8 minute read
1000 Hours Service
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 2 fuel filters 4*
The filter consist of two parallel-coupled filter units. 1.Wash the filters externally and unscrew them, wrench in toolkit. Dispose of filters according to environmental requirements. 2.Tighten the new filters by hand. •Never use tools to tighten the filters! The filters may be damaged and the fuel flow 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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2.2 Bleed fuel system:
1.Open the bleeder screw (1) on the main filter. 2.Pump with the hand pump (2) until bubble-free fuel flows out at the main bleeder screw.
3.Close the bleeder screw. Pump a few times using the hand pump. If the engine is difficult to start after bleeding: •Slacken the injection pump overflow valve (3) one half turn and try starting again. If the engine still does not start: •Pump the hand pump until bubble-free fuel flows from the overflow valve.
•Tighten the overflow valve when the engine has started.
WARNING
The engine may be hot! Use gloves when pumping with the hand pump to avoid burning your hands.
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2.3.Check batteries 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, due to tropical version 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. See also chapter 2, safety instructions.
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!
2.4.Air filter 10*
Outer element:
Clean element every 1000th hour of operation or if the air filter warning light illuminates at full load on the engine. Replace it after 6 times of cleaning, or at least once a year. 1.Loosen v-clamp and retainer, remove outer element.
Do not remove inner element when cleaning outer element! 2.Clean retainer and inside of filter housing. 3.Direct dry compressed air (less than 7 bar) to the element from inside along its folds, then direct it from the outside along its folds, and then from inside again. 4.Check that the element is clean and undamaged, and reinstall it.
Inner element:
Replace element every 3rd replacement of the outer element, or at least every 3rd year. 1.Remove outer element. Then remove inner element.
2.Cover the air inlet port. 3.Clean inside of filter housing, and remove inlet cover. 4.Fit a new inner element and the inner element retainer into the housing, and tighten the nut. 5.Install a new or cleaned outer element and outer element retainer, and tighten wing nut. 6.Install cover.
CAUTION
• Do not attempt to reinstall a cleaned inner element. • Do not clean or replace the element when the engine is running. • Replace the element if small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning. • If the element is usable, wrap it and store it a dry place. • 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 replaced.
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2.5.Check / clean prefilter of the air filter 10*
1.Loosen wing bolt (1) 2.Remove the prefilter (2) and clean with compressed air, if necessary. 3.Reassemble, turn the prefilter so that the dust cap (3) is pointed downwards (max angle: 20°). 4.Check air filter warning light at full engine load.
3.Fuel tank
3.1.Drain condensation, at least once a year 13*
It is an advantage to do this procedure after the dump truck has been stationary for a while (e.g. weekend) if possible. 1.Open engine bonnet. 2.Place a suitable container to catch spillage. 3.Use a hexagonal key (1) to remove the blanking plug (2) from the drainer.
4.Install draining hose (3) (tool kit). 5.Drain until water/sediment-free fuel comes out.
6.Remove draining hose and reinstall the blanking plug.
NOTE
If a large amount of dirt and contamination has collected into the tank: • Drain all fuel. • Remove the flange for the hoses (in the engine compartment) and clean inside of the tank.
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4.Transmission
4.1.Change oil 20*
Replace filter 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 first 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 (1). 4.Unscrew drain plug (2) under the transmission and drain the oil into a suitable container (3). 5.Clean the drain plug with magnetic insert, replace seal if necessary and reinstall the plug. •Tightening torque: 80 Nm.
Replace filter elements:
6.Unscrew the filter elements (4). 7.Apply oil to the seals on the new elements. 8.Screw the filter elements in until contact with the sealing surface is obtained. Tighten the elements firmly by hand.
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Clean stranier:
9.Unscrew the three nuts (5) and washers (6). 10.Remove the cover (7) 11.Replace the O-ring on the cover, if necessary. 12.Remove the strainer (8) and clean it. 13.Reassemble and torque nuts to 23 Nm.
continued overleaf
Fill new oil:
14.Fill new oil according to the transmission oil list and oil specification sheet (chapter 6) through the dip stick tube. 15.Insert the dip stick again and turn handle clockwise to tighten the sealing.
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Check:
16.Start the engine and check oil level (9) (see daily maintenance, for procedure) at low idle. Both too low and too high level can cause serious internal damage! 17.Warm up the oil and check for leaks. Recheck level and adjust if necessary.
NOTE
• Do not overfill! 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.
5.Front differential
5.1 Change oil, at least once a year 30*
•Change front diff. oil shall also be carried out after the first 500 hours of operation. 1.Open level / filling plug (1), special spanner in tool kit. 2.Unscrew drain plug (2). 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 specification sheet (chapter 6), through the level / filling plug, level shall be at lower edge of hole when dump truck is horizontal. 6.Clean the filling plug, replace seal if necessary and reinstall. •Tightening torque: 80 Nm.
CAUTION
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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 first 500 hours of operation. 1.Open level/filling 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 specification sheet (chapter 6), through the level/filling plug, level shall be at lower edge of hole when dump truck is horizontal. 6.Clean the filling plug, replace seal if necessary and reinstall. •Tightening torque: 80 Nm.
CAUTION
7.Front reduction gears
7.1.Change oil, at least once a year 33*
•Change front reduct. gear oil shall also be carried out after the first 500 hours of operation. 1.The dump truck must be horizontal. 2.Turn the hub, so that the plug is pointed downwards (1). 3.Unscrew the plug. 4.Drain the oil into a suitable container.
5.Turn the hub 90o, so that the level indicator is horizontal.
6.Fill new oil, according to the oil specification sheet (chapter 6), through level/filling 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.Recheck oil level after test driving.
CAUTION
8.Electrical system
8.1.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.
