Maintenance MACHINE SOUS TERRAINE

Maintenance
Manual
(Deutz F6L/F8L413FW)
MAINTENANCE
MANUAL
2 (61)
TKU--- C 01040--- 1 EN 4004
 SANDVIK TAMROCK CORP., TURKU PLANT 09/2004

3 (61)
TKU--- C 01040--- 1 EN 4004
PREFACE
Congratulations on your choice of a TORO loader.

This manual describes the maintenance of this TORO 301 loader. Only those who have
been given proper training and are authorized should operate the loader. Each operator
should familiarize themselves with the machine and fully understand the contents of the
Operator‘s manual, Maintenance manual and the General Safety Instructions before
operating it.
Read the Operator’s Manual and General Safety

Instructions before starting work!
WARNING
This responsibility refers in particular to the personnel working with TORO occasionally only,
e.g. during set--up or maintenance.
Continuing research and development of TORO loader’s may have caused changes to your
machine which are not included in this manual.
If the machine is equipped with optional equipment e.g. remote--control system you should
familiarize yourself with separate instruction manual, where the operation is explained.
This manual must permanently be available in the cabin when operating the TORO.
Always obey national mandatory rules relating to accident preventation and enviromental
protection. The generally recognized technical rules for safe and professional operation
must also be observed.
For demanding maintenance and repairs, we recommend that you contact your nearest
authorized Sandvik Tamrock Service. Our maintenance personnel have the skills and
special tools required for the most demanding tasks.
Through correct use and by following the maintenance instructions, you can expect a high
degree of utilization and long operating life of your loader.
Always obey safety rules!

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PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Importance of periodic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. General safety precautions during operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3. General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4. Location of the main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5. Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1. Hydraulics maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2. Electric system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3. Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5. Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.1. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.2. Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.3. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.4. Brake Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5.5. Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5.6. Grease nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6. Filling capasities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7. Special notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7.1. Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7.2. Refilling fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8. First service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3. MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1. Every shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2. Every week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3. Every 125 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4. Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.6. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.7. Every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.8 Every 3000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4. MAINTENANCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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GENERAL
1. GENERAL
1.1. Importance of periodic maintenance

The TORO 301 is designed for hard work in difficult and demanding mine conditions. To
ensure trouble--free and economical operation, it is extremely important to follow the
service schedule regularly. When following the service schedule closely you can easily
detect possible defects in the machine which can be repaired before they become serious.
This will ensure a low repair cost and minimize disturbances in production.
The following pages give various service points for the TORO 301 with their
corresponding service intervals. We urge all end users to review the Deutz Operation
Manual for additional information regarding servicing.
1.2. General safety precautions during operations

We recommend that records be kept on services and wearing part replacements. Regular
maintenance at correct intervals increases productivity, reliability, economy, and safety of
the equipment.
Even maintenance work can be dangerous, unless caution is observed. Everybody
involved in maintenance work should understand the possible hazards, and use safe
working methods. Before starting any maintenance or repair work, read the
manufacturer’s instructions and follow them.
Personnel must not wear long loose hair, nor slack clothing nor jewelry including rings,
because of danger of injury.
Use personal protection suits and other protective equipment as far as necessary or
mandatory.
Do not make any modifications, extensions or rebuilding to the machine, which would
affect safety. Consult the supplier or manufacturer. This also includes the built--in and
adjustment of safety devices and valves, as well as the welding frame structures.
Spare parts must correspond to the manufacturer’s technical specifications. Conformity
is guaranteed in case of genuine parts only.
Notify the location and use of fire extinguishers!
It is indispensably necessary to have suitable specialized workshop equipment for high
maintenance performance.
Any maintenance or repair work on the unit must be performed by trained or instructed
personnel only. Work performed on electric appliances by electricians and on hydraulic
appliances by mechanical Technicians with particular knowledge and experience.
Observe any activity specified in this manual as to adjustment, maintenance and
inspection times, as well as any indication to the replacement of parts.
Clean and wash the equipment regularly, and always before and after maintenance and
repair work. Before cleaning the machine with water or by steam jet or other cleansers,
cover the alternator, connection boxes and major connections. Remove the covers after
cleaning!
Never attemp to clean, adjust, repair or lubricate the TORO while it is in motion or
the engine is running.
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GENERAL
1.3. General repair instructions

