1000 Hours Service

Fuel fi lter

Water separating fuel fi lter 1000 Hours Service Maintenance to be performed every 1000 hours of operation.

1. Driver's seat

1.1. General safety check • Check for play in seat gliders. Max. allowed in length or sideways 1 mm. Grease the gliders. • Check shock absorbers for oil leakages. • Check seat mounting to the dump truck. • Check safety belt and lock mechanism for wear and damage. • Check that no pins are loose / worn in the seat base. • Replace worn/damaged parts.

2. Engine

2.1 Replace fuel fi lter 4* Replace water separating fuel fi lter 4*

The fi lters consist of one fi lter unit each.

The fi lters are located on the left hand side of the engine.

The fuel fi lter in the front of the engine and the water separating fuel fi lter on the rear of the engine, see illustration. 1. Wash the fi lters externally and unscrew it. Discard the fi lters according to environmental requirements. 2. Fit the new genuine fi lters and tighten it by hand. • Never use tools to tighten the fi lters! The fi lters may be damaged and the fuel fl ow hampered. 3. Bleed the fuel system, procedure on next page, item

2.2.

4. Start engine and check for leaks.

CAUTION

Observe extreme cleanliness when working with the fuel system. Otherwise may operational interruption easily occur and the injection equipment may be damaged.

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2 1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.2 Bleed the fuel system: 1. Attach a clear plastic hose to the bleeder nipple (1) to channel fuel into a container. The bleeder nipple is located at the end of the fuel manifold at the front of the engine. 2. Open the bleeder nipple (1). 3. Pump with the hand pump (2) until bubble-free fuel fl ows out of the opened bleeder nipple. • If the system is completely empty, it will take approx. 250 strokes. • After changing the fuel fi lters, it will take approx. 170 strokes. • Approx. 150 strokes are required to bleed the fuel manifold. 4. Close the bleeder nipple and remove the hose. 5. Undo the banjo screw for overfl ow valve (3) slightly. Pump the hand pump (2) additional 20 strokes until the overfl ow valve opens.

If the engine fails to start after bleeding: • Open the bleeder nipple again and pump the hand pump until bubble-free fuel fl ows out. • Tighten the bleeder nipple. Star t the engine and check for leaks.

WARNING

The engine may be hot! Use gloves when pumping with the hand pump to avoid burning your hands.

2.3. Check batteries, at least once a year 11* • Checking battery charge shall also be carried out after the first 8 hours of operation.

Use a hydrometer to check the density of the electrolyte.

The density of a fully charged battery should be: 1.240 at higher than +20 oC 1.280 at +20 oC, 1.294 at 0 oC, 1.308 at -20 oC.

Recharge the battery if the density is lower than 1.20.

A discharged battery freezes at -5 oC.

WARNING

The electrolyte level must be correct when charging! During recharge a explosive gas is emitted. Open cell plugs and ventilate properly to avoid explosion!

Small superfi cial cracks in the belt can be accepted

Fig. 1 At large and deep cracks or if small pieces are missing, the belt should be replaced. Fig. 2 The multi-groove belt shows signs of wear. Can be refi tted.

Fig. 3 The wear is down to the chord. The multi-groove belt must be replaced.

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.4. Check multi-groove belt condition, at least once a year • Checking of multi-groove belt condition shall also be carried out after the fi rst 8 and 100 hours of opera-

tion.

• Stop the engine to inspect the multi-groove belt (1), see item 2.4.1 for procedure. • Change the belt (1) if damaged or worn, see fi gures 1-3 below. • Check that the automatic belt tensioner (2) is in proper working order and keeps the multi-groove belt suffi ciently tightened.

2.4.1 Inspect the multi-groove belt. • Loosen the multi-groove belt from the belt pulleys but leave it around the fan shaft so that the direction of rotation for the multi-groove belt is not changed. • Check the multi-groove belt carefully. If the multi-groove belt has one or more cracks, as shown in fi g. 1, it should be replaced. • Also check the wear on the multi-groove belt as shown in fi g. 2 and 3.

NOTE

Do not change the direction of rotation of the multi-groove belt if it is refi tted.

Fig. 1

Dust cap

Fig. 2

Fig. 3 1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.5. Air fi lter 10*

The air fi lter is located on the top of the engine, under the bonnet. • Always stop the engine before servicing the air fi lter. • Open the bonnet and apply the bonnet catcher. • Cleaning and replacement of outer and inner element, see this page and next page.

Outer element:

Clean element every 1000 hours of operation or if the air fi lter warning light illuminates at full load on the engine. • Replace the outer element after 5 times of cleaning, or at the latest after 2 years. 1. Loosen all clamps and remove the cover (fi g. 1). 2. Remove outer element with a light turning movement (fi g. 2). Do not remove inner element when cleaning outer element! 3. To blow out the fi lter element, use tube with a bent end which is attached to a compressed air gun; the end of the tube must be bent by approx. 90°. It must be of suffi cient length to reach down to the bottom of the filter element. Blow out the fi lter element using dry compressed air (max. 5 bar) by moving the tube up and down inside the fi lter element until there is no more dust coming out (fi g. 3).

