TORO 400: Low Profile

Maintenance
Manual
TORO 400
Low Profile
TORO 400 Low Profile
(Cabin, Mercedes--Benz OM906LA)
MAINTENANCE
MANUAL
2 (69)
TKU--- C 01101--- 1 EN 4506
© SANDVIK MINING AND CONSTRUCTION OY, LOADERS TURKU 11/2006

TORO 400 Low Profile 3 (69)
TKU--- C 01101--- 1 EN 4506
PREFACE
Congratulations on your choice of a TORO loader.

This manual describes the maintenance and safety requirements for this TORO 400 LP
loader. Only those who have been given the proper training and are allowed to operate the
loader. All operators should familiarize themselves with the machine and fully understand
the contents of the operator’s manual, maintenance manual and general safety instructions
before operating it.
Read the Operator’s Manual and General Safety

Instructions before starting the work!
WARNING
This responsibility is particularly pertinent for personnel who work with the loader only
occasionally -- e.g., during setup or maintenance.
Continuing research and development at TORO loader’s may have caused changes to your
machine that are not dealt with in this manual.
If the machine is equipped with optional equipment -- e.g., a remote control system, you
should familiarize yourself with separate instruction manual, where the operation is
explained.
This manual must always remain available in the cabin for ready access when operating the
TORO loader.
Always obey the national legislation in force where accident prevention and environmental
protection are concerned. Generally accepted technical guidelines for safe and professional
operation must also be observed.
For demanding maintenance and repair operations, we recommend that you contact your
nearest authorized Sandvik Mining and Construction 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!

4 (69)
TKU--- C 01101--- 1 EN 4506
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Importance of regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. General safety precautions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3. General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Lifting methods and lifting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5. Location of the main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6. Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1. Maintenance of hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2. Electrical system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3. Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5. Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.1. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.2. Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.3. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.4. Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.5. Grease nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6. Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7. Special notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7.1. Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7.2. Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.8. First servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3. MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1. Every shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2. Every week . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3. Every 125 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4. Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.5. Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.6. Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.7. Every 1500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.8. Every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4. MAINTENANCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
TKU--- C 01101--- 1 EN 4506

GENERAL
1 GENERAL
1.1. Importance of regular maintenance

The TORO 400 LP is designed for hard work in difficult and demanding mine conditions.
To ensure trouble--free and economical operation, it is extremely important to adhere to
the schedule for regular maintenance. By following this schedule closely, you can easily
detect possible defects in the machine which can be repaired before they become serious.
This will ensure low repair costs and minimize production disturbances.
The pages that follow give information on servicing various TORO 400 LP components
and the corresponding service intervals. We urge all end users to review the Mercedes
Benz Operating Instructions for additional information regarding servicing.
1.2. General safety precautions during operation

We recommend that records be kept on servicing and wearing part replacements. Regular
maintenance procedures at the correct intervals increase productivity, reliability, economy
and the 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. Be sure to follow them.
Personnel must not wear long, loose hair or loose clothing, nor should they wear jewelry,
including rings, because of the risk of injury.
Use personal protection suits and other protective equipment as far as is necessary or
mandatory.
Do not perform any modifications, extensions or rebuilding of the machine that 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 of frame structures.
Spare parts must meet the manufacturer’s technical specifications. Conformity to these
standards is guaranteed only when genuine spare parts are used.
Notify the location and use of fire extinguishers!
It is absolutely necessary to have suitable specialized workshop equipment to ensure
high--quality maintenance work.
Any maintenance or repair work on the TORO loader must be performed by properly
trained or instructed personnel only. Work must be performed on electrical appliances by
electricians and on hydraulic appliances by mechanical technicians with knowledge and
experience particular to the work to be done.
6 (69)
TKU--- C 01101--- 1 EN 4506
GENERAL
Carry out any activity specified in this manual with respect to adjustment, maintenance
and inspection times, in addition to heeding any indications for 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 with other
cleansers, cover the alternator, connection boxes and major connections. Remove the
covers after cleaning!
Never attempt to clean, adjust, repair or lubricate the TORO loader while it is in
motion or the engine is running.
1.3. General repair instructions

The person responsible for maintenance and repairs should be clearly identified.
-- Do not do any work that you are not authorized to do.
-- Secure extensively, as far as necessary, the area where the maintenance work will
be performed.
-- Inform the users of the equipment of the start of maintenance or any special work
on the loader.
-- 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 be removed only by a person who is fully aware of the
situation.
-- If required, ensure that suitable and safe ladders or working platforms are available
for use in repair and maintenance work.
-- Do not use any of the equipment as steps. If maintenance work must be done high
up, or in an otherwise dangerous place or position, use the safety devices
necessary 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 right tools for the maintenance task.
-- Before commencing maintenance or repair work, ensure that the vehicle is on level
ground and won’t move.
-- Pay special attention to the exhaust pipe--work and the exhaust gas cleaning
system. Ensure sufficient ventilation.
TKU--- C 01101--- 1 EN 4506