The person responsibility for maintenance and repairs should be clearly defined.
-- Do not do any work that you are not authorized to do.
-- Secure extensively, as far as necessary, the area of maintenance works.
-- Inform the users of the equipment of the start of special and maintenance work.
-- If the equipment or a part of it has been stopped for maintenance or repair, make
sure that it cannot be started accidentally.
D Turn main switch off
D Remove ignition key
D Put a DANGER DO NOT START or corresponding warning sign on the main
switch. The sign must only be removed by a person who is fully aware of the
situation.
-- If required, ensure suitable and safe ladders or working platforms are available for
repair and maintenance work.
-- Do not use parts of the equipment as steps. If maintenance work must be done high
up, or in an otherwise dangerous place or position, use necessary safety devices
to prevent falling.
-- All platforms, steps, grips, rails, ladders, and other similar parts must be kept clean
of oil, dirt, snow, and ice to prevent accidents.
-- Always use the correct tools for the maintenance task.
-- Before commencing maintenance or repair work ensure that the vehicle is on level
ground, and it doesn’t move.
-- Pay special attention to the exhaust piping and the exhaust gas cleaning system.
Ensure sufficient ventilation.
-- Use lift jack only on level, hard and firm ground. Always before using a jack, be sure
wheels on other side of the vehicle are blocked.
To avoid possible slipping of the jack, secure the vehicle with adequate supports and
blocks underneath the vehicle.
-- Exhaust all the air from the tire before loosening the wheel nuts/bolts. Should you
forget to do this, a broken rim part under pressure can fly apart and cause serious
injury.
-- Do not try to repair wheel parts by brazing, welding or reworking. Be sure to replace
with new parts of the same size, type and make.
-- Never transport a fully inflated spare tire mounted on demountable rims. They should
have just enough air pressure to hold the rim parts firmly in place. Only after the tire
and rim assembly have been fastened with all the wheel nuts/bolts properly torqued,
should the tire be inflated to the correct operating pressure.
-- When inflating, mounting or dismounting tires a safety rack, cage or some other
protection should be used
-- During tire inflation, do not stand in front of the assembly. Use an extension hose, so
that you may be able to stand to one side.
-- When replacing heavy parts, use correct lifting apparatus and techniques.
-- After preventive maintenance and repairs, always tighten unscrewed fasteners.
Reassemble all dismantled safety appliances immediately after the work is done.
Insure all safety system’s are tested before unit is returned to work.
-- Care for safe and environment protecting disposal of process materials and
exchange parts.
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GENERAL
1.4. Location of the main components
1 2
1. Front frame 3. Engine ass’y

2. Rear frame 4. Power train
Front frame
1
1. Bucket
2
2. Swing lever
3. Boom 3
4. Lift cylinders
5. Tilt cylinder
4 4
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GENERAL
Rear frame
6
9
4 3 5
7
10
11
1
8
8
8
1. Fuel tank 6. Breather

2. Hydraulic oil level 7. Transmission oil filters
3. Return filter element for bucket-- 8. Service hatches
and steering hydraulics
9. High pressure oil filter for hydraulics
4. Return filter element for brake
hydraulics 10. Operator’s cabin/canopy
5. Batteries 11. Main switch
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GENERAL
Engine ass’y
8 8 6
3 5
2
7
1
4
1. Alternator 5. Engine oil cooler

2. Hydr. blower 6. Air filter
3. Centrifugal filter 7. Air restriction indicator
4. Engine oil filter 8. Transmission oil cooler
Power train 3
1. Front axle 6 1
2. Rear axle
3. Transmission
4. Torque converter
5. Drive shaft 4
6. Parking brake
7. Oil filling 2 5 5
8. Dipstick
9. Filling/checking plug
8
7 9
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GENERAL
1.5. Locking devices

Frame locking bar
How to install frame locking bar.
1. Remove the bar from its holder in
the cabin.
2. Remove the pins from the frame
lugs.
3. Insert the locking bar into the middle
of frame lugs so that the cabin sided
pin drops into the hole as shown in
attached picture.
4. Return to the cabin and turn on the
engine. Slowly move the steering
little to the left or to the right until the
second pin dropps.
Note: Observe the pin dropping. When it
has dropped stop turning.
To remove the locking bar

1. Climp into the cabin, turn on the
engine and turn the unit a little to the
left or to the right until the pins have
no pressure acting on them.
2. Then stop the unit, step out and
remove the pins and the locking bar.
3. Replace the pins to the frame lugs
and the locking bar to the holder in
the cabin.
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GENERAL
Boom locking pins

How to install the locking pin.
1. Climb into the cabin and raise the

boom. Turn off the engine. Remove
the pins from their holders in the
cabin and step out.
2. Place the pins correctly into their
holes on the boom as shown in
attached picture.
3. Lower the boom slowly against the
stops.
To remove the pins
1. Walk around the unit and ensure
no--one is working on the unit or
under the boom.
2. Sound the horn 3 times and have a
look around. When it is safety start
the engine.
3. Raise the boom and then turn off the
engine.
4. Remove the pins. Don’t walk under
the boom under any circumstances.
5. Go back into the cabin, sound the
horn again 3 times and turn on the
engine, lower the boom slowly
against the stops and place the
bucket on the ground.
6. Replace the pins to their holders in
the cabin.
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MAINTENANCE AND LUBRICATION
2. MAINTENANCE AND LUBRICATION

The TORO 301 is designed for hard work in difficult and demanding mine conditions. To
ensure trouble--free and economical operation, it is extremely important to follow the
service schedule. When following the service schedule closely you can easily detect
possible defects in the machine which can be repaired before they become serious. This
will ensure a low repair cost and minimize disturbances in production.
The following pages give various service points for the TORO 301 with their
corresponding service intervals. All end users should review the Engine Manuals for
additional regarding servicing.
2.1. Hydraulics maintenance

