Preventive Maintenance Procedures

General Inspection
1. At the beginning of each shift, or after the machine has sat for a while, walk around it and
inspect its general condition. Look for hydraulic oil, fuel, transmission oil and gear oil
leakage. Check for low tire pressure, and bent or broken structural pieces. Check all
accessible electrical components and wiring to look for cracked wiring insulation, loose
connections or damaged parts. Correct any of these conditions immediately.

Machine Cleaning
1. Clean the floor of the operator's compartment daily. Objects such as rocks, cans, cups, rags,
etc. on the floor can cause restriction of the foot controls which could cause an accident.
2. Every two weeks, or more often if necessary, steam clean the entire machine except
electrical connections and the instrument panel. Open or remove access doors and covers to
the transmission and hydraulic compartments. Ensure that all belly pans and other areas that
may collect oil and dirt are kept clean. After steam cleaning, lube all grease fittings with
multipurpose grease as specified previously in this section.
NOTE: Always clean the machine immediately whenever an oil leak occurs.

Dry Type Air Cleaner

Function
The air cleaner prolongs engine life by removing grit and dust from the air entering the engine.
Grit and dust, combined with engine oil, form a highly abrasive compound which can ruin the
engine in a very short time.

! WARNING!

Never service the air cleaner while the engine is running.

Inspection
3. Inspect the air transfer duct between the air cleaner and the engine to be sure that all clamps
are tight, all flange joints are tight and there are no cracks in the ducting.
4. Tighten the air cleaner mounting bolts and clamps that hold the air cleaner chassis.

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 Preventive Maintenance Procedures

5. Check for dents and damage to the air cleaner housing which could cause a leak which
would result in unfiltered air being drawn into the engine.
6. Check the service indicator on a daily basis.
7. Replace the primary air cleaner element assembly with a new element whenever the red flag
appears in the indicator window.
8. Reset the indicator prior to starting the engine.
9. Service the dry type air cleaner as shown on previous page.
10. Replace the air cleaner safety element every third primary element change or when red
warning flag in the exterior service indicator reappears although the primary element has
been serviced.
CAUTION: Safety elements are not designed to be cleaned, only replaced at specified intervals.
Use only genuine elements supplied by the manufacturer. Elements of other makes
may not be of the manufacturer's standards and could be a hazard to the engine.
11. Every 250 hours, if the machine is not equipped with an air cleaner service indicator, or if
the indicator is not working properly, use a manometer to check intake air restriction.
Connect it to the port provided on the air transfer duct. The manometer should indicate no
more than 20 inches (508 mm) of water vacuum at high idle. Greater vacuum probably
means that the air cleaner is dirty, but may also indicate a blocked air transfer duct or other
problem.
NOTE: If no port is provided on the air transfer duct and the machine is equipped with an air
cleaner service indicator, either the indicator itself, or the line leaving the air cleaner
going to the indicator, can be disconnected and a manometer attached.

Fuel System
1. Check the fuel level daily and fill as necessary with diesel fuel of the quality specified in
Fuel & Lubricant Specifications. Fill the tank at the end of each shift to avoid excessive
condensation forming on the inside of the tank walls when the machine is not in operation.
Never risk running out of fuel.
2. Also check the water separator daily (if equipped). If water is present inside the glass,
remove the drain plug and, if necessary remove the vent plug, to allow the water to drain
from the separator. Replace the element when the glass becomes clouded.
3. Every 125 hours, remove the drain plug located on the bottom of the fuel tank to drain water
and sediment which has accumulated inside the tank. Also, loosen the drain cock on the
bottom of the primary fuel filter and drain off water and sediment.
4. Every 125 hours, clean the fuel pre-filter, if fitted. Unscrew the clamping nut at the bottom
of the bowl. Swing the wire clip and nut to one side, then remove the glass bowl, screen and
seal. Clean the bowl and screen in clean diesel fuel. Make sure that the seal groove is clean
and install a new seal. Replace the element and bowl. Make sure the bowl seats squarely
before tightening the clamping nut. If a hydraulic governor is fitted, check and top up the oil
level as required.