GENERAL
-- Use a lift jack only on level, hard, and firm ground. Before using a jack, always be sure
the wheels on the other side of the vehicle are blocked. To prevent the possibility of
the jack slipping, secure the vehicle by using adequate supports and blocks
underneath it.
Crushing hazard. Can cause severe injury or death. MAKE SURE THAT
THERE ARE NO UNAUTHORIZED PERSONS IN THE DANGER AREA.
Tyre may overturn during handling.
WARNING
-- Deflate the air from tire so that it just has enough air pressure to hold the rim parts
firmly in place before loosening the wheel nuts/bolts. If 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
them with new parts of the same size, type, and make.
-- Never transport a fully inflated spare tire mounted on demountable rims. Such tires
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 proper torque applied to all the
wheel nuts/bolts should the tire be inflated to the correct operating pressure.
-- In 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 can stand to one side.
-- When replacing heavy parts, use correct lifting apparatus and techniques.
-- After preventive maintenance and repairs, always tighten fasteners that have been
unscrewed. Reassemble all dismantled safety appliances immediately after the work
is done. Ensure that all safety systems are tested before the unit is returned to
normal work.
-- Pay attention to safety and environmental protection when disposing of process
materials and old parts.
8 (69)
TKU--- C 01101--- 1 EN 4506
GENERAL
1.4. Lifting methods and lifting points
Always respect the law and all the local safety regulations in lifting work.
WARNING
Keep in mind the total weight of the loader, given in the technical data of
WARNING these instructions.
The lifting points (four) have been marked with hook symbols.
Open the cover on

the rear lifting
points.
D The lifting device used must be of the correct type and have INCORRECT
sufficient lifting capacity. The loader or parts of it must not be
lifted with any devices that are not specifically designed for
lifting purposes.
D You must always know the exact weight of the load, and never
exceed the lifting capacity specified by the manufacturer of the
lifting device.
D The lifting routes should be planned so that the load is not
moved over persons or such places where persons may be
present.
D Make sure that the lifting equipment are in proper condition. CORRECT
D Wire ropes and chains used for lifting must be checked
regularly. Damaged wire ropes must be marked clearly and
discarded at once.
D Install the frame locking bar always before lifting the loader.
D Lift the load only a few centimetres at first to make sure that
it is properly fastened and in balance. Do not continue lifting
until you are sure of proper fastening and balance.
D Never wind the ropes around the hook of the hoist. The
lifting ropes must be fastened according to the
manufacturer’s instructions.
TKU--- C 01101--- 1 EN 4506

GENERAL
1.5. Location of the main components
1
3
2 4
1. Front frame 3. Engine ass’y

2. Rear frame 4. Power train
Front frame
2
1. Bucket
3
2. Swing lever
3. Boom
4. Lift cylinders
5. Tilt cylinders
5 5
4 4
10 (69)
TKU--- C 01101--- 1 EN 4506
GENERAL
Rear frame
8 7
7
6 2
9
1 6
4
5
1. Fuel tank 6. Operator’s cabin

2. Oil cooler 7. Service hatches
3. Hydraulic oil tank
4. Main switch 8. Fuel filters
5. Battery box 9. Air conditioning unit
Engine ass’y
5
3 9
8 4
10
2 1
1. Alternator
2. Turbocharger
3. Fuel filter
4. Engine oil filters
6
5. Oil dipstick
6. Fuel prefilter with water separator
7. Transmission oil filters
8. Exhaust manifold 7
9. Intake manifold
10. Engine Control Unit connectors
TKU--- C 01101--- 1 EN 4506

GENERAL
Power train
1. Front axle
2. Rear axle
3. Transmission
4. Torque converter
5. Driveshaft
4 2 5 3 5 5 1
1.6. Locking devices

Frame locking bar
WARNING
How to install the frame locking bar.

1. Remove the bar from its holder.
2. Remove the pins from the frame
lugs.
3. Insert the locking bar into the middle
of frame lugs so that cabin sided pin
drops into the hole as shown in
attached picture.
4. Return to the cabin and turn on the
engine and slowly move the steering
from left to right a little until the front
frame pin drops down into the
second hole. It’s necessary that
second person helps the operator by
giving signs of bars movement,
because observing the locking bar
from the cabin is difficult.
5. Ensure that the bar is fixed.
Note: Observe the pin. When it drops

down, stop turning.
To remove the locking bar.
1. Climb into the cabin. Sound the horn and have a good look around. 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.
3. Replace the pins to the frame lugs and the locking bar to its holder.
12 (69)
TKU--- C 01101--- 1 EN 4506
GENERAL
Boom safety stand (optional)

WARNING
How to install the safety stand.
1. Get into the cabin. Sound the horn

and have a look around to see that it
is safe to turn on the engine.
2. Switch on the engine and raise the

boom high enough and tilt the bucket
downwards.
3. Turn off the loader and step out of the
cabin.
4. As quickly as possible without walking under the boom place the stand under the boom
with you standing away from the boom and bucket.
5. When you are happy with the position of the stand go back into the cabin and sound
the horn again and again have a good look around to make sure it is safe to turn on
the engine. Turn on the engine and lower the boom slowly onto the stand.
6. When you are satisfied with the position of the boom turn off the engine and go and
check the stand to make sure the boom is supported safely and properly.
7. When you are happy that all possible safety procedure’s have being completed, it is
safe to work under the boom.
8. From time to time or if you have left the unit of a long period of time it is important that
you check that all the safety devices are in good contidion and are fitted correctly
before continuing work on the unit.
To remove the safety stand.

1. Walk around the unit and ensure no--one is working on the unit or under the boom.
2. Sound the horn and have a look around. When it is safety start the engine.
3. Raise the boom so that the safety stand can be removed and then turn off the engine.
4. Remove the safety stand. Don’t walk under the boom under any circumstances.
5. Go back into the cabin, sound the horn again and turn on the engine, lower the boom
slowly against the stops and the bucket to the ground.
TKU--- C 01101--- 1 EN 4506