Maintenance, repair, and installation of hydraulic equipment must only be carried out by
experienced hydraulics experts.
D Do not attempt any such repairs that you do not fully understand.
D Never do any repair work on the hydraulic circuit if the system is pressurized.
D Always stop the engine before tightening or repairing a leaking hose connection.
D Do not try to locate a leak from a hose or a connection by feeling with your hand.
The high-pressure oil spray from the leak can penetrate the skin and cause a
serious injury. A high-pressure oil spray can also start a fire.
D Avoid direct skin contact with oil. Prevent oil from getting into your eyes; use eye
protection.
D Do not work under a device or component that is held up only by the hydraulics.
Use separate supports in conjunction with maintenance and repair.
D Do not remove boom cylinders or their valves unless the boom is properly
supported and system non--pressurized.
D Pipe connections, hose lengths, and hose types must correspond with the
specifications. When replacing or repairing hoses, use original SANDVIK
TAMROCK spare parts or hoses and fittings recommended by the manufacturer.
Ensure that the pressure ratings of the hoses and connecting fittings correspond
with the working pressures.
D Any alterations or modifications require a written authorization from the
manufacturer.
Pressure tests
General
D The hydraulic oil temperature should be 60...80 _C
D Connect and disconnect pressure gauge(s) only when the circuit is non
pressurized.
D Use only special couplings for pressure testing
D Do not overtighten couplings. When special couplings are used, finger tight is
adequate. Over tightening causes harmful leakage.
D Use hose(s) long enough to read the gauge(s) while sitting in the cabin
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Tests
Pilot system pressure
. Engine at low idle
. Pressure should be 25 bar (2,5 MPa)
Steering system pressure
. Install the frame locking bar between front and rear frames
. Turn the machine to full left hand turn
. Engine revs 1000--1500 rpm.
. Steering system pressure should be 125 bar (12,5 MPa)
Bucket hydraulic pressure
. Engine at 1000--1500 rpm.
. Lower the boom down against the stops and keep the control valve in
“boom down” position.
. Pressure should be 210 bar (21,0 MPa)
2.2. Electric system maintenance

D Work on electric equipment or materials is only to be carried out by qualified
electricians, or other professionals, or assistants under their supervision and
control, observing electrotechnical regulations.
D The local electrotechnical and electric safety regulations must always be
observed.
D Always use only original electric components.
D If disturbances in electric supply occur, stop the vehicle at once.
D Voltage must be cut off from the parts of the equipment or device that are to be
checked, serviced, or repaired, if the regulations so require. Check that the
disconnected parts are dead, and then lock the main switch or arrange a work
earthing if necessary.
D Do not touch battery terminals, alternator terminals, or wiring cables while the
engine is operating. Severe electrical shock, which may lead to personal injury may
result from improper shielding of electrical components.
D Check the electric devices of the equipment regularly. Faults, such as loose wires
and damaged insulation must be repaired at once.
D When handling high-voltage components, remember that capacitors may have an
electric charge, even if the voltage is cut off. Short the capacitors with an earthing
rod.
D Before making any changes on the electric devices, SANDVIK TAMROCK’s
electric engineering department must be consulted, and a written
authorization received, to ensure the operation of the device does not
change.
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Working on live components

D If the component must be live, a fellow worker must be standing by to cut off voltage
at the emergency or main switch in an emergency situation. Follow the electric
safety regulations.
D Use a red-and-white safety chain and warning signs to encircle the working area.
D Use only insulated tools.
D Observe special caution.
2.3. Battery maintenance

Always wear eye protection, protective overalls, and protective gloves when
servicing batteries.
D Always disconnect the negative (-) pole first, and then the positive (+) pole. Always
connect the positive pole (+) first, and then the negative (-) pole.
D Reversing battery polarity can result in personal injury caused sudden discharge
of electrolyte from the battery vents and/or the sudden rupture of the battery case
caused by explosion of internal hydrogen gas.
D To prevent sparking when connecting a battery charger, pull the charger supply
cord or switch the charger off before connecting the charging wires to the battery
terminals. Open the battery cell caps slightly during charging to allow the
generating gases to escape.
D The acid in the battery burns skin, eats holes in clothing, and can cause blindness
if it gets in the eyes. If you get battery acid on your skin, flush the spot at once with
water. Flush the eyes with plenty of water, and call a doctor.
D When servicing batteries, remember that lead-acid batteries generate (during
charging and discharging) oxygen and hydrogen which form a highly explosive
mixture. A spark or an open flame can cause an explosion. If necessary, ventilate
the battery compartment properly before disconnecting or connecting the cables.
D To prevent explosion, the electrolyte level must be maintained and checked
regularly. Add distilled water, if required, before starting, never immediately after
use. With a high enough electrolyte level, the cells have less space for gases.
D Use an flashlight when checking electrolyte levels, never an open flame.
D The battery terminals should never be shorted as sparks can cause the battery to
explode.
D Do not test electric devices by making the contact with the battery terminal.
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2.4. Welding
Before starting to weld, determine the material to be welded, and the welding method and
fillers. Contact SANDVIK TAMROCK Service, if necessary.
D Do not repair steering equipment by welding.
D Welding must be left to qualified personnel.
D Before electric welding, the main switch must be disconnected. Also Remote
Control equipment (optional) must be disconnected.
D If welding must be done close to any of the control modules, disconnect the module
wiring before welding.
D The ground cable of the welding machine must be connected to the welding place
as close as possible. The ground cable may not be connected so that the current
can flow through a bearing, joint coupling, sealing surface, lever, or control cable.
D Use a protective mask when welding.
D Arrange adequate ventilation.
D Arrange protection against fire.
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2.5. Lubricants
2.5.1. Engine
Classification API CD/CE, MIL--L--2104 C (in conjunction with MIL--L--46152A) or
CCMC D4.
CCMC D5 (”SHPD”) can also be used.
Engine oil API CC/CE or MIL--L--46152 can be used when halving the interval.
Diesel fuel sulphur content max 0.5 % (by wt). In case of sulphur content from 0.5 up to 1.0
% or prevailing ambient temperature below --10 _C the oil change intervals must be halved.
Viscosity above --20 _C SAE 15W/40

