Toro 007 User manual

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MAINTENANCE
MANUAL
(Detroit S50)
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2 (64)
TKU C 01140 --- 1 EN 0404
SANDVIK TAMROCK CORP., TURKU PLANT 04/2004
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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 operator’s manual, maintenance manual, and general safety instructions before
operating it.
Read the operator’s manual and “General Safety
Instructions” before starting the work!
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 equipment’s 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 ahigh
degree of utilization and long operating life of your loader.
Always obey safety rules!
WARNING
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4 (64)
TKU C 01140 --- 1 EN 0404
PREFACE 3.....................................................................................
1. GENERAL 5................................................................................
1.1. Importance of regular maintenance 5.................................................
1.2. General safety precautions during operation 5.........................................
1.3. General repair instructions 6.........................................................
1.4. Location of the main components 7...................................................
2. MAINTENANCE AND LUBRICATION 10........................................................
2.1. Maintenance of hydraulics 10.........................................................
2.2. Electrical system maintenance 11.....................................................
2.3. Battery maintenance 12...............................................................
2.4. Welding 12..........................................................................
2.5. Lubricants 14........................................................................
2.5.1. Engine 14.........................................................................
2.5.2. Transmission 14...................................................................
2.5.3. Transfer gearbox (Up--Box) 14.......................................................
2.5.4. Hydraulics 14......................................................................
2.5.5. Axles 15..........................................................................
2.5.6. Grease nipples 15..................................................................
2.6. Filling capacities 15..................................................................
2.7. Special notes 15.....................................................................
2.7.1. Cooling system 15.................................................................
2.7.2. Refueling 16.......................................................................
2.8. First servicing 16.....................................................................
3. MAINTENANCE OPERATIONS 17..............................................................
3.1. Every shift 17........................................................................
3.2. Every week 25.......................................................................
3.3. Every 125 hours 27...................................................................
3.4. Every 250 hours 29...................................................................
3.5. Every 500 hours 35...................................................................
3.6. Every 1000 hours 38..................................................................
3.7. Every 1500 hours 42..................................................................
3.8. Every 2000 hours 43..................................................................
3.9. Every 4000 hours 44..................................................................
4. MAINTENANCE PROGRAM 45................................................................
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GENERAL
5 (64)
TKU C 01140 --- 1 EN 0404
1. 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 Operator’s
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
manufacturer’s 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 manufacturer’s 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.
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GENERAL
6 (64)
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.
DTurn main switch off
DRemove ignition key
DPut 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 won’t move.
-- Pay special attention to the exhaust pipe--work and the exhaust gas cleaning
system. Ensure sufficient ventilation.
-- Use a lift jack only on level, hard, and firm ground. Before using a jack, always be sure
the wheels on the other side of the vehicle are blocked. To prevent the possibility 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
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1
3
2
4
4
5
GENERAL
7 (64)
TKU C 01140 --- 1 EN 0404
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
1
24
3
1. Front frame
2. Rear frame
3. Engine ass’y
4. Power train
Front frame
1. Bucket
2. Swing lever
3. Boom
4. Lift cylinders
5. Tilt cylinder
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GENERAL
8 (64)
TKU C 01140 --- 1 EN 0404
Rear frame
5
6
2
78
8
3
4
2
1
7
1. Fuel tank
2. Oil cooler
3. Hydraulic oil level
4. Main switch
5. Battery box
6. Radiator / intercooler / fuel cooler
7. Operator’s cabin
8. Service hatches
Engine ass’y
5
1
2
3
6
4
1. Alternator
2. Turbocharger
3. Engine oil filters
4. Engine coolant filter
5. Fuel filter
6. Air filter
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155 3 2
54
GENERAL
9 (64)
TKU C 01140 --- 1 EN 0404
Power train
1. Front axle
2. Rear axle
3. Transmission /
torque converter
4. Transfer gearbox
5. Driveshaft
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MAINTENANCE AND LUBRICATION
10 (64)
TKU--- C 01140 --- 1 EN 0404
2. MAINTENANCE AND LUBRICATION
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.
DDo not attempt any such repairs that you do not fully understand.
DNever do any repair work on the hydraulic circuit when the system is pressurized.
DAlways stop the engine before tightening or repairing a leaking hose connection.
DDo 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.
DAvoid direct skin contact with oil. Prevent oil from getting into your eyes; use eye
protection.
DDo not work under a device or component that is held up only by the hydraulics.
Use separate supports in conjunction with maintenance and repair.
DDo not remove boom cylinders or their valves unless the boom is properly
supported and the system non--pressurized.
DPipe 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.
DAny deviations require written authorization from the manufacturer.
Pressure tests
General
DThe hydraulic oil temperature should be 60...80 _C.
DConnect and disconnect pressure gauge(s) only when the circuit is not
pressurized.
DUse only special couplings for pressure testing.
DDo not over--tighten couplings. When special couplings are used,
finger--tightening is adequate. Over--tightening leads to harmful leakage.
DUse hose(s) long enough to read the gauge(s) while the operator is sitting in the
cabin.
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MAINTENANCE AND LUBRICATION
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
DWork 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.
DLocal electrotechnical and electric safety regulations must always be observed.
DAlways use only original electrical components.
DIf disturbances in the electricity supply occur, stop the vehicle at once.
DVoltage 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.
DDo 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.
DCheck the electrical devices of the machinery regularly. Faults, such as loose wires
and damaged insulation, must be repaired at once.