GENERAL
Boom support bars

WARNING
How to install the support bars.
1. It is recommended that before you

install the boom support bars the
frame locking bar is fitted in place as
described in the previous page.
2. Ensure the boom is in the hauling
position. Climb up on a safe platform
and remove the srews that keep the
boom support bars on the front
frame. Lift the supports from their
holder and replace the mounting
parts.
3. Climb into the cabin and sound the

horn to let everyone know that you
are about to turn on the engine. Have
a good look around to see that it is
safe to turn on the engine.
4. Turn on the engine and raise the

boom high enough and tilt the bucket
downwards. Turn off the engine.
5. Climb up onto a safe platform and

remove the locking pins from their
holders from the both sides of the
boom. Hang the boom supports
correctly into their notches, lock with
the pins and secure with the screws
as shown in attached picture. Make
sure that no--one is walking under the
boom under any circumstances.
6. Get into the cabin and turn on the

engine. Lower the boom slowly so
that the lower ends of the service
supports catch the notches on both
sides of the front frame side plates.
While lowering the boom. It is
necessary to have a second person
to give directions to the operator as it
is difficult to see the boom service
support while seated in the cabin.
14 (69)
TKU--- C 01101--- 1 EN 4506
GENERAL
To remove the support bars.
1. Walk around the unit and ensure no--one is working on the unit or under the boom.
2. Sound the horn and have a look around. When it is safety start the engine.
3. Raise the boom so that the support bars can be removed and then turn off the engine.
4. Climb up onto a safe platform and remove the pins and boom support bars. Replace
the lock pins and the screws back into the boom(lubricate the screws from time to
time). Place the support bars and the mounting parts back onto the front frame holder.
Don’t walk under the boom under any circumstances.
5. Go back into the cabin, sound the horn again and turn on the engine, lower the boom
slowly against the stops and the bucket to the ground.
TKU--- C 01101--- 1 EN 4506

MAINTENANCE AND LUBRICATION
2. MAINTENANCE AND LUBRICATION

The TORO 400 LP is designed for hard work in difficult and demanding mine conditions.
To ensure trouble--free and economical operation, it is extremely important to adhere to
the service schedule indicated. By paying close attention to the service schedule, you can
easily detect possible defects in the machine or other problems that can be addressed
before they become serious. This will ensure low repair costs and minimize disturbances
to production.
The following pages give information for servicing various TORO 400 LP components and
other items for servicing, with their corresponding service intervals. All end users should
review the Engine Manuals for additional information regarding servicing.
2.1. Maintenance of hydraulics

Maintenance, repair, and installation of hydraulic equipment must be carried out only 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 when 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 in a hose or a connection by using your hand. The
high-pressure oil spray from the leak can penetrate the skin and cause serious
injury. 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 the 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 not
pressurized.
D Use only special couplings for pressure testing.
D Do not over--tighten couplings. When special couplings are used,
finger--tightening is adequate. Over--tightening leads to harmful leakage.
D Use hose(s) long enough to read the gauge(s) while the operator is sitting in the
cabin.
16 (69)
TKU--- C 01101--- 1 EN 4506
Tests
Pilot system pressure
. Engine at low idle.
. Pressure should be 35 bar (3.5 MPa).
Steering system pressure
. Install the frame locking bar between the front and rear frames.
. Engine speed: 1000--1200 rpm.
. Turn the machine to full left--hand turn position.
. Steering system pressure should be 210 bar (21.0 MPa) with the stick
steering.
Bucket hydraulic pressure
. Engine at 1000--1200 rpm.
. Lower the boom against the stops and keep the control valve in ”boom
down” position.
. Pressure should be 200 bar (20.0 MPa).
2.2. Electrical system maintenance

D Work on electrical equipment or components is only to be carried out by qualified
electricians.
D Local electrotechnical and electric safety regulations must always be observed.
D Always use only original electrical components.
D Do not touch battery terminals, alternator terminals, or wiring while the engine is
operating. Severe electrical shock, which may result in injury, could occur due to
improper shielding of electrical components.
D Check the electrical devices of the machinery regularly. Faults, such as loose wires
and damaged insulation, must be repaired at once.
D Before making any changes concerning the electrical devices, SANDVIK
MINING AND CONSTRUCTION’s electrical engineering department must be
consulted and a written authorization received, to ensure that the operation
of the device does not change.
TKU--- C 01101--- 1 EN 4506

Working on live components

D If the component must be live during the work, another worker must be standing
by to cut off voltage at the emergency or main switch should an emergency
situation occur. Follow electrical 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, then the positive (+) pole. Always
connect the positive pole (+) first, then the negative (-) pole.
D Reversing battery polarity can result in personal injury caused by sudden
discharge of electrolyte from the battery vents and/or the sudden rupture of the
battery case due to explosion of internal hydrogen gas.
D To prevent sparking when connecting a battery charger, disconnect the charger
supply cord or switch the charger off before connecting the charging wires to the
battery terminals. Open the battery’s cell caps slightly during charging to allow the
gases generated to escape.
D The acid in the battery burns the 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 oxygen and
hydrogen during charging and discharging, 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 -- and never immediately
after use. With a high enough electrolyte level, the cells have less space for gases.
D Use a 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 electrical devices by making contact with the battery terminal.
18 (69)
TKU--- C 01101--- 1 EN 4506
2.4. Welding
Before starting to weld, determine the material to be welded and select an appropriate
welding method and fillers. Contact SANDVIK MINING AND CONSTRUCTION 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 The control unit connectors must only be removed or inserted when the electrical
system has been switched off.
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 When welding painted area, paint must be removed from the adequate area to
avoid the fumes from the paint.
D Arrange adequate ventilation or use welding fume extractor.
D Use a protective mask and other personal protective devices when welding.
D Arrange protection against fire.
TKU--- C 01101--- 1 EN 4506

2.5. Lubricants
2.5.1. Engine
Mercedes--Benz OM 906 LA
Specifications for Operating Engine oil 228.5 /

Mercerdes--Benz Specifications for Service Products.
Engine oil which are tested and approved in with 228.3 / 228.0 Mercedes--Benz
Specifications for Service Products can be used when halving the interval.
Viscosity above ..--25_C SAE 5W--40 / SAE 5W--30