--25 _C ... +20 _C SAE 10W/30
--15 _C ... +10_C SAE 20W/20
+5 _C ... +30 _C SAE 30
above +25 _C SAE 40
See engine Operation Manual for more details.
2.5.2. Transmission
Classification Allison C--4 or Caterpillar TO--4
Viscosity --20 _C...+ 15 _C SAE 10W
above + 0 _C SAE 30
2.5.3. Hydraulics
Hydraulic oils meeting DIN 51524 HVLP or ISO 6743--4 HV can be used
Viscosity
above --15 _C ISO VG 32 (SAE 10W)
above + 0 ISO VG 46 (SAE 20)
Operating temperatures during normal operation

about 45 _C ISO VG 32
(Motor oils API class CD, or hydraulic oils with wear preventive characteristics
corresponding to those of DIN 51524 HVLP or ISO 6743--4 HV can be used)
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2.5.4. Brake Hydraulics

Hydraulic oils meeting DIN 51524 HVLP or ISO 6743--4 HV can be used
Viscosity
above --15 _C ISO VG 32 (SAE 10W)
Operating temperatures during normal operation

(Motor oils API class CD, or hydraulic oils with wear preventive characteristics
corresponding to those of DIN 51524 HVLP or ISO 6743--4 HV can be used)
2.5.5. Axles
Classification MIL--L--2105 C or API GL--5 + LS (Limited Slip)
Viscosity above -- 25 _C. SAE 80W/140
above -- 12 _C SAE 85W/140
2.5.6. Grease nipples

Lithium based greases with penetration 265/295 (NLGI 2) and dropping point 180 _C should
be used.
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2.6. Filling capacities

Engine oil (F6L) 16,5 l (with filter)
13,0 l (without filter)
Engine oil (F8L;opt.) 22,5 l (with filter)
17,0 l (without filter)
Transmission 37 l
Axles 2 x 35 l
Hydraulics 160 l
Fuel tank 180 l
Water tank 180 l (with water scrubber)
2.7. Special notes

If the machine is fitted with optional equipment as e.g. automatic central lubrication
system, please read instructions for those equipment carefully, and follow the service
schedule given in the maintenance instructions.
2.7.1. Cooling system

D Clean if the engine overheats or solution is dirty.
Note! Overheating indicates a fault. Stop the engine and repair the fault before more
serious damage is caused.
See engine Operation Manual for more details.
2.7.2. Refilling fuel

The following precautions must be observed when replenishing fuel:
D Do not fill fuel tank when the engine is running.
D Do not overfill
D Take care not to spill fuel on hot surfaces.
D Fuel filling should be done in a well ventilated space.
D Smoking, open flame, and sparks are dangerous when the fuel tank is being filled.
D Clean up spilled fuel before starting the engine.
D Keep the fuel replenishing pipe in contact with the fuel tank, or arrange earthing
to prevent sparking caused by static electricity.
D If fuel quick fill system is to be used, insure you are familiar with systems
manufacturer’s operating and safety requirements.
19 (61)
TKU--- C 01040--- 1 EN 4004

2.8. First service

Check lubricants currently used meet site specific operating requirements as per Sandvik
Tamrock Lubricant Specifications.
The following steps should be carried out during the first week of use (in addition to the
normal scheduled services):
After the first 50 hours

-- Change transmission oil and filter element
-- Change engine oil and filter
-- Change fuel filters
-- Check valve clearances (readjust if necessary)
-- Check and tighten the bolts of exhaust manifolds
-- Check that air filter and air pipes are tight
-- Check and tighten the bolts of oil sump and engine mountings
-- Check/tighten bolts of axles, wheels, gearbox and other major components
-- Tighten the screws of oscillating axle
M12 bolts to 85Nm (dry)
M16 bolts to 210 Nm (dry)
-- Tighten the screws of parkbrake and drive shafts
-- Check V--belts
-- Make a visual overall check for leaks and possible damages
20 (61)
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MAINTENANCE OPERATIONS
3. MAINTENANCE OPERATIONS
3.1. Every shift
D Check engine oil
Machine on level ground. Measure the
oil level engine stopped (after stopping
the engine allow the oil drain to crank--
case for about 20 minutes before
checking the oil level).
The oil level must be between the LOW
and FULL marks on the dipstick.
D Check V--belts
Check condition visually, Adjust if
necessary.
Check belt for worn, grease coated, oil
soaked and missing material. Replace
as necessary.
D Check air filter indicator and assembly condition

Inspect air restriction indicator; service
air cleaner elements as required.
Inspect the entire air system for leaks.
Tighten any loose connections.
Empty the discharge valve from dust by

pressing apart the lips of the discharge
slot.
21 (61)
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D Check oil bath air cleaner (option)
Inspect the entire air system for leaks.