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 Preventive Maintenance Procedures

5. Every 1000 hours, or more often if engine power decreases due to contaminated fuel,
replace the fuel filter element. On the primary fuel filter, unscrew the filter housing by hand
to remove the shell that contains the filter element. Do not spill any fuel. Renew the
element. Clean the seal groove and install a new, slightly oiled seal. Make sure that the
housing is squarely installed on the seal before final tightening. Use both hands to tighten
the filter.
CAUTION: Do not use tools.
6. Bleed the system. Check for leaks. On the secondary fuel filters, care should be taken when
unscrewing the elements as fuel will run out. When installing the new elements, slightly oil
the rubber seal and screw elements into place until tightly seated, then hand tighten both
filters using both hands. Bleed the system and recheck the filter for tightness and leaks.
7. Every 3000 hours, remove the engine fuel injectors and have them checked by a qualified
diesel fuel system mechanic. Clean, repair or replace the injectors if necessary.

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 Preventive Maintenance Procedures

Engine Lubrication System

1. New engines have normally a higher oil consumption which necessitates the oil being
checked twice a day during the running-in period (the first 200 hours). Thereafter, one oil
check per day will be sufficient. This check should be made with the engine stopped and in
a horizontal position. The coating of oil should extend to the upper mark of the dipstick.
Never let the oil fall below the lower mark. Use only engine oil as specified in the lubricant
specifications.
2. The engine oil must generally be changed every 250 hours or monthly, or more often where
adverse conditions prevail. Colour cannot be relied upon as indicating the need for an oil
change. The oil should be drained only when the engine is warm, since warm oil drains
more quickly and completely. After the oil has been changed, run the engine for three
minutes, then recheck the oil level with the engine stopped. Wait two minutes for the oil to
drain down before rechecking. Add oil as necessary to bring the oil level to the top mark on
the dipstick. Do not overfill. Refer to the engine manufacturer's manual for additional
lubricating oil information.
3. The engine oil filter element must be replaced every time the engine oil is changed. When
installing the new element, slightly oil the rubber gasket and screw element into place until
tightly seated, then fully tighten by hand. Start the engine and check for leaks.
CAUTION: Change the oil and replace the initial oil filter after the first 50 hours of operation.
4. Every 3000 running hours replace the crankcase breather valve assembly. Refer to engine
manufacturer's service manual.

Cooling System (If Fitted)

Every 125 hours, or more often if necessary, clean the cooling fins on the cylinders, cylinder
heads and oil coolers. Accumulation of dust on these parts means reduced cooling efficiency
which could result in overheating, particularly when the dust is combined with fuel and/or oil.
Remove necessary parts to gain access to all cooling fins, and steam clean if possible. A wire
brush and compressed air may also be used. If diesel fuel is used for cleaning, it is important to
rinse with a soda solution afterwards to prevent formation of grease deposits. After cleaning, run
the engine until warm to evaporate any water left on the engine.
Every 250 hours, check and adjust the alternator v-belts.

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 Preventive Maintenance Procedures

Exhaust System

Water Exhaust Conditioner (if equipped)

1. At the beginning of each eight or ten hour shift, fill the water exhaust conditioner with
water.
2. Every other shift, add one-quarter cup of automatic dishwasher soap powder to the water in
the conditioner. Turn the engine at moderate speed to agitate the water and soap, then drain,
flush and refill the tank.
3. Every 250 hours, use a manometer to check exhaust restriction, connecting it to the port
provided on the exhaust pipe or exhaust conditioner. The back pressure should not exceed
30 inches (762 mm) of water at high idle. Greater back pressure indicates a dirty or damaged
exhaust conditioner.
Catalytic Exhaust Conditioner
The catalytic exhaust conditioner requires no scheduled maintenance; requirements can only be
determined with the use of a manometer (see item “3” above). If service becomes necessary, refer
to ECS service information contained in this service manual.
Every 1000 hours, check the bolts connecting the exhaust and intake manifolds to the cylinder
head for tightness, and retighten where necessary.

