D25-D245 Sandvik
D25-D245 Sandvik
D25-D245 Sandvik
(Caterpillar C15, C16 & C18 Engine- High or Low Pressure Compressor)
March 2002
Serial Number 732596 & Up
(Rev. 9-06)
BLASTHOLE
1814 kg / 4,000 lb
California Proposition 65
WARNING:
This Product Contains And, When Used, Produces Chemicals Known
To The State Of California To Cause Cancer, And Birth Defects Or
Other Reproductive Harm.
11-06
Introduction
SANDVIK MINING and CONSTRUCTION drilling equipment is carefully designed, tested and manufactured. When
operated and serviced by trained and qualified personnel, this machine will give safe and reliable service. There are
SANDVIK MINING and CONSTRUCTION offices world-wide to answer questions concerning the safe operation and
maintenance of this equipment.
To minimize the risk of accidents and injuries, all persons involved in the operation and servicing of this machine MUST
read and understand the following safety precautions and the manuals developed for this machine.
While we believe that we have properly identified several potential hazards that could result in property damage or injury
or death to personnel, there are certain hazards which may be present that we have not contemplated. It therefore is
the responsibility of the drill owner, operator and crew to be certain that the drill is properly equipped and safe to operate
to assure accident free operation.
Management's Responsibilities
• See that all operators of this equipment are thoroughly trained (with special emphasis on safety), competent, physi-
cally fit and if required, licensed.
• Assign specific crew members specific safety responsibilities and instruct them how to report any unsafe conditions.
• See that the operation and maintenance of this drill is in compliance with all Federal, State and local codes, regula-
tions and standards.
• Ensure that the work area is appropriately illuminated when drilling is performed at night.
• Maintain a complete first aid kit at the drill site. At least two members of the drilling crew or personnel in the area
where the drill is operated should be familiar with first aid and Cardiac Pulmonary Resuscitation.
• Contact the utility companies for the exact location of underground transmission lines in the drilling area.
condition exists. It is the responsibility of the drill operator to ensure that the drill is properly equipped, safe to operate
and that the site conditions make it possible for safe operation:
• The operator must see that all emergency stops, "operational aids" and "warning signals" are functional before oper-
ating.
• The operator must be alert, physically fit, and free from the
influences of drugs, alcohol and medications that might
impair eyesight, hearing or reactions
• The operator should not attempt to start, operate or service the drill unless he has been properly trained and read this
manual.
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11-06
• Check access ladders and decking for damage and slipping hazards such as mud, oil or ice.
• At the end of the shift, the operator must properly secure the drill to prevent the machine from being operated by
unauthorized individuals.
• The operator must never permit personnel to ride on the machine except in the passenger compartment.
The person in charge must have a clear understanding of the work to be done and consider all the hazards at the site.
He must develop a plan to do the job safely and explain the plan to the crew members involved. Factors such as these
should be considered:
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11-06
Operating Precautions
• Raising or lowering the mast, and drilling with an unsupported or unleveled machine can result in excessive structural
stress to the machine frames or can cause the machine to overturn.
Do not raise or lower the mast or attempt to drill until the machine is fully supported and leveled by the lev-
eling jacks.
• Drilling with an unlocked mast can result in excessive pressure at the mast raising cylinders causing the mast to fall.
Do not attempt to drill until the mast locking pins are fully engaged.
.
• Do not park or position the machine on grades that exceed the tilt
ratings.
Park or position the machine on level ground or across (hori-
zontal) grade
• Park or position the machine to allow the wind to carry engine exhaust fumes away from the operator.
Exhaust fumes from diesel engines are lethal.
• Drill pipe that is free to slide through the opening in the top plate
could be released from the loader while traveling.
Before lowering the mast, index the loader to a position
such that the top plate of the loader prevents all drill pipe
from moving past the top plate
• Before entering any enclosure, be sure that the door is secured open. Avoid entrapment, be sure that no one is
inside any enclosure before closing and latching the doors.
Enclosures can cause suffocation.
• Before starting any service or maintenance work, always perform a safety/risk analysis of the task.
Performing maintenance work without the proper tools and personal protection equipment can cause seri-
ous injury or death.
viii
11-06
• Riding the rotary head up and down the mast is a crushing hazard.
Never ride the rotary head for any reason!!! It was not designed to be an elevator.
When there is a need for an operator or helper to work on the rig in the working area or danger zone and this work
involves activation of one or several machine functions, this work shall only be done under the following conditions:
a. There must be two safety trained people present, one should supervise the safety of the other doing the servicing.
Supervision should be done from the operator’s station to ensure immediate access to an emergency stop at all
times.
b. The area where the service work is to be done should be properly illuminated.
c. A reliable mode of communication should be establish between the servicing person and the supervisor.
d. The rig must be completely shut down and all methods of starting disabled before servicing work begins.
Fire Prevention
• Keep the machine clean of vegetation, coal dust and oily rags.
• Clean-up any oil and fuel spills particularly around hot surfaces
and heat producing components.
• Check the Fire Suppression System (FSS), if fitted, for damaged hoses or cylinders.
• Check all electrical lines and connections including battery terminals for a tight fit, wear, abrasion, and corrosion.
• Do not use the drilling machine in oil, gas or waterwell operations unless the well head is properly equipped with blow-
out preventers and safety equipment required by law or as recommended in the American Petroleum Institute's doc-
ument API 54.
• Check all machine ignition points (engine block, exhaust manifolds, mufflers, turbo-chargers, etc...) to make sure they
are not in contact with any hoses.
• Never inject ether or other starting aids into the engine and compressor intake filter(s). Ether or other aids drawn into
the compressor can cause an explosion.
• Engine oil, hydraulic fluid and compressor oil are flammable. Do not operate a machine with leaking or worn hoses or
lines.
• Do not clean washable filter elements with flammable solvents, diesel fuel, kerosene, or gasoline.
• Do not attempt to perform welding repairs until all flammable materials including oil and fuel spills oily rags, and rock
and coal dust, have been isolated or removed from the machine.
• Keep tools away from exposed live electrical parts such as terminals, to avoid arching.
• If charging the batteries, always turn the charger off before making or breaking connections to the battery.
• The compound (ethyl ether) used in the engine starting aid system is extremely flammable. Changing the cylinders
and servicing this system should be done in a well ventilated area. Do not store or install the cylinders in tempera-
tures above 160° F (71° C).
