PDF Operator's Manual John Deere 1070E 1170E Harvester - 4 MB
This is the factory Operator's Manual for the John Deere 1070E and 1170E Interim Tier 4 CTL Harvesters.
It contains vital instructions for safe operation, proper control functions, and routine service schedules.
Adhering to the guidelines in this manual will enhance your productivity and help prevent premature wear.
It is the most important document for any operator to read before using these powerful machines.
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CTL Harvester
1WJ1070E002224-
1WJ1170E002359-
OPERATOR'S INSTRUCTIONS
John Deere 1070E / 1170E
Interim Tier 4
F680525 (06/2017) ENGLISH
Worldwide Construction
And Forestry Division
Published in Finland
Original Instructions
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FOREWORD ENGINE IDENTIFICATION
ENGINE IDENTIFICATION
The engine serial number plate is located on the
right-hand side of engine block behind the fuel
filter.
A. Serial number plate location
B. Serial number, for example:
CD6068R000000
CD = Manufacturing unit, Saran, France
6 = Number of cylinders
68 = Liter designation
R = Interim Tier 4/Stage IIIB emission
certified engine
C. Engine model number, for example: 6068HTJ90
6 = Number of cylinders
68 = Liter designation
H = Aspiration, turbo + air to air intercooler
TJ = Engine user, JD Forestry
90 = User’s type code
NON-ROAD EMISSIONS CONTROL WARRANTY STATEMENT
U.S. AND CANADA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
To determine if the John Deere engine qualifies for the additional warranties set forth below, look for the
"Emissions Control Information" label located on the engine. If the engine is operated in the United States
or Canada and the Emissions Control information label states: "This engine complies with US EPA
regulations for nonroad and stationary diesel engines”, or “This engine conforms to US EPA nonroad
compression-ignition regulations”, refer to the "U.S. and Canada Emission Control Warranty Statement."
If the engine is operated in California, and the label states: "This engine complies with US EPA and CARB
regulations for nonroad diesel engines”, or “This engine conforms to US EPA and California nonroad
compression-ignition emission regulations”, also refer to the "California Emission Control Warranty
Statement.”
Warranties stated on this certificate refer only to emissions-related parts and components of your engine.
The complete engine warranty, less emissions-related parts and components, is provided separately. If
you have any questions about your warranty rights and responsibilities, you should contact John Deere
at 1-319-292-5400.
JOHN DEERE'S WARRANTY RESPONSIBILITY
John Deere warrants to the ultimate purchaser and each subsequent purchaser that this off-road diesel
engine including all parts of its emission-control system was designed, built and equipped so as to
conform at the time of the sale with Section 213 of the Clean Air Act and is free from defects in materials
and workmanship which would cause the engine to fail to conform with applicable US EPA regulations for
a period of five years from the date the engine is placed into service or 3,000 hours of operation,
whichever first occurs.
Where a warrantable condition exists, John Deere will repair or replace, as it elects, any part or
component with a defect in materials or workmanship that would increase the engine’s emissions of any
regulated pollutant within the stated warranty period at no cost to you, including expenses related to
diagnosing and repairing or replacing emission-related parts. Warranty coverage is subject to the
limitations and exclusions set forth herein. Emission- related components include engine parts developed
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SAFETY OPERATING
CABIN PROTECTIVE STRUCTURES
Cabin is tested according to international ROPS,
FOPS and OPS standards.
Do not operate the machine with the door open,
secondary exit open or any of the safety covers
or protective devices removed.
It is important to keep the operator protective
structure in place (doors, screens, windows,
windshield, etc.) to minimize hazards from
whipping or intruding objects.
The protection offered by ROPS, FOPS and OPS
will be impaired if cabin
is subjected to structural damage
is involved in an overturn incident
is in any way altered by welding, bending,
drilling, or cutting
To maintain ROPS, FOPS and OPS protection,
replace damaged cabin parts immediately. A
damaged structure should be replaced, not
reused. It is forbidden to modify the window
fastening.