! WARNING!

Check the exhaust manifold only when the engine is cold. Contact with a hot exhaust can
cause serious burns!

Air Start System (Optional)

1. Every shift: drain the air tank of water
2. Every 125 operating hours, check the oil level in the air line lubricator. Refill it when half
empty with hydraulic oil.

Engine Valves
1. Check engine valves clearance after the first 50 hours of operation and every 500 hours
thereafter. Refer to the engine manufacturer's manual for detailed adjustment procedure.

Engine Temperature Gauge/Sensor

1. Every 1000 hours, check the engine temperature gauge/sensor for accuracy.

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 Preventive Maintenance Procedures

Transmission/Torque Converter
1. Every day, check oil level in the transmission/torque converter. Check the oil level with the
engine running at low idle, the transmission in neutral, and the oil at normal operating
temperature. Maintain the oil level at the full mark. Use only transmission oil as described in
the lubricant specifications in this section.
2. Every 250 hours, or more frequently if dust conditions prevail, remove and clean the torque
converter and transmission breather and replace the oil filter. If low dust conditions are
prevalent, this may be extended to 500 hours. Check the filter each time for traces of metal
or seal particles as they may be a sign of premature wear or an upcoming failure.
NOTE: The transmission oil and filter must be changed whenever the transmission or torque
converter has been repaired.
3. Every 500 hours, change the transmission oil. If low dust conditions are prevalent, this may
be extended to 1000 hours. Proceed as follows:

! WARNING!

With the transmission oil at 150-200° F (66-93° C), drain the transmission thoroughly.
Remember, fluids at these temperatures can cause serious scalding injuries.
• Remove the transmission filter and discard the element. Install new element using a
new gasket. Remove and clean the transmission and torque converter breather.
• Secure all drain plugs and refill the transmission with transmission oil. Refer to the
lubricant specifications at the beginning of this section for the proper oil and quantity.
• Run the engine at low idle until the transmission oil pressure gauge has indicated at
least 180 psi (1241 kPa) for several minutes. This is to ensure that both the torque
converter and the transmission have oil.
• When the pressure is sufficient, check for leaks, then run the engine at governed speed
to bring the transmission oil to operating temperature.
• Check the oil level and add as required. For detailed service information, refer to the
manufacturer's manual in section 4.

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 Preventive Maintenance Procedures

Drivelines and Axles

Tires and Wheels

1. Check the air pressure in the tires daily.
2. This pressure is critical for optimum tire life. Also inspect the tires for cuts, breaks or other
damage.
3. Check the wheel nuts for the correct torque every 250 hours of operation. Each time a wheel
has been removed, check the lug nuts daily until satisfied that they will remain tight. This is
necessary as the wheel nuts may become loose.
4. Because of their importance to safety, the multi-piece rim/wheels are designed with a high
safety factor built into them. Therefore, they must be inspected every 1000 hours and
whenever the tire has been removed for any reason.

! WARNING!

Carefully inspect the rim/wheel components for cracks, bends, distortion or other damage.
Do not attempt to repair by welding, heating or hammering. If any of the parts are
damaged, they must be replaced with new parts. If this is not done, they may fly off with
killing force during inflation or fail in use.
5. Clean all rust and dirt from the rim/wheel parts and apply a coat of good grade primer.
Allow the paint to dry thoroughly before remounting tire. The rim/wheel parts used with
tubeless tires form an important part of the air chamber. Check rim/wheel parts carefully for
distortion or mutilation that would prevent an effective seal when the tire and rim are
reassembled. Rubber o-ring are air seals for tubeless tire and rim assemblies and should be
carefully handled to provide an airtight seal.

! WARNING!

Service personnel must be alerted to the risk involved when working on multi-piece rim
wheels. Refer to Occupational Safety and Health Administration (OSHA) Regulation 29
CFR Part 1910.177.