• The anti-freeze compound (methanol) used in the air line anti-ice systems is flammable. Refill the system with com-
pound only in well ventilated areas, away from heat, open flames and sparks. Do not store or expose this system or
the compound to temperatures above 150° F (65° C), or in direct sunlight.
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11-06
GENERAL
The following safety precautions were developed to minimize the risk of injury during inclement weather when using
Driltech drilling equipment.
All persons involved in the planning, operation and serving of Driltech equipment MUST read and understand the follow-
ing safety precautions, the manuals developed for this machine and the Safe Operating Practices outlined in the front of
this manual.
While we believe that we have properly identified several potential hazards that could result in property damage or per-
sonnel injury, there are certain hazards which may be present that we have not contemplated.
Bad weather conditions as they relate to this topic include lightning, thunderstorms and severe rainfall.
MANAGEMENT’S RESPOSIBILITIES
High winds, rainfall and cloud cover are often precursors to actual cloud to ground strikes notifying individuals to take
action. Many reported lightning accidents occur with sun, clear skies and no rain present at the beginning as the storm
approaches because; people ignore these precursors. Generally the lightning threat diminishes with time after the last
sound of thunder, but may persist for more than 30 minutes.
• Be aware of daily weather conditions within a 100 mile (161 Km) radius of the mine property.
• Notify equipment operators of impending storms. Communication to equipment operators may be given via two way
radio and/or in person.
b. lower masts to a horizontal position or position feed rails into feed supports.
c. give the drill engine an adequate cool down period prior to shutting machine down.
d. leave machine cabin or operator platform and transport to central meeting location.
• Give equipment operators an all clear signal after the storm has cleared the area.
Note To Supervisors!
Recognize that equipment operators should be given adequate time to prepare the machine to move to specific loca-
tions for safe keeping. Crawler mounted drill machines have a maximum travel speed not exceeding 2.2 mph (3.5 kph).
•When operating machines in a construction application, equipment operators shall move the drill machine to higher
stable ground.
Never leave a drill machine in any construction zone roadway, river bed or drainage ditch.
•Move the drill machine to stable ground away from high walls and any threat where rock or water erosion may
allow unstable ground to fall or slide.
A publication written in MSHA Holmes Safety Association Bulletin April 2001 gives a simple flash bang formula to calcu-
late lightning proximity.
The FLASH BANG method is determined by counting the seconds between the visible lightning and the sound of thun-
der. This delay in seconds when divided by 5 will give an approximate value in miles as to how close the active lightning
is to your worksite.
Example: when you see lightning and it takes (10) ten seconds to hear the thunder divide by (5) five. The approximate
distance of lightning proximity is 2 miles (3.2 km).
If the flash bang measurement is 30 seconds or less seek shelter immediately and remain indoors, away from electrical
devices, water and metal components.
Supervisors shall notify equipment operators in a timely manner. This is to allow the drill operator adequate time to per-
form the required operation principals needed and secure the machine in a safe manner.
• Equipment operators shall retrieve drill pipe from blastholes, secure drilling tools and lower mast to a horizontal
position into the mast rest supports.
Understand that the mast in a vertical position with drill pipe in the ground is capable of attracting high volt-
age lightning.
NOTE !
If the operator and machine are inside or near a blast area follow procedures written in USA Federal Metal and Non-
metal Mine safety Standards 30CFR 56/57/58 manual.
• Equipment operators shall move the machine to secure ground as noted in the rainfall and flooding description.
• Equipment operators shall give adequate engine cool down period prior to shutting machine down. Adequate
engine cool down periods range between 3 to 5 minutes.
Follow engine manufacture specifications as a standard.
xii
11-06
• Equipment operators shall secure the machine, close doors and windows, leave the machine cabin and dismount
the machine in a proper 3 point contact with the boarding ladder.
• Equipment operators shall drive or be transported to a central meeting location away from bad weather and storm
conditions.
There are exceptions to the rules when bad weather develops and time does not permit adequate machine preparation
- shutdown principals.
Exceptions
If you do get caught in an electircal storm and have little or no time to prepare, remember that, no place is absolutely
safe from the lightning threat, however, some places are safer than others.
When operators are inside a enclosed stable structure such as a machine cabin or the truck cab it is recommended that:
NOTE!
Wait inside the enclosed cab as long as it takes for the storm or lightning to subside. Do not attempt to dismount the
machine when lightning is in your immediate work area.
If lightning is present within a 20 mile (32 km) radius of your location be aware of your surroundings when outdoors.
Seek adequate shelter immediately.
If lightning is present within the 20 mile (32 km) radius, and a decision is made to dismount the machine, use a standard
3 point contact down the boarding ladder to dismount the machine.
Move away from the machine quickly and into a enclosed vehicle or adequate shelter. Maintain a distance greater than
100 yards (92 m) to prevent electrical draw in the event lightning did strike the mining equipment.
Lightning detectors are available aftermarket as a measuring instrument to determine lightning proximity. Blasting crews
are aware of lightning hazards and may have a lightning detector on site.
If you are caught in the open with lightning nearby and shelter is not available the safest position to be in is to be
crouched down on the balls of your feet. Keep your feet as close to one another as possible.
Do not allow your hands (or other body parts) to touch the ground. Use your hands to cover your ears and brace for a
loud thunderous bang.
Lightning struck victims carry no electrical charge and should be given first aid treatment immediately!
MACHINE MAINTENANCE
If lightning does strike a drill machine parked in any position (mast up or down) expect major component failures. A total
machine inspection is in order.
Prior to climbing on board a machine known to have been struck by lightning use the back side of either hand (knuckle
side) to lightly touch the boarding ladder.