Following issues must be considered when the
machine is used or equipped for other purpose
than it is designed for by the manufacturer:
Overall weight of the machine without load
(towed equipment and any load excluded) must
not exceed the maximum weight defined for the
cabin and mentioned below the machine type
plate (ROPS-weight, Roll Over Protection
Structure). Contact manufacturer’s
representative to clarify the demands of the
ROPS standard when necessary.
If the machine’s center of gravity is changed
due to machine buildup the maneuverability of
the machine will also change and does not
necessarily correspond to the original demands
determined by the manufacturer.
The manufacturer can not guarantee machine
safety if the machine has been used contrary to
the operator’s instructions given or has been
equipped with accessories not approved by the
manufacturer.
NOTE: An optional heavy duty window guard is
recommended for operations in late thinning and
regeneration felling sites.
CABIN WINDOWS
Polycarbonate windows are part of cabin protective structures and important for the protection of the
operator and the safe operation of the machine. Inspect the windows system regularly, and if surface
crazing or cracks are observed, replace windows using only John Deere replacement parts to ensure the
original operator protection level. Inspect the windows after any significant impact to the windows or
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SAFETY OPERATING
Temperature in engine compartment may go up
immediately after engine is stopped. Be on
guard for fires during this period. If necessary,
open access doors to cool the engine faster.
Keep machine clean. Check and clean covered
compartments, including engine bay, belly plates
etc.
Remove dust and debris especially from the
surroundings of the exhaust pipe and the engine
heater (if equipped).
Wash the machine regularly.
Clean the radiator grille and cooling ducts
regularly.
Inspect the machine daily for potential fire
hazards and make any necessary repairs
immediately.
Inspect electrical wiring and connections, fuel
and hydraulic hose runs and fixation to ensure
they are secure and not rubbing against other
components.
Clean up any excess grease and oil
accumulation and repair the leak immediately.
Use only nonflammable solutions for cleaning
the machine or components.
Store rags in a safe, fireproof location.
Store flammable fluids away from fire hazards.
Do not incinerate or puncture pressurized
containers.
Anti-slip chains and tracks can cause sparks
and fire in dry terrain. Avoid using these
appliances in such conditions unless other
safety risks are involved.
Before starting repair work, such as welding,
the surrounding area should be cleaned and a
fire extinguisher should be close by.
Maintain a charged fire extinguisher on the
machine at all times and know how to use it.
WHAT TO DO IF THE MACHINE
CATCHES FIRE?
Turn the engine off.
Turn the master disconnect switch off.
If possible, fight the fire using the portable fire
extinguisher or other fire suppression
equipment.
Ensure that the fire does not spread to the
surrounding area.
Call for help if necessary.
Hand-held fire extinguishers can be used through
the arpertures that are bordered with the
extinguisher decals.
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SAFETY MAINTENANCE
SERVICE TIRES SAFELY
Explosive separation of a tire and rim parts can
cause serious injury or death.
Do not attempt to mount a tire unless you have
the proper equipment and experience to perform
the job.
Always maintain the correct tire pressure. Do not
inflate the tires above the recommended
pressure. Never weld or heat a wheel and tire
assembly. The heat can cause an increase in air
pressure resulting in a tire explosion.
When inflating tires, use a clip-on chuck and
extension hose long enough to allow you to stand
to one side and NOT in front of or over the tire
assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts.
SERVICE AIR CONDITIONER
SAFELY
The air conditioner must be serviced and repaired
by authorized personnel only.
Air conditioner fluid (R134a) contains fluorinated
greenhouse gases. 2.3 kg air conditioner fluid
contains 3.0 equivalent tonnes of carbon dioxide.
Heating of the refrigerant cylinder implies
increase of pressure and the danger of explosion.
The refrigerant dryer must not be heated above
50°C (122°F), as this may otherwise cause it to
explode due to excessive pressure of the
refrigerant. In the event of fire spray the dryer
liberally with water to keep it cool.
The gas is asphyxiating without forewarning. The
gas is colourless, it is heavier than air and
spreads close to the ground.
Splashes of the fluid cause frost injuries to the
skin and serious eye damage. Spilled refrigerant
fluid has extremely low temperature and it
vaporizes quickly. Dissipates in contact with fire,
giving off toxic fumes.
