Increased backpressure (2 to 3 inches

water gauge higher from clean purifier
when at high idle), excessive smoke, or
high levels of odor or irritation during
operation of the LHD loader indicates
that the purifier is not functioning
at optimum performance and should be
cleaned.
Cleaning of the purifier: Dry brush inlet
face to catalyst, air--clean through outlet
face of catalyst, soak catalyst in cleaning
solution (1 hour), solvent--air--clean through
outlet face, and air--clean through outlet face.
Do not use solvents containing chlorine, sulfur, metals, or leaded gasoline.
Grease fan drive bearing fitting
Use a hand grease gun and lubricate the

bearings with one shot of lithium--based
multipurpose grease.
Do not overfill the housing.
Change transmission oil and filter
Drain oil from the bottom of the transmission

and reinstall drain plug, using a new gas-ket if required. Be careful when draining
hot oil.
Change oil filter.
Fill torque converter and transmission
through filler opening until fluid comes up
to LOW mark on transmission dipstick.
Run engine for two minutes at idle to prime
torque converter and hydraulic lines.
Recheck level of fluid in transmission with engine running at idle.
Add quantity necessary to bring fluid level to LOW mark on dipstick. Recheck with hot oil.
Bring oil level to FULL mark on dipstick.
40 (64)
D
TKU--- C 01140--- 1 EN 0404
Check the tightening of axle fastening bolts
Tightening torques (dry) . . . . . Axle fastening nuts . . . . . . . . . . 1000 Nm

. . . . . . . . . . . . . . . . . . . . . . . . . . . Axle fastening lock nuts . . . . . 500 Nm
Change oil in front and rear differentials, and in planetary hubs
Remove plug at bottom of axle housing and

allow sufficient time for lubricant to drain.
With planetary wheel ends, rotate wheel
until filler hole is down. Remove plug and
allow sufficient time for draining. Be sure
planet cover oil level hole is in proper
position when refilling wheel ends.
Always ensure that the arrow is in down position when checking oil level in planetary hubs.
Refer to the picture.
D
Test the hydraulic pressures
The hydraulic oil temperature should be 60...80 _C.

Connect and disconnect pressure gauge(s) only when the circuit is not pressurized.
Use only special couplings for pressure testing.
Do not over--tighten couplings. When special couplings are used, finger--tight is adequate.
Over--tightening causes harmful leakage.
Use hose(s) long enough that the gauge(s) can be read while one is sitting in the cabin.
Pilot system pressure
-- Attach a pressure gauge to the
quick--disconnect fitting as shown in
the picture.
-- Engine at low idle
-- Pressure should be 35 bar
(3.5 MPa)
41 (64)
TKU--- C 01140--- 1 EN 0404
Steering system pressure

-- Install the frame locking pin between front
and rear frames.
-- Connect a pressure gauge to the
quick--disconnect fitting after the steering
main valve.
-- Engine speed of 1000 --1500 rpm.
-- Turn the machine to full left--hand turn.
-- Steering system pressure should be
120 bar (12.0 MPa).
Hydraulic pumps pressures

-- The hydraulic pumps pressures can be checked from
the quick--disconnect fittings.
-- Engine at 1000--1500 rpm.
-- Lower the boom against the stops and keep
the control valve in boom down position.
-- Pressure should be 250 bar (25.0 MPa) (points 1 and 2).
---
Standby pressure for steering pump: 40 bar (4.0 MPa)

(point 1).
Standby pressure for bucket pump: 20 bar (2.0 MPa)
(point 2).
Check pressure accumulators
Pre--charge pressures (nitrogen pressure)

-- Brake system accumulators: 12 and 90 bar
-- Boom suspension: 60 bar
-- Emergency steering (option): 60 bar
42 (64)
TKU--- C 01140--- 1 EN 0404
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 suppression
system manufacturer, authorized distributor, or the designee in accordance with the Ansul
Maintenance Manual.
NOTE! For other than Ansul systems, have the system serviced by an authorized system
supplier or dealer.
Always follow the local regulations.
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 fast
coupling.
WARNING
After filling the hydraulic tank, bleed ALL air
from the suction towers to avoid pump
cavitation.

D
Check engine tuning
Check valve clearances.

