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Toro 007 Maintenance Manual

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Summary of Contents for Toro 007

  • Page 1 Maintenance Manual...
  • Page 2 (Detroit S50) MAINTENANCE MANUAL...
  • Page 3 2 (64) TKU C 01140--- 1 EN 0404  SANDVIK TAMROCK CORP ., TURKU PLANT 04/2004...
  • Page 4 PREFACE Congratulations on your choice of a TORO loader. This manual describes the maintenance of this TORO 007 loader. Only those who have been given proper training and are authorized to do so should 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...

  • Page 5: Table Of Contents

    4 (64) TKU C 01140--- 1 EN 0404 PREFACE ..................GENERAL .

  • Page 6: General

    GENERAL 1.1. Importance of regular maintenance The TORO 007 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.

  • Page 7: General Repair Instructions

    6 (64) TKU C 01140--- 1 EN 0404 GENERAL 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.

  • Page 8: Location Of The Main Components

    7 (64) TKU C 01140--- 1 EN 0404 GENERAL 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. 1.4.
  • Page 9 8 (64) TKU C 01140--- 1 EN 0404 GENERAL Rear frame Fuel tank Battery box Oil cooler Radiator / intercooler / fuel cooler Hydraulic oil level Operator’s cabin Main switch Service hatches Engine ass’y Alternator Engine coolant filter Turbocharger Fuel filter Engine oil filters Air filter...
  • Page 10 9 (64) TKU C 01140--- 1 EN 0404 GENERAL Power train Front axle Rear axle Transmission / torque converter Transfer gearbox Driveshaft...

  • Page 11: Maintenance And Lubrication

    MAINTENANCE AND LUBRICATION MAINTENANCE AND LUBRICATION The TORO 007 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.

  • Page 12: Electrical System Maintenance

    11 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE AND LUBRICATION Tests Pilot system pressure . Engine at low idle. . Pressure should be 35 bar (3.5 MPa). Steering system pressure . Install the frame locking pin between the front and rear frames. .

  • Page 13: Battery Maintenance

    12 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE AND LUBRICATION Working on live components 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.
  • Page 14 13 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE AND LUBRICATION If welding must be done close to any of the control modules, disconnect the module wiring before beginning welding. The ground cable of the welding machine must be connected as close as possible to the welding location.

  • Page 15: Lubricants

    14 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE AND LUBRICATION 2.5. Lubricants 2.5.1. Engine Classification API CH--4 Viscosity SAE 15W--40 Use oil of API category CH--4. API CF--4 or CG--4 oils may be used when CH--4 oils are not available; however, their use requires a shorter oil change interval.

  • Page 16: Transfer Gearbox (Up--Box)

    15 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE AND LUBRICATION 2.5.5. Axles Classification MIL--L--2105 C or API GL--5 + LS (Limited Slip) Viscosity above --25 _C. SAE 80W/140 --25 _C...+15 _C SAE 85W/140 2.5.6. Grease nipples Lithium--based greases with penetration 265/295 (NLGI 2) and dropping point 180 _C should be used.

  • Page 17: Refueling

    16 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE AND LUBRICATION 2.7.2. Refueling The following precautions must be observed when adding fuel: Do not fill the fuel tank when the engine is running. Do not overfill. Take care not to spill fuel on hot surfaces. Addition of fuel should be done in a well--ventilated space.