Reference material
Federal Metal and Nonmetallic Mine Safety and Health Standards 30CRF 56/57/58 Ninth Edition (1999).
xiv
TABLE OF CONTENTS
SAFE OPERATING PRACTICES FOR DRILL- DRAULIC OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
ERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
AIR COMPRESSOR LUBRICANT RECOMMENDA-
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 8
Management's Responsibilities . . . . . . . . . . . . . . . . . . iii
The Operator’s Responsibilities . . . . . . . . . . . . . . . . . . iii
Operator's Safety Check . . . . . . . . . . . . . . . . . . . . . . . v SECTION 2 PREVENTIVE MAINTENANCE. 2- 1
Planning the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . vii
SERVICE AND OIL CHANGE INTERVALS . . . . . 2- 1
General Maintenance Safety Practices . . . . . . . . . . . . viii
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
MAINTENANCE RECOMMENDATIONS . . . . . . . 2- 1
COOLANT, FUEL and LUBRICANT SPECIFICA- HEATING, CUTTING AND WELDING EQUIPMENT US-
TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 1 AGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 3
Table of Contents
AIR CLEANERS - ENGINE & COMPRESSOR . . 2A- 2 EVERY 50 HOURS OR WEEKLY . . . . . . . . . 2C- 1
Changing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-2 AIR SWIVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C- 1
Primary Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-2 Grease Air Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1
Safety Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-3
Primary Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-3
INITIAL 50 HOURS OF OPERATION . . . . . . . . . 2C- 1
Safety Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-4
Body & Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . .2A-4
Inspect Dust Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2A-5
EVERY 250 HOURS OR MONTHLY . . . . . . . 2D- 1
OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . 2A- 5
Change Air Conditioner/Heater Filter Element . . . . . . . .2A-5 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D- 1
Check Engine Mount Torque . . . . . . . . . . . . . . . . . . . . . 2D-1
DUST COLLECTOR . . . . . . . . . . . . . . . . . . . . . . 2A- 5 Change Crankcase Oil and Filters . . . . . . . . . . . . . . . . 2D-1
Change the Filter Elements . . . . . . . . . . . . . . . . . . . . . .2A-5 Engine Valve Lash (Initial) . . . . . . . . . . . . . . . . . . . . . . . 2D-2
WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E- 4
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-4
MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E- 5
Inspect the Drill Pipe Safety Hoop . . . . . . . . . . . . . . . . 2E-5
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2F- 1
Re-Torque Compressor Mounts . . . . . . . . . . . . . . . . . . 2F-1
Change Air/Oil Separator Element . . . . . . . . . . . . . . . . 2F-2
Change Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . 2F-3
Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F-3
Table of Contents
SECTION 1
SAE 10W-30 -18°C (0°F) 40°C (104°F) Use only multi-purpose grease (MPGM) which
SAE 10W-40 -18°C (0°F) 50°C (122°F) contains 3 to 5% molybdenum disuphide. NLGI
No, 2 Grade is suitable for most temperatures.
SAE 15W-40 -9.5°C (15°F) 50°C (122°F) Use NLGI No. 1 or No. 0 Grade for extremely
SAE 30 0°C (32°F) 40°C (104°F) low temperatures.
SAE 30 5°C (41°F) 50°C (122°F)
Page 1-2
Compressor Oils (COMP) Refrigeration Oil (REF)
As with any oil Do not mix different types of oils. Use an ISO 100 refrigeration oil.
Contamination of synthetic oils with traces of
AFT may lead to foaming or plugging of orifices.
REFILL CAPACITIES
When operating between 80 and 100°F (27 and
38°C) and with relative humidity above 80%, a
synthetic hydrocarbon type fluid is recom-
COMPONENT GALLON LITRE
mended. Currently, Shell Corena is used at the
factory unless the receiver tank decal indicates RECEIVER TANK 70 265
otherwise. FUEL TANK 200 757
Compressor oil change intervals will change PUMP DRIVE GEARBOX 3 qt. 3
depending on the type of oil used. The oil manu- ROTARY DRIVE GEARBOX 5.5 21
facturers recommendations supersede the rec-
ommended interval suggested in this manual. CENTRALIZED LUBRICA- 30 lb. 13.5 kg
TIONS SYSTEM or or
55 lb. 208 kg
ENGINE CRANKCASE 9 34
Use Engine Service Classification CC (MIL-L- (CATERPILLAR C15)
2104B), CC/SF (MIL-L-46152B), CD (MIL-L- COOLANT 25 95
2104D) or industrial-type hydraulic oils that are (CATERPILLAR C15)
certified by the oil supplier to have anti-wear,- approximately
foam, -rust, and -oxidation additive properties WINCH 2 pt. 1
for heavy duty usage.
CRAWLER FINAL DRIVE (ea.) 2 8
At the time of shipment this machine was filled WATER INJECTION 230 870
TANK(WO/DUST COLLECTOR
with Citgo 32 AW hydraulic oil.
WATER INJECTION TANK(W/ 120 454
DUST COLLECTOR
Multipurpose - Type Gear Lubricant (MPL) WATER INJECTION PUMP 1 qt. 1
SAE 5W -20(SPC)
ENGINE CRANKCASE SAE 5W-20
CH-4 SAE 10W
SAE 10W-30
SAE 15W-40
SAE 30
SAE 40
-40°F ISO 32
COMPRESSOR
ISO 46
COMP ISO68
Note oil change intervals
CD SAE 10W
UNDERCARRIAGE, CD SAE 30
FINAL DRIVE GEARBOX CD SAE 40W
MPL
CD SAE 50W
32AW
HYDRAULIC SYSTEM 46AW
HYDO 68AW
100AW
Page 1-4
996
EQUIVALENT HYDRAULIC OILS
ANTECH EXXON/ESSO X
CHEVRON AW CHEVRON X
CITGO AW CITGO X X X
DURO AW ARCO X X
(Page 1 of 2)
NUTO-H EXXON/ESSO X X X
UNIVIS N EXXON/ESSO X X
(Page 2 of 2)
Page 1-6
MINIMUM PERFORMANCE STANDARDS FOR HYDRAULIC OILS
The following are typical properties of hydraulic oils for use in severe duty applications of axial pis-
ton and vane pumps. Any oil which meets these or similar properties or which is listed in the
approved list of Equivalent Hydraulic Oils may be used.
32 46 68 100
ISO VISCOSITY GRADE
(32AW) (46AW) (68AW) (100AW)
Viscosity, SSU
100°F (37.8°C) 155 220 325 500
210°F (98.9°C) 43.9 48.2 54.6 64
Viscosity Index,
ASTM D 2270 106 105 104 99
Interfacial Tension,
D 971
77°F:dyn/cm 31 31 31 32
Flash, P-M: °F (°C) 400 (205) 405 (208) 450 (233) 465 (241)
Flash, OC: °F (°C) 425 (219) 430 (222) 470 (244) 490 (255)
Fire, OC: °F (°C) 455 (235) 470 (244) 500 (260) 545 (285)
Carbon Residue,
Ramsbottom:% 0.30 0.30 0.36 0.37
Neutralization No.