+5_C .. +30_C SAE 10W--30 / SAE 10W--40
above ..+20_C SAE 15W--40 / SAE 15W--50
Diesel fuel sulphur content max 0.3 % (by weight). In case of sulphur content more then 0,3
% by weight, the replacement intervals for engine oli and filters should be halved. If sulphur
content exceeds 0.8% by weight, the replacement intervals should be reduced to 30% of
values listed.
The use of engine oil brands which have not been apporoved may lead to increased wear
of engine. Do not use any Oil additives.
See Mercedes--Benz Operating Instructions for more details.
2.5.2. Transmission
DANA SOH R 32421
When choosing the optimum viscosity grade of fluid, duty cycle, preheat capabilities, and/or
geographical location must be taken into consideration.
Oil classification. API CD/SE or CD/SF

See separate DANA Maintenance & Service Manual for recommended lubricants.
Viscosity --20_C...+15_C SAE10 W--30

above ..+0_C SAE30
Note! Normal drain periods and filter change intervals are for average environmental and
duty--cycle conditions. Severe or sustained high operating temperatures or very dusty
atmospheric conditions will cause accelerated deterioration and contamination. For
extreme conditions judgment must be used to determine the required change intervals.
20 (69)
TKU--- C 01101--- 1 EN 4506
2.5.3. Hydraulics
Hydraulic oils meeting DIN 51524 HVLP or ISO 6743--4 HV standards can be used
Viscosity
Operating temperatures during normal operation
about 45_C ISO VG 32

above --15_C ISO VG 32 (SAE 10W)

above +0_C ISO VG 46 (SAE 20)
above +5_C ISO VG 68 (SAE 30)
(Motor oils of API class CD, or hydraulic oils with wear--preventive characteristics
corresponding to the DIN 51524 HVLP or ISO 6743--4 HV standards, can be used)
2.5.4. Axles
Classification MIL--L--2105C
Viscosity above --40_C. SAE 75W/140
above --25_C SAE 80W/140
above --12_C SAE 85W/140
See Dana 19D Series Maintenance and Service Manual for more details.
2.5.5. Grease nipples

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

Engine oil 24 L (with filters min)
Engine oil 29 L (with filters max)
Transmission 50 L
Axles 44 L (with LCB)
Axles 35,5 L (without LCB)
Hydraulic oil tank appr. 400 L
Fuel tank appr. 300 L
Cooling system. 38.5 L
TKU--- C 01101--- 1 EN 4506

2.7. Special notes

If the machine is fitted with optional equipment such as an automatic central lubrication
system, please read the instructions for the additional equipment carefully and adhere to
the service schedule given in the maintenance instructions.
2.7.1. Cooling system

Note! Overheating indicates a fault. Stop the engine and repair the fault before more
serious damage is caused. Make sure that the engine radiator is not covered and that it
is not clogged.
D Whenever draining and refilling the cooling system, always recheck the coolant
level after the engine reaches its normal operating temperature.
Note! Never open the filler cap when hot.
When checking engine coolant level, stop the engine and allow it and the radiator to cool
down. If an overheated engine must be stopped, allow the radiator to cool down before
checking the coolant level. If there is no time for that, use thick gloves and protective
clothing when opening the radiator’s filling cap. Stand to the side, turn your face away, and
open the cap a little. Wait until the pressure is released and coolant stops running out, then
open the cap slowly.
D Adding new coolant too fast can cause air pockets in the cooling system.
D Operate with a thermostat in the cooling system all year round.

2.7.2. Refueling
The following precautions must be observed when adding fuel:
D Do not fill the fuel tank when the engine is running.
D Do not overfill.
D Take care not to spill fuel on hot surfaces.
D Addition of fuel should be done in a well--ventilated space.
D Smoking, open flames, and sparks are dangerous when the fuel tank is being filled.
D Clean up spilled fuel before starting the engine.
D Keep the filling pipe in contact with the fuel tank, or arrange grounding to prevent
sparking caused by static electricity.
D If fuel quick fill system is to be used, ensure that you are familiar with the system
manufacturer’s operating and safety requirements.
D If the ambient temperature is less than 0_C, winter--grade fuel (suitable down to
--20_C) should be used.

22 (69)
TKU--- C 01101--- 1 EN 4506
2.8. First servicing

Check that the lubricants being 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 the transmission oil filter elements
-- Change engine oil and filter elements
-- Change fuel filters
-- Check and tighten the exhaust manifolds’ bolts
-- Check that the air filter and air pipes are tight
-- Check valve clearence (readjust if necessary)
-- Check and tighten bolts of oil sump and engine mountings
-- Check/tighten bolts of the axles, wheels, gearbox, and other major components
-- Tighten the screws of the oscillating axle
M12 bolts to 72 Nm (lub)
M16 bolts to 160 Nm (lub)
-- Tighten the screws of driveshafts
-- Check V--belts
-- Make a visual overall check for leaks and possible damages
TKU--- C 01101--- 1 EN 4506

MAINTENANCE OPERATIONS
3. MAINTENANCE OPERATIONS
3.1. Every shift
Check engine oil
Machine on level ground. Measure the oil

level with engine stopped (after stopping
the engine, allow the oil drain to crankcase
for about 5 minutes before checking the oil
level).
The oil level must be between the LOW and
FULL marks on the dipstick.
Check V--belts
Check condition visually and adjust if

necessary.
Check belt for worn, grease coated, oil
soaked, or missing material. Replace if
necessary.
See Mercedes--Benz Operating
Instructions for more details.
Check air filter indicator and assembly condition
Inspect air restriction indicator and service

air cleaner elements as required.
Inspect the entire air system for leaks.
Tighten any loose connections.
24 (69)
TKU--- C 01101--- 1 EN 4506
Check intake ducting and connections for leaks
Check exhaust ducting and connections for leaks
Check transmission oil level
Machine on level ground.