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 Preventive Maintenance Procedures

Hydraulic System

Hydraulic Oil and Filter

1. Check the hydraulic oil level every 10 hours of operation. The oil level should be even with
the top sight glass in the tank. Check the oil level only when the oil is at operating
temperature, with the bucket lowered and resting flat on the ground.
CAUTION: The hydraulic in-line filter elements must be re placed after the first 50 hours of
operation and at least every 500 hours of operation thereafter.
2. Start the engine and allow it to run until the hydraulic oil has warmed to normal operating
temperature. While the hydraulic oil is warming, check the filter for external leakage. If the
filter bowl seal is leaking, replace the o-ring and back-up ring. If leakage persists, check
sealing surfaces for scratches or cracks. Replace any defective parts.
3. Every 500 hours, remove the in line filter elements from the filter assembly, mounted on top
of hydraulic tank and install new elements and a new o-ring.
4. Drain hydraulic tank after the first 50 hours of operation and every 1000 hours thereafter as
follows:
CAUTION: Use extreme caution when opening the hydraulic tank filler cap. Allow the built-up tank
pressure to vent off before completely removing the filler cap. Replace the filler cap
when the pressure has vented to prevent ingress of dirt into the hydraulic tank.
5. Drain tank by removing the plug from the bottom of the tank.
6. Open tank access port and remove and clean suction strainers. Also inspect inside tank side
and bottom for rust, contamination, etc. Steam clean, wire brush if necessary, then wash out
with solvent.
CAUTION: Do not paint the interior of the hydraulic tank.
7. Install suction strainers, then close the access port and install drain plug. Refill tank with
hydraulic oil to the top sight glass level.
8. To get hydraulic oil down to the pumps, first place a suitable container under the pump inlet
connections, then loosen. Gravity will cause the oil to flow through. As soon a a bubble free
flow is seen, tighten connections. Remove oil container and wipe up any spillages.
9. Start engine and check oil level when the hydraulic system is at normal operating
temperature. Also check system for leaks.
Accumulators and Check Valves
1. Every 125 hours, check accumulators for proper precharge (gas) pressure. Also make sure
check valves are working properly.
2. Depending on machine design, there may up to five (5) accumulators in the hydraulic
system.
3. All accumulators are of the piston type. A full technical description and repair guide can be
found in the hydraulic section of this service manual.

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 Preventive Maintenance Procedures

NOTE: The gauge on the instrument panel does not indicate park brake circuit pressure or park
brake accumulator precharge pressure. Check the precharge pressure in park brake
accumulator as instructed in the accumulator test procedure. Remove oil pressure in park
brake accumulator by pulling the drain valve located on the park brake manifold.
4. Operate the engine until the hydraulic pressure gauge indicates full system pressure (2000
psi/13.8 MPa).
NOTE: Check and record for future reference, the distance the machine will articulate and the
number of full brake applications obtainable when the hydraulic system is charged to full
system pressure (2000 psi/13.8 MPa) and the engine is stopped.
Accumulator Test Procedure
This test requires the use of a charging and gauging assembly. See Parts Manual to order.
1. Block wheels and apply parking brake.
2. Reduce all accumulator pressure to zero by opening the rotary drain valve of the brake drain
valve manifold.

! WARNING!

The hydraulic fluid must be drained from the fluid of the accumulator before checking the
precharge (gas) pressure.
3. Remove valve guard and cap from each accumulator to be checked.
4. Mount charging and gauging assembly on the accumulator. Retract air check shaft by
turning bar handle counterclockwise until it stops.
5. Mount the air check swivel to accumulator gas valve stem, compressing the gasket in the
swivel to prevent gas leakage.
6. Close the bleeder valve on charging and gauging assembly and turn bar handle clockwise
until the shaft depresses accumulator valve core. The accumulator precharge pressure
should now be observable on the gauge. If pressure is below 800 psi (5.5 MPa), charge the
accumulator with nitrogen. If accumulator has the proper precharge pressure, turn bar
handle counterclockwise, loosen bleeder valve, and unscrew swivel from the accumulator.
Accumulator Charging Procedures
1. Before pre-charging an accumulator follow the procedure described in the manufacturer's
service document.
2. Connect the gland nut to the outlet nozzle of the nitrogen bottle. With the bar handle turned
clockwise to depress valve stem in the accumulator, open nitrogen bottle valve SLOWLY.
Occasionally close valve to settle in position, thus giving an accurate reading of precharge
pressure.