Tighten any loose connections.
Oil change and filter cleaning is necessary
when the oil in the filter thickens or
becomes muddy in appearance. Check
whether the oil filling is still usable.
For further information, Engine Operation
Manual.
Empty the discharge valve from dust by
pressing apart the lips of the discharge
slot.
D Check intake ducting and connections for leaks
D Check exhaust ducting and connections for leaks

22 (61)
TKU--- C 01040--- 1 EN 4004

D Check transmission oil level

Place machine on level ground.
Parking brake engaged
The engine at low idle
The gear shift lever in Neutral position
Transmission oil in operating temperature
D Check tyres and wheel nuts
Condition
Tyre wear and air pressure visually
Visually for loose or missing wheel nuts
D Check hydraulic oil level

Boom in down position, and bucket on
ground. Oil level should be between the
sight glasses.
D Grease oscillating axle

Grease point located at central lubrication
manifold on rear frame.
(If automatic central lubrication is not

installed)
23 (61)
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D Grease centre articulation pins
Grease point located at central lubrication

manifold on rear frame.

installed)
D Grease steering cylinder pins
Rear pins through the lubrication manifold

on the rear frame and front pins directly
through the nipples.

installed)
D Grease drive shaft Universal joint

at centre articulation
Use a hand grease gun.
24 (61)
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D Grease lift cylinder pins, tilt cylinder pins and lift arm pins
Grease pins directly through the nipples
with a hand grease gun.

installed)
Grease dogbone pins
D Fill automatic central lubrication system (option)

Check the system visually and fill it.
Check that all lubrication points are well
greased.
D Grease ejector cylinder pins (option)

Grease pins directly through the nipples
with a hand grease gun.
25 (61)
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D Test service and parking brake function

Leakage and Brake function
Brake test:
Check that the pressure in the brake system is at correct operating level before testing.
Brakes should hold:
LCB--brakes
Service brake . . . . . . . . . . . . . . . 1600 rpm/1st gear
Parking brake . . . . . . . . . . . . . . 2250 rpm/1st gear
Emergency brake . . . . . . . . . . . 1600 rpm/1st gear
Posi--stop brakes
Service brake . . . . . . . . . . . . . . . 1800 rpm/1st gear
Parking brake . . . . . . . . . . . . . . 1800 rpm/1st gear
Emergency brake . . . . . . . . . . . 1800 rpm/1st gear
D Check that all the controls are functioning correctly

Raise the lift arms, dump the bucket, roll
back the bucket and lower the lift arms at
1000 -- 1500 engine rpm.
Articulate the machine from left to right.
D Check major components for oil leaks and mounting

Make sure that the safety locks are removed. Make a general visual inspection of the
machine, check for oil leaks and loose hoses, frayed wires or other apparent maintenance
needs; if anything looks suspicious call a service person.
26 (61)
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D Check Hand Portable Fire Extinguisher (option)

Gauge pointer on green area
No corrosion
Firmly mounted
Visual seals in place
D Check lights
Front
Rear
Optional lights
D Check gauges and indicator lights

When the engine is operating at its
normal temperature the gauge pointer is
in the green sector. If the pointer moves
to the red sector the engine is getting too
hot. Stop the engine and trace the
trouble.
Engine oil pressure; Minimum oil
pressure with a warmed up engine at
slow idle should be at least 0,5 bar.
Brake system oil pressure; Warning light
illuminates when pressure drops too low.
Alternator charging voltage; appr. 26--28V.
Transmission oil pressure; should be
between 16,5 -- 19,3 bar.
D Check remote control system (option)

Check the RC--system functioning according to Remote Control system instructions.
27 (61)
TKU--- C 01040--- 1 EN 4004

D Fill fuel tank

Shut--off engine before filling.
Insure machine is suitably grounded.
Do not overfill.
Do not fill fuel tank to the top. Fuel
expands when it becomes warm and can
overflow.
D Fill water tank (Machines with exhaust scrubber)

28 (61)
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3.2. Every week

D Wash hydraulic oil cooler (option)
WARNING
Do not use high pressure cleaning units.
It may result cooler core damage.
HOT WATER CLEANING WITH SOAP
(biodegradable detergent) CAN BE
USED, MAX PRESSURE 82 bar
(1200 PSI).
D Grease drive shafts

Grease all drive shaft U--joints.
D Check tyre pressures
17.5x25 L5S, Bridgestone

Front 500 Kpa (5,0 bar)
Rear 350 Kpa (3,5 bar)
29 (61)
TKU--- C 01040--- 1 EN 4004

D Grease the stationary ends of boom / bucket pins
D Clean exhaust water scrubber (option)

Remove lock on top and plug on bottom.
Let the engine run 1500 rpm and spray
water in the scrubber until water becomes
clear. Reassemble lock and plug.
If the machine is equipped with catalytic
exhaust gas purifier, check the purifier
after every 1000 hours of use.
30 (61)
TKU--- C 01040--- 1 EN 4004

D Test Transmission, bucket-- and steering hydraulics (F6L)

The transmission and hydraulics should be at operation temperature during measuring.
A Transmission: Press brake pedal, connect highest gear and accelerate. The engine
should achieve about 2150 -- 2250 rpm stalling speed.
B Bucket hydraulics: Lower the boom down against the stops, keep the control valve
in “boom down” position and accelerate. The engine should achieve about 2030 -- 2130
rpm stalling speed.
S Steering hydraulics: Turn the loader against the stops, keep the control valve in
selected positon and accelerate. The engine should achieve about 2370 -- 2470 rpm
stalling speed.
D Test Transmission, bucket-- and steering hydraulics (F8L, option)

The transmission and hydraulics should be at operation temperature during measuring.
A Transmission: Press brake pedal, connect highest gear and accelerate. The engine
should achieve about 2270 -- 2370 rpm stalling speed.
B Bucket hydraulics: Lower the boom down against the stops, keep the control valve
in “boom down” position and accelerate. The engine should achieve about 2310 -- 2410
rpm stalling speed.
S Steering hydraulics: Turn the loader against the stops, keep the control valve in
selected positon and accelerate. The engine should achieve about 2370 -- 2470 rpm
stalling speed.
31 (61)
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3.3. Every 125 hours