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MACHINE SYSTEMS AND COMPONENTS INTERIM TIER 4 (STAGE III B) ENGINES
AFTERTREATMENT SYSTEM
In accordance with emissions regulations, a
reduction of 50 per cent in nitrogen oxide and a
reduction of 90 per cent in particulate matter is a
requirement of the latest IT4 engines.
To reduce nitrogen oxide emissions, the engine
combustion temperatures must be lowered. This
is achieved by recirculating a greater and cooler
amount of exhaust gas using a VGT turbocharger
and an EGR cooler.
However, lower combustion temperatures cause
PM levels to rise. Therefore, a catalysed exhaust
filter that contains a diesel oxidation catalyst
(DOC) and diesel particulate filter (DPF) is used
to control the PM levels.
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MACHINE SYSTEMS AND COMPONENTS ELECTRIC SYSTEM
BATTERIES
Harvesters are equipped with two 12 V lead/acid batteries. The first battery (1) supplies 12 V and it is
connected through cascading connection to the second battery (2), which totally supplies 24 V.
In harvesters batteries are located both sides of the rear frame.
Battery nominals:
Capacity: 154 Ah
Cold crank (EN): 1150 A
Top dimensions (mm): 513x178x223
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MACHINE SYSTEMS AND COMPONENTS ELECTRIC SYSTEM
WIRING HARNESS FUSES AND RELAYS
Some fuses and relays of special equipment are located near each equipment.
Glow relay and fuse, K49 (1) and F49 (2), are only on the 4.5 liter and 6.0 liter engines.
Centralized lubrication system relay K55 (3) is located next to the lubrication pump.
Puradyn filter relay K56 (4) is located next to the puradyn filter.
Position Relay number Object
1. K49 Glow relay
2. F49 Glow fuse (50A)
3. K55 Centralized lubrication system relay
4. K56 Puradyn filter relay
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MACHINE SYSTEMS AND COMPONENTS ELECTRIC SYSTEM
ELECTRICAL ENGINE COMPONENTS 5/6
1. Fuel dosing pump (Y5502)
The variablespeed dosing pump is controlled by the ECU. During active regeneration and fuel purging, the
pump draws fuel from the fuel filter and directs it to the fuel dosing unit. The ECU controls the fuel dosing
pump operation with enable and speed commands.
2. Water-In-Fuel sensor (B5600)
The Water-In-Fuel (WIF) sensor is located on the bottom of the primary fuel filter in the water separator
bowl. The WIF sensor measures fluid resistance to detect the presence of water in the fuel. Sensor
information is used by the ECU for engine protection purposes. If water is detected, the ECU will derate
the amount of fuel supplied to the engine.
3. HCI fuel dosing inlet sensor (B5000)
The fuel temperature and pressure at the inlet of the fuel dosing unit are measured by the fuel dosing inlet
sensor. The ECU uses these measurements to control fuel delivery to the fuel dosing nozzle.
4. HCI fuel dosing shut-off valve (Y5000)
The ECU controls the opening and closing of the fuel dosing shut-off valve according to the regeneration
phases. Normally the fuel dosing shut-off valve is closed.
5. HCI fuel dosing control valve (Y5001)
The control valve operation is controlled by the ECU according to the current regeneration phase. The
fuel dosing control valve regulates the fuel dosing unit operation.
6. HCI fuel dosing outlet sensor (B5106)
The ECU uses the sensor to detect abnormal fuel pressures after the fuel leaves the fuel dosing unit.
7. Engine crankcase pressure sensor (B5105)
The ECU uses the engine crankcase pressure sensor to monitor the amount of pressure in the crankcase
of the engine. This pressure value indicates when the crankcase ventilation filter needs replacing, or if
there is a problem with the crankcase pressure relief valve.
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MACHINE SYSTEMS AND COMPONENTS ELECTRIC SYSTEM
DAMPING SENSORS, CH6 AND CH7 BOOMS
1. Jib boom end damping sensor (B26.3)
The sensor controls the end damping of the jib boom movements. The function speed is slowed
when the sensor is activated.