  • Page 18: Maintenance Operations

    17 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS MAINTENANCE OPERATIONS 3.1. Every shift D D D D Check engine oil Machine on level ground. Measure oil level with engine stopped (after stopping the engine, allow oil drain to the crankcase for about 20 minutes before checking the oil level).
  • Page 19 18 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check air filter indicator and assembly condition Consult air restriction indicator; service air cleaner elements as required. Inspect the entire air system for leaks. Tighten any loose connections. D D D D Check intake ducting and connections for leaks D D D D Check exhaust ducting and connections for leaks...
  • Page 20 19 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check fuel filter element The filter cover will not fill completely during engine operation. It will gradually fill over time, and the fuel level will rise as the filter element becomes clogged.
  • Page 21 20 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check tires and wheel nuts Check condition. Visually check tire wear and air pressure. Visually check for loose or missing wheel nuts. D D D D Check hydraulic oil level Boom in down position and bucket on ground.
  • Page 22 21 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Test service and parking brake function Check for leakage and test brake function. Brake test: Check that the pressure in the brake system is 150--185 bar before testing. Brake test: Press brake pedal, engage first gear, and rev the engine.
  • Page 23 22 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check Hand Portable Fire Extinguisher Gauge pointer in green area. No corrosion. Firmly mounted. Visually check that seals are in place. D D D D Check lights Front Rear Optional lights...
  • Page 24 23 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Fill automatic central lubrication system (option) Check the system visually and fill it. Check that all lubrication points are well greased. D D D D Grease lift cylinder pins, tilt cylinder pins, and lift arm pins Use central lubrication manifold.
  • Page 25 24 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Grease ejector cylinder pins (option) Grease pins directly through the nipples with a hand grease gun. D D D D Grease side tipping cylinder pins (option) Grease pins directly through the nipples with a hand grease gun.
  • Page 26 25 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS 3.2. Every week D D D D Wash radiator + oil coolers Open the cooler hatches for proper cleaning. WARNING Do not use high--pressure cleaning units. It may result in cooler core damage. HOT WATER CLEANING WITH SOAP (biodegradable detergent) CAN BE USED, MAX.
  • Page 27 26 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check tire pressures 18.00 x 25 L5S Bridgestone Front: 550 kPa (5.5 bar) Rear: 400 kPa (4.0 bar) D D D D Test transmission and the bucket and steering hydraulics The transmission and hydraulics should be at operating temperature during measurement.
  • Page 28 27 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS 3.3. Every 125 hours D D D D Check wheel nut’s tightening torques UNF 3/4, 610 Nm (dry) D D D D General cleaning Operator’s compartment (do not use high-- pressure water when cleaning the cabin).
  • Page 29 28 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D 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 D D D D Check cables Visually check the cables for...
  • Page 30 29 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS 3.4. Every 250 hours D D D D Change engine oil and filters Run engine until operating temperature is reached; then shut down. Drain oil pan and reinstall drain plug, using a new gasket if required.
  • Page 31 30 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Service the air filter elements The air filter element must be replaced when the service indicator shows red. Always clean the sealing surface of the outlet tube and make sure that all contami-- nant is removed before the new filter is inserted.
  • Page 32 31 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Measure the coolant nitrite concentration and change cooling system filter, if needed Never open the filler cap when hot. Drain and clean if the engine overheats or solution is contaminated.
  • Page 33 32 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check alternator Check alternator terminals for loose connections and corrosion. Check mounting Check V--belts. Replace if necessary. When replacing, always inspect fan bearings. D D D D Check oil level in planetary hubs and differentials Always ensure that the arrow is in down position when checking oil level in plane-- tary hubs.
  • Page 34 33 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check center articulation Check for visible signs of wear. Check that the lubrication works. D D D D Lubricate operator seat linkages and brake pedal links Remove the rubber bellows, and lubricate the seat linkage.
  • Page 35 34 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Grease the stationary ends of boom / bucket pins Use a hand grease gun. D D D D Check fire suppression system Check ”quick check” that the system is operable.
  • Page 36 35 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS 3.5. Every 500 hours D D D D Check cooling system hoses Check for signs of deterioration and replace if necessary. D D D D Drain water from fuel tank D D D D Check fan shroud D D D D Check exhaust system fastenings Check exhaust manifold fastening nuts,...
  • Page 37 36 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check axle fastenings visually D D D D Measure wear to the brake linings Apply the parking brake. Push in pin until it contacts reaction plate. If the wear indicator pin reaches the same level as the outer surface of the nut, the brakes are worn out and should be...
  • Page 38 37 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Change transmission oil filter Clean the filter adapter. Add quantity necessary to bring fluid level to FULL mark on dipstick. D D D D Change return oil filter element for bucket and steering hydraulics D D D D Check center articulation with dial gauge Place a dial gauge with a magnetic stand on the upper hinge plate of the front frame.
  • Page 39 38 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check oscillating axle tightening torques Bolt tightness (dry) M 12 (8.8) bolts ..80 Nm M 16 (8.8) bolts ..210--240 Nm 3.6.
  • Page 40 39 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check catalytic exhaust gas purifiers (optional) Increased backpressure (2 to 3 inches water gauge higher from clean purifier when at high idle), excessive smoke, or high levels of odor or irritation during operation of the LHD loader indicates that the purifier is not functioning at optimum performance and should be...
  • Page 41 40 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Check the tightening of axle fastening bolts Tightening torques (dry) ..Axle fastening nuts ..1000 Nm .
  • Page 42 41 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS Steering system pressure Install the frame locking pin between front and rear frames. Connect a pressure gauge to the quick--disconnect fitting after the steering main valve. Engine speed of 1000 --1500 rpm. Turn the machine to full left--hand turn.
  • Page 43 42 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS D D D D Service fire suppression system The fire suppression system, including alarms, shutdown, and associated equipment, shall be thoroughly examined and checked for proper operation by the fire suppression system manufacturer, authorized distributor, or the designee in accordance with the Ansul Maintenance Manual.
  • Page 44 43 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS 3.8. Every 2000 hours D D D D Change V- -belts Change V--belts. During replacement, always inspect fan bearings. D D D D Service the hand extinguisher Have the extinguisher serviced by an authorized supplier or dealer.
  • Page 45 44 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE OPERATIONS 3.9. Every 4000 hours D D D D Drain and replace coolant Drain the radiator and engine block. Flush the cooling system. Install new coolant pre--charge filter. Fill slowly to avoid air pockets; keep the radiator bleeder screw open.
  • Page 46 45 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM MAINTENANCE PROGRAM Every shift Page Done Check engine oil ............Check V--belts .
  • Page 47 46 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every week Page Done Check engine oil ............Check V--belts .

