Cat CL115 Compact Loader Maintenance Manual BI016250 - PDF DOWNLOAD

BI016250 A6474X386 November 2012

Maintenance Manual CL115 Compact Loader

SAFETY.CAT.COM

BI016250

__________________________________________________________

This manual is intended to provide GENERAL product information. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

This machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to Caterpillar’ s instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© Caterpillar 2012 ALL RIGHTS RESERVED

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Table of contents Safety Precautions ............................................................................ 4 General Maintenance Instructions .................................................... 5 Special Fasteners.............................................................................. 7 Torque Charts ................................................................................... 8 Maintenance...................................................................................... 10 Specific Torque Values ............................................................. 10 Lubricant and Fluid Capacities.................................................. 10 Lubrication and Maintenance Chart .......................................... 11 Specific Lubrication and Maintenance Procedures................... 15 Pre-shift ................................................................................ 15 Daily ..................................................................................... 22 Weekly.................................................................................. 30 First 50 Hours of Service...................................................... 48 Every 100 Hours of Service ................................................. 50 Every 500 Hours of Service ................................................. 56 Every 1,000 Hours of Service .............................................. 60 Every 6 Months .................................................................... 61 Lubricant Specifications .................................................................... 62

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Safety Instructions _______________________________________________ Safety Precautions

The following safety precautions should be observed whenever operating or performing any maintenance, repair, or adjustment procedure on this machine.

Additional precautions may appear in each section of this book. All precautions listed applicable to this machine, as well as all applicable regulatory agency rules and regulations must be followed at all times.

Only qualified personnel are permitted to make repairs to permissible equipment. The permissibility of any permissible component must be verified after any maintenance or repair work and at regular intervals. Failure to maintain permissible components to OEM standard may result in a fire or explosion. Serious injury or death could occur.

!

DANGER

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WARNING Do not attempt to operate this machine until you have been sufficiently trained on this machine and have read and understood this manual and are familiar with all controls and indicators. Operating this machine without the proper training and knowledge may result in serious injury or death to the operator or other personnel.

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WARNING Do not move any hydraulic control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement may result in serious injuries or death.

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WARNING Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended loads. You could be seriously injured or killed by falling loads.

!

WARNING Some procedures or test may require the cover of the electrical controller to be removed and some may require the controller to be energized during the procedure. Tall all necessary precautions to prevent electrical shock while working within the controller. An MSHA certified electrician must supervise and inspect all work.

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WARNING Do not alter, bypass, or remove and emergency or machine stop device. Failure to heed this warning may result in serious injury or death.

!

WARNING Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. Pressurized hydraulic fluid or falling loads may result in serious injury or death.

!

WARNING Whenever performing maintenance, be sure to collect and properly dispose of all fluids.

Do not let fluids (coolant, engine oil, hydraulic oil, etc) drip or drain onto the ground.

Dispose of in accordance with all laws and regulations.

!

WARNING When performing maintenance, be aware that fluids (hydraulic oil, engine oil, coolant) may be hot. Contact with hot fluids may result in burns.

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__________________________________ General Maintenance Instructions Introduction

Maintenance at regular intervals increases the operational safety and prolongs the service life of the machine. This manual contains recommendations on machine and component inspections, machine lubrication, lubricant (oil) change procedures, filter maintenance, and adjustment procedures to properly maintain the machine.

Tools

General tools are required for maintenance. If a procedure requires a specialty tool or material, it will be identified in the procedure.

Illustrations and Procedures The maintenance intervals and procedures given in this manual are based on typical machines and typical mine conditions. Mine conditions and machine configuration may require the recommended intervals or maintenance procedure be modified from those given.

The illustrations used in this manual are for a typical machine and may vary from your machine. If repair work is required, always refer to the specific drawing in the parts pook supplied with your machine.

Maintenance Notes

Before performing maintenance on this machine, observe the following: 1. In order to avoid individual components not being serviced or being inadequately serviced, a general maintenance plan should be developed.

2. Use only original spare parts when replacing components.

3. All electrical work must be supervised and inspected by a certified electrician.

4. Anyone performing maintenance on this equipment must be trained on machine operation.

5. Shutdown the machine on level ground.

6. Test all controls to ensure that the machine will not move.

7. Chock all four wheels in each direction.

8. Connect the steering lockout device.

9. If an assembly must be left in an elevated position, place appropriate blocking under the assembly. Make sure that the blocking can support the weight of the assembly without slipping or failing.

10. If drive shafts are to be run, the machine must be jacked clear of the ground so that all four wheels are free to rotate. Securely block the machine, including the center section with appropriate blocking. Make sure that the blocking can support the weight of the assembly without slipping or failing.

11. Relieve all hydraulic pressures and position the levers and controls, if applicable, in the Neutral or Off position.

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General Maintenance Instructions___________________________________ 12. Do not perform maintenance on a circuit while there is a load resting on the hydraulic cylinder. Booms must be securely blocked with the boom in the raised position if maintenance is to be performed.

13. Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

14. Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

15. Cleanliness cannot be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

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________________________________________________ Special Fasteners Introduction

Various types of specialty fasteners, self-locking bolts and nuts, lock wiring, etc., may be in use on the machine. It is important that these fasteners be used in the correct manner to provide the locking qualities required.

Locking Wire Fasteners

When using a single locking wire, insert the wire through the fastener from the inside to the outside of the bolt circle, advancing in a clockwise direction (Fig. 1).

When using wired pairs, insert the wire in the left hand fastener (as viewed from the center of the bolt circle) from the inside to the outside of the bolt circle. Insert the right end of the wire through the right hand fastener (Fig. 1).

Fig. 1: Lock wire fasteners

Self-Locking Screws

1. Self-locking screws are generally used where measured torque is required.

2. Use a hand wrench, not a power wrench, to tighten to get an accurate reading.

3. Performance is reduced with each use. Limit reuse to twice.

4. If assembly requires shimming, establish the shimming requirements using standard fasteners. After shimming requirements are established, replace standard fastener with self-locking and torque as required.