ASTM D 974
Total Acid No. 0.68 0.68 0.68 0.68
Driltech encourages the user to participate in an oil analysis program with the oil supplier. This
could result in an oil change interval differing from what is stated in these tables.
NOTE!
Mixing synthetic oils with an ATF may lead to operational problems, foaming, or plugging of orifices.
Do not mix different types of fluids.
-40°F to +95°F (-40°C to +35°C) 1000 Hours 32 Mobil SHC-624, 924 & 1024
+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Mobil SHC-626, 926 & 1026
When operating between +80 and 100°F (+27 and 38°C) with a relative humidity above 80%, syn-
thetic hydrocarbon type fluid Mobil SHC or equivalent as recommended above should be used.
All lubricant recommendations are based on 1200 rpm maximum WARM-UP speed.
Page 1-8
SECTION 2 follow list items according to the service interval.
Use the hourmeter to determine when each ser-
PREVENTIVE MAINTENANCE vice is due. Calendar intervals (daily, weekly,
monthly, etc.) may be used if they allow for
more convenient maintenance scheduling, pro-
GENERAL
vided they approximate the hourmeter readings.
This section of the manual provides a step-by-
When performing scheduled maintenance, all
step guide to performing scheduled lubrication
services due at more frequent intervals should
and maintenance for your drill. A thorough study
also be performed. For example, at “Every 250
of this manual is recommended before mainte-
Hours or Monthly” service, also perform the
nance of the machine is attempted.
items listed at “Every 50 Hours or Weekly” and
“Every 8 Hours or Shift Change.”
Careful attention should be given to the service
and maintenance instructions for the various
The recommended maintenance schedule is
components and systems of the machine.
designed for average conditions. When operat-
Experience indicates that the procedures
ing in temperature extremes, dusty or wet con-
described herein are preferred practices and
ditions, the period between maintenance
that failure to comply with them can materially
operations should be shortened. For example,
shorten the useful life of the equipment and/or
check fluid levels more frequently than the rec-
reduce its standard performance.
ommended intervals if leaking is suspected or
observed.
Some photographs in this section may show
details or attachments that are different from
A number of services may need to be per-
your unit, due to optional equipment and/or
formed on a “When Required” basis, as deter-
advancement of product design. Contact your
mined by service indicators on the machine
Sandvik Mining And Construction dealer for
details of lubrication or maintenance not cov-
ered in this publication.
MAINTENANCE RECOMMENDATIONS
The parts manual should be referred to when it
Wipe grease fittings clean and ensure that
is necessary to order repair parts. For prompt
grease gun nozzles are clean before injecting
and efficient parts service, contact your
grease.
Sandvik Mining and Construction dealer, giving
the model and serial number of the machine,
Always keep caps, plugs, dipstick tubes and
along with the part number and description of
their surroundings clean before removing for
the items required, as their personnel are fully
servicing.
qualified to assist and advise you on any ser-
vice or operational problems that may be
When servicing, watch for:
encountered. Sandvik Mining and Construction
• Leaks
Field Representatives are also available to you
• Fire hazards (accumulated fuel, oil, grease,
for advice and assistance on special problems.
debris)
• Loose or missing hardware
• Signs of wear
SERVICE AND OIL CHANGE INTERVALS
• Damage
The Lubrication and Maintenance Charts that
Preventive Maintenance - Page 2-1
and the chance of mixing fluids.
USE OF CORRECT TOOLS AND PROCE- THE DRILL MONITOR SYSTEM (DMS)
DURES
The optional DMS control panel in the opera-
When servicing the drill, use the correct tools tor’s cab is the Drill Monitor System. This panel
and tensioning procedures outlined in this man- provides warning signals to the operator or
ual. Overtighting plugs, filter, adaptors, etc. will automatically shuts down the machine (for criti-
cause undue stress on components and may cal out-of-limit conditions) in the event that the
weaken or fracture the component under pres- monitored conditions are not within safe limits.
sure. Remember, if you are unsure as to the Several of the “When Required” maintenance
correct procedure in performing a job, DO NOT checks are dictated by the signalling from the
attempt to start it. DMS. For more information on the functions of
this system refer to section 2 of the Operation
When filling the hydraulic reservoir, always Guide.
check the oil level with the cylinders fully
retracted. If oil is added when the cylinders are
extended, the increase in volume of oil to the COMPRESSOR AND HYDRAULIC SYSTEMS
tank may cause the tank to overfill and rupture
when the cylinders are retracted.
Cleanliness
Oil Contamination
WIGGINS SERVICE STATION
Water or air in a hydraulic system can cause
If your machine is equipped with a Wiggins ser- pump failure. If hydraulic oil appears cloudy,
vice station it should be used whenever replen- water or air is entering the system and the oil
ishing fluids to reduce the risk of contamination should be drained, the system flushed and
2-2
cleaned, and refilled with new oil. Points of • Corrosion
entry for air or water such as suction hoses or • Foaming/aeration
loose clamps, faulty seals or gaskets, and areas • Solidification/emulsification
where water may pool and be drawn into the • Component bearing failure
system should be checked and remedied. • Acid formation
• Overheating
Leaks
Initial Start-Up
If a leak has developed in a system, it is
because there is a fault which may not be On the initial start-up of the machine, the
noticeable or immediately evident. A leak is hydraulic actuators may move without notice or
generally a symptom of a fault such as: without any control input signal due to air
• Overheating. entrapment in the circuits. Ensure that all per-
• Overpressure sonnel are clear prior to starting. Normally,
• Excessive vibration through a mechanical cycling the component several times will cause
component fault. the air to bleed off. However, if the condition
• Incorrect operating procedure. continues it will require technical assistance.
• Poor maintenance procedure.
When fixing a leak, try to identify the real cause. Hose Replacement
Always disconnect the ground terminals from Use only the water and coolants specified in the
the batteries before welding on the machine to “COOLANT, FUEL and LUBRICANT SPECIFI-
prevent damage to electronic controls. CATION” topic in this manual and refer to Cater-
pillar® bulletin SEBD 0518-06.
The ground cable of the welding machine must
be connected to the work piece, as close as If the engine is to be operated or stored in an
possible to the area being welded. The ground area with temperatures below 32°F (0°C), the
cable should not be connected in such a way to cooling system must be protected to the lowest
allow current to flow through a bearing, joint expected ambient temperature.
coupling, sealing surface, lever or control cable.