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 Preventive Maintenance Procedures

! WARNING!

When correct precharge pressure has been attained, tightly close the nitrogen cylinder
valve. Correct precharge pressure is 1150 psi.
3. Use the bleeder valve of the gauging head assembly to release gas pressure in excess of
1150 psi. Back out bar handle and unscrew the swivel.

! WARNING!

When bleeding gas pressure from an accumulator without the charging and gauging
assembly, depress the valve core with an implement to keep hands and body clear of
discharging gas. Nitrogen gas under pressure can burn or otherwise harm skin.

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 Preventive Maintenance Procedures

Electrical System

Batteries

! WARNING!

Never smoke or permit any kind of spark or open flame near the batteries. They emit
hydrogen gas when charging. If ignited, serious acid and heat burns could result. Also keep
in mind that battery electrolyte is a strong acid. It can be highly injurious to the eyes, skin
and clothing. If accidentally splashed with acid, flush the affected area with large amounts
of water. Follow immediately by bathing the area with a mixture of baking soda and water.
To further neutralize the acid, seek medical aid immediately.
1. Check the electrolyte level in each cell after unscrewing the caps. In some cases electrolyte
level testers are provided; the levels should be high enough to wet the bottom of these. An
alternative method is to insert a clean wooden stick into the cell until it touches the top of the
lead plates. The electrolyte should wet the stick between a depth of about 1/2 inch to 2-1/2
inches (13 mm to 63 mm). If the electrolyte level is low, top up with distilled water only.
2. Check each of the battery cell caps, and clean in solvent if any are covered or plugged with
grease. The caps act as vents to release the gas that normally builds up during charging.
3. Inspect the battery terminal connection clamps. They should be free of corrosion. As
needed, remove and clean them, and the battery case, with a mixture of soda and water,
using a stiff wire brush on the terminals. after cleaning, flush with clear water; thoroughly
dry the terminal posts and coat lightly with petroleum jelly. This will help to prevent further
corrosion at the terminals.
4. From time to time, or whenever starting problems occur, check the battery strength. This is
done with a hydrometer and/or a Heavy Duty Discharge Tester. A normal reading should be
between 1.275 and 1.300-sg.
Alternator and Starter
1. Every 1000 hours, have the alternator and starter inspected by qualified automotive
electrical service personnel.
Engine Temperature Gauge/Sensor
1. Every 1000 hours, check the engine temperature gauge and sensor for accuracy.
Fire Extinguisher
Every 10 hours, check the fire extinguisher to ensure that the pressure gauge indicates proper
pressure. Also check that it is secured properly to the machine and that it is ready for operation.

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 Preventive Maintenance Procedures

! WARNING!

Fire extinguisher must be serviced by qualified and certified personnel.