DWhen handling high-voltage components, remember that capacitors may be
charged even if the voltage is cut off. Discharge the capacitors with a grounding
rod.
DBefore making any changes concerning the electrical devices, SANDVIK
TAMROCK’s electrical engineering department must be consulted and a
written authorization received, to ensure that the operation of the device
does not change.
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MAINTENANCE AND LUBRICATION
12 (64)
TKU--- C 01140 --- 1 EN 0404
Working on live components
DIf 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.
DUse a red-and-white safety chain and warning signs to encircle the working area.
DUse only insulated tools.
DObserve special caution.
2.3. Battery maintenance
Always wear eye protection, protective overalls, and protective gloves when
servicing batteries.
DAlways disconnect the negative (-) pole first, then the positive (+) pole. Always
connect the positive pole (+) first, then the negative (-) pole.
DReversing 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.
DTo 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 battery’s cell caps slightly during charging to allow the
gases generated to escape.
DThe 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.
DWhen 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.
DTo 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.
DUse a flashlight when checking electrolyte levels, never an open flame.
DThe battery terminals should never be shorted, as sparks can cause the battery
to explode.
DDo 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.
DDo not repair steering equipment by welding.
DWelding must be left to qualified personnel.
DBefore electrical welding, the main switch must be disconnected. Also, Remote
Control equipment (optional) must be disconnected.
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MAINTENANCE AND LUBRICATION
13 (64)
TKU--- C 01140 --- 1 EN 0404
DIf welding must be done close to any of the control modules, disconnect the module
wiring before beginning welding.
DThe 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.
DUse a protective mask when welding.
DArrange adequate ventilation.
DArrange protection against fire.
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MAINTENANCE AND LUBRICATION
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 Operator’s Guide for more details.
2.5.2. Transmission
Classification Allison C--4 or Caterpillar TO--4
Viscosity --20 _C...+15 _C SAE 10W
above +0 _C SAE 30
2.5.3. Transfer gearbox (Up--Box)
Oil type: Shell Omala HD 220 or equivalent
ISO Viscosity grade 220
Viscosity 40 _C 222.4 cSt
100 _C 25.8 cSt
Viscosity index 148
Pour point --48 _C
Flash point 245 _C
4Ball EP (Weld) 290 kg
2.5.4. Hydraulics
Hydraulic oils meeting DIN 51524 HVLP or ISO 6743--4 HV standards can be used
Viscosity
above --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 operation
about 45 _C ISO VG 32
about 60 _C ISO VG 46
about 70 _C 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)
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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. SAE 80W/140
-- 2 5 _C...+15 _C SAE 85W/140
2.5.6. 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 29 L (with filters)
Engine coolant 55 L
Transmission 72 L
Transfer gearbox 9 L
Axles 2 x 44 L
Hydraulic oil tank 250 L
Fuel tank 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
DDrain 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.
DWhenever 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 radiator’s 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.
DAdding over 19 liters per minute can cause air pockets in the cooling system.
DOperate with a thermostat in the cooling system all year round.
DCoolant 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 Operator’s Guide).
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MAINTENANCE AND LUBRICATION
16 (64)
TKU--- C 01140 --- 1 EN 0404
2.7.2. Refueling
The following precautions must be observed when adding fuel:
DDo not fill the fuel tank when the engine is running.
DDo not overfill.
DTake care not to spill fuel on hot surfaces.
DAddition of fuel should be done in a well--ventilated space.
DSmoking, open flames, and sparks are dangerous when the fuel tank is being filled.
DClean up spilled fuel before starting the engine.
DKeep the filling pipe in contact with the fuel tank, or arrange grounding to prevent
sparking caused by static electricity.
DIf fuel quick fill system is to be used, ensure that you are familiar with the system
manufacturer’s operating and safety requirements.
2.8. First servicing
Check that the lubricants being used meet site--specific operating requirements as 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
Maintenance
Manual
Maintenance
Manual
Operator's
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Operator's
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17 (64)
MAINTENANCE OPERATIONS
TKU--- C 01140 --- 1 EN 0404
3. MAINTENANCE OPERATIONS
3.1. Every shift
D
DD
DCheck 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.
D
DD
DCheck V--belts
Check condition visually and adjust if
necessary.
Check belt for worn, grease--coated, oil--
soaked, or missing material. Replace
if necessary.
D
DD
DCheck 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.
Maintenance
Manual
Maintenance
Manual
Operator's
Manual
Operator's
Manual
Maintenance
Manual
Maintenance
Manual
Workshop
Manual
Workshop
Manual
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Manual
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Manual
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18 (64)
MAINTENANCE OPERATIONS
TKU--- C 01140 --- 1 EN 0404
D
DD
DCheck 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.
D
DD
DCheck intake ducting and connections for leaks
D
DD
DCheck exhaust ducting and connections for leaks
Maintenance
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Maintenance
Manual
Operator's
Manual
Operator's
Manual
Maintenance
Manual
Maintenance
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Manual
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19 (64)
MAINTENANCE OPERATIONS
TKU--- C 01140 --- 1 EN 0404
D
DD
DCheck 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.
D
DD
DCheck transmission oil level
Machine on level ground.
Parking brake engaged.
Engine at low idle.
Gearshift lever in neutral position.
Transmission oil at operating temperature.
D
DD
DCheck 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.
Maintenance
Manual
Maintenance
Manual
Operator's
Manual
Operator's
Manual
Maintenance
Manual
Maintenance
Manual
Workshop
Manual
Workshop
Manual
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