Clean the cooling system if scale is present or
If welding is performed near pins or in places there is evidence of oil contamination. In either
where flexing may cause shanges in the align- case, overheating may result.
ment of bushings, remove the pins and check
the alignment after welding. When refilling the cooling system, add coolant
no faster than 20 qts (20 l) per minute to prevent
air pockets from developing.
AIR INTAKE SYSTEM
After refilling the system, run the engine with the
The engine and compressor air intake filters radiator cap(s) removed until the coolant level
should be serviced when the service indicates stabilizes. Top off the radiator if necessary.
to do so or the Drill Monitoring System (DMS)
indicator illuminates.
FUEL SYSTEM
Observe the limits on the number of times the
filter elements can be cleaned and when the Use only the fuels specified in the “COOLANT,
safety element should be replaced. FUEL and LUBRICANT SPECIFICATION” topic
in this manual.
ELECTRICAL SYSTEM Have your fuel supplier drain water and sedi-
ment from his fuel storage tanks at weekly inter-
When jump-starting the machine, follow the vals to prevent contamination from being
instructions in the Operators Manual to avoid pumped into the machine’s tank.
equipment damage or injury to personnel.
Always fill the tank at the end of the shift to drive
Always disconnect the batteries before welding out moisture laden air from the tank but do not
on the machine or alternator damage will result. fill the tank to the brim as fuel will expand as it
warms and may overflow
Keep all electrical compartments closed and
properly sealed during machine operation. Allow fuel to settle for a few minutes after filling
before draining water and sediment..
COOLING SYSTEM After changing fuel filters, bleed the fuel circuit
to remove air.
All water is corrosive at engine operating tem-
2-4
RECOMMENDED TORQUE VALUES FOR STANDARD HARDWARE - UNC
NOTE: These torque values are to be used for general assembly procedures. Special torque requirements may be
specified on assembly and installation procedures.
NOTE: All fasteners are to be free of dirt and rust at time of assembly. Lubrication is not to be applied to threads unless
so specified.
NOTE: These torque values are to be used for general assembly procedures. Special torque requirements may be
specified on assembly and installation procedures.
NOTE: All fasteners are to be free of dirt and rust at time of assembly. Lubrication is not to be applied to threads unless
so specified.
2-6
WHEN REQUIRED MAINTENANCE CHECKS
Date...................................
Coolant Condition
Page 2A
8 HOUR or SHIFT CHANGE MAINTENANCE CHECKS
Date...................................
Page 2B
50 HOUR or WEEKLY MAINTENANCE CHECKS
Date...................................
Page 2C
250 HOUR or MONTHLY MAINTENANCE CHECKS
Date...................................
Page 2D
250 HOUR or MONTHLY MAINTENANCE CHECKS
CONTINUED
Date...................................
Page 2D (cont’d)
500 HOUR or 3 MONTH MAINTENANCE CHECKS
Date...................................
Page 2E
1000 HOUR or 6 MONTH MAINTENANCE CHECKS
Date...................................
Page 2F
2000 HOUR or 1 YEAR MAINTENANCE CHECKS
Date...................................
Page 2G
WHEN REQUIRED
FUEL SYSTEM
c40-53
Replace Ether Starting Aid Cylinder
! DANGER
ETHER IS POISONOUS !!
Avoid breathing vapors and repeated skin
STRAP
contact, keep out of the reach of children,
use only in well-ventilated areas, and do not
store cylinders in living areas or operator’s
compartment.
! DANGER
ETHER IS FLAMMABLE !! COOLING SYSTEM
Observe the following precautions while
handling ether cylinders:
• Do not smoke while changing cylinders. Check Cooling System
• Do not store cylinders at temperatures
above 49°C (120°F).
• Do not store cylinders in direct sunlight ! WARNING
• Do not puncture or burn cylinders. Steam can burn. Allow the coolant to cool.
• Discard cylinders in a safe place. Open the radiator filler cap slowly.
PRIMARY
ELEMENT
SERVICE
INDICATOR/NUT COMPRESSED AIR
VACUATOR
VALVE
B. After cleaning, inspect the element with a
light bulb as shown. Replace the element if
necessary.
Primary Element
1. Loosen the wing nut and gently slide the pri- PRESSURIZED WATER
mary element out of the air cleaner assembly.
! CAUTION
2. Inspect the service indicator for the safety
Using compressed water above 40 psi (with-
element. Remove and replace the element if
out nozzle) (280 kPa) can damage the filter
the indicator is in the red zone.
element.
A. Direct water ALONG (not across) the pleats
3. Inspect the inside of the filter housing and if
inside and outside the element.
cleaning is required remove the safety element.
Be careful not to allow dust to enter the intake
B. Air dry the element Do Not dry with a light
duct.
bulb.
Page 2A-2
C. After drying, inspect the element with a light element and tighten the wingnut.
bulb as shown. Replace the element if neces-
sary. 7. Inspect all air cleaner and air duct connec-
tions for leakage before starting the engine.
Safety Element
WASHING WITH DETERGENT 2. Remove the split pin and nut that hold the
A. Remove excess dust with compressed air safety element in place.
or water as described earlier.
B. Wash the element in warm water with a 3. Remove and discard the safety element.
non-sudsing household detergent or Donaldson The safety element should not be cleaned.
D-1400 Washing Compound.
C. Rise the element with clean water from both 4. Clean the inside of the filter housing espe-
sides if necessary. cially around the areas of the element sealing
D. Let dry in warm circulating air of less than surfaces.
160°F (71°C).
E. After drying, inspect the element with a light 5. Install a new safety element.
bulb as shown. Replace the element if neces-
sary. 6. Install the primary element.
INSPECTION
‘T’ STYLE AIR CLEANER
Primary Element
SAFETY
ELEMENT
21237s1 SPLIT PIN
PRIMARY
ELEMENT
SERVICE
INDICATOR/NUT
COVER
COVER
GASKET
CUP CLAMP
5. If the element is dented or bunched it must The safety element should not be cleaned.
be replaced. Never rap or hit the element to
remove dirt. 4. Clean the inside of the filter housing espe-
cially around the areas of the element sealing
surfaces.
Safety Element
5. Install a new safety element.
The safety element should be replaced every
third time the primary element is replaced or as 6. Install the primary element.
indicated by the service indicator in the safety
filter hold down nut as shown.