Parking brake engaged.
Engine at low idle.
The gearshift lever in neutral position.
Transmission oil in operating temperature.
Lower inspection tap closed and upper tap
opened.
Transmission oil should drain from upper
inspection tap.
When the inspection is made, close the
upper tap.
Be careful with hot oil.
TKU--- C 01101--- 1 EN 4506

Check tires and wheel nuts
Check condition.
Visually check tire wear and air pressure.
Visually check for loose or missing wheel
nuts.
Check hydraulic oil level
Boom in down position and bucket on

ground. Oil level should be seen in the
upper sight glass.
Check air conditioning unit
Check the conditioning unit visually.

Read separate instructions of maintenance
work from the air conditioner maintenance
manual.
Check engine coolant level
Check before starting the engine.

Coolant level should be seen via the sight
glass.
Do not remove the pressure control cap or
attemp to drain the coolant until the engine
has cooled.
Use extreme caution when removing the
cap. A sudden pressure release from a
heated cooling system can result in a loss
of coolant and possible personal injury
(scaling, eye injury, etc.) from the hot liquid.
26 (69)
TKU--- C 01101--- 1 EN 4506
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 . . . . . . . . . . . . . . . 1700 rpm/1st gear
Parking Brake . . . . . . . . . . . . . . . 1700 rpm/1st gear
Emerg. Brake . . . . . . . . . . . . . . . . 1700 rpm/1st gear
Note! When testing parking brake hold with a unit equipped with LCB--brakes. Parking
brake test button must be pushed and kept down to get 1st gear engaged.
Posi--stop brakes
Service Brake . . . . . . . . . . . . . . . 2000 rpm/1st gear
Parking Brake . . . . . . . . . . . . . . . 2000 rpm/1st gear
Emerg. Brake . . . . . . . . . . . . . . . . 2000 rpm/1st gear
-- Check that emergency brake applies when brake button is pushed -- service brake signal
light should come on.
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.
Check the emergency steering system (option)

Check the emergency steering system’s function (option). Turn the ignition key to the “0”
position to turn off the engine. When the engine has stopped, turn the ignition key to the
“1” position. Push the emergency steering test button on the instrument panel. Power pack
should start and the signal light on the instrument panel illuminates. Concurrently turn the
steering lever or the steering wheel, the machine should turn.
Note! The machine cannot be turned, if the cabin door is open.
TKU--- C 01101--- 1 EN 4506

Check major components for oil leaks and proper mounting

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

No corrosion.
Firmly mounted.
Visually check that seals are in place.
Check driving/working lights
Front
Rear
Optional lights
Check gauges and indicator lights
Check the indicator lights.

When the engine is operating at its normal
temperature the gauge pointer is in be-
tween 80_C --100_C . If the pointer moves
to the 120_C the engine is getting too hot.
Stop the engine and trace the trouble.
Engine oil pressure; Minium oil pressure
with a warmed up engine at slow idle
should be at least 50 kPa (0,5 bar) and at
rated speed at least 250 kPa (2,5 bar).
Brake system oil pressure; warning light
illuminates when pressure drops too low.
Alternator charging voltage;
approx. 26--28 V.
Transmission oil pressure; should be
16.9 – 19.6 bar.
28 (69)
TKU--- C 01101--- 1 EN 4506
Fill fuel tank
Shut off engine before filling.

Do not overfill.
Do not fill fuel tank to the top. Fuel expands
when it becomes warm and can overflow.
Fill automatic central lubrication system (option)
Check the system visually and fill it.

Check that all lubrication points are well
greased.
Grease lift cylinder pins, tilt cylinder pins, and lift arm pins
Rear pins of the cylinders trough the

lubrication manifold on the front frame and
front pins directly through the nipples.
(If automatic central lubrication is not
installed)
Greas dogbone pins.
Note! Due to different mine conditions it may be needed to grease the unit more
than once a shift.
TKU--- C 01101--- 1 EN 4506

Grease center articulation pins
Grease point located at central lubrication

manifold on rear frame.
installed)
Grease steering cylinder pins
Rear pins through the lubrication manifold

on the rear frame and front pins through the
lubrication manifolds on the front frame.
installed)
Grease oscillating axle
Grease point located at lubrication block on

rear frame near the middle hinge.
installed)
30 (69)
TKU--- C 01101--- 1 EN 4506
Grease drive shaft Universal joint at centre articulation
Use hand grease gun.
Grease ejector cylinder pins (option)
Grease pins directly through the nipples

with a hand grease gun.
Check remote control system (option)

Check RC system function according to Remote Control system instructions.
TKU--- C 01101--- 1 EN 4506

3.2. Every week

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).
Note! Due to different mine conditions it
may be needed to wash the oil cooler
more that every week.
Check tire pressures
20.5R x 25 L5 Bridgestone
Front: 625 kPa (6.25 bar)
Rear: 400 kPa (4.0 bar)
Test transmission and the bucket and steering hydraulics

The transmission and hydraulics should be at operating temperature during
measurement.
A Transmission: Press brake pedal, engage highest gear, and accelerate. The engine
should achieve about a 2200--2400 rpm stalling speed.
B Bucket hydraulics: Lower the boom against the stops, keep the control valve in ”boom
down” position, and accelerate. The engine should achieve about a 2240--2400 rpm
stalling speed.
C Steering hydraulics: Turn the loader against the stops, keep the control valve in the
selected position, and accelerate. The engine should achieve about a 2360--2400 rpm
stalling speed.
32 (69)
TKU--- C 01101--- 1 EN 4506
3.3. Every 125 hours

Check wheel nut’s tightening torques
UNF 3/4, 610 Nm (lub)
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 electronic
components.
Do not apply solvent to hot surfaces.
TKU--- C 01101--- 1 EN 4506

Check cabin/canopy door and lock condition.
Check that the cabin/canopy door and lock

works properly.
Check junction boxes
Open all junction boxes.