Lock Nuts

1. Lock nuts with nylon or fiber inserts should not be reused.

2. Lock nuts with a spring steel lock ring in the head can be reused.

3. Hand thread the nut to engage the threads before using a power wrench.

4. Bolt or stud threads should extend beyond the nut.

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Torque Values ___________________________________________________ Introduction

The following charts list the recommended torque values for common fasteners used on the Continuous Miner. Use these torque values unless the drawing or instructional material states otherwise.

Do not use these tables for any bolt grades except those specifically listed.

Use a calibrated torque wrench for accuracy.

Table 1: Imperial Bolts

Grade 8 Imperial Bolts Torque Recommendations (calculated at 75% proof load) Bolt size Dry Lubricated (inches) ft-lbs ft-lbs 1/4 12 6 5/16 25 12 3/8

44

22

7/16

70

35

1/2

107

53

9/16

154

77

5/8 3/4

212 376

106 188

7/8

606

303

1

909

454

1-1/8

1287

644

1-1/4

1875

938

1-3/8

2382

1191

1-1/2

3161

1581

1-3/4

4988

2494

2

7500

3750

2-1/4

10969

5484

2-1/2

15000

7500

2-3/4 3

17794 23507

8897 11753

3-1/4

30286

15143

3-1/2

38266

19133

3-3/4

47545

23773

4

58100

29085

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___________________________________________________ Torque Values Table 2: Metric Bolts Metric Bolts Torque Recommendations (calculated at 75% proof load) Property Class

8.8

10.9

12.9

M6 - M16: 800 M20 - M30: 830

1040

1220

Minimum Tensile Strength (MPa) Nominal Size and Thread Pitch

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

Dry ft-lbs (in-lbs)

Lubricated ft-lbs (in-lbs)

M5 X 0.80 M6 X 1.00

(54) (92)

(41) (69)

(78) (133)

(59) (99)

(91) (156)

(68) (116)

M7 X 1.00

(156)

(116)

(222)

(167)

(260)

(195)

M8 X 1.25

(2250

(169)

(333)

(242)

(377)

(284)

M10 X 1.50

37

28

53

40

62

47

M12 X 1.75

65

49

93

69

108

81

M14 X 2.00

104

78

148

111

173

130

M16 X 2.00

161

121

230

172

269

202

M18 X 2.50

222

167

318

238

372

279

M20 X 2.50

314

235

449

337

525

394

M22 X 2.50

428

321

613

460

716

537

M24 X 3.00

543

407

776

582

908

681

M27 X 3.00

796

597

1139

854

1331

998

M30 X 3.50

1079

809

1543

1158

1804

1353

M33 X 3.50

1468

1101

2101

1576

2455

1842

M36 X 4.00

1886

1415

2699

2024

3154

2366

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Maintenance Schedule ____________________________________________ Introduction

This section outlines the frequency at which maintenance tasks should be carried out. Depending on operating conditions, more frequent intervals may be required.

Torque Values

Table 3 lists some specific fasteners that must be checked during maintenance and their torque values (lubricated). Lubricated thread torque values should be used any time the bolt threads are covered with oil, grease, anti-seize or thread -locking compounds.

Table 3: Torque values Size

Location Steering cylinder pins

Grade

1-1/4”nut

Torque (ft-lbs) 1480 - 1500

Tire-Wheel mounting nuts Axle mounting bolts Center section Center section Driveline bolts Driveline bolts

Lubricants

217 7/8”X 12” 1-1/4”X 9 7/8”X 9” 7/16”X 1-1/4” 1/2”X 2”

8 8 8 8 8

455 1840 620 65 - 75 70 - 80

Table 4 lists lubricant specifications and fluid capacities that should be observed when adding or changing a lubricant or greasing a component.

Table 4: Lubricants and fluid capacities Location Fuel tank

Approximate capacity 35 gal (132.5 L)

Notes

Per MSHA requirements

Hydraulic oil tank

Mobilfluid 424

70 gal (189 L)

1

Gear box (reducer)

Spec. 100-6

Lubrication points

Spec. 100-3

11 gal (42 L) or as required As Required

3

Axle housing

Hypoid gear oil SAE 90W

8.4 gal (32 liters)

2

Planetary wheel ends

Hypoid gear oil SAE 90W

6.8 qt (6.5 liters)

2

Cooling oil

4 gal (15 L) each

Wet disc brakes

Specification

Specification sheets, listing both the physical characteristics and vendors and lubricants that are known to meet each specification, are given at the end of this section.

Notes: 1. With ejector blade completely retracted (if equipped with bucket).

2. The axle housing and planetary wheel end assemblies do not have a common oil source. Each assembly must be filled separately. Make sure the level check and fill holes in the planetary wheel end cover are in the proper position (fill hole should be at the 3 o'clock or 9 o'clock position). When filling the axle housing and planetary wheel ends, allow enough time for the lubricant to fill the various cavities and around component parts in each assembly. Continue adding oil into each assembly until the required oil level is reached.

3.

Pump grease into fitting until old grease can be observed coming out of the component.

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____________________________________________Maintenance Schedule Table 5: Lubrication and maintenance schedule Item

Description

Places

Lubricant

Low sulfur diesel 10W40 API CF/ 4

Specification

Pre-shift 1 2 3 4 5 6

Headlights (Inspect) Reflectors and warning tags Fuel level Engine oil level Engine air cleaner Radiator coolant level

4 Inspect Check Check Check Check

7

Transmission oil level

Check

8 9

Soot Filter (Replace as necessary) Fuel pre-filter (drain)

Inspect 1

Avia Antifreeze Extra Glysantin G 48 DEA radiator antifreeze Shell GlycoShell SAE 20W CAT TO-4 Allison C4

Daily 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Air tank Center section pivots Steering cylinders (rod and base end) Oscillating bearing Lift cylinder Tilt cylinders Ejector cylinders Drive shaft bearing carrier Lift frame Fasteners (Nuts, bolts and screws) Electrical cables, conduits and glands Hydraulic hoses and connections Tires (Inspect) Hydraulic oil level (Check)

