Periodic service

DELIVERY Hrs: ________ Date: ______________ Stamp / Sign.: Fill in the boxes according to the maintenance performed on the dump truck serial no.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

SERVICE Hrs: ________ Date: ______________ Stamp / Sign.: SERVICE Hrs: ________ Date: ______________ Stamp / Sign.:

Index

Index

Symbols

1000 Hours Service 178 2000 Hours Service 191 4000 Hours Service 198 40 Hours Service 159 500 Hours Service 162 8 Hours Service 149

Accumulators 32, 157 AEB-Tester 146 Air conditioner system 159, 160, 161, 174, 176, 177 Air conditioning system hazard prevention 20 Air fi lter 181 Air fi lter warning light 51 Articulation lock 31 Ashtray 78 Automatic central lubrication 160, 161, 176, 177 Automatic central lubrication indicator 53, 55 Automatic Transmission Fluid (ATF) 132

Batteries 168, 179 Battery charge warning light 51 Battery hazard prevention 19 Battery power assistance 114 Bearings 202 Before operation 95 Bleed fuel system 179 Body support 29 Brake lines 196 Brake pedal 67 Brakes 22, 100 Brake system 156, 171, 196 Brake system warning light 50 Braking/stopping the dump truck 102 Breather element 185 Bulbs 208

Cab and engine compartment light 58 Cab certifi cation 33 Cab light 78 Cab ventilation 71, 159, 174 Central lubrication 160, 161, 176, 177 Centrifugal cleaner 163 Change coolant 198 Change oil, engine 162 Change oil, front differential 188 Change oil, front reduction gears 190 Change oil, hydraulic system 199 Change oil, rear differential 189 Change oil, tandem housings 148, 196, 200 Change oil, transmission 142, 183 Check/adjust valve clearance 191, 192 Check batteries 168, 179 Check battery terminals 168 Check braking (holding) capacity 156 Check cab ventilation fi lter element 175 Check clearance of bearings 202 Check coolant level 151 Check driver's seat 149 Check fuel injectors 146 Check fuel level 152 Check function, engine and retarder brake 158 Check function, engine brake 158 Check function, main brake 157 Check function, steering 158 Check glycol content in the coolant 194 Check lining thickness 171 Check multi-groove belt 180 Check of the centrifugal cleaner 152 Check oil level, drive line 146, 169 Check oil level, engine 151 Check oil level, front differential 169 Check oil level, front reduction gears 170 Check oil level, hydraulic system 154 Check oil level, rear differential 169 Check oil level, tandem housings 170 Check oil level, transmission 153 Check protection against corrosion in the coolant 195 Checks after stopping the engine 108 Check the appearance of the coolant 193 Check the coolant 193 Check tyre pressures 160 Check wheel nuts torque 173 Check wiring 190 Cigarette lighter 69 Clean centrifugal cleaner 163 Clean prefi lter, cab ventilation 159 Clean strainer 142, 183 Clothing and personal protection items 12 Cold weather 112 Column switch 64 Consumeable parts 216 Controls 63 Coolant 193, 198 Cooling system 197 Correct tyre pressures 110

D

Daily Service 149 Dangerous loads 24 Difference in tyre diameter 110 Differentials 104 Direction light indicator 53 Do not go close to high-voltage cables 18 Drive line 169, 201 Driver's seat 75, 178 Dump truck knowledge 11 Dump truck transportation 32

E

Electrically heated driver's seat switch 60 Electrical system 190, 208 Emergency braking 102 Emergency exit 15, 70 Emergency retarder 23 Emergency steering 22

Emergency steering warning light 50 Engine 146, 150, 162, 178, 191, 206 Engine, general condition check 150 Engine and retarder brake 158 Engine and retarder brake capacity chart 213 Engine and retarder brake mode 97 Engine and retarder brake operation 101 Engine bonnet 27 Engine brake 100, 158 Engine brake indicator 53 Engine controller switch for code reading 60 Engine coolant level warning light 52 Engine coolant temperature warning light 51 Engine oil pressure warning light 51 Engine overspeed 23 Engine revolution counter and hour meter 45 Exhaust heating 24 Exhaust system 202 Expansion tank coolant level 21 External cleaning of the radiator 167 External door opener/lock 76

F

Filling capacities 126, 130 Filling fuel or oil 21 Fire extinguisher 14 Fire prevention 16 Fire prevention for fuel and oil 13 First 100 hours 84 First 500 hours 85 First 8 hours 84 First aid kit 14 FOPS 15 Foreword 5 Forward drive position 96 Front differential 188 Front reduction gears 190 Fuel fi lter 150, 178 Fuel gauge 45 Fuel injectors 146 Fuses 208