D Check wheel nut’s tightening torques
410 Nm (lubricated)
D General cleaning
Operator’s compartment (do not use high
pressure water when cleaning the cabin).
Engine compartment Before cleaning the
machine with water or by steam jet or
other cleansers, cover the alternator,
connection boxes and major connections.
Do not apply steam or solvent directly to
the alternator, starting motor or DDEC
electronic components.
Do not apply solvent to hot surfaces.
D Check cabin/canopy door and lock condition
Check that cabin/canopy door and lock

works properly.
32 (61)
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D Check the instrument panel

Open instrument panel and check
-- Mounting of components
-- Condition of wiring
D Check junction boxes (If installed)

Open all electric junction boxes
-- Check that all boxes are dry
-- Ensure mounting of the components and junction boxes
-- Visually check the possible loose wires inside the junctionboxes
D Check cables
Visually check the cables for
-- Wearing
-- Sharp bends
-- Other possible damage
33 (61)
TKU--- C 01040--- 1 EN 4004

D Check automatic central lubrication

system (option)
Operation.
Timer.
Correct grease amount.
Individually check all grease points.
Check workshop manual if more
information is required!
D Clean cooling fins and oil cooler

Engine must be stopped.
With compressed air, cleaning agent
and water, or high pressure steam.
Remove cooling air cowling.
Blow air from exhaust air side, spray with
cleaning agent and wash with water jet,
or clean with steam jet.
Refit cooling air cowling, run engine up to
service temperature.
Check Deutz Operation manual if more
information is needed.
34 (61)
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D Change engine oil and filters
Run engine until operating temperature
is reached; then shut down.
Drain oil pan and reinstall drain plug,
using a new gasket if required.
Change oil filter.
Clean the filter adapter.
Fill the new filters with clean lubricating
oil, and lightly coat the filter seals with the
same oil.
Add oil as required to bring the oil level to the FULL mark on the dipstick.
Start engine and run at low idle. Check lube oil pressure gauge reading.
Shut engine down. Wait 15 min.
Recheck oil level and add oil if needed, bringing oil level to FULL mark on the dipstick.
D Clean centrifugal oil filter

See Deutz Operation Manual.
D Service the air filter elements

The air filter element must be replaced
when the service indicator shows red.
Always clean the sealing surface of the
outlet tube and make sure that all
contaminant is removed before the new
filter is inserted.
Always clean the inside of the outlet tube
carefully. When the filter element is
changed, the safety element must be
kept in place.
The safety element must be changed
every second time the air filter element
is replaced.
35 (61)
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D Check alternator
Check alternator terminals for loose
connections and corrosion.
Check mounting.
Check V--belts. Replace if necessary.
When replacing, always inspect fan
bearings.
D Check engine mountings

Check the condition of mounting pads.
Tighten and/or repair if necessary.
D Check batteries
Electrolyte level.
Cable connections.
Cleanliness.
Always wear eye protection, protective

overalls, and protective gloves when
servicing batteries. The acid in the
battery burns skin, eats holes in clothing,
and can cause blindness if it gets in the
eyes.
36 (61)
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D Check oil level in planetary hubs and differentials

Always ensure, that the arrow is in down
position when checking oil level in
planetary hubs. Refer to attached picture.
D Change brake flushing return filter

Location arrowed in attached picture.
D Check centre articulation

Check for visual signs of wear.
Check that the lubrication works.
37 (61)
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D Lubricate operator seat linkages, brake and throttle pedal linkages and gear
selector linkages
Lubricate throttle-- and stop cylinder

linkages.
D Lubricate door and hatch hinges

Lubricate door and hatch hinges, check
that the cabin door and lock (or latch)
works properly.
D Check fire suppression system (option)

Check “quick check” that the system is
operable.
Check that the system has not been
tampered and there is no obvious physical
damage, or condition to prevent operation
Follow the service recomendations of any
localy fitted fire suppression system.
38 (61)
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D Check valve clearances
Check with engine cold.
Inlet valves 0,2 mm.
Outlet valves 0,3 mm.
See Engine Operation and Workshop

Manual, or contact your nearest Deutz
dealer.
D Change fuel filter elements

Turn the handle on the shutoff valve to
the closed position.
Change the primary and secondary fuel
filters.
Fill new filters with clean fuel and coat
the gasgets lightly with fuel.
Turn the handle on the shutoff valve to
the open position.
Start the engine and check for leaks.
For further information, check Deutch Operation
Manual.
D Check exhaust system fastenings

Check exhaust manifold fastening nuts,
exhaust flange, and other connections
for tightness.
39 (61)
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D Drain water from fuel tank
D Change transmission oil filters

Add quantity necessary to bring fluid
level to FULL mark on dipstick.
D Change brake system high pressure oil filter element

40 (61)
TKU--- C 01040--- 1 EN 4004

D Check axle fastenings and oscillation axle tightenings
Tightening torques
Wheel nuts . . . . . . . . . . . 410 Nm (lub.)
Axle fast. bolts . . . . . . . . 500 Nm (dry)
Oscillation . . . . . . . . . . . . M12 85 Nm (dry)
..................... M16 210 Nm (dry)
D Check drive shaft flanges and bolts

