15 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 fuel filter 4*
The filter consist of one filter unit. It is located on the left hand side of the engine (on the rear end). 1.Wash the filter externally and unscrew it. Discard the filter according to environmental requirements. 2.Fit the new genuine filter and tighten it by hand. •Never use tools to tighten the filter! The filter 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.
2.2 Bleed the 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 bleed 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.
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!
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Small superficial 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 refitted.
Fig. 3 The wear is down to the chord. The multi-groove belt must be replaced.
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 first 8 and 100 hours of operation. •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 figures 1-3 below. •Check that the automatic belt tensioner (2) is in proper working order and keeps the multi-groove belt sufficiantly 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 fig. 1, it should be replaced. • Also check the wear on the multi-groove belt as shown in fig. 2 and 3.
NOTE
Do not change the direction of rotation of the multi-groove belt if it is refitted.
2.5. Air filter 10*
The air filter is located on the top of the engine, under the bonnet.
• Always stop the engine before servicing the air filter. • Open the bonnet and apply the bonnet catcher. • Cleaning and replacement of outer and inner element, see this page and next page.
Fig. 1
Dust cap
Fig. 2
Fig. 3
Outer element:
Clean element every 1000 hours of operation or if the air filter 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 (fig. 1). 2.Remove outer element with a light turning movement (fig. 2).
Do not remove inner element when cleaning outer element!
3.To blow out the filter 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 sufficient length to reach down to the bottom of the filter element.
Blow out the filter element using dry compressed air (max. 5 bar) by moving the tube up and down inside the filter element until there is no more dust coming out (fig. 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 (fig. 4). 6.Never carry on using a damaged outer element. In case of doubt, always fit 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. 5
Fig. 6
Servicing the dust cap
The dust cap require very little maintenance. Possible dust packs to be removed by squeezing the cap (fig. 5).
Inner element:
• Replace element every 5th cleaning of the outer element, or at the latest after 2 year. • 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. screw driver) to push through the seal of the inner element from the inside to the outside and pull both the straps upwards (fig. 6). 4.Use both straps to take hold of the inner element and then pull out with a light turning movement (fig. 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 downwards (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.
Drain plug
3. Transmission
3.1. 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 (located behind the cab). 4.Access to the drain plug through transmission bottom guard (rear cover). 5.Unscrew drain plug, at the bottom of the transmission and drain the oil into a suitable container.
6.Clean the drain plug with magnetic insert, replace seal if necessary and reinstall the plug. •Tightening torque: 80 Nm.
CAUTION
Use gloves when checking the oil level or filling oil. The exhaust pipes and nearby area may be hot and fingers and hands could be burnt.
Replace filter elements (located in the engine compartment, left hand side, at the rear end of the engine):
7.Clean well around the filters.
8.Place a suitable container beneath the filters to catch spillage. 9.Unscrew the filter elements.
10.Check for wear particles in the oil. 11.Apply oil to the seals on the new elements. 12.Screw the filter elements in until contact with the sealing surface is obtained. Tighten the elements firmly by hand.
continued overleaf
Access to remove the strainer
Rear cover
1
2
3
Clean stranier:
13.The strainer is located on the left hand side of the drain plug. 14.Unscrew the three nuts (1) and washers (2). 15.Remove the cover (3). 16.Replace the O-ring on the cover, if necessary. 17.Remove the strainer (4) and clean it. 18.Reassemble and torque nuts to 23 Nm.
Fill new oil:
19.Fill new oil, according to the transmission oil list and oil specification sheet (chapter 6), through the dip stick tube. 20.Insert the dip stick again and turn handle clockwise to tighten the sealing.
Check:
21.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! 22.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.
3.2. Run the AEB-Tester
AEB = Automatic Filling Parameter Adjustment
The AEB-Tester should also be run after the first 100 and first 500 hours of operation. To optimize the transmission, run the AEB-Tester. 1.Remove the cover on the backwall (remove the instructor's seat back rest, if that is fitted). 2.Follow the procedure described in the table on next page. The gear display will show the AEB's actions. ("Display message" in the table on the next page).
TCU = Transmission Control Unit
Run the AEB-Tester continued..............
AEB = Automatic Filling Parameter Adjustment TCU = Transmission Control Unit
How to run the AEB-Tester Display message
1 Warm up the transmission oil, the oil must have a temperature at 70 - 80OC Normal operating messages
2 - Move the gear selector to Neutral position. - Engage the parking brake 3 Turn OFF the starter switch 4 Plug the AEB-Tester into the diagnostic contact no. 607 5 Start the engine "PL"
6 Set engine speed to low idle rpm "PL" if starts condidtions are OK
Remarks
TCU must recognize "PL" for at least 2 sec. before you can press the button.
7 Press button on the AEB Tester "ST" if starts conditions are OK The button must not be released before TCU has started the AEB or quit with an error code.
8 Keep the button depressed until the AEB has started "K1" …… (Information about the AEB state)
9 Wait until AEB is finished "OK" (AEB has been successful)
10 Turn OFF the starter switch and unplug the AEB-Tester 11 Remount the cover on the backwall TCU has started the AEB and goes to adjusting K1, K2, …, KR. (Button may be released).
• If the oil temperature is too low or too high, following message will apear on the gear display:
T or T . Adjust the oil temperature and try again. • If there is a malfunction, turn the starter switch off and start the engine again. • The AEB will not start if any error codes are shown on the gear display, except error code "F6"
4. Hydraulic system
4.1. Replace breather element 42*
• 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
4.2. Replace hydraulic return filter element 43*.
• Replacement of hydraulic return filter element shall also be carried out after the first 100 hours of operation. 1. The filter is located on the back of the hydraulic tank. Remove the cover to get into the filter. 2. Clean well around the filter housing. 3. Place a suitable container beneath the draining hose to catch spillage. 4. Use a filter key to unscrew the old filter (counterclockwise). Remove also the old O-ring. The old filter contains 4 litres oil. Discard the filter element, and oil according to environmental requirements. 5. Check for wear particles in the oil. 6. Clean the O-ring groove, apply oil to the new O-ring and install it.
7. Apply oil or grease to the threads and install a new filter element by turning it clockwise until seals make contact.
Then tighten by hand 1/4 to 1/3 turn more. 8. Fill 4 litres hydraulic oil, as specified in chapter 6, lubricants, through the oil filler on the top of the filter unit (under the cover on the top of the hydraulic tank). 9. Screw the oil plug back into place and clean off any oil spill. 10.Start engine and check for leaks.
CAUTION
Fill 4 litres hydraulic oil throguh the oil filler.
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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.Access to the drain plug through transmission bottom guard. 2.Open level / filling 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 specification sheet (chapter 6), through the level / filling plug, level shall be at lower edge of hole when dump truck is horizontal. 7.Clean the 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 plug, replace seal if necessary and reinstall. •Tightening torque: 80 Nm.
CAUTION
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.
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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 first 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 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
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.