Drain 2 3 9 2 3 4 1 4 Inspect Inspect Inspect 4 1

Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3

Spec. 100-12

Weekly 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Steering cylinder pins Center section pins and nuts Tire-wheel mounting bolts Engine, converter, and transmission Mounting bolts Front drive line Rear drive line Middle drive line Converter drive line Axle mounting bolts Oscillating bearing Fire suppression system Pressure filter (Main) (Inspect/change as required) Return filter (Inspect/change as required) Auxiliary pump pressure filter (Inspect/change as required) Axle oil level (Check)

Inspect Inspect Inspect Inspect 2 2 2 4 Inspect Inspect Inspect 1

Spec. 100-3 Spec. 100-3 Spec. 100-3 Spec. 100-3

1 1 2

Hypoid gear oil SAE 90W

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Maintenance Schedule ____________________________________________ Table 5, continued: Lubrication and maintenance schedule Item

Description

Places

39

Planetary wheel end oil level (Check)

4

40 41 42 43 44

Wet disc brake wear indicator (Check) Permissibility checks Carbon monoxide (CO) sampling Air regulator filters (drain) Air compressor water separator (demister)

4

Lubricant

Specification

Hypoid gear oil SAE 90W

2 Drain

Every three months 45

Axle oil (Change)

2

46

Planetary wheel end oil (Change)

4

47 48 49 50 51 52 53

Hydraulic oil (Change) Tank suction strainer (Clean/change) Air regulator filters (2) Air compressor water separator filter (demister) Air compressor intake filter Crankcase breather Engine monitoring system, exhaust filter 1st 50 Hours of service Engine oil and filter Every 100 hours of service Radiator Engine oil and filter Fuel pre-filter Fuel final filter (2) Every 500 hours of service Transmission filter Radiator coolant

1 1 Change Change Change Change Change

Scrubber heat exchanger Every 1000 hours of service Scrubber heat exchanger Every 6 months Permissibility checks

Inspect

54 55 56 57 58 59 60

61 62 63

Change Clean Change Change Check Change Change

Hypoid gear oil SAE 90W Hypoid gear oil SAE 90W Spec. 100-12

10W40 API CF/ 4

10W40 API CF/ 4

Avia Antifreeze Extra Glysantin G 48 DEA radiator antifreeze Shell GlycoShell

Clean

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____________________________________________Maintenance Schedule Fig. 2: Lubrication and maintenance chart 9

10 1 4

5

1

10 3 43, 49 35

37

8

10 57

58

44 50

54 56

8

59

36

12, 14, 15, 16, 17 1

1

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Maintenance Schedule ____________________________________________ Fig. 2: Lubrication and maintenance chart, continued

11, 25

18

22

35

3

55, 60

12, 24

36

39

6

13

47, 48

23

26

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__________________________________________Maintenance Instructions Specific lubrication and maintenance procedures Pre-shift The purpose of this section is to describe the maintenance procedures that are required every shift: 1. Inspect the headlights 2. Check all reflectors and warning tags 3. Check the fuel level 4. Check the engine oil level 5. Check the engine air cleaner 6. Check the radiator coolant level 7. Check the transmission/convertor oil level 8. Inspect the soot filter 9. Drain the fuel pre-filter

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Maintenance Instructions __________________________________________ Headlights

Turn on headlights and visually inspect for bulbs that need replaced or for signs of damage.

Reflectors and Warning Tags

Visually inspect the condition and readability of all warning tags, labels and reflectors for signs of wear or damage. Replace any found missing or damaged.

Diesel Fuel Level

Check the diesel fuel level in the fuel tank at the beginning of each shift by checking the fuel gauge mounted beside the fuel fill cap (Fig. 3). Add low sulfur diesel fuel as required.

Fig. 3: Diesel fuel level gauge and fill cap

Fill cap

Fuel gauge

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__________________________________________Maintenance Instructions Engine Oil Level

The engine oil dipstick is calibrated to measure the oil level in a cold engine, before starting. To check the oil level (Fig. 4): 1. Remove engine oil dipstick and wipe clean.

2. Insert dipstick all the way, remove it, and read the level.

3. If additional oil is required. Remove the filler cap from the engine and add oil until the correct level is reached. Never run the engine at low oil levels.

Fig. 4: Engine oil dipstick and fill cap

Fill cap

Dipstick location

Fill cap Dipstick location

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Maintenance Instructions __________________________________________ Engine Air Cleaner

Check the service indicator on the engine air cleaner filter and change as indicated. To check the indicator, open the cap on the end of the air cleaner (Fig. 5). The red t-shaped indicator is located in the center of the filter element. The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used. It may be necessary to adjust the air cleaner service interval based upon use. At a maximum, the air cleaner should be changed every 100 hours of service.

Fig. 5: Engine air cleaner

Air filter cap remove to view indicator

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__________________________________________Maintenance Instructions Coolant Level

There are four places where the coolant level must be checked: two on the radiators and two on the expansion tank (Fig. 6).

Note: Never open the service cap on a hot cooling system. To avoid burns, check and add coolant while the system is cool.

Two sight glasses on the side of the radiators are used to check coolant level in the radiator. These sight glasses should be full. If the coolant level is low, open the appropriate service cap and add coolant.

There are two sight glasses for the expansion tank located to the left of the radiator. These sight glasses should be full. If the coolant level is low, remove the plugs from the fill ports and add coolant.

Fig. 6: Coolant level check Sight glass (2) Fill ports (2)

Sight glass

Fill cap

Sight glass

Fill cap

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Maintenance Instructions __________________________________________ Transmission Fluid Level

Check the transmission fluid level with the engine at idle speed (approximately 650 rpm), the transmission in neutral, and the transmission fluid hot using the transmission dipstick (Fig. 7) . Add transmission fluid (SAE 20W, CAT TO-4, or Allison C4) as required.