• Never wash out or brush out the outer element.

When blowing out make sure that no dust is allowed to enter the inside area of the outer element. 4. Punch a mark in the edge of the inner element each time the outer element is cleaned. 5. Check the cleaned element for damage of the paper element and of the rubber seals. • Cracks and holes in the paper element can be discovered by shining through light from an electric bulb (fi g. 4). 6. Never carry on using a damaged outer element. In case of doubt, always fi t a new outer element. 7. Reinstall the outer element, the cover, and fasten all the clamps. Turn the cover so that the dust cap is pointed downwards (max angle: 15°).

See also precautions on next page

Fig. 4

Fig. 5 1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Servicing the dust cap

The dust cap require very little maintenance.

Possible dust packs to be removed by squeezing the cap (fi g. 5).

Fig. 6

Fig. 7 Inner element: • Replace element every 5th cleaning of the outer element, or after 2 years. • Do not clean the inner element and do not reuse it after it has been taken out.

Only open the seal in order to replace the inner element.

1. Loosen all clamps and remove the cover. 2. Remove outer element. 3. Remove the inner element; Use a suitable tool (e.g. screwdriver) to push through the seal of the inner element from the inside to the outside and pull both the straps upwards (fi g. 6). 4. Use both straps to take hold of the inner element and then pull out with a light turning movement (fi g. 7).

5. Install a new inner element into the housing. 6. Install a new or cleaned outer element. 7. Reinstall the cover, and fasten all the clamps. Turn the cover so that the dust cap is pointed down wards (max angle: 15°).

CAUTION

• Do not attempt to reinstall a cleaned inner element. • Do not clean or replace the elements when the engine is running. • Replace the outer element if small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning. • Do not use an element in which folds, gasket or seal are damaged. • When cleaning the element, do not hit or hammer it. • Do not dismantle the inner element unnecessarily. • Punch a mark in the edge of the inner element each time the outer element is cleaned.

Cap Drain nipple

Rear cover 1000 Hours Service Maintenance to be performed every 1000 hours of operation.

3. Transmission

3.1. Change oil 20* Replace fi lter element 21* Clean strainer 22*, at least once a year • Changing transmission oil, replacement of transmission filter and cleaning of the strainer shall also be carried out after the fi rst 100 hours of operation.

Drain oil: 1. The dump truck must be standing on level ground. 2. The oil must be at operating temperature. 3. Unscrew the dip stick (located behind the cab). 4. Remove cover plate under the transmission, by removing the 4 M12 bolts. 5. Remove cap. 6. Place drain hose with connection on drain nipple. 7. Once transmission oil is emptied remove hose and replace cap.

CAUTION

Use gloves when checking the oil level or fi lling oil. The exhaust pipes and nearby area may be hot and fi ngers and hands could be burnt.

Replace fi lter elements (located on the left hand side): Access to the fi lters through the engine bottom guard 8. Remove the engine bottom guard (front cover)

9. Clean well around the fi lters. 10. Place a suitable container beneath the fi lters to catch spillage. 11. Unscrew the fi lter elements. 12. Check for wear particles in the oil. 13. Apply oil to the seals on the new elements. 14. Screw the fi lter elements in until contact with the sealing surface is obtained. Tighten the elements fi rmly by hand.

continued overleaf

Access to remove the strainer

Rear cover

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1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Clean strainer: 15. The strainer is located on the left hand side of the drain plug. 16. Unscrew the three nuts (1) and washers (2). 17. Remove the cover (3). 18. Replace the O-ring on the cover, if necessary.

19. Remove the strainer (4) and clean it. 20. Reassemble and torque nuts to 23 Nm. 21. Remount the all bottom guards and covers.

Fill new oil: 22. Fill new oil, according to the transmission oil list and oil specifi cation sheet (chapter 6), through the dip stick tube. 23. Insert the dip stick again and turn handle clockwise to tighten the sealing.

Check: 24. Start the engine and check oil level (see daily maintenance, for procedure) at low idle. Both too low and too high level can cause serious internal damage! 25. Warm up the oil and check for leaks. Re-check level and adjust if necessary.

NOTE

• Do not overfi ll! Both too high and too low level can cause serious internal damage! • For rough operation conditions the oil and the filter element must be changed more often (every 500 hours) and the strainer must be cleaned as well.

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

4. Hydraulic system

4.1. Replace breather element 42* • Accumulators contain oil under high pressure! Empty the accumulators, before unscrewing the element. Procedure is described in chapter 2, item 27. • Unscrew the old element on the hydraulic tank (under the cover). • Check the o-ring for deterioration, apply oil and screw on a new element.