Fire Suppression System (If Equipped)
Description
The system consists of extinguisher assembly(s), remote actuator(s), spray nozzle and safety
relief valve(s).
In case of fire, the fire suppression system can be actuated from the operator's compartment. The
remote actuator is a small steel bottle containing gas under pressure. The gas from the actuator
exerts pressure on a pneumatic receiver/actuator that mechanically punctures the gas cartridge
mounted on each dry chemical chamber. The expellant gas from this cartridge pressurizes the dry
chemical chambers.
The gas (compressed gas) being introduced into the dry chemical storage chamber is held by a
bursting disc (located in the union receiver on the outlet of the dry chemical chamber) until the
rupture pressure is reached. When the rupture pressure is reached, the bursting disc shatters and
dry chemical is expelled from the strategically located nozzles to extinguish the fire.
Periodic Service
1. Visually check the appearance of the system components for mechanical damage every 10
hours of operation.
2. Check the nozzle and hoses every 125 hours of operation to make sure that they are not
damaged and that the nozzles are closed with a plastic blow-off cap or with silicone grease.
3. Every 6 months, service the complete fire suppression system as described in the fire
suppression equipment section of this document. The includes checking the level of dry
chemical, weighing the cartridges, checking the bursting disc, examining the gaskets for
elasticity, etc.
In Case of Fire
If a fire starts, they way you react is very important. As soon as you become aware of a fire, do the
following four things:
1. Shut the machine down. If possible turn off battery disconnect switch.
2. Quickly actuate the fire suppression system by pulling the safety ring pin and pushing down
the plunger on one of the actuators. One is located in front of the operator above the dash.
The other on the right-hand skirt weldment.
3. Get away from your machine. Take a hand portable extinguisher along if you can.
4. Stand by with hand portable extinguisher.
Explanation
1. If you leave the machine running, it may add fuel to the fire or restart the fire with sparks.
2. React quickly so the fire is caught before it grows too large.

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 Preventive Maintenance Procedures

3. By leaving the immediate fire area, you are protected from windblown flames, explosions or
other dangers created by the fire.
4. Heat remaining from the fire could cause re-ignition after the fire suppression system has
discharged. Because of this, it is important that someone stand by, at a safe distance, with a
hand portable extinguisher. This standby should be maintained until all possibility of re-
ignition is past.
What to Expect
When a fire suppression system discharges, there is considerable noise accompanied by clouds of
dry chemical. While breathing foreign particles is not pleasant, the agent FORAY is non-toxic and
exposure during a fire will not harm you.
After the Fire is Out
Machinery should not be restarted until it has been serviced and cleaned (water may be used to
remove the dry chemical). Immediately recharge the fire suppression system. You needed it once,
you may need it again.
Monthly Inspection
To provide reasonable assurance that your fire suppression system is charged and operable:
1. Note general appearance of system components for mechanical damage or corrosion. (all
points)
2. Check nameplate(s) for readability.
3. Remove fill cap.
4. Make certain tank is filled with free-flowing Ansul FORAY dry chemical to a level of not
more than 3 inches from the bottom of the fill opening.
5. Secure fill cap, hand tighten.
6. Remove expellant gas cartridge and examine disc - seal should be unruptured.
7. Return cartridge to pneumatic actuator/cartridge receiver, hand tighten and secure in
bracket.
8. Check hose, fittings and nozzles for mechanical damage and cuts.
9. Check nozzle openings - slot on F-1/2 nozzle should be closed (capped) with silicone grease
or covered with plastic blow-off cap.
10. Remove cartridge from manual actuator(s), and examine disc - seal should be unruptured.
11. Return cartridge to manual actuator(s) assembly, hand tighten.
12. Replace any broken or missing lead and wire seals and record date of inspection.
Semi-Annual or 3000 Hour Inspection
To provide maximum assurance that the fire suppression system will operate effectively and
safely:
1. Note the general appearance of the dry chemical tank for mechanical damage or corrosion.
2. Check nameplate for readability, corrosion and security.
3. Remove filler cap.

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 Preventive Maintenance Procedures