Body & Tube Assembly
1. Remove the primary element as described
earlier. Remove the dust cup and check the tubes. If
the tubes have become plugged, remove the
2. Remove the split pin and nut that hold the dust with a bottlebrush. If heavy plugging is evi-
safety element in place. dent, clean the tubes with compressed air (the
primary and secondary filters must be installed),
3. Remove and discard the safety element. or with water no hotter than 160°F (72°C). Do
Page 2A-4
not steam clean!
AIR CONDITIONER/
HEATER AIR CLEANER
Inspect Dust Cup PRE-CLEANER
ELEMENT
DUST COLLECTOR
C40-
THUMB SCREWS
FILTER ELEMENT
OPERATOR’S CAB
WING NUT
! CAUTION
Do not run the dust collector fan if drill dust
is venting from the fan exhaust. Severe
damage to the fan, the fan shaft and it’s
bearings will occur.
Page 2A-6
EVERY 8 SERVICE HOURS
OR DAILY
ENGINE
c25-3
Measure Crankcase Oil Level
COOLING SYSTEM
FILLER
FILLER
CAP
! WARNING
Steam can burn. At operating temperature,
engine coolant is hot and under pressure.
! WARNING 2
40-60 OIL LEVEL
Cooling System Conditioner contains alkali. SIGHTGLASS
Avoid contact with skin and eyes to prevent
personal injury.
NOTE !
• Inspect for coolant leaks, damaged or deteri- The oil level should be maintained so that it
orated hoses and obstructed radiator cores. is visible in the center sightglass.
• Any of these may cause damage to the
engine through overheating. ! CAUTION
Do not mix compressor oils. Incompatible
COMPRESSOR fluids may cause compressor damage or
reduced oil change intervals.
NOTE!
Water can cause compressor failure. If the oil
Page 2B-2
appears cloudy, water is entering the system. Some models do not have a dirt alarm indicator
Determine the point of entry and rectify the on the filter housing. In this case the filter con-
problem, then drain, flush and refill the system. dition is monitored by a warning lamp on the
instrument panel.
.
25- 51
ELEMENT
INDICATOR
245-8
BATTERY
BOX
HYDRAULIC SYSTEM
Check Oil Return Line Sightglass Check Oil Level in Reservoir Tank
When the engine is running, inspect the sight- 1. Fully retract all hydraulic cylinders and shut-
glass (1) to ensure that oil is visibly flowing. If down the engine.
oil is not visible, clean the in line strainer (2).
2. Look at the sight gauge. The oil level must
1 be maintained to the decal line. Add oil if
necessary.
245-30
HYDRAULIC
OIL
245-9 SIGHT
GAUGE
2 COMPRESSOR FILTER
HYDRAULIC
TANK
REGULATOR
GAUGE
Check Servo Replenishing Filters Dirt
Alarms
NOTE !
Water can cause pump failure. If the oil
appears cloudy, water is entering the system.
Determine the point of entry and rectify the
problem, then drain, flush and refill the system.
Page 2B-4
! CAUTION
• Do not overlubricate the universal joints.
1
• Seal rupture can occur and allow ingress
245-34 of dirt.
SERVO
FILTERS
Check Oil Level
FILL PLUG
DRIVESHAFT
PUMP DRIVE
GEARBOX 245-16
Lubricate Pump Driveshaft
UNDERCARRIAGE
2. Clean the grease fitting in each universal Visually inspect the undercarriage for rocks,
joint and lubricate with two strokes from a hand debris and built-up dirt. Clean idlers and
grease gun. sprockets as necessary.
Check Air Cleaner Element Indicator Check Central Lubricator Grease Level
Check the indicator located on the air inlet pipes Remove the clips securing the lid to the tank.
as shown. Service the elements as needed as Replace the canister if necessary.
explained in the “When Required” maintenance
checks.
CLIP
245-36
Inspect Vacuator Valves 2. Check the oil level through sightglass (2). If
oil is needed, unscrew the bowl and add Engine
Vacuator valves should be inspected very 8 Oil (CG) as required.
hours of machine service. Check to see that the
valve is not inverted, damaged or plugged.
Replace as needed.
SAFETY
ELEMENT
PRIMARY 245-37
ELEMENT
SERVICE 1 2
INDICATOR/NUT
VACUATOR
VALVE
Page 2B-6
MISCEALLANEOUS
FILLER
CAP
Inspect Winch Wire Rope
LEVEL
Check Bit/Hammer Lubricator Oil SIGHTGAUGE
3mm (1/8”)
245-41
FEED CHAIN
ADJUSTMENT
HOIST CHAIN
ADJUSTMENT
• Do not use a pressure grease gun, as this Replace Hydraulic Servo Replenishing Filter
can cause damage to the seals. Elements
Refer to the “500 Hour Maintenance Checks.”
1. Remove the protective cap to expose the
lubrication fitting.
Change Winch Oil
2. Lubricate the air swivel with two strokes of a Refer to the “1000 Hour Maintenance Checks”.
hand grease gun.
LUBRICATION
FITTING
MONTHLY ! WARNING
Hot oil or components can cause burns if
they contact skin.
ENGINE
1. With the oil warm and the engine stopped,
drain the crankcase by removing the plug from
Check Engine Mount Torque
the oil pan and allowing the oil to drain into a
suitable container.
Remove the belt cover and inspect the front and
rear engine mounts for cracks or signs of move-
ment and the bolts for tightness.
c40-65
OIL PAN
c25-10
PLUG
ENGINE
3. Use a strap wrench to remove the oil filter.
MOUNTS
(REAR)
c40-66
OIL FILTER
c25-11 REMOVE
TO ACCESS
FRONT MOUNTS
NOTE !
Do not overtighten the filter. Inspect
7. Refill the crankcase. See the “Refill Capaci- Inspect the belts for wear. Replace the belts if
ties” and “Fuel, Coolant and Lubricant Specifi- worn, cracked or frayed.
cations” tables.
8. Start the engine and run long enough to Check Belt Adjustment
ensure that the lube system cavities and filter
have oil. 1. Remove the capscrews securing the belt
cover and remove the cover to access the
belts..
DIPSTICK
BELT
COVER
C25-11
c40-63 REMOVE
TO ACCESS
BELTS
OIL FILLER
C40-63
Adjust valve lash (clearance) at the first oil 1. Loosen the alternator pivot bolt and the lock-
change. All subsequent adjustments are to be nut on the belt tensioner rod.
performed at the “Every 3000 Service Hour”
interval.