-- Check that all boxes are dry
-- Ensure that the components and junction
boxes are mounted properly
-- Visually check for possible loose wires
inside the junction boxes
Check cables
Visually check the cables for

-- Wearing
-- Sharp bends
-- Other possible damage
34 (69)
TKU--- C 01101--- 1 EN 4506
Check the instrument panel
Open instrument panel and check

-- Mounting of components
-- Condition of wiring
Grease driveshafts and shaft bearing
Grease all driveshafts U--joints.

Grease driveshaft bearing.
Check automatic central lubrication system
Operation.
Timer.
Correct grease amount.
Individually check all grease points.
In order to prevent impurities from coming
into the system, the SGH 50 pump unit is
provided with a high--pressure filter, which
has to cleaned every six months.
It is due to check at certain intervals that the
lubricating pipes are undamaged and the lu-
bricant reaches the lubrication points.
Check workshop manual if more information
is required.
TKU--- C 01101--- 1 EN 4506

Service the air filter elements
The air filter element must be replaced

when the service indicators 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.
Check engine mountings
Check the condition of mounting pads.

Tighten and/or repair if necessary.
36 (69)
TKU--- C 01101--- 1 EN 4506
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.
Check alternator
Check alternator terminals for loose

connections and corrosion.
Check mounting.
Check V--belts. Replace if necessary.
See Mercedes--Benz Operating
Instructions for more details.
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.
TKU--- C 01101--- 1 EN 4506

Change brake flushing return filter
Location arrowed in attached picture.
Check center articulation
Check for visual signs of wear.

Check that the lubrication works.
Lubricate operator seat linkages, brake and throttle pedal linkages

38 (69)
TKU--- C 01101--- 1 EN 4506
Lubricate door and hatch hinges.
Lubricate door and hatch hinges, check that

the cabin door and lock (or latch) works
properly.
Grease the stationary ends of boom / bucket pins
Use a hand grease gun.

TKU--- C 01101--- 1 EN 4506

Check fire suppression system (option)
Check ”quick check” that the system is

operable.
Check that the system has not been
tampered with and that there is no obvious
physical damage or problems that would
prevent operation.
Follow the service recommendations of any
locally fitted fire suppression system.
Change coarse and fine air filters
Filters change interval depends on

dustness and humidity of the mine.
For further information, check air
conditioner maintenance manual.
40 (69)
TKU--- C 01101--- 1 EN 4506

Change engine oil and filters
Run the engine until operating temperatue

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.
Lightly coat the new filter seals with clean
lubricating 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 5 min.
Recheck oil level and add oil if needed,
bringing oil level to FULL mark on the dip-
stick.
For further information, check
Mercedes--Benz Operation Instructios.
Check exhaust system fastenings
Check exhaust manifold fastening nuts,

exhaust flange, and other connections for
tightness.
Check axle fastenings and oscillation axle tightenings
Tightening torques (lub)

Wheel nuts . . . . . . . . . . . . 610 Nm
Axle fastening nuts . . . . . 1000 Nm
Axle fastening lock nuts . 500 Nm
Oscillation M 12 (8.8) . . . 72 Nm
M 16 (8.8) . . . . . . . . . . . . 160 Nm
M 24 (8.8) . . . . . . . . . . . . 600 Nm
TKU--- C 01101--- 1 EN 4506

Measure wear to the brake linings
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.
Drain water from fuel tank
Check cooling system hoses
Check for signs of deterioration and replace

if necessery.
42 (69)
TKU--- C 01101--- 1 EN 4506
Check the tightening torques of power train flanges and bolts
Tightening torques
UNF 3/8 . . . . . . . . . . . . . . . . 45 Nm
UNF 1/2 . . . . . . . . . . . . . . . . 110 Nm
M10 . . . . . . . . . . . . . . . . . . . 49 Nm
M12 . . . . . . . . . . . . . . . . . . . 85 Nm
U--shaft bearing M20 . . . . 410 Nm
Change transmission oil filters

Add quantity necessary to bring fluid level
to upper inspection tap.
Change return oil filter element for bucket and steering hydraulics
TKU--- C 01101--- 1 EN 4506

Check center 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, consult the
workshop manual.
Change high pressure oil filter elements
Change the filter every 500 hours or, if the

alarm is showed on the display.
Red shows in window before by--pass
opens to indicate element needs changing.
Change micro air filter
Filters change interval depends on

dustness and humidity of the mine.
For further information, check air
conditioner maintenance manual.
44 (69)
TKU--- C 01101--- 1 EN 4506

Check valve clearances
Check the valve clearence when the engine

is cold (at least 30 minutes after the engine 2 3
was stopped, even if it was only operated 4
for a brief period).
Clean dirty cylinder head covers before re-
moving.
1
Check with engine cold.
1 Intake valves 0,4 mm.
2 Outlet valves 0,6 mm.
3 Adjustment screw
4 Lock nut
For furter information, check Mercedes--
Benz Operating Instructions.
Check catalytic exhaust gas purifiers
The sulphur content of the fuel has an effect

on the service life and frequency of mainte-
nance of the catalytic converter. The struc-
ture is designed so that the back pressure
does not become detrimentally high.
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.
Contact your nearest Sandvik service centre in the event that

complicated maintenance and repair work is required. Sandvik’s trained
maintenance personnels guarantee a successful repair result.
CAUTION
TKU--- C 01101--- 1 EN 4506

Change transmission oil and filters
Drain oil from the bottom of the

transmission and reinstall drain plug, using
a new gasket if required. (Emptying hose
with a ball valve might also be used for
draining oil).
Be careful when draining hot oil.
Change oil filter.
Fill torque converter and transmission
through filler opening until fluid drains from
the lower inspection tap. close the tap.
Run engine for 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 drain from the lower tap. Recheck with
hot oil. Bring oil level to drain from the upper
tap.
Do not forget to close the taps.
Change oil 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 when refilling wheel ends.
Always ensure that the arrow is in down
position when checking oil level in planetary
hubs. Refer to the picture.
46 (69)
TKU--- C 01101--- 1 EN 4506
Test the hydraulic pressures