4. Examine the filler cap gaskets for elasticity - clean and coat lightly with a good grade of
high heat resistant grease.
5. Inspect threads on filler cap and in filler opening for nicks, burrs, cross-threading, rough or
feathered edges.
6. Check pressure relief vent in filler opening threads for obstruction.
7. Make certain tank is filled with free-flowing Ansul FORAY dry chemical to a level of not
more than 3 inches from bottom of fill opening.
8. Secure fill cap, hand tighten.
9. Disengage bursting disc union.
10. Examine the bursting disc. If necessary, move the tank slightly to view disc. The bursting
disc should be properly seated with the washer side facing out (smooth side in) and should
be undamaged (smooth, not scored or ruptured).
11. Engage bursting disc union (wrench tighten).
CAUTION: Over tightening can damage bursting disc.
12. Be sure the dry chemical tank is firmly mounted in its bracket.
13. Loosen the bolts which restrain the cartridge or remove extinguisher cartridge guard
assembly.
14. Inspect the expellant gas cartridge assembly for evidence of mechanical damage or
corrosion.
15. Unscrew the cartridge from the pneumatic actuator/cartridge receiver and weigh it. Replace
if its weight is not within 1/4 ounce on A-101-10 models, 1/2 ounce on A-101-20/30 models
of the weight stamped on the cartridge.
16. Inspect threads on cartridge and in pneumatic actuator/cartridge receiver for nicks, burrs,
cross-threading, rough or feathered edges.
17. Check pressure vent in pneumatic actuator/cartridge receiver for obstruction.
18. Examine cartridge receiver gasket for elasticity. clean and coat lightly with a good grade of
high heat resistant grease. Return cartridge pneumatic actuator/cartridge receiver, hand
tighten. Tighten the bracket bolt(s) uniformly or return cartridge guard assembly.
19. Check hose, fittings and nozzles for mechanical damage.
20. Check nozzle openings - slot should be closed (capped) with silicone grease or covered with
plastic blow-off cap.
21. Check remote actuator - remove cartridge and weigh (replace if weight is 1/4 ounce less
than stamped on cartridge). Inspect threads on cartridge and in actuator for nicks, burrs,
cross-threading, rough or feathered edges. Check pressure safety vent in actuator body for
obstruction. Examine actuator cartridge gasket for elasticity - clean and coat lightly with a
good grade of high heat resistant grease. Pull ring pin and operate actuator button several
times to check for free movement.
22. Seal ring pin to puncture lever with lead and wire seal. Return cartridge to remote actuator,
hand tighten.
23. Record date of maintenance.

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 Preventive Maintenance Procedures

Recharge Procedure
1. Pull ring on safety relief valve to relieve actuation pressure.
2. Disconnect actuation system hose at cartridge receiver/actuator assembly.
3. Open bursting disc union assembly.
4. Remove dry chemical tank from its bracket.
5. Replace ruptured bursting disc with new disc. FLAT SIDE OF DISC MUST FACE TANK.
Verify that the proper disc is being used by referring to the machine parts list for part
number. Assemble bursting disc union, wrench tighten.
6. Fill tank to rated capacity with Ansul FORAY dry chemical as specified on nameplate.
7. Clean fill opening threads and gasket, and the fill cap threads. Coat the gasket lightly with a
good grade of high heat resistant grease.
8. Secure the fill cap, hand tighten.
9. Return the tank to its bracket and secure it.
10. Loosen the u-bolts on the expellant gas cartridge bracket or remove cartridge guard.
11. Unscrew and remove the empty nitrogen cartridge.
12. Make certain that the puncture pin on the pneumatic actuator/cartridge receiver is fully
retracted.
13. Obtain a new expellant gas cartridge and verify the proper part number by referring to this
machine's parts list. Weigh the new cartridge. The weight must be within 1/2 ounce of the
weight stamped on the cartridge.
14. Screw the fully charged expellant gas cartridge into the pneumatic actuator/cartridge
receiver. Hand tighten.
15. Secure the expellant gas cartridge assembly in its proper position in the bracket with the
cartridge retaining bolt(s) or return cartridge guard.
16. Check all hoses and fittings for mechanical damage. Replace and hose that has been
exposed to fire.
17. Check the nozzles for mechanical damage. Clean them and install blow-off caps or silicone
grease.
18. Pull up the button on the dashboard actuator and insert the ring pin.
19. Remove the spent cartridge.
20. Screw a fully charged cartridge into the remote actuator, hand tighten. Verify part number by
referring to this machine's parts list.
21. Connect actuation system hose at cartridge receiver/actuator assembly, wrench tighten.
22. Attach a lead and wire seal to the ring pin and actuation button or lever.
23. Notify operating personnel suppression system is back in service and record date of
recharge.

