- 1. Check the engine turbocharger and, if necessary, clean it.
- 2. Change the oil in the pump drive gearbox and conveyor gearboxes.
- 3. Wash the pump drive gearbox and the two speed transmission breathers.
- 4. Change the hydraulic oil and clean the in-tank strainer. Clean the hydraulic oil tank breather and filler strainer.
- 5. Change the hydraulic oil suction, charge pressure, auxiliary pressure and return filter elements.
- 6. Change the oil in the differential.
- 7. Change the two speed transmission oil.
- 8. Clean and repack the front wheel bearings.
- 9. Clean and repack the drive wheel bearings.
- 10. Lubricate those points shown in the 1000 hour column of the lubrication chart.
Checking And Cleaning The Engine Turbocharger
- 1. Remove the air inlet duct and compressor housing. Check for dirt or dust buildup.
- 2. Remove all foreign matter. Determine and correct the cause of the buildup. Use a soft brush on the compressor wheel - uneven deposits can affect rotor balance and cause bearing failure.
- 3. With the compressor housing removed, push the compressor wheel towards the turbine wheel and turn the rotating assembly by hand. Check for binding and rubbing. Listen carefully for unusual noises. If binding or rubbing is evident, remove the turbocharger for dismantling and inspection.
Changing The Oil In The Pump Drive Gearbox And Conveyor Gearboxes
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INADVERTENT STARTING OF THE ENGINE COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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- 1. Remove the drain plug, allow the oil to drain then reinstall the drain plug.
- 2. Remove the check plug and fill plug or breather
- 3. Fill the gearbox through the fill plug port or breather port until check plug level is reached (see page 5-1 for lubricant specification).
Washing The Pump Drive Gearbox And Two Speed Transmission Breathers
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INADVERTENT STARTING OF THE ENGINE COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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- 1. Remove the breather from the gearbox.
- 2. Wash in clean nonflammable solvent.
- 3. Blow dry with air or allow to drain dry.
- 4. Reinstall.
Changing The Hydraulic Oil
When changing the hydraulic oil, cleanliness must be kept in mind at all times. Perform the work in a clean area, use clean tools, keep your hands clean and clean up the outside of the hydraulic oil tank before starting.
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THE HYDRAULIC OIL AT OPERATING TEMPERATURE CAN CAUSE SERIOUS BURNS. LET THE MACHINE STAND IDLE UNTIL THE OIL HAS COOLED AND THE TANK IS COMFORTABLE TO TOUCH. |
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- 1. Remove the drain plug from the bottom of the tank and allow the oil to drain.
- 2. Remove the cover from the tank.
- 3. Remove the strainer from the tank and wash it in clean nonflammable solvent.
- 4. Check the inside of the tank for contamination. If excessive contamination is found, the tank should be removed from the machine and cleaned, and all hydraulic oil filters changed.
- 5. Reinstall the strainer in the tank.
- 6. Clean the tank cover and replace it immediately, using a new gasket.
- 7. Install the drain plug.
- 8. Refill the tank with clean, water-free hydraulic oil conforming to the specification on page 5-1.
Cleaning The In-Tank Strainer
See "Changing the Hydraulic Oil" above.
Cleaning The Hydraulic Oil Tank Breather And Filler Strainer
Remove the breather and strainer from the tank, wash thoroughly in clean nonflammable solvent, drain dry or blow dry with air and reinstall on the tank.
Changing The Hydraulic Oil Filter Elements For The Ground Drive, Conveyor Drive And Return Systems
The ground drive, conveyor drive and return system filters all have spin-on filter elements.
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AT OPERATING TEMPERATURES THE HYDRAULIC OIL AND FILTER HOUSINGS CAN CAUSE SERIOUS BURNS. LET THE MACHINE STAND IDLE UNTIL THE HYDRAULIC OIL HAS COOLED AND THE FILTER HOUSINGS ARE COMFORTABLE TO TOUCH. |
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To change an element:
- 1. Unscrew an element from the filter head. Be sure the gasket comes off with the element.
- 2. Coat the gasket of the new element with clean hydraulic oil.
- 3. Screw the element onto the filter head until the gasket is seated in the gasket groove.
- 4. Turn the element 1/2 to 3/4 turn more.
- 5. Check the hydraulic oil tank level, add oil if necessary, start the engine and check for oil leaks around the filter element.