2. Boom lift end damping sensor (B26.2)
The sensor controls the end damping of the main boom lifting movement. The function speed is
slowed when the sensor is activated.
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CONTROLS DRIVING CONTROLS
IGNITION SWITCH
1. STOP, power off (the key can be removed)
2. RUN1, power supply to most systems
3. RUN2, power supply also to engine (driving and
operating mode)
4. START, starter motor running (spring-return to
RUN2 position)
The ignition switch prevents double ignition. The
key must be returned to position STOP after an
unsuccessful attempt at starting.
NOTE: The PC starts automatically after the
engine is running in cabins equipped with XL4 or
XM4 PC.
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CONTROLS LIGHTS AND WIPERS
DRIVING LIGHTS
To drive the machine on public roads additional driving lights must be installed on it. The lights are
controlled from right arm rest panel.
Machine on-road driving equipment and operating switches are following:
1. Front driving lights
2. Rear driving lights
3. Side-view mirrors
4. Switch for front and rear driving lights
5. Left blinker switch
6. Right blinker switch
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CONTROLS PRE-HEATER MODEM
PRE-HEATER MODEM
If the machine is equipped with pre-heater remote controller (1), the pre-heater can be remote controlled
with web browser client, phone calls, SMS messages or cell phone application.
A window mountable antenna (2) is installed to rear window with double sided adhesive tape.
Every remote controller has a device specific QR code (3). The QR code is a picture that presents a
unique 16 character identification code of device. The QR code is used to identify the device when
logged in with a web browser or cell phone.
1. Activate a SIM-card
2. Check that the SIM-card is working properly by a cell phone.
3. If required, change the SIM-card PIN-code by the cell phone.
4. Install the SIM-card to the pre-heater remote controller.
NOTE: PIN code for the SIM card must be one of the following: ”1234”, ”0000” or the PIN
code query must be disabled completely.
NOTE: If the SIM card installed in REMUC does not have any kind of fixed rate data plan, switch data
connection off by sending SMS “IP OFF” to REMUC.
SMS INTERFACE
Pre-heater can be controlled with the mobile phone SMS messages. System control messages are
consisted of key words and parameters.
NOTE: The commands must be send in English as described below.
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OPERATING THE MACHINE AFTERTREATMENT SYSTEM
FILTER CLEANING SWITCH
The control panel is equipped with a three-position control switch for controlling the regeneration.
1. Request stationary filter cleaning (3 second press) – Activates stationary (manual) regeneration with
elevated idle speed up to 1800 rpm. The parking brake must be ON and the soot level must be above 3.
2. Auto filter cleaning – Enables filter cleaning by allowing active regeneration when requested by the
ECU.
3. Disable filter cleaning – Disables filter cleaning by preventing active regeneration.
It is preferable to keep the filter cleaning switch in the auto position for optimal engine operation. Use the
disabled setting only when required. Disabled filter cleaning and repeatedly aborted regeneration reduces
DPF lifetime.
NOTE: Passive regeneration occurs at all times during normal engine operation.
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OPERATING THE MACHINE BOOM AND HARVESTER HEAD
USING THE BOOM
Observe the lifting ratings given on the boom decal. The weight of the harvester head is included in the
load to be lifted. When handling a maximum load, exercise great caution.
Operate the control levers smoothlyÍľ avoid jerky movements. Always exercise extra caution when a boom
or the booms are in their extreme positions.
Keep an eye on the machine stability. Constant alertness is required, particularly when operating on
sloping ground. If necessary, decrease loads or drive the machine closer.
When you notice that the machine is about to fall over, pull extension in, move the outer boom in, and
lower the load smoothly onto the ground.
It is possible that you exceed the lifting capacity of the boom (the booms will go over relief) if you pick up
a load that is close to the machine and then move this load away from the machine. When this happens
you must bring the load closer to the machine by pulling the outer boom or extension inwards. This is
necessary because otherwise the power of the main boom cylinder will not be sufficient to handle the
load.
Bear in mind the potential deactivation of the frame brake, should you move the machine while also
operating the boom.