Page 2D-2
• Battery electrolyte contains sulfuric acid.
It will cause severe personal injury if it
contacts skin or eyes.
LOCKNUT
C25-51
ALTERNATOR
BELT
TENSIONER
• Batteries give off explosive hydrogen 5. Replace the fill caps and close the cover.
gas.
FUEL
PRIMING
PUMP
PLUNGER
C40-61
SECONDARY
FUEL
FILTERS
2. Pump the plunger to fill the new filter ele-
ment. Continue pumping until resistance is felt,
4. Clean the filter base. Be sure to remove all indicating that the filter is full.
of the old seal.
3. Turn the pump handle knob clockwise to
5. Apply a light coat of clean fuel to the new fil- lock the plunger.
ter seals.
4. Start the engine and check for fuel leaks.
6. Install the new filters by hand. When the
seal contacts the base, tighten 3/4 turn more.
NOTE !
Do not overtighten the filters.
Page 2D-4
COOLING SYSTEM
NOTE !
Ensure that a MAINTENANCE (not a PRE-
CHARGE) conditioner cartridge is used for this
service, unless the coolant is also being OPTIONAL CARTRIDGE LOCATION
changed.
SHUTOFF
VALVES c40-61 245-23
FINGER
GUARD
HARDWARE
COOLANT
CONDITIONER
CARTIDGE
COMPRESSOR 2
COMPRESSOR 7
MAIN OIL FILTER
c25-8 4
BASE
SHOWN
WITH MANUAL INDICATOR
ing to prevent dirty oil from the elements from
dripping into the housing.
! CAUTION
! WARNING Be sure to inspect the inside of the filter
base to ensure that the element grommet
Ensure the engine is shutdown and the
was removed at the time the lower element
internal pressure relieved.
was removed.
1. Unscrew the filter housing cap (1).
4. Replace the ‘O’ ring and backup rings on the
cap and base if necessary.
2. Remove the cap (1), spring (2) and washer
(3).
5. Install two new elements, ensuring they are
joined with the plastic connector.
3. Quickly remove the two filters from the hous-
6. Install the washer, spring and cap.
Page 2D-6
7. Check the oil level and replenish if neces- 2. Wash the screen clean with a non-flamma-
sary. ble solvent and dry with compressed air.
8. Start the engine and inspect for leaks. 3. Reinstall the strainer and plug.
NOTE !
Only Schroeder elements are authorized for use
in the compressor system. Use of any other Change or Sample Compressor Oil
brand must be authorized by the Driltech Engi-
neering Department. NOTE !
The oil change interval depends on the type of
oil and whether or not oil analysis is being used.
See the ‘Recommended Lubrication Viscosity
Clean Oil Return (Scavenge) Line Strainer Chart’ in section 1 of this manual for details.
! WARNING ! WARNING
Avoid touching hot oil or components -
Be sure the engine is shutdown and pres- these can cause burns.
sure relieved before proceeding.
25- 51
RECEIVER TANK
DRAIN
BATTERY
BOX
PLUG
3
245-34 1
SERVO 2
REPLENISHING
FILTERS
! WARNING
Avoid skin contact with hot oil or compo-
nents - burns will result.
Page 2D-8
8. Start the machine and inspect for leaks.
BALL VALVE
NOTE!
Only Schroeder elements are authorized for use
in the hydraulic system. Use of any other brand
must be authorized by the Driltech Engineering
Department.
1190e-35
Clean Hydraulic Reservoir In-Line Air
Strainer
! WARNING
The air line to the hydraulic tank may be
pressurized. Vent air pressure by opening
2. Locate the filter assembly located between the air vent ball valve.
the hydraulic tank and the mast pedestal
Unthread the bolts and remove the element 1. Shut down the engine and vent air pressure
housing to expose the elements. by opening ball valve (1).
6. Replace the O-ring on the cover. 1. Unscrew breather/filter assembly (4) and
discard.
7. Check the oil level and replenish if neces-
sary.
250 Hour Maintenance Checks - Page 2D-9
PUMP DRIVE GEARBOX
Breather/Filter
4
PUMP
DRIVE
NOTE !
Ensure that the check valve assembly (5) has
been retained in the fitting and not removed with
the breather/filter assembly.
! CAUTION ! WARNING
Do not overtighten the filter/breather Ensure the keys are removed and the
assembly. machine has been tagged-out before
proceeding.
4. Screw the new filter assembly onto the
check valve fitting by hand. 1. Undo the four bolts (1) and remove belt drive
guard (2).
Inspect the mounts at the four corners of the 3. Measure the belt deflection using thumb
tank for signs of cracks or movement and re- pressure (approximately 12 kg (25 lbs) midway
torque the mounting bolts. between the pulleys. Deflection should be 13 to
19 mm (1/2 to 3/4 inch).
Page 2D-10
2. Replace the drain plug.
1
1
2
To adjust:
! WARNING 245-45
Use caution and avoid touching hot oil or
components - these can cause burns.
NOTE !
The oil should be warm when changed. FILL/LEVEL
PLUG
1. Remove fill plug (1) and drain plug (2) and
allow the oil to drain into a suitable container.
3. Brush SAE 40, or heavier, on all chain sur- Check Track Tension and Adjust if Neces-
faces. to provide a barrier against dirt and sary
moisture, and prevent corrosion.
1. Propel the machine backwards for a dis-
tance of 20 meters on level ground. Bring the
machine to a SLOW STOP and shutdown the
Inspect and Lubricate Chain Sprockets engine.
Inspect all sprockets for wear and lubrication 2. Place a straightedge, long enough to reach
even if an auto-lubrication system is used. The from the idler to the upper roller, on top of the
lower sprockets are particularly susceptible to track.
3mm (1/8”)
245-41
FEED CHAIN
ADJUSTMENT
HOIST CHAIN
ADJUSTMENT
Page 2D-12
TRACK LOOSENING
! WARNING
• Grease may vent from the valve at high
pressure.
• Never look at the valve to see if grease is
coming out of it - watch the idler and
track chain for movement.
• Loosen the relief valve one turn only.
GROUSER • If the track does not loosen, close the
relief valve and contact your Caterpillar®
dealer.