  • Page 48: Maintenance Program

    47 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM When completed Date ..... . . Engine hours ....Special Notes Approved .
  • Page 49 48 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 125 hours 1/2 Page Done Check engine oil ............Check V--belts .
  • Page 50 49 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 125 hours 2/2 Page Done Grease center articulation, steering cylinder pins, and oscillating axle* ..Grease dogbone pins ..........Grease driveshafts .

  • Page 51: Check V--Belts

    50 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 250 hours 1/1 Page Done Change engine oil and filters ..........Check V--belts .
  • Page 52 51 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 250 hours 2/2 Page Done Fill fuel tank ............Fill the automatic central lubrication tank (option) .
  • Page 53 52 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 500 hours 1/2 Page Done Change engine oil and filters ..........Check V--belts .
  • Page 54 53 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 500 hours 2/2 Page Done Check the emergency steering system (option) ......Check brake releasing pump function .
  • Page 55 54 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 1000 hours 1/2 Page Done Change engine oil and filters ..........Check V--belts .
  • Page 56 55 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 1000 hours 2/2 Page Done Test bucket hydraulics, test B ..........Record = .
  • Page 57 56 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM When completed Date ..... . . Engine hours ....Special Notes Approved .
  • Page 58 57 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 1500 hours 1/2 Page Done Change engine oil and filters ..........Check V--belts .
  • Page 59 58 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 1500 hours 2/2 Page Done Test steering hydraulics, test S ..........Record = .
  • Page 60 59 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 2000 hours 1/2 Page Done Change engine oil and filters ..........Change V--belts .

  • Page 61: Check Hand Fire Extinguisher

    60 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 2000 hours 2/2 Page Done Test bucket hydraulics, test B ..........Record = .
  • Page 62 61 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM When completed Date ..... . . Engine hours ....Special Notes Approved .
  • Page 63 62 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 4000 hours 1/2 Page Done Change engine oil and filters ..........Change V--belts .
  • Page 64 63 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM Every 4000 hours 2/2 Page Done Test transmission hydraulics, test A ......... . Record = .
  • Page 65 64 (64) TKU--- C 01140--- 1 EN 0404 MAINTENANCE PROGRAM When completed Date ..... . . Engine hours ....Special Notes Approved .

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