Changing The Auxiliary Pressure Filter Element
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AT OPERATING TEMPERATURES THE HYDRAULIC OIL AND FILTER HOUSING CAN CAUSE SERIOUS BURNS. LET THE MACHINE STAND IDLE UNTIL THE HYDRAULIC OIL HAS COOLED AND THE FILTER HOUSING IS COMFORTABLE TO TOUCH. |
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- 1. Unscrew the bowl from the filter head and remove the bowl.
- 2. Remove the old element and discard it.
- 3. Flush the bowl with clean nonflammable solvent and dry it with filtered air.
- 4. Insert a new filter element into the bowl and install the bowl on the head.
- 5. Loosen the pressure line at the outlet port in the filter head.
- 6. Crank the engine, a few seconds at a time to prevent starting the engine, until air-free hydraulic oil comes from the outlet port in the filter head.
- 7. Tighten the pressure line at the outlet port.
Changing The Differential Oil
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THE DIFFERENTIAL OIL MUST BE DRAINED AND REFILLED IN THREE SEPARATE COMPARTMENTS; THE CENTER COMPARTMENT AND BOTH END COMPARTMENTS. |
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INADVERTENT ENGAGEMENT OF THE DRIVE SYSTEM COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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- 1. Remove the drain plugs and allow the oil to drain.
- 2. Install the drain plugs and remove the check plugs.
- 3. Add lubricant through the check plug ports until check plug level is reached. (See page 5-1 for lubricant specifications.)
- 4. Install the check plugs.
Changing The Two Speed Transmission Oil
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INADVERTENT ENGAGEMENT OF THE DRIVE SYSTEM COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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- 1. Remove the drain plug and allow the oil to drain.
- 2. Install the drain plug, remove the fill plug and check plug.
- 3. Add lubricant until check plug level is reached. (See page 5-1 for lubricant specifications.)
- 4. Install the check plug and fill plug.
Cleaning And Repacking The Front Wheel Bearings
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INADVERTENT ENGAGEMENT OF THE GROUND DRIVE SYSTEM COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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- 1. Block all wheels except the one to be worked on.
- 2. Raise the front of the machine on the side to be worked on. REMEMBER THE BOGIE IS FREE TO PIVOT VERTICALLY ON THE BOGIE BEARING.
- 3. BLOCK THE MACHINE UP.
- 4. Remove the dust cap from the wheel.
- 5. Remove the cotter pin, slotted nut and washer.
- 6. Remove the wheel assembly from the spindle.
- 7. Remove the seal and check the condition of the bearings by turning the inner race while lightly pressing on it. The bearing should turn smoothly. If a bearing is damaged, pull it from the hub.
- 8. Thoroughly clean all components.
- 9. Press a new bearing into the hub, if needed.
- 10. Install a new seal.
- 11. Repack the hub cavity with lubricant (see page 5-1 for specification).
- 12. Install the wheel assembly on the spindle. Tighten the slotted nut on the spindle so there is no drag on the bearings and no end play in the hub, then install the cotter pin.
- 13. Install the dust cap.
Cleaning And Repacking The Drive Wheel Bearings
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INADVERTENT ENGAGEMENT OF THE GROUND DRIVE SYSTEM COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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- 1. Block all wheels except the one to be removed.
- 2. Jack up the wheel that is to be removed and block up the machine so that the machine will not fall if the jack slips.
- 3. REMOVE THE VALVE CORE TO COMPLETELY DEFLATE THE TIRE AND RUN A PIECE OF WIRE THROUGH THE VALVE STEM TO BE SURE IT IS NOT PLUGGED.
- 4. Attach a lifting device to the tire and wheel assembly and remove the assembly from the machine.
- 5. Remove the drive chain from the sprocket attached to the hub.
- 6. Attach a lifting device to the hub and sprocket assembly.
- 7. Remove the cover, cotter pin, slotted nut and washer.
- 8. Move the hub and sprocket assembly away from the machine.
- 9. Remove the seal and check the condition of the bearings by turning smoothly. If a bearing is damaged, pull it from the hub.
- 10. Thoroughly clean all components.
- 11. Press a new bearing into place in the hub, if needed.
- 12. Install a new seal.
- 13. Repack the hub cavity with extreme pressure, multipurpose grease conforming to the specification given on page 5-1.
- 14. Install the hub assembly on the axle. Tighten the slotted nut on the axle so there is no drag on the bearings and no end play in the hub, then install the cotter pin.
- 15. Install the drive chain and adjust the tension.
- 16. Install the tire and wheel assembly with the loose flange and locking ring toward the machine. Tighten the lug nuts to 750 to 900 lb.-ft. (1024 to 1229 Nm).
- 17. Install the valve core and inflate the tire.