Fig. 7: Transmission dipstick

Transmission dipstick

Soot Filter

With the machine running, check the exhaust backpressure gauge in the operator’ s compartment. If the gauge reads 60”of water, replace the soot filter (Fig. 8) by opening the cover on top of the machine to access the filter canister.

Next, unscrew the nut on the top of the canister and remove the cover. The filter element can then be pulled out of the canister.

Fig. 8: Soot Filter Access cover

Retaining nut

Canister cover

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__________________________________________Maintenance Instructions Fuel Pre-Filter

Drain the water collected in the bowl of the fuel pre-filter (Fig. 9) at the beginning of each shift.

Fig. 9: Fuel pre-filter

Fuel pre-filter

Water collection bowl

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Maintenance Instructions __________________________________________ Daily The purpose of this section is to describe the maintenance procedures that are required to be performed daily: 1. Drain the air tank 2. Grease the following: a. Center section pivots b. Steering cylinders c.

Oscillating bearing

d. Lift cylinder e. Tilt cylinders f.

Ejector cylinders

g. Drive shaft bearing carrier h. Lift frame 2. Inspect all fasteners 3. Inspect electrical cables, conduits, and glands 4. Inspect hydraulic hoses and connections 5. Inspect the tires 6. Check the hydraulic oil level

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__________________________________________Maintenance Instructions Air Tank

Open the needle valve in the air tank (Fig. 10) and bleed the tank of accumulated water. There is an external air connection (Fig. 10) available to recharge the air system, if required.

Note: Weather conditions (temperature and humidity) can greatly affect the pneumatic system. Less humid conditions may mean that the air tank does not need to be bled as frequently. Cooler and/or more humid conditions may result in adverse starting conditions. When the air goes from high to low pressure (storage vessel to starter), moisture in the air may freeze on the vanes in the starter, causing the starter to stick in place and, therefore, not allowing the machine to start. Multiple start attempts will exacerbate this situation. To “unstick” or thaw the starter, pour hot water over it.

Fig. 3: Air tank needle valve Air tank needle valve and external air connection

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Maintenance Instructions __________________________________________ Center Section Pivot

Oscillating Bearing

Lubricate the center section pivot points (2 places) with Spec. 100-3 through the grease fittings located on the side of the front frame (Fig. 11). Pump grease into the fittings until new grease can be observed coming out of the center section pins.

Lubricate the oscillating bearing (9 places) with Spec. 100-3 through the grease fittings located around the bearing (Fig. 11). Pump grease into the fittings until new grease can be observed coming out of the bearing.

Fig. 11: Center section and oscillating bearing lubrication points

Oscillating bearing

Center section pivot

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__________________________________________Maintenance Instructions Steering Cylinders

Lubricate the steering cylinders bearings (4 places) with Spec. 100-3. The rod end bearing of each cylinder is lubricated through the grease fittings located on each rod end and the base end bearing of each cylinder is lubricated through grease fittings located on the remote grease block (Fig. 12). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 12: Steering cylinder lubrication points

Steering cylinder rod end grease fitting (typical both sides)

Steering cylinder base end (right)

Steering cylinder base end (left)

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Maintenance Instructions __________________________________________ Tilt Cylinder Lubrication

Lift Cylinder Lubrication

Lubricate the tilt cylinders (4 places) with Spec. 100-3. The rod end bearing of each cylinder is lubricated through the grease fittings located on each rod end and the base end bearing of each cylinder is lubricated through grease fittings located on the remote grease block (Fig. 13). Pump grease into the fittings until new grease can be observed coming out of the pins.

Lubricate the lift cylinder (2 places) with Spec. 100-3. The rod end bearing of the cylinder is lubricated through the grease fitting located on the rod end and the base end bearing of the cylinder is lubricated through the grease fitting located on the remote grease block (Fig. 13). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 13: Lift and tilt cylinder lubrication points Tilt cylinder base end

Lift cylinder base end (left)

Lift cylinder base end (right)

Lift cylinder (rod end) (typical both sides) Tilt cylinder (rod end)

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__________________________________________Maintenance Instructions Ejector Cylinder Lubrication

Lubricate the ejector cylinders (4 places) with Spec. 100-3 through the grease fittings located on the rod and base end of each cylinder (Fig. 14). Pump grease into the fittings until new grease can be observed coming out of the pins.

QA Cylinder Lubrication

Lift Frame Pivot Lubrication

Lubricate the QA cylinder (1 place) with Spec. 100-3 through the grease fitting located on the base end of each cylinder (Fig. 14). Pump grease into the fitting until new grease can be observed coming out of the pin.

Lubricate the lift frame pivot (2 places) with Spec. 100-3 through the grease fittings (shown below with bucket) located on the back of the frame (Fig. 14).

Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 14: Ejector, QA, and lift frame pivot lubrication points

Ejector cylinder

QA cylinder

Lift frame pivot Ejector cylinder

Lift frame pivot

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Maintenance Instructions __________________________________________ Drive Shaft Bearing Carrier Lubrication

Lubricate the drive shaft bearing carrier with Spec. 100-3 through the grease fitting located on the remote grease block (Fig. 15). Pump grease into the fitting until grease can be observed coming out of the bearing.

Fig. 15: Drive shaft bearing carrier lubrication point Drive shaft bearing carrier

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__________________________________________Maintenance Instructions Fasteners

Loose fasteners will cause premature wear and failure to the machine and it’ s components. Visually inspect for loose fasteners and tighten as required.

Electrical Cables, Conduits, and Glands

Visually inspect all electrical cables, conduits, and glands for signs of wear or damage.

Hydraulic Hoses and Connections

Visually inspect all hydraulic hoses and connections for signs of wear, damage, or leakage.

Tires

Visually inspect all tires for signs of wear or damage.

Hydraulic Oil Level

Check the hydraulic oil level by looking at the sight glass located on the oil tank (Fig. 16). If the oil level is low, add oil (Spec. 100-12).