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 Preventive Maintenance Procedures

! WARNING!

Never send a machine out for operations with a discarded or defective fire suppression
system.
Front and Rear Axle Assemblies
NOTE: Includes differential, and wheel end housing.
1. Every 125 hours check oil levels in each housing.
NOTE: Make sure that the machine is on level ground.
2. Operate the machine first to warm the oil, if possible. Move the machine to align the wheel
end level plugs. (arrow on hub cover pointing straight down). Let the axle stand for five
minutes after running to allow oil to drain back to normal levels. Remove the wheel end and
differential level plugs.
3. Check oil level; oil should be to the bottom of the level plug hole. Top up if required using
fresh oil of the same grade. Replace all plugs securely. For the liquid cooled brakes,
examine the level in the reservoirs mounted, one in each frame. Replace reservoir cap
securely. Use the same type of hydraulic oil as in the hydraulic system. Repeat procedures
on the other axle.
4. Every 500 hours repeat the procedures above and remove the front and rear axle breathers.
Examine condition and, if damaged, replace. Otherwise clean in diesel fuel or solvent.
Reinstall after thoroughly drying with compressed air.
5. Every 1000 hours, repeat all other timed interval procedures and after making sure the oil is
warm, remove the drain plugs on the differential and wheel end housing. Examine the drain
plugs and the old oil for signs of metallic contamination. Replace the drain plugs and fill
with light flushing oil. Run to flush gearing thoroughly. Drain and examine oil for any
contamination. When flushing oil has completely drained, refill differential and wheel ends
to correct level with oil of the correct grade. Make sure that all plugs are replaced and
tightened. Also, drain the liquid cooled brake housings. Examine oil fluid for contamination.
Replace drain plug, make sure level plug has been removed and refill to correct level with
hydraulic fluid as used in the hydraulic system. Run machine again and check for leaks.
Drivelines and Carrier Bearing
1. Every 125 hours, lube the grease fittings on the drivelines and carrier bearing as follows.
• universal joint fittings, slip joint fitting on torque converter-to-transmission driveline
• universal joint fittings, slip joint fitting, 1 carrier bearing fitting on transmission-to-
front differential driveline
• universal joint fittings, slip fitting on transmission-to-rear differential driveline.
2. If the pressure test indicates bypass or leakage within any of the wheel ends brakes, the
machine must be taken out of service and the brakes repairs.

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 Preventive Maintenance Procedures

Liquid Cooled Brakes

Scheduled Maintenance
Every 1000 hours, perform the following procedure:
1. Operate the machine to warm the oil in the axle.
2. Park the machine on level ground in an area clear of traffic flow.
3. Shut down the machine and apply the park brake. Install safety blocks at all four wheels and
install the center articulation locking bar.
4. Rotate the wheel to move the fill-drain plug to the “12 o'clock” position. Remove the wheel
plug and install a threaded length of pipe which extends beyond the outside of the wheel
assembly.
5. Rotate the wheel to move the drain pipe to the “6 o'clock” position. Drain oil into a suitable
container.
6. Inspect the magnetic drain plugs and drained oil for metallic content and contamination.
7. If a high metallic content exists:
• Fill the wheel end cavity with flushing oil and operate the machine for a short time.
• Drain the flushing oil and refill to correct level with correct grade gear oil (see Fuel
and Lubricant Specifications).
8. Replace and retighten drain plug.
9. Clean up any spilled oil from the axle housing and wheel end.
10. Wash with solvent and dry with shop cloths.
11. Do not allow oil to seep between the wheel and hub mounting flanges.
CAUTION: The penetration of oil into this area may cause the loss of wheel clamping forces,
allowing slight movement and wheel stud fatigue oil breakage.
12. Drain liquid cooled brake housing.
13. Check for sludge contamination.
14. Replace and retighten drain plug.
15. Replace drained oil either directly into the wheel end brake housing oil into the brake
coolant reservoir.

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 Preventive Maintenance Procedures

Notes

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