G

Gear display 46 Gear position N 96 Gear position V 96 Gear selector 68 Gear shifting 96 Gear shift program 96 General condition check, drive line 201 General condition check, engine 150 General condition check, tanks 201 General condition check, transmission 201 General description 7 General precautions 11 General safety check, driver's seat 178 Getting on and off the dump truck 12

H

Hazard light switch 59 High-voltage cables 18 High beam indicator 53 High pressure 32 High temperatures 13 Hoisting 31 How to adjust the parking brake 172 Hydraulic fi lter warning light 52 Hydraulic return fi lter element 144, 145, 186, 187 Hydraulic system 154, 185, 199, 202, 207

I

Important operating instructions 106 Indicator lights 49 Inspect brake lines 196 Inspect the hydraulic hoses 202 Instructor seat 76 Instruments 44 Intended use 7 Inter-axle differential lock 61 Inter-axle differential lock indicator 53 Inter axle differential 104 Internal cleaning, cooling system 197 Internal door opener 76 Introduction 7

L

Labels 33 Lifting 31 Loading 108 Lock-up indicator 52 Long term storage 113 Lubricants 121 Lubrication 155 Lubrication, cab rear hinges 156 Lubrication, door and fender hatches 155

M

Machine turning 21 Main light switch 58 Maintenance 135 Maintenance precautions 137 Maintenance table 139, 140, 141 Main warning light, engine failure 51 Main warning light, transmission failure 52 Manual gear shifting 97 Manual release of parking brake 115, 116 Manual release of the tip valve 116 Measurements 205 Metering conversion table 209 Mirror heating switch 60

N

Neutral gear position 96 Normal operation 99

O

Oil specifi cation sheet 125, 129 Operating Controls 41 Operating hints 98 Operating Instructions 87 Operating the dump truck 95 Operation of brakes 22 Operator's cab 17

Parking brake 100, 156, 172 Parking brake indicator 50 Parking brake switch 61 Parking the dump truck 107 Performance chart 210 Periodic service 219 Pinion bearing 189 Precautions before starting the engine 16 Precautions for mirrors, windows and lights 18 Precautions for optional accessories 14 Precautions on worksites 88, 89 Precautions when handling at high temperatures 13 Preselection of gears 97 Product signs 217 Proper maintenance 111 Protection against falling objects 15

Radiator 167 Radio/Cassette player 79 Rear differential 189 Reference information 216 Refrigerant 20 Relays 208 Replace breather element 185 Replace fuel fi lter 150, 178 Replace hydraulic return fi lter element 144, 145, 186, 187 Replace transmission fi lter element 142, 183 Replace turbo fi lter 166 Retarder brake 100, 158 Retarder brake capacity chart 213 Retarder brake indicator 53 Retarder brake mode 97 Retarder brake switch 59 Retractable roller sunblind on front window 78 Reversing (back-up) operations 99 Roll-over protection 15 ROPS 15 Rotating beacon switch 58 Rules to follow when fi lling fuel or oil 21 Running-in operation 83 Running-in period 81 Running-in services 84 Run the AEB-Tester 146

Safety at the worksite 16 Safety check, exhaust system 202 Safety equipment 77 Safety information 6 Safety Instructions 9 Safety labels 33 Safety rules 11 Seat belt on driver's seat warning light 52 Service brake 100, 156 Service position 30 Side window 77 Specifi ed loading 111 Speedometer 48 Starter switch 69 Starting in cold weather 94 Starting the engine 93 Steering 103, 158 Steering column 66 Stopping the engine 107 Switches 57

T

Tandem housings 148, 196, 200 Tanks 201 Technical Data 203 Test switch for brake warning light 59 Throttle pedal 67 Tiltable cab 27 Tip- and steering cylinders 173 Tip control lever 69 Tipping 109 Tool kit content 209 Top tailgate 26 Torque limits for bolts 216 Towing the dump truck 115 Transit, long distance drive-away on road 111 Transmission 142, 144, 153, 183, 201, 206 Transmission oil list 132 Transmission oil temperature gauge 48 Transportation 32 Travelling on slopes 22 Troubleshooting 117 Troubleshooting for Lincoln lubrication system 54 Turbo fi lter 166 Tyre handling 110 Tyre pressures 110, 207 Tyres 160

U

Unauthorised modifi cation 12 Up, down and crossgradient travel 105

V

Valve clearance 191, 192 Ventilation for enclosed areas 17

W

Wading 23 Walk around check 149 Warming up period 96 Warning / indicator lights 49 Warning light, engine failure, co-ordinator 51 Warning triangle 14 Weekly Service 159 Welding 25 Wheel chocks 30 Wheels 173 When starting the engine 18 Worker protection rules, refrigerant 20 Working and back-up lights 58 Working lights and extra high beam 58

Yearly recommended maintenance 201