Fig. 16: Hydraulic oil level

Fill cap

Sight glass

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Maintenance Instructions __________________________________________ Weekly The purpose of this section is to describe the maintenance procedures that are require to be performed weekly: 1. Grease the following: a. Front, rear, middle, and converter drive lines b. Front drive line flange bearing 2. Inspect the following fasteners: a. Steering cylinder pins b. Center section pins and nuts c.

Wheel mounting bolts

d. Engine, converter, and transmission mounting bolts e. Axle mounting bolts 3. Inspect the oscillating bearing 4. Inspect the fire suppression system 5. Inspect, and change as required, hydraulic oil filters 6. Check the axle oil level 7. Check the planetary wheel end oil level 8. Check the wet disc brake wear indicator 9. Perform all required permissibility checks 10. Perform carbon monoxide (CO) sampling 11. Drain the air regulator filters (2 filters) 12. Drain the air/water separator (demister) 13. Drain the air tank

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__________________________________________Maintenance Instructions Steering Cylinder Pins

Inspect the steering cylinder pins and nuts for looseness or wear (Fig. 17).

Tighten ( 1480 - 1500 ft. lbs.) where necessary and replace any worn parts.

Center Section Pins

Inspect the center section pins and nuts for looseness or wear (Fig. 17).

Tighten ( 680 - 720 ft. lbs.) where necessary and replace any worn parts.

Fig. 17: Steering cylinder pins and center section pins and nuts Steering cylinder pin (typical 4 places)

Wheel Mounting Nuts

Center section pin (typical 2 places)

Check the wheel mounting nuts (Fig. 18). The mounting nuts should be torqued to 217 ft-lbs lubricated. Use Loctite 242 on wheel mounting bolts.

Fig. 18: Wheel mounting nuts

Wheel mounting nuts (typical all four wheels)

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Maintenance Instructions __________________________________________ Mounting Bolts - Engine, Converter, Transmission, Carrier Bearing, and Flange Bearing

Check the engine, converter, and transmission mounting bolts on both front and rear drive assemblies (Fig. 19). The mounting bolts should be torqued to 280 - 320 ft-lbs lubricated. Use Loctite 242 on mounting bolts.

Mounting Bolts - Axle

Check the axle mounting bolts on both front and rear axles (Fig. 19). The mounting bolts should be torqued to 455 ft-lbs lubricated. Use Loctite 242 on mounting bolts.

Fig. 19: Mounting bolts (typical)

Engine mounting bolts

Converter mounting bolts

Axle mounting bolts

Transmission mounting bolts

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__________________________________________Maintenance Instructions Drive Line Lubrication

Lubricate the drive lines with Spec.100-3 through the grease fittings located on the bearings on the ends of each drive line (Fig. 20). Pump grease into the fittings until new grease can be observed coming out of the bearing.

Fig. 20: Drive line lubrication points (typical)

Converter drive line lubrication points Middle drive line lubrication points

Front drive line lubrication points

Mounting Bolts - Oscillating Bearing

Rear drive line lubrication points

Check the oscillating bearing mounting bolts (Fig. 21). The mounting bolts should be torqued to 1340 - 1360 ft-lbs lubricated. Use Loctite 242 on mounting bolts.

Fig. 21: Oscillating bearing mounting bolts

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Maintenance Instructions __________________________________________ Fire Suppression System

Check the fire suppression system (Fig. 22) 

Inspect the general appearance of system components for mechanical damage or corrosion.



Check nameplates for readability.



Remove fill cap and check that the extinguisher is filled with free flowing Ansul multi-purpose ABC dry chemical to a level not more than 3 inches (75 mm) from the bottom of the fill opening. Replace the fill cap and hand tighten



Remove expellant gas cartridge and examine disc - seal should not be ruptured. Return the cartridge to pneumatic actuator/cartridge receiver, hand tighten and secure in bracket.



Inspect the hoses, fittings, and nozzles and replace any found damaged.



Check the nozzle openings. The slot should be packed with silicone grease. If the nozzles are open or need to be repacked, the lines should be checked for blockage and blown clear before repacking them with clean silicone grease.



Remove cartridge from manual actuators and examine disc - seal should not be ruptured. Return the cartridge to manual actuator assembly and hand tighten.



Check the extinguisher tank for signs of damage or corrosion.



Replace any broken or missing lead and wire seals.

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__________________________________________Maintenance Instructions Fig. 22: Fire suppression system

Nozzle Nozzle Fires suppression tanks

Nozzle

Hose

Fire extinguisher

Actuator

Pressure switch

Nozzle

Nozzle

Nozzle (located inside fan venturi)

Nozzle

Nozzle

Actuator

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Maintenance Instructions __________________________________________ Pressure Filter, Bypassing

Open the access cover on the top of the machine and inspect the bypassing pressure filter dirt alarm (Fig. 23) located on the head of the filter. If the alarm indicates the filter element is dirty (red indicator is popped out), replace element.

Pressure Filter, Nonbypassing

Open the access cover on the top of the machine and inspect the nonbypassing pressure filter gauge (Fig. 23). The filter element should be changed at approximately 90 psi. Note: If hydraulic functions on the machine become sluggish, this element most likely needs changed.

Return Filter

Open the access cover on the top of the machine and inspect the return filter dirt alarm (Fig. 23) located on the head of the filter. If the alarm indicates the filter element is dirty (red indicator is popped out), replace element.

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__________________________________________Maintenance Instructions Fig. 23: Filter location Pressure (bypassing) filter

Return filter indicator

Return filter

Pressure (bypassing) filter indicator

Pressure (non bypassing) filter gauge

Pressure (non bypassing) filter

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Maintenance Instructions __________________________________________ Axle Oil Level

Check the axle oil level in both axles.

1. Park the machine on solid level ground, clean dirt and debris from around the check/fill plug and remove the plug.

2. The oil should just barely flow from the check/fill plug hole when full.

3. Should it be necessary to add oil, add oil (Hypoid gear oil, SAE 90) through the check/fill plug hole slowly, just until it starts to flow back out. Allow sufficient time for the oil to travel throughout the axle when filling.

Planetary Wheel End Oil Level

Check the planetary wheel end oil level on each wheel end (Fig. 24).