CAUTION

Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Fill 4 litres hydraulic oil through the oil fi ller. 4.2. Replace hydraulic return fi lter element 43*. • Replacement of hydraulic return fi lter element shall also be carried out after the fi rst 100 hours of operation. 1. Accumulators contain oil under high pressure! Empty the accumulators, before unscrewing the fi lter. Procedure is described in chapter 2, item 27. 2. The fi lter is located on the back of the hydraulic tank. Remove the cover to get into the fi lter. 3. Clean well around the fi lter housing. 4. Place a suitable container beneath the draining hose to catch spillage. 5. Use a fi lter key to unscrew the old fi lter (counterclockwise). Remove also the old O-ring. The old fi lter contains 4 litres oil. Discard the fi lter element, and oil according to environmental requirements. 6. Check for wear particles in the oil. 7. Clean the O-ring groove, apply oil to the new O-ring and install it. 8. Apply oil or grease to the threads and install a new fi lter element by turning it clockwise until seals make contact. Then tighten by hand 1/4 to 1/3 turn more. 9. Fill 4 litres hydraulic oil, as specifi ed in chapter 6, lubricants, through the oil fi ller on the top of the fi lter unit (under the cover on the top of the hydraulic tank). 10. Screw the oil plug back into place and clean off any oil spill. 11. Start engine and check for leaks. The accumulators will be recharged with oil when the engine is re-started.

CAUTION

Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.2. Replace hydraulic high pressure fi lter element 43a*. • R ep l a c e m e n t o f hy d r a u l i c h i g h p r e s s u r e f i l t e r element shall also be carried out the fi rst 100 hours of operation. 1. Accumulators contain oil under high pressure! Empty the accumulators, before unscrewing the fi lter. Procedure is described in chapter 2, item 27. 2. The fi lter is located on the inside of the main frame and the engine. 3. Clean well around the fi lter housing. 4. Place a suitable container beneath the draining hose to catch spillage. 5. Use a fi lter key to unscrew the old fi lter (counterclockwise). Remove also the old O-ring. 6. Check for wear particles in the oil. 7. Clean the O-ring groove, apply oil to the new O-ring and install it. 8. Apply oil or grease to the threads and install a new fi lter element by turning it clockwise until seals make contact. Then tighten by hand 1/4 to 1/3 turn more. 9. Screw the oil plug back into place and clean off any oil spill. 10. Start engine and check for leaks. The accumulators will be recharged with oil when the engine is re-started.

CAUTION

Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

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1000 Hours Service Maintenance to be performed every 1000 hours of operation.

5. Front differential

5.1 Change oil, at least once a year 30* • Change front diff. oil shall also be carried out after the fi rst 500 hours of operation. 1. Access to the drain plug through transmission bottom guard. 2. Open level / fi lling plug (1), special spanner in tool kit. 3. Unscrew drain plug (2). 4. Drain the oil into a suitable container. 5. Clean the drain plug, replace seal if necessary and reinstall. • Tightening torque: 80 Nm. 6. Fill new oil, according to the oil specifi cation sheet (chapter 6), through the level / fi lling plug, level shall be at lower edge of hole when dump truck is horizon- tal. 7. Clean the plug, replace seal if necessary and rein stall. • Tightening torque: 80 Nm.

CAUTION

Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug.

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

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6. Rear differential

6.1. Change oil, at least once a year 31* • Change rear diff. oil shall also be carried out after the fi rst 500 hours of operation. 1. Open level/fi lling plug (1). 2. Unscrew drain plug (2) underneath the housing. 3. Drain the oil into a suitable container. 4. Clean the drain plug, replace seal if necessary and reinstall. • Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specifi cation sheet (chapter 6), through the level/fi lling plug, level shall be at lower edge of hole when dump truck is horizontal. 6. Clean the plug, replace seal if necessary and reinstall. • Tightening torque: 80 Nm.

CAUTION

Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug.

Inspection cover 7. Pinion bearing

7.1. Inspect the pinion bearing, on both sides of the tandem housings 1. Remove the inspection cover. 2. Check the general condition of the pinion bearing. Check for wear, cracks, deterioration, damages . • Replace the bearing if necessary. 3. Reinstall the inspection cover.

NOTE

For rough operating conditions, the pinion bearing should be checked more often.

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

8. Front reduction gears

8.1. Change oil, at least once a year 33* • Change front reduct. gear oil shall also be carried out after the fi rst 500 hours of operation. 1. The dump truck must be horizontal. 2. Turn the hub, so that the plug is pointed downwards. 3. Unscrew the plug (1). 4. Drain the oil into a suitable container. 5. Turn the hub 90o, so that the level indicator is horizontal (2). 6. Fill new oil, according to the oil specifi cation sheet (chapter 6), through level/fi lling plug, level shall be at lower edge of hole when dump truck is horizontal. 7. Clean plug, replace seal if necessary and reinstall. • Tightening torque: 80 Nm. 8. Re-check oil level after test driving.

CAUTION

Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug.

9. Electrical system

9.1. Check wiring

The wiring harness must not be damaged. Check that the cables on the articulation hinge and on the rear frame/ body are not squeezed, have sharp bends or loose/bad connections.

10. Continue with all items in 500 Hours Service.