3. Where the track sags the most, measure the
distance between the top of the track grouser 1. To slacken the chain, undo the relief valve
and the bottom of the straight edge. When the (2), NO MORE than one turn.
track is adjusted correctly, the distance should
be 40 to 55 mm (1-5/8 to 2-1/8 inches). 2. Tighten relief valve (2) to 34 Nm (25 ft lbs)
when the desired track tension is reached.
FILL/
LEVEL
PLUG
PRIMARY
ELEMENT
CENTRAL LUBRICATION SYSTEM
SERVICE
INDICATOR/NUT
1. Disassemble the filter and clean the parts in
VACUATOR a non-flammable solvent.
VALVE
WATER TRAP
FILTER
MISCELLANEOUS
2
1 3
! WARNING
• Fuel leaked or spilled onto hot surfaces
or electrical components can cause a
catbrthr.tif fire.
ELEMENT
BOWL
DRAIN VALVE
COVER
PUMP DRIVE SCREWS BALL VALVE
DIPSTICK
245-49
3. Install the drain plug. 2. Slowly unthread the filter cover screws and
remove the spring loaded filter cover to expose
4. Refill the housing through the fill port, the elements.
located on top of the housing, and replace the
fill plug. See the “Recommended Lubricant Vis-
cosities” table. Check the oil level using the dip- 3. Quickly remove the elements from the hous-
stick provided. ing and drain the oil into an appropriate con-
tainer.
! CAUTION
4. Inspect the housing for contaminents. Clean
Overfilling the gearbox can cause overheating
the housings.
and damage will result.
5. Install two new elements, ensuring they are
5. Start the engine and inspect for leaks.
joined with the plastic element connector.
245-50
1471-S 245-45
FILL/LEVEL
PLUG
FILTER
ELEMENTS
4. Replace the fill/level plug. Operate the
ELEMENT rotary head and check for leaks.
CONNECTOR
1. with the mast raised and the rotary head 1. Drain the water tank by removing the drain
lowered to a working height, remove the two plug and opening the valve.
drain plugs from the gearbox and allow the oil to
drain into a suitable container. 2. Unscrew the fitting and remove the strainer
from the tank.
Page 2E-4
AIR INLET - ENGINE & COMPRESSOR
SERVICE
245-19 SIGHT INDICATOR/NUT
GAUGE VACUATOR
VALVE
COVER
LATCHES
SAFETY
ELEMENT
SPLIT PIN
PRIMARY
21237s1 ELEMENT
SUPPORT WELDS
SERVICE
INDICATOR/NUT
MOUNTING HARDWARE
GASKET
COVER
‘T’ Style Air Cleaner
MAST
Page 2E-6
EVERY 1000 HOURS OR
DRAIN
6 MONTHS VALVE
245-11
HYDRAULIC SYSTEM
NOTE!
The oil should be warm when changed.
245-49 C25-9
MOUNTING
HARDWARE
245-8
7
ELEMENT
INDICATOR
! WARNING
Be sure that the engine is stopped and pres-
sure relieved before working on the receiver
tank. 5. Install a new element (7) in place.
HIGH PRESSURE COMPRESSOR SYSTEMS
6. Install retaining plate (5) and nuts (4).
1. ENSURE the engine is shut down and the Torque to 6.9 kg/m (50 ft. lb.).
internal pressure relieved.
7. Inspect the condition of cover gasket (3).
2. Remove the bolts (1) from cover (2). Replace if damaged.
3. Lift off the filter cover (2) and gasket (3). 8. Replace cover (2) and torque bolts (1) to 190
Remove the nuts (4) and retaining plate (5). - 210 FT LB (256 - 283 Nm).
4. Lift out the filter element (7) and wipe the LOW PRESSURE COMPRESSORS
element seal and base areas clean.
NOTE!
! WARNING
Inspect the element for damage. Never install Be sure that the engine is stopped and pres-
damaged elements back into the compressor sure relieved before working on the receiver
system. tank.
2 3 ! WARNING
4
Avoid touching hot oil or components -
these can cause burns.
6
5 ! WARNING
Ensure the engine is shutdown and internal
pressure relieved.
c40-50
LOW PRESSURE
COMPRESSOR
SYSTEM
25- 51
RECEIVER TANK
DRAIN
! WARNING
Installing a filter element without staples in BATTERY
the upper gasket can cause a static charge BOX
and result in fire. Do not remove the staples
from the upper sealing gasket.
245-53
245-51
BREATHER
WINCH
MOTOR
Page 2F-4
EVERY 2000 HOURS OR
1 YEAR
COOLING SYSTEM
245-52
Change Coolant
! WARNING
Steam can burn. Allow coolant to cool
before draining. Remove the radiator filler
RADIATOR DRAIN
cap slowly to relieve pressure. VALVE
SHUTOFF
VALVES
c25-6
! CAUTION
Add coolant only when the engine is
stopped and the radiator filler cap is cool
enough to touch with your bare hand.
245-52 ! CAUTION
Allow time for the oil to flow through the
gears and ensure that the entire quantity of
oil specified for each compartment is added.
Do not operate the machine with low final
drive oil - final drive failure will result.
RADIATOR MOUNTS
6. Replace the fill/level plug.
! WARNING
Use caution and avoid touching hot oil or
components - these can cause burns.
Page 2G-2
SECTION 3
MACHINE STORAGE Removal from Short Term Storage
Perform the following steps to prepare the 7. Make a thorough visual inspection of the
machine proper for short term storage: entire machine before operating it for the first
time following storage. Check, especially, for
1. Clean the entire machine. damaged or deteriorated hydraulic hoses.
5. Drain all gear cases and clean the magnetic 2. Lubricate all points equipped with grease fit-
plugs and breathers. Replace the drain plugs tings.
and refill each housing and case with the oil
type specified in Section 1. 3. Check the oil levels in the gear housings
including the winch and crawler final drive. Add
6. Contact the engine manufacturer for engine oil as required of the types specified in Section
storage procedures. 3.
7. Clean the battery compartment using a soda 4. Drain the hydraulic reservoir down to the
and water solution, if necessary, to remove cor- proper level.
rosion. Wrap the cable terminals with water-
proof tape, after cleaning. 5. Remove the preservative grease from the
cylinder rod pistons and other machined sur-
8. Run the engine until the hydraulic oil is faces, if applicable.
warm. Then drain the hydraulic system com-
pletely.
3--2