1. Park the machine on solid level ground.

2. Make sure the check/fill plug is in the proper position. Rotate the wheel end as required until the check/fill plug is at the 3 o’ clock or 9 o’ clock position.

3. Clean dirt and debris from around the check/fill plug and remove the plug.

4. The oil should just barely flow from the check/fill plug hole when full.

5. Should it be necessary to add oil, add oil (Hypoid gear oil, SAE 90) through the check/fill plug hole slowly, just until it starts to flow back out. Allow sufficient time for the oil to travel throughout the wheel end when filling.

Fig. 24: Planetary wheel end oil level

Drain plug location

Fill/check plug location

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__________________________________________Maintenance Instructions Brake Wear Indicator

Brake wear is checked with a wear indicator, protected by an acorn nut, located on the inboard face of each brake (Fig. 25). Remove the nut and depress the plunger protruding from the indicator wear face. If the plunger can be depressed past the indicator face, the brakes are worn and should be serviced.

Replace the acorn nut after checking wear.

Fig. 25: Brake wear indicator (typical)

Brake wear indicator

Permissibility Checks

Using the checklists located in the MSHA documentation section of this manual, check the permissibility of the power system and the machine/electrical system.

Carbon Monoxide (CO) sam- Perform carbon monoxide sampling following all applicable regulations. pling

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Maintenance Instructions __________________________________________ Air Regulator Filters (drain)

There are two air regulators with filters/water separators located on the machine (Fig. 26). Every week, the water should be drained. Note: Operating conditions may warrant a different drain interval. For example, if operating in a very humid environment, the water may need drained more frequently.

Fig. 26: Air regulator filter locations

Engine monitoring system compressed air regulator

Compressed air regulator

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__________________________________________Maintenance Instructions Air/water separator (demister)

The compressed air/water separator (demister) (Fig. 27) should be drained weekly.

Fig. 27: Air/water separator (demister)

Air/water separator (demister)

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Maintenance Instructions __________________________________________ Every three months The purpose of this section is to describe the maintenance procedures required to be performed every three months: 1. Change the axle oil 2. Change the planetary wheel end oil 3. Change the hydraulic oil and clean/change suction strainer

Axle Oil Change

Change oil in both axles.

1. Park the machine on solid level ground, clean dirt and debris from around the drain plug.

2. Remove drain plug and allow oil to completely drain from the axle.

3. Clean and reinstall drain plug.

4. Clean dirt and debris from around the check/fill plug and remove plug.

5. Add oil (Hypoid gear oil, SAE 90W) through the check/fill plug hole slowly, just until it starts to flow back out. Allow sufficient time for the oil to travel throughout the axle when filling.

6. Clean and reinstall check/fill plug.

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__________________________________________Maintenance Instructions Planetary Wheel End Oil Change

Change oil in each planetary wheel end (Fig. 28).

1. Park the machine on solid level ground, clean dirt and debris from around the drain plug and remove the plug.

2. Make sure the check/fill and drain plugs are in the proper position.

Rotate the wheel end as required until the check/fill plug is at the 3 o’ clock or 9 o’ clock position and the drain plug is located on the bottom.

3. Remove drain plug and allow oil to completely drain from the planetary wheel end.

4. Clean and reinstall drain plug.

5. Clean dirt and debris from around the check/fill plug and remove the plug.

6. Add oil (Hypoid gear oil, SAE 90W) through the check/fill plug hole slowly, just until it starts to flow back out. Allow sufficient time for the oil to travel throughout the planetary wheel end when filling.

7. Clean and reinstall check/fill plug.

Fig. 28: Planetary wheel end oil change

Drain plug location

Fill/check plug location

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Maintenance Instructions __________________________________________ Hydraulic Oil Change Suction Strainer Change

Change oil and clean or change the suction strainer in the hydraulic oil tank (Fig. 29).

1. Park the machine on solid level ground, clean dirt and debris from around the drain plug located on the back of the tank.

2. Remove drain plug and allow oil to completely drain from the tank.

3. Clean and reinstall drain plug.

4. Clean dirt and debris from around suction strainer access cover located on top of the tank.

5. Remove the bolts that secure the access cover.

6. Reaching down into the tank, unscrew the suction strainer and remove from tank.

7. If the strainer is not torn or damaged, it can be cleaned using kerosene and a soft brush and dried thoroughly. If strainer is damaged, it must be replaced.

8. Replace the strainer in the tank and hand tighten.

9. Replace the access cover.

10. Refill the tank with oil (Spec. 100-12).

11. Start the machine and allow the hydraulic pump to run in order to purge air from the system.

12. Shutdown the machine and recheck the oil level. Add oil if necessary.

Fig. 29: Hydraulic oil tank

Oil level sight glass Oil fill

Drain ports

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__________________________________________Maintenance Instructions Air Regulator Filters (change)

Change the filter in the two air regulators with filters/water separators located on the machine (Fig. 30). Note: Operating conditions may warrant a different change interval. For example, if operating in a very humid environment, the filter may need to be changed more frequently.

Fig. 30: Air regulator filter locations Engine monitoring system compressed air regulator

Compressed air regulator

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Maintenance Instructions __________________________________________ Air Compressor Intake Filter (change)

Change the air compressor intake filter (Fig. 31). Note: Operating conditions may warrant a different change interval.

Crankcase breather (change) Change the crankcase breather (Fig. 31).

Fig. 31: Air compressor intake filter and crankcase breather locations

Crankcase breather

Air compressor intake filter

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__________________________________________Maintenance Instructions Air/water separator (demister) (change)

Change the compressed air/water separator (demister) (Fig. 32) filter.

Fig. 32: Air/water separator (demister)

Air/water separator (demister)

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Maintenance Instructions __________________________________________ First 50 hours of service After the first fifty hours of service, the engine oil and filter need to be changed.

Engine Oil and Filter Change To change the engine oil (Fig. 33): 1. Park the machine on level ground and chock all four tires in each direction.