Tightening torques (dry)
M 10 . . . . . . . . . . . . . . . . . . . . . . 49 Nm
M 12 . . . . . . . . . . . . . . . . . . . . . . 85 Nm
Support bearing M 20 . . . . . . . 410 Nm
Check the fastening bolts of the parking brake (loaders with LCB--brakes only)
M 16 . . . . . . . . . . . . . . . . . . . . . . 210 Nm
D Change return oil filter element for bucket-- and steering hydraulics
41 (61)
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D Check centre articulation with dial gauge

Place a dial gauge with a magnetic stand
on the upper hinge plate of the front
frame.
Press the bucket against
the ground so that the front
frame rises from the ground
and so you may observe the
readings of the dial gauge.
The reading should be
0,2...0,4 mm.
If the play is smaller or larger, use shims
to adjust it.
For further information look the workshop
manual.
D Check brake system

Measure brake linings wear
Pressurize service brake high enough,
that the low brake pressure light will not
illuminate during the test.
Push in pin until it contacts reaction
plate. If the wear indicator pin reach the
same level as the back side of the cast
brake housing. The brakes are worn out
and should be overhauled.
Check pressure accumulators.

Check accumulator nitrogen pre--charge
pressure (60 bar).
42 (61)
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D Change transmission oil and filters
Drain oil from the bottom of the
transmission and reinstall drain plug,
using a new gasket if required.
Be carefull when draining hot oil.
Change oil filters.
Fill torque converter and transmission
through filler opening until fluid comes up
to LOW mark on transmission dipstick.
Run engine two minutes at idle to prime
torque converter and hydraulic lines.
Recheck level of fluid in transmission
with engine running at idle.
Add quantity necessary to bring fluid
level to LOW mark on dipstick. Recheck
with hot oil.
Bring oil level to FULL mark on dipstick.
D Change oils in front and rear differentials, and in planetary hubs

Remove plug at bottom of axle housing
and allow sufficient time for lubricant to
drain. With planetary wheel ends, rotate
wheel until filler hole is down. Remove
plug and allow sufficient time for
draining. Be sure planet cover oil level
hole is in proper position refilling wheel
ends.
Always ensure, that the arrow is in down

position when checking oil level in
planetary hubs. Refer to attached pic--
ture.
D Change hydraulic oil fluid

Clean hydraulic oil tank.
Clean or replace suction screens.
Replace tank breather.
43 (61)
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D Test the hydraulic pressures

The hydraulic oil temperature should be 60...80 _C.
Connect and disconnect pressure gauge(s) only when the circuit is non pressurized.
Use only special couplings for pressure testing.
Do not overtighten couplings. When special couplings are used, finger tight is adequate.
Over tightening causes harmful leakage.
Use hose(s) long enough to read the gauge(s) while sitting in the cabin.
Pilot system pressure

-- Install a pressure gauge to the
quick disconnect fitting as shown
in attached picture.
-- Engine at low idle
-- Pressure should be 25 bar
(2,5 MPa)
Steering system pressure

-- Install the frame locking bar
between front and rear frames
-- Connect a pressure gauge to
quick disconnect fitting following
the steering main valve
-- Engine revs 1000--1500 rpm
-- Turn the machine to full left hand
turn
-- Steering system pressure should
be 125 bar (12,5 MPa)
44 (61)
TKU--- C 01040--- 1 EN 4004

Bucket hydraulic pressure

-- Connect a pressure gauge to the
quick disconnect fitting on the
bucket main valve manifold
-- Engine at 1000--1500 rpm
-- Lower the boom down against
the stops and keep the control
valve in “boom down” position.
-- Pressure should be 210 bar
(21,0 MPa)
D Check engine crankcase pressure

Check and record the crankcase pressure.
Check the crankcase breather.
See Deutz Workshop Manual.
D Check emergency steering system (option)

Check steering engine stopped.
Check accumulator nitrogen pre--charge pressure (60 bar)
45 (61)
TKU--- C 01040--- 1 EN 4004

D Service fire suppression system (option)

Note the general appearance of the dry
chemical tank for mechanical damage.
Check that the tank is filled with free--
flowing dry chemical.
Inspect the expellant gas cartridge for
mechanical damage. Weigh the cart--
ridge and replace it if the weight is not
within specifications stamped on the
cartridge.
NOTE! If system other than Ansul, have
system serviced by authorised system
supplier or dealer.
Always follow the local regulations.
D Check catalytic exhaust gas purifiers (Option)

Increased backpressure (2 to 3 inches
water gauge higher from clean purifier
when at high idle), excessive smoke, or
high levels of odor or irritation during
operation of the LHD loader indicates
that the purifier is not functioning at
optimum performance and should be
cleaned.
Cleaning of the purifier: Dry brush inlet
face to catalyst, air--clean through outlet
face of catalyst, soak catalyst in cleaning
solution (1 hour), solvent--air--clean
through outlet face, and air--clean
through outlet face.
Do not use solvents containing
chlorine, sulfur, metals, or leaded
gasoline.
46 (61)
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D Change V--belts
When replacing, always inspect fan
bearings.
D Service the hand extinquisher

Have the extinquisher serviced by
authorised supplier or dealer.
Always follow the local regulations.