Always when possible move the extension boom in before processing a stem to avoid excessive strain
on the outer boom.
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GENERAL MAINTENANCE FLUIDS AND LUBRICANTS
Handle fuel carefully. Do not fill the fuel tank when engine is running. DO NOT smoke while you fill the
fuel tank or service the fuel system.
Fill the fuel tank at the end of each day’s operation to prevent water condensation and freezing during
cold weather.
Keep all storage tanks as full as practicable to minimize condensation.
Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering.
Monitor water content of the fuel regularly.
When using bio-diesel fuel, the fuel filter may require more frequent replacement due to premature
plugging.
Check engine oil level daily prior to starting engine. A rising oil level may indicate fuel dilution of the
engine oil.
When fuel is stored for an extended period or if there is a slow turnover of fuel, add a fuel conditioner to
stabilize the fuel and prevent water condensation. Contact your fuel supplier for recommendations.
LUBRICITY OF DIESEL FUEL
Most diesel fuels manufactured in the United States, Canada, and the European Union have adequate
lubricity to ensure proper operation and durability of fuel injection system components. However, diesel
fuels manufactured in some areas of the world may lack the necessary lubricity.
IMPORTANT: Make sure the diesel fuel used in your machine demonstrates good lubricity
characteristics.
Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO
12156-1.
If fuel of low or unknown lubricity is used, add John Deere Fuel-Protect Diesel Fuel Conditioner (or
equivalent) at the specified concentration.
LUBRICITY OF BIODIESEL FUEL
Significant improvement in lubricity can occur with biodiesel blends up to B20. The gain in lubricity above
a 20% blend is limited.
NOTE: Biodiesel blends above 20% should not be used on Interim Tier 4 engines.
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GENERAL MAINTENANCE HYDRAULIC PRESSURE MEASUREMENTS
This section includes instructions for measuring and adjusting of hydraulics pressures using a separate
pressure gauge or by utilizing on-board pressure sensors connected to TimberMatic™. Further
information over TimberMatic™ measurements can be obtained from TimberMatic ™ manuals.
Carry out pressure checks on a flat surface and ensure there is sufficient space around the machine in
case it moved. No-one should be allowed near the machine.
Due to safety reasons, only authorized and trained professionals are allowed to adjust hydraulic
pressures of the machine.
Always switch off the diesel engine when a gauge is connected to the machine.
Inspect pressure gauges regularly and do not use damaged fittings or hoses.
IMPORTANT: Use calibrated pressures gauges only. If you are unsure about adjusting pressures,
contact an authorized service workshop.
DRIVE HYDRAULICS
Charge pressure
Charge pressure valve setting
NOTE: TimberMatic™ service lock must be opened.
Maximum drive pressure / Drive pump cut-off setting
Drive motor flushing pressure
Drive motor cut-off setting
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GENERAL MAINTENANCE HYDRAULIC PRESSURE MEASUREMENTS
BOOM VALVE LS RELIEF
PRESSURES
IMPORTANT: Do not use the values shown in the
hydraulic schematics. Use the values in the
attached PDF appendix.
1. Ensure that the machine is in normal operating
temperature.
2. Connect a 40 MPa (5800 psi) gauge to the
measuring point (236 / MLS) on the LS valve
block of A10 pump.
NOTE: Boom movement requests, work
pump and LS pressures can also been seen
in the TimberMatic™ page 2.2.C.1.
3. Active the working rpm and boom.
NOTE: Be careful when operating function to
extreme to avoid collision or hose failures.
Grapple a tree or otherwise prevent rotating
when the rotator pressures are measured.
4. Operate each boom function separately to
extreme and read the gauge.
IMPORTANT: All boom functions have to be
checked separately.
IMPORTANT: Some boom functions have
separate LS pressures for A and B
movements.
5. If the pressure differs more than ± 0.5 MPa (72
psi) from the allowed maximum LS-pressure,
adjust from the screw (1) on the boom valve
block of the specific boom function.
NOTE: In K170 sections inner adjustment
screws are for A movements and in L90
sections right adjustment screws are for A
movements.