2. Place an oil tray beneath the engine.

3. Unscrew the drain plug and drain the oil.

4. Fit oil drain plug with new gasket and tighten firmly.

5. Fill with oil and then check the oil level.

To change the engine oil filter (Fig. 33): 1. If fitted with torsion lock, loosen screws and slide clamps downwards.

2. Undo the filter cartridge with commercial tool and spin off.

3. Catch any dripping oil.

4. Clean any dirt from the filter carrier rim.

5. Lightly oil the rubber gasket of the new oil filter cartridge.

6. Screw in the new cartridge finger tight against the gasket.

7. Check that the cartridge is correctly seated against the gasket and tighten with a final half-turn.

8. If fitted with torsion lock, slide clamps up into position and tighten screws.

9. Check the oil level and oil pressure.

10. Check the cartridge seal.

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__________________________________________Maintenance Instructions Fig. 33: Engine oil filter and oil drain plug

Oil drain plug

Remote oil filter

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Maintenance Instructions __________________________________________ Every 100 hours of service The purpose of this section is to describe the maintenance that must be performed every 100 hours of service: 1. Clean the radiator 2. Change the engine oil and filter 3. Change the fuel pre-filter 4. Change both final fuel filters

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__________________________________________Maintenance Instructions Radiator Cleaning

To clean the radiators (Fig. 34): 1. Place a cleaning bath under the radiators.

2. Remove the service plate.

3. Blow out the heat exchanger with compressed air from the front and then from the back. Be careful not to damage the cooling fins.

4. Wash out loosened dirt with a hose.

5. Spray the heat exchanger with a commercial cold cleaning agent and let stand for about 10 minutes.

6. First spray clean with a water jet from the front and then from the back. Do not directly spray sensitive engine components (generator, cables, electronic components, fan drive, etc.) with a water jet .

7. Remove oil and grease residues with a steam or hot water jet set at a gentle setting.

8. Refit the service plate and run the engine up to normal operating temperature to evaporate any remaining water.

Fig. 34: Radiators

Radiators

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Maintenance Instructions __________________________________________ Engine Oil and Filter Change To change the engine oil (Fig. 35): 1. Park the machine on level ground and chock all four tires in each direction.

2. Place an oil tray beneath the engine.

3. Unscrew the drain plug and drain the oil.

4. Fit oil drain plug with new gasket and tighten firmly.

5. Fill with oil and then check the oil level.

To change the engine oil filter: 1. If fitted with torsion lock, loosen screws and slide clamps downwards.

2. Undo the filter cartridge with commercial tool and spin off.

3. Catch any dripping oil.

4. Clean any dirt from the filter carrier rim.

5. Lightly oil the rubber gasket of the new oil filter cartridge.

6. Screw in the new cartridge finger tight against the gasket.

7. Check that the cartridge is correctly seated against the gasket and tighten with a final half-turn.

8. If fitted with torsion lock, slide clamps up into position and tighten screws.

9. Check the oil level and oil pressure.

10. Check the cartridge seal.

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__________________________________________Maintenance Instructions Fig. 35: Engine oil filter and oil drain plug

Oil drain plug

Remote oil filter

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Maintenance Instructions __________________________________________ Fuel Pre-Filter Change

To change the fuel pre-filter (Fig. 36): 1. Close fuel stopcock and place the fuel pan beneath the fuel pre-filter.

2. Remove drain plug and drain off fuel.

3. Unscrew clamping screw and remove filter housing with filter insert.

4. Clean sealing surface of the filter bracket and filter insert housing of any dirt.

5. Insert new sealing ring and filter insert. Push the filter insert up to approximately 3 cm over the edge of the housing onto the guide in the filter housing. Press filter housing with filter insert and sealing ring against the filter console and screw into place with clamping screw. It must be possible to push the upper seal on filter insert over the guide bracket on filter console.

6. Tighten drain plug and open fuel stopcock.

7. Check for leaks after the engine has been started.

To change the final fuel filters (2) (Fig. 36):

Fuel Filter Change

1. Close the fuel stopcock.

2. Undo the fuel filter cartridge with commercial tool and spin off.

3. Catch any fuel.

4. Clean any dirt from the filter carrier rim.

5. Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge.

6. Screw in the new cartridge finger tight against the gasket.

7. Check that the cartridge is sealed correctly against the gasket and tighten with a final half-turn.

8. Open the fuel stopcock.

9. Check for leaks. .

10. Repeat Steps 1 through 9 for second filter.

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__________________________________________Maintenance Instructions Fig. 36: Fuel filter locations

Fuel pre-filter

Final fuel filter (2)

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Maintenance Instructions __________________________________________ Every 500 hours of service The purpose of this section is to describe the maintenance that must be performed every 500 hours of service: 1. Clean the converter/transmission filter 2. Change the radiator coolant 3. Inspect the scrubber heat exchanger

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__________________________________________Maintenance Instructions Transmission Filter Change To change the transmission filter (Fig. 37): 1. Loosen the filter cartridge with commercial tool and spin off.

2. Clean any dirt from the filter carrier rim.

3. Lightly oil the rubber gasket of the new oil filter cartridge.

4. Screw in the new cartridge finger tight against the gasket.

5. Check that the cartridge is correctly seated against the gasket and tighten with a final half-turn.

6. Check the transmission oil level and oil pressure. Check the cartridge seal.

Fig. 37: Transmission filter

Transmission filter

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Maintenance Instructions __________________________________________ Radiator Coolant Change

To change the coolant in both radiators (Fig. 38): 1. Drain the coolant. a. Place a container under the drain plug. b. Unscrew the service cap and then unscrew the drain plug (accessed through a cut out on the bottom of the frame) on the bottom of the radiator. c.

Drain the coolant. In case of clogging, rinse the radiator through with clean water.

d. Tighten drain plug.

2. Fill the radiator. a. Open the service cap on top of the radiator. b. Slowly add coolant until the sight glass on the side of the radiator is completely filled.. c.