The hydraulic oil temperature should be 60...80_C.
Connect and disconnect pressure gauge(s) only when the circuit is not 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 35 bar
(3.5 MPa).
Bucket hydraulic pressure
-- Connect a pressure gauge to

the quick--disconnect fitting as
shown in attached picture.
-- Engine at 1000--1200 rpm.
-- Lower the boom down against
the stops and keep the control
valve in ”boom down” position.
-- Pressure should be 200 bar
(20.0 MPa)
TKU--- C 01101--- 1 EN 4506

Steering system pressure
Location of the measuring point may differ

as shown in attached picture, depending
how the machine is equipped.
-- Install the frame locking bar
between front and rear frames.
-- Connect a pressure gauge to the
quick--disconnect fitting after the
steering main valve.
-- Engine revs 1000 -- 1200 rpm.
-- Turn the machine to full left hand
turn.
-- Steering system pressure
should be:
(stick) 120 bar (12.0 MPa).
Check pressure accumulators
Pre--charge pressures (nitrogen pressure)

-- Brake system accumulators(LCB): 90 bar
(P--S): 80 bar
-- Parking brake accumulators(LCB): 90 bar
-- Boom suspension (option): 60 bar
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 cartridge
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.
48 (69)
TKU--- C 01101--- 1 EN 4506
Change hydraulic oil
Clean hydraulic oil tank.

Clean or replace suction screens.
Change breather filter for hydraulic tank
Inspect the cooling system
Inspect coolant level, adjust to correct level

if necessery.
Fill cooling system with compressed air
through tester.
Test pressure approx. 1.0 bar (14psi) and
test time approx. 5 to 10 minutes, after this
release pressure.
Benz Oparating Instructions.
TKU--- C 01101--- 1 EN 4506


Change fuel filter elements
A three--way valve is installed in the lowest

point of the fuel return line.
Turn the handle on the three--way valve to
the maintenance position (vertical).
In maintenance position the line to the fuel
tank is blocked and the line to the engine is
open so that the fuel can be drained from
the fuel filter when cap is open.
In order to simplity maintenance, a hose
has been installed to the discharge side, so
that the fuel can be easily drained to a con-
tainer.
Note! The direction of the flow is under-
standable from the stem marking.
Clean the outside of the fuel prefilter and

cover any hoses / lines under the prefilter.
Unscrew cap (1) and pull it out of the filter
housing together with filter element.
Clean cap and filter element. 1
Replace the filter element if it is very dirty or
damaged.
Check sealing ring for the cap and replace
if necessery.
Insert the filter element in the cap and screw
the cap into the filter housing. Tightening
torgue: 25Nm.
50 (69)
TKU--- C 01101--- 1 EN 4506
Open the drain valve (3) and loosen the

vent screw. Collect the fuel / water mixture 4
from the filter element in a suitable
receptacle.
Unscrew the filter element.
Remove the separator (2) vessel from the
filter element and clean or replace as nec-
essary.
Refit in the reverse order. Use new sealing
rings when fitting.
Screw the filter element onto the filter head 2
tightly by hand.
3
Close the drain valve and fill the prefilter us-
ing the fuel pump (4). Then close the vent
screw. Turn the handle on the three--way
valve to the opened position (horizontal).
Start the engine and bleed the fuel system.
Leave the engine runing for about 1 minute.
The fuel system bleeds automatically.
TKU--- C 01101--- 1 EN 4506

Drain and renew coolant
Open the engine cooling system radiator

cap slowly. Relieve excess pressure.
Only check and correct the coolant level
when the coolant temperatue is below
50_C.
Drain the radiator and engine block.
Flush the cooling system.
Only use prepared coolant with 50% by

volume antifreeze / corrosion inhibitor for
topping up.
Fill slowly to avoid air pockets, keep the ra-
diator bleeder screw open.
52 (69)
TKU--- C 01101--- 1 EN 4506

Service the hand extinguisher (option)
Have the extinguisher serviced by an
authorized supplier or dealer.
Always follow the local regulations.
TKU--- C 01101--- 1 EN 4506

MAINTENANCE PROGRAM
4. MAINTENANCE PROGRAM
Every shift Page Done
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Check air filter indicators and assembly condition . . . . . . . . . . . . . . . . . . . . . . . . . 23
Check intake and exhaust ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Check transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Check tires and wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Check hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Check air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Check engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Test service and parking brake function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check that all controls are functioning correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check the emergency steering system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check major components for oil leaks and proper mounting . . . . . . . . . . . . . . . . 27
Check hand fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check driving/working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check gauges and indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fill the automatic central lubrication system (option) . . . . . . . . . . . . . . . . . . . . . . . 28
Grease lift cylinder pins, tilt cylinder pins, and lift arm pins* . . . . . . . . . . . . . . . . . 28
Grease center articulation and steering cylinder pins* . . . . . . . . . . . . . . . . . . . . . . 29
Grease oscillating axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Grease driveshaft U--joint at centre articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Grease ejector cylinder pins (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Check remote control system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
* if automatic central lubrication is not installed
When completed
Date . . . . . . . . . . . . . . . . . . . . . . . Engine hours . . . . . . . . . . . . . . . .

Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54 (69)
TKU--- C 01101--- 1 EN 4506
MAINTENANCE PROGRAM
Every week Page Done
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Check air filter indicators and assembly condition . . . . . . . . . . . . . . . . . . . . . . . . . 23
Wash hydraulic oil cooler (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check tire pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Test transmission hydraulics, test A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Test bucket hydraulics, test B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Test steering hydraulics, test C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fill the automatic central lubrication system (option) . . . . . . . . . . . . . . . . . . . . . . . 28
Grease center articulation and steering cylinder pins . . . . . . . . . . . . . . . . . . . . . . . 29
Grease driveshaft U--joint at centre articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

TKU--- C 01101--- 1 EN 4506

MAINTENANCE PROGRAM
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56 (69)
TKU--- C 01101--- 1 EN 4506
MAINTENANCE PROGRAM
Every 125 hours 1/2 Page Done
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Check air filter indicator and assembly condition . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Check wheel nut’s tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check the instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Check cabin door and lock condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Check junction boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Check and fill the automatic central lubrication system (option) . . . . . . . . . . . . . . 34
Grease driveshafts and driveshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TKU--- C 01101--- 1 EN 4506

MAINTENANCE PROGRAM

General cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58 (69)
TKU--- C 01101--- 1 EN 4506
MAINTENANCE PROGRAM
Check engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Check engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Service the air filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Change coarse and fine air filters (if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check oil level in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . 36
Change brake flushing return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TKU--- C 01101--- 1 EN 4506

MAINTENANCE PROGRAM

Grease the stationary ends of boom/bucket pins . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Lubricate operator seat linkages, brake and throttle pedal linkages . . . . . . . . . . 37
Lubricate door and hatch hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check center articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Check fire suppression system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 (69)
TKU--- C 01101--- 1 EN 4506
MAINTENANCE PROGRAM
Change engine oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Check exhaust system fastenings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check cooling system hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Change micro air filter (if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Change transmission oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Change return oil filter element for bucket and steering hydraulics . . . . . . . . . . . 42
Change high pressure oil filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Drain water from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Check the tightening torques of power train flanges and bolts . . . . . . . . . . . . . . . 42
Check axle fastenings and oscillation axle tightenings . . . . . . . . . . . . . . . . . . . . . . 40
Measure wear to brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TKU--- C 01101--- 1 EN 4506

MAINTENANCE PROGRAM

Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Check center articulation with dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62 (69)
TKU--- C 01101--- 1 EN 4506
MAINTENANCE PROGRAM

Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Check valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Inspect cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Clean cooling fins and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check catalytic exhaust gas purifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Change transmission oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Change breather filter for hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Change hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Change oil in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TKU--- C 01101--- 1 EN 4506

MAINTENANCE PROGRAM

Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Test the hydraulic pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspect the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Service fire suppression system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

64 (69)
TKU--- C 01101--- 1 EN 4506
MAINTENANCE PROGRAM
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TKU--- C 01101--- 1 EN 4506

MAINTENANCE PROGRAM
Change fuel filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Drain and renew coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Check V--belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Change transmission oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
66 (69)
TKU--- C 01101--- 1 EN 4506
MAINTENANCE PROGRAM

Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspect the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Grease driveshafts and driveshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TKU--- C 01101--- 1 EN 4506

MAINTENANCE PROGRAM

Check valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Inspect cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Check batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Change fuel filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Check catalytic exhaust gas purifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Change transmission oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Change breather filter for hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Change hydraulic oil fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Change oil in planetary hubs and differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
68 (69)
TKU--- C 01101--- 1 EN 4506
MAINTENANCE PROGRAM

Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Record = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Test the hydraulic pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Check cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lubricate operator seat linkages, throttle and brake pedal linkages . . . . . . . . . . 37
Service hand fire extinguisher (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Service fire suppression system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

TKU--- C 01101--- 1 EN 4506

MAINTENANCE PROGRAM
When completed
Special Notes
Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORO 400: Low Profile

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TORO 400: Low Profile

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Maintenance

© SANDVIK MINING AND CONSTRUCTION OY, LOADERS TURKU 11/2006

TKU--- C 01101--- 1 EN 4506

Congratulations on your choice of a TORO loader.

Read the Operator’s Manual and General Safety

Always obey safety rules!

2. MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

TKU--- C 01101--- 1 EN 4506

1.1. Importance of regular maintenance

1.2. General safety precautions during operation

1.3. General repair instructions

TKU--- C 01101--- 1 EN 4506

1.4. Lifting methods and lifting points

Open the cover on

TKU--- C 01101--- 1 EN 4506

1.5. Location of the main components

1. Front frame 3. Engine ass’y

1. Fuel tank 6. Operator’s cabin

TKU--- C 01101--- 1 EN 4506

1.6. Locking devices

How to install the frame locking bar.

Note: Observe the pin. When it drops

Boom safety stand (optional)

How to install the safety stand.

1. Get into the cabin. Sound the horn

2. Switch on the engine and raise the

To remove the safety stand.

TKU--- C 01101--- 1 EN 4506

Boom support bars

How to install the support bars.

1. It is recommended that before you

3. Climb into the cabin and sound the

4. Turn on the engine and raise the

5. Climb up onto a safe platform and

6. Get into the cabin and turn on the

To remove the support bars.

TKU--- C 01101--- 1 EN 4506

2. MAINTENANCE AND LUBRICATION

2.1. Maintenance of hydraulics

2.2. Electrical system maintenance

TKU--- C 01101--- 1 EN 4506

Working on live components

2.3. Battery maintenance

TKU--- C 01101--- 1 EN 4506

Specifications for Operating Engine oil 228.5 /

Viscosity above ..--25_C SAE 5W--40 / SAE 5W--30

See Mercedes--Benz Operating Instructions for more details.

DANA SOH R 32421

Oil classification. API CD/SE or CD/SF

Viscosity --20_C...+15_C SAE10 W--30

Operating temperatures during normal operation

about 45_C ISO VG 32

above --15_C ISO VG 32 (SAE 10W)

2.5.5. Grease nipples

2.6. Filling capacities

TKU--- C 01101--- 1 EN 4506

2.7. Special notes

2.7.1. Cooling system

See Mercedes--Benz Operating Instructions for more details.