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GENERAL MAINTENANCE ENGINE HOODS
LIFTING THE HOODS
To lift the hood, proceed as follows:
1. Open the latches (front hood).
2. Turn on the main switch.
3. Hood lifting switches are located on the main switch panel.
A. Locking latches
B. Main switch
C. Front hood lifting
D. Rear hood lifting
E. Service lights
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PERIODIC MAINTENANCE OPTIONAL EQUIPMENT MAINTENANCE
LUBRICATION FREQUENCY AND VOLUME AMOUNT ADJUSTMENT
NOTE: Time settings are pre-set by John Deere. Pause time 2 hour and working time 4 mins.
Adjustment switches
1. Reservoir
2. Pause time setting switch (lubrication interval, pre-set pos. 2 / 2 hour)
3. Operating time setting switch (amount per lubrication event, pre-set pos. 2 / 4 mins
4. Test button
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PERIODIC MAINTENANCE EVERY 50 HOURS OR WEEKLY
CHECK HIGH/LOW GEAR OIL LEVEL
Check oil level in the high/low gear with the dipstick. Oil level should be within ± 5mm from the dipstick
mark. Dipstick can be accessed by opening the right side battery access cover.
If necessary, add oil through the filling pipe up to the mark of the dipstick.
A. Dipstick
B. Filling pipe
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PERIODIC MAINTENANCE EVERY 50 HOURS OR WEEKLY
GREASE THE BOOM
The boom contains multiple greasing points on boom tilt bearings (A), slewing system bearings (B), rocker
system bearings (C), lift boom bearings (D) and jib boom bearings (E).
The boom is greased by automatic lubrication system, manual centralized greasing or manual greasing.
NOTE: The automatic grease pump can be forced to run for four minutes by holding down the operating
switch (F) on the dashboard for two seconds.
The rotator and linkage are not part of automatic lubrication system and must be greased separately.
For optimum greasing of the upper slew housing bearing do the following:
1. Tilt the boom towards the cab and extend the boom.
2. Swing the boom to its full extent on one side and grease.
3. Swing to the other side and grease.
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PERIODIC MAINTENANCE EVERY 500 HOURS
REPLACE FUEL FILTERS
Due to High Pressure Common Rail system design, fuel in filter is likely to be under high pressure. To
avoid possible personal harm, open drain valves on bottom of both filters to relieve pressure prior to
removing filter.
IMPORTANT: Replace fuel filter elements anytime TimberMatic™ alarms and service code indicates
plugged fuel filters (low fuel pressure).
IMPORTANT: Primary and final filters must be replaced at the same time.
IMPORTANT: If the machine is equipped with an optional water separator, also the separator filter must
be drained and replaced at the same time.
NOTE: Location of fuel system components may vary depending on engine specification.
Replace fuel filters as follows:
1. Thoroughly clean fuel filter assembly and surrounding area. Disconnect water in fuel sensor wiring (D)
from primary fuel filter (A).
2. Connect a hose to primary filter drain valve (C) on bottom of filter and drain fuel into a suitable
container.
3. Remove water separator bowl from primary fuel filter (A). Drain and clean bowl.
NOTE: Dry bowl with compressed air. Check the water separator bowl and seal for shape and
cleanliness.
4. Remove the filter element by pulling filter element down.
5. Inspect filter mounting base for cleanliness. Clean as required.
6. Connect a hose to final filter drain valve (E) on bottom of filter and drain fuel into a suitable container.
7. Remove the final fuel filter element (B) by rotating counterclockwise.
8. If the machine is equipped with an optional water separator filter (F):
a. Disconnect the optional fuel heater connector (H).
b. Connect a hose to the optional water separator drain valve (G) on bottom of filter and drain fuel
into a suitable container.
c. Remove water separator bowl from the optional fuel filter (F). Drain and clean bowl.
NOTE: Dry bowl with compressed air. Check the water separator bowl and seal for shape and
cleanliness.
d. Place a new O-ring on the optional fuel filter bowl.
NOTE: Apply a thin film of fuel on O-ring.
e. Replace a new filter element and screw the separator bowl to the filter.
f. Reconnect the optional fuel heater connector (H).