Close the cap.

d. Start the engine and warm up until the thermostat opens- the upper coolant line warms up tangibly. e. Briefly run the engine at nominal output (fixed setting) to clear any air pockets. f.

Turn off the engine and let cool.

g. Open service cap and add coolant until the sight glass on the side of the radiator is completely filled. h. Run the engine, let cool, and check the coolant level in the radiator.

Add coolant as necessary.

3. Repeat steps 1 and 2 for the second radiator.

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__________________________________________Maintenance Instructions Fig. 38: Radiator coolant change

Fill port

Scrubber Heat Exchanger Inspection

Sight glass

Sight glass

Fill port

The inlet and outlet ports of the scrubber heat exchanger should be visually examined to insure that there is no coolant in the exhaust outlet (indicating a leaking tube bundle or cracked housing) and that the cooling fins do not contain any appreciable accumulation of soot (identified by a pressure drop of greater than 8 inches across the exchanger).

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Maintenance Instructions __________________________________________ Every 1000 hours of service The purpose of this section is to describe the maintenance that must be performed every 1000 hours of service: clean the scrubber heat exchanger Scrubber Heat Exchanger Cleaning

To clean the scrubber heat exchanger: 1. Install manufactured port plugs in the exhaust inlet and outlet. The plugs should include a ¾”NPT port.

2. Attach a ball valve to the exhaust outlet plug.

3. Pour two to three ounces of dishwashing soap into the exhaust inlet plug.

4. Fit a water hose connection on the exhaust inlet plug.

5. Open the vent plug on the back of the heat exchanger.

6. With the ball valve oriented in the off position, allow the tank to fill up until water begins to flow from the vent plug.

7. Reinstall the vent plug.

8. Turn on the water hose.

9. Crack the ball valve to allow pressurized water to escape. Allow this to occur for several minutes, then open the ball valve fully until the soap is suspected to have been removed.

10. Visually inspect the cooling fins.

11. Reconnect the exhaust pipes.

If this process does not reduce the back pressure, the tube bundle must be removed from the exchanger and pressure washed.

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__________________________________________Maintenance Instructions Every six months The purpose of this section is to describe the maintenance that must be performed every six months: permissibility checks.

Permissibility Checks

Using the checklists located in the MSHA documentation section of this manual, check the permissibility of the power system and the machine/electrical permissibility as indicated.

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Lubricant Specifications___________________________________________ Introduction

The following lubricants specifications are referenced throughout this manual.

Any lubricant used must meet these standards listed. For your convenience, a list of manufacturers and lubricants that have been identified as meeting these standards is given for each specification.

Failure to use lubricants that meet the standard listed may reduce component life and may void any associated warranty.

Spec. 100-3: Extreme pressure motor bearing grease and hand grease specification Limit NLG1 Grade Number 2

Type 2

Worker Penetration (ASTM D-217)

265-295

280

Dropping Point (ASTM D-566) Bomb Oxidation (ASTM D-942)

Min. 350° F (177° C) Not more than 10 PSI DROP

373° F 2.5

Rust Inhibitors

Required

Yes

Wheel Bearing Test (ASTM D-1263) (6 Hours @ 235° F )

Not more than 5% loss

Water Washout (ASTM D-1264)

Loss not more than 5% @ 100° F Loss not more than 15% @ 175° F

Grease Mobility

Not less than 0.1 gram flow per Second @ 0° F

Timken OK Load (ASTM D-2509)

Not less than 50 lbs.

(50 lbs.)

Four Ball EP Test (ASTM D-2569)

Load wear index not less than 30.0 Weld point not less than 200 kg. Min.

31 200

4.25 4.00

Four Ball Wear Test (ASTM D-2266) Not more than 0.60 mm. SCAR diameter 0.44 (20KG., 1800 RPM, 130° F, One Hour)

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___________________________________________Lubricant Specifications Spec. 100-3: Extreme pressure motor bearing and hand grease approved suppliers 1

Supplier Amoco Oil Company

2 3 4 5 6 7 8

Gulf Oil Mobil Oil Corporation Chevron U.S.A. Sun Oil Company Unocal 76 Shell Oil Company Century - Fuchs

9 10 11 12 13

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers Conoco Inc.

14

Hydrotex

Brand name Amolith Grease 2 EP Rykon Premium Grease 2 EP Gulfcrown Grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease, or Replex 2, or Uniwrl 2, or Uniwrl EMB, or Hullith GP 2, or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith Grease No. 2, or Super Sta Grease No. 2 LC-65 Hyplex

15 16

Phillips Atlantic Richfield Company

Philube EP Grease Litholine H EP-2 Grease

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Lubricant Specifications___________________________________________ Spec. 100-12: Universal multi-purpose tractor hydraulic fluid specification Values Viscosity, ASTM Pour Point (ASTM D-97)

-36°C (-33°F)

Flash Point (ASTM D-92)

198 - 220 °C (389 - 428 °F)

Viscosity SUS @ 100° F 283-347

352

SUS @ 210° F 50-58

56

CST @ 40° C

55 - 65

CST @ 100° C

9.3 - 10.3

Viscosity Index (ASTM D-2270)

142 - 149

Fluids must meet or exceed and/or be recommended for service by one or more of the following industry or manufacturer specifications: 1. API GL-4 2. Caterpillar TO-2 3. John Deere JDM J20C 4. Denison HF-0, HF-1, HF-2 (T5D & P46 pumps only) 5. Vickers 35VQ25 6. Ford New Holland FNHA-2-C-201.00 7. Kubota UDT 8. Volvo WV 101/BM 9. AGCO (Deutz-Allis) Power Fluid 821XL 10. ZF TE-ML-03E

Spec. 100-12: Universal multi-purpose tractor hydraulic fluid approved suppliers 1 2 3 4 5 6 7

Supplier Exxon/Mobil Century/Fuchs Shell Chevron BP Lubricants Quaker State Conoco

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid Tractran UTH Quaker State FCI HD Powertran Fluid

Even though each of these fluids meet the same performance requirements, it is not recommended to mix products from various suppliers.

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