D Check injectors
Clean if necessary.
Injection pressure 125 + 8 bar
Tightening 30 Nm + 60_ + 60_
See Engine Operation and Workshop
Manual, or contact your nearest Deutz
dealer.
47 (61)
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MAINTENANCE PROGRAM
4. MAINTENANCE PROGRAM
Every shift Page Done
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check air filter indicator and assembly condition . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check oil bath air cleaner (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Check transmission oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Check tyres and wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Check hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Grease oscillating axle* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Grease center articulation pins* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Grease steering cylinder pins* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Grease drive shaft universal joint at center articulation . . . . . . . . . . . . . . . . . . . . . 23
Grease lift cylinder pins, tilt cylinder pins and lift arm pins* . . . . . . . . . . . . . . . . . . 24
Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fill the automatic central lubrication system (option) . . . . . . . . . . . . . . . . . . . . . . . 24
Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Check that all the controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . 25
Check major components for oil leaks and mounting . . . . . . . . . . . . . . . . . . . . . . . 25
Check hand Fire Extinguisher (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check driving / working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fill water tank (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
* if automatic central lubrication is not installed
When completed
Date . . . . . . . . . . . . . . . . . . . . . . . Engine hours . . . . . . . . . . . . . . . .
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 (61)
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MAINTENANCE PROGRAM
Every week Page Done
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wash hydraulic oil cooler (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Clean exhaust water scrubber (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Check tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Check hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Grease drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Grease the stationary ends of boom / bucket pins . . . . . . . . . . . . . . . . . . . . . . . . . 29
Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Test steering hydraulics, test S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fill the automatic central lubrication system (option) . . . . . . . . . . . . . . . . . . . . . . . 24

49 (61)
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MAINTENANCE PROGRAM
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM
Every 125 hours1/2 Page Done
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clean cooling fins and oil coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Clean axhaust water scrubber (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Check wheel nut’s tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Grease drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Check and fill the automatic central lubrication system (option) . . . . . . . . . . . . . . 33
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Check junction boxes (If installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Check the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
51 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM
Every 125 hours2/2 Page Done

Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
General cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check cabin/canopy door and lock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM
Every 250 hours 1/2 Page Done
Change engine oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Clean centrifugal oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Service the air filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Check alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check oil level in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . 36
Change brake flushing return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check center articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
53 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM

Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lubricate door and hatch hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Check fire suppression system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lubricate seat linkages, pedal linkages and gear selector linkages . . . . . . . . . . 37
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check exhaust system fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Change fuel filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Drain water from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Change transmission oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check oil level in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . 36
Change brake system high pressure oil filter element . . . . . . . . . . . . . . . . . . . . . . 39
Change return oil filter element for bucket-- and steering hydraulics . . . . . . . . . . 40
Check axle fastenings and oscillation axle tightenings . . . . . . . . . . . . . . . . . . . . . . 40
Check center articulation with dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Check drive shaft flanges and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
55 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM
Check brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check fire suppression system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check engine crackcase pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Change transmission oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Change oils in front and rear differentials and in planetary hubs . . . . . . . . . . . . . 42
Change hydraulic oil fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
57 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM

Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Test the hydraulic pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Service fire suppression system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Check catalytic exhaust gas purifiers (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Check emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM

Change V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Check engine crackcase pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
59 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM

Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Service hand Fire Extinguisher (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Check engine crankcase pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check drive shaft flanges and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
61 (61)
TKU--- C 01040--- 1 EN 4004

MAINTENANCE PROGRAM

Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance MACHINE SOUS TERRAINE

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Maintenance

TKU--- C 01040--- 1 EN 4004

 SANDVIK TAMROCK CORP., TURKU PLANT 09/2004

TKU--- C 01040--- 1 EN 4004

Congratulations on your choice of a TORO loader.

Read the Operator’s Manual and General Safety

Always obey safety rules!

TKU--- C 01040--- 1 EN 4004

2. MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TKU--- C 01040--- 1 EN 4004

1.1. Importance of periodic maintenance

1.2. General safety precautions during operations

TKU--- C 01040--- 1 EN 4004

1.3. General repair instructions

TKU--- C 01040--- 1 EN 4004

1.4. Location of the main components

1. Front frame 3. Engine ass’y

TKU--- C 01040--- 1 EN 4004

1. Fuel tank 6. Breather

TKU--- C 01040--- 1 EN 4004

1. Alternator 5. Engine oil cooler

TKU--- C 01040--- 1 EN 4004

1.5. Locking devices

To remove the locking bar

TKU--- C 01040--- 1 EN 4004

Boom locking pins

1. Climb into the cabin and raise the

TKU--- C 01040--- 1 EN 4004

2. MAINTENANCE AND LUBRICATION

2.1. Hydraulics maintenance

TKU--- C 01040--- 1 EN 4004

2.2. Electric system maintenance

TKU--- C 01040--- 1 EN 4004

Working on live components

2.3. Battery maintenance

TKU--- C 01040--- 1 EN 4004

TKU--- C 01040--- 1 EN 4004

Viscosity above --20 _C SAE 15W/40

See engine Operation Manual for more details.

Operating temperatures during normal operation

TKU--- C 01040--- 1 EN 4004

2.5.4. Brake Hydraulics

Operating temperatures during normal operation

2.5.6. Grease nipples

TKU--- C 01040--- 1 EN 4004

2.6. Filling capacities

2.7. Special notes

2.7.1. Cooling system

2.7.2. Refilling fuel

TKU--- C 01040--- 1 EN 4004

2.8. First service

After the first 50 hours

TKU--- C 01040--- 1 EN 4004

D Check air filter indicator and assembly condition

Empty the discharge valve from dust by

TKU--- C 01040--- 1 EN 4004

D Check oil bath air cleaner (option)