Check injector heights.
See Engine Service Manual,
section 12 or contact your nearest
Detroit dealer.
43 (64)
TKU--- C 01140--- 1 EN 0404

D
Change V--belts
Change V--belts.
During replacement, always inspect fan
bearings.
Service the hand extinguisher
Have the extinguisher serviced by an

authorized supplier or dealer.
Always follow the local regulations.
44 (64)

D
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 the
radiator bleeder screw open.
Change thermostats and seals
TKU--- C 01140--- 1 EN 0404
45 (64)
TKU--- C 01140--- 1 EN 0404
4.
MAINTENANCE PROGRAM
MAINTENANCE PROGRAM
Every shift
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Done
46 (64)
MAINTENANCE PROGRAM
Every week
TKU--- C 01140--- 1 EN 0404
Page
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
Done
47 (64)
TKU--- C 01140--- 1 EN 0404
MAINTENANCE PROGRAM
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 (64)
MAINTENANCE PROGRAM
Every 125 hours 1/2
TKU--- C 01140--- 1 EN 0404
Page
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Check wheel nuts tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Check cabin door and lock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check junction boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Done
49 (64)
TKU--- C 01140--- 1 EN 0404
MAINTENANCE PROGRAM
Every 125 hours 2/2
Page

Grease driveshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
General cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Done
50 (64)
MAINTENANCE PROGRAM
Every 250 hours 1/1
TKU--- C 01140--- 1 EN 0404
Page
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
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Done
51 (64)
TKU--- C 01140--- 1 EN 0404
MAINTENANCE PROGRAM
Every 250 hours 2/2
Page
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Done
52 (64)
MAINTENANCE PROGRAM
Every 500 hours 1/2
TKU--- C 01140--- 1 EN 0404
Page

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
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Done
53 (64)
TKU--- C 01140--- 1 EN 0404
MAINTENANCE PROGRAM
Every 500 hours 2/2
Page

Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Check center articulation with dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Done
54 (64)
MAINTENANCE PROGRAM
Every 1000 hours 1/2
TKU--- C 01140--- 1 EN 0404
Page

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
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Done
55 (64)
TKU--- C 01140--- 1 EN 0404
MAINTENANCE PROGRAM
Page

Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Test the hydraulic pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Grease fan drive bearing fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Service fire suppression system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Done
56 (64)
MAINTENANCE PROGRAM
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TKU--- C 01140--- 1 EN 0404
57 (64)
TKU--- C 01140--- 1 EN 0404
MAINTENANCE PROGRAM
Page

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
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Done
58 (64)
MAINTENANCE PROGRAM
TKU--- C 01140--- 1 EN 0404
Page

Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Done
59 (64)
TKU--- C 01140--- 1 EN 0404
MAINTENANCE PROGRAM
Page

Change V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Done
60 (64)
MAINTENANCE PROGRAM
TKU--- C 01140--- 1 EN 0404
Page

Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Service hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Done
61 (64)
TKU--- C 01140--- 1 EN 0404
MAINTENANCE PROGRAM
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62 (64)
MAINTENANCE PROGRAM
TKU--- C 01140--- 1 EN 0404
Page

Change V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Drain and replace coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Change thermostats and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Done
63 (64)
TKU--- C 01140--- 1 EN 0404
MAINTENANCE PROGRAM
Page

Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Record =
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Service hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Done
64 (64)
MAINTENANCE PROGRAM
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TKU--- C 01140--- 1 EN 0404

Maintenance Manual

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

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Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Maintenance Manual

Hochgeladen von

Copyright:

Verfügbare Formate

Maintenance

TKU C 01140--- 1 EN 0404

SANDVIK TAMROCK CORP., TURKU PLANT

TKU C 01140--- 1 EN 0404

TKU C 01140--- 1 EN 0404

Importance of regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General safety precautions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location of the main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 125 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 1500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 4000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TKU C 01140--- 1 EN 0404

1.1. Importance of regular maintenance

1.2. General safety precautions during operation

TKU C 01140--- 1 EN 0404

1.3. General repair instructions

TKU C 01140--- 1 EN 0404

1.4. Location of the main components

TKU C 01140--- 1 EN 0404

Engine coolant filter

TKU C 01140--- 1 EN 0404

MAINTENANCE AND LUBRICATION

TKU--- C 01140--- 1 EN 0404

MAINTENANCE AND LUBRICATION

2.1. Maintenance of hydraulics

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

TKU--- C 01140--- 1 EN 0404

MAINTENANCE AND LUBRICATION

2.2. Electrical system maintenance

Work on electrical equipment or components is only to be carried out by qualified

MAINTENANCE AND LUBRICATION

TKU--- C 01140--- 1 EN 0404

Working on live components

2.3. Battery maintenance

TKU--- C 01140--- 1 EN 0404

MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION

TKU--- C 01140--- 1 EN 0404

Use oil of API category CH--4.

Allison C--4 or Caterpillar TO--4

Transfer gearbox (Up--Box)

Oil type: Shell Omala HD 220 or equivalent

Operating temperatures during normal operation

TKU--- C 01140--- 1 EN 0404

MAINTENANCE AND LUBRICATION

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

above --25 _C.

2.6. Filling capacities

2.7. Special notes

Note! Never open the filler cap when hot.

MAINTENANCE AND LUBRICATION

TKU--- C 01140--- 1 EN 0404

The following precautions must be observed when adding fuel:

2.8. First servicing

TKU--- C 01140--- 1 EN 0404

3.1. Every shift