9. Install new dust seal onto mounting base of the final fuel filter making certain it is in place on filter base.
NOTE: Apply a thin film of fuel on dust seal.
10. Screw a new final fuel filter element into fuel filter header then tighten to 10 Nm (7.5 lb.-ft.).
11. Place new O-ring on primary fuel filter bowl.
NOTE: Apply a thin film of fuel on O-ring.
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PERIODIC MAINTENANCE EVERY 1000 HOURS
Step 2
Undo the bolt (3) in the left hinge of the hood and tilt the hood backwards as far as the slot (4)
allows. Support the hood as shown.
Usage Tool Size
Hinge bolt Hex socket wrench 8 mm
Step 3
Install the transport support sleeve (5) over the flexible section (6) of the exhaust pipe and tighten
sufficiently to prevent the pipe from bending. Do not over-tighten.
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PERIODIC MAINTENANCE EVERY 1000 HOURS
Step 13
Undo the mounting screws of the rocker cover (15 in total). Lift the rocker cover off the engine as
follows:
1. First, lift the right edge of the cover.
2. Lift the cover slightly and push it backwards so that the front edge has enough room to be lifted
up between the CAC pipes.
3. Bringing the right edge first, lift the cover forward right away from the engine bay.
Usage Tool Size
Cover mounting screws Socket wrench 13 mm
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PERIODIC MAINTENANCE EVERY 1000 HOURS
REPLACE HYDRAULIC TANK OIL FILTERS
IMPORTANT: The return case (A) filter is equipped with pressure sensor for clogging. If the pressure
sensor sets off an alarm, renew the filters. Otherwise, stick to maintenance periods.
IMPORTANT: The off-line filter (B) is optional equipment without pressure sensor for clogging. It must be
renewed at the same time as the return filter.
1. Clean the hydraulic tank around the cover.
2. Screw cover fastening screws and remove cover.
3. Remove the filter assemblies. Filter element and the canister must be lifted together from the tank. If
the filter element is removed from the canister in or on the tank, the contaminants of the filter can spoil
hydraulic fluid.
4. Put the filter elements and the canisters into a proper container. Remove filter elements from canisters
by twisting in counterclockwise.
5. Clean the canisters.
6. Replace the filters. Filter element locks easier if it’s slightly pressed while twisting. Secure that the filter
elements are locked inside the canisters before bringing the filter assemblies into the tank.
7. Place springs on the filter assemblies, close the cover and screw in fastening bolts. The spring serves
to secure the filter joint, thus ensuring that no oil will bypass the filter.
A. Return filter covers
B. Off-line filter cover
C. Filter element
D. Filter canister
Usage Tool Size
Hydraulic tank filter cover fastening screw Ring spanner/socket wrench 17 mm
Hose on offline filter cover Ring spanner 19 mm
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PERIODIC MAINTENANCE EVERY 1000 HOURS
CLEAN ROTATOR MAGNETIC PLUG
1. Position the rotator unit to upright position so that the magnetic plug is at the lowest point.
2. Place a container below the plug.
3. Unscrew the plug, clean it and drain two liters of oil.
4. Screw in the magnetic plug and tighten it with a torque of 20 Nm (15 lb-ft).
A. Magnetic plug
Usage Tool Size
Magnetic plug opening Allen key 6 mm
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PERIODIC MAINTENANCE EVERY 2000 HOURS
CHANGE HUB GEAR OIL
Oil level must be checked separately on each single axle and HD-bogie axle hub gear as follows:
1. Position the wheel end so that the drain port in lowest possible position. Clean the surrounding area of
wheel hub plugs.
2. Drain the oil. First remove the upper plug. Then remove the drain plug and let the oil flow completely into
a container.
3. Then turn the wheel hub so that the drain port is on the horizontal centerline of the axle.
4. Add new oil through the fill port until the oil comes out from the drain port.
5. Close the plugs with renewed copper washers/o-rings.
A. Drain plug
B. Fill plug
C. Wheel hub at draining position
D. Wheel hub at filling position
Usage Tool Size
Wheel hub oil plugs Allen key 10 mm
263
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