Maintain the fuel filter system by replacing the primary and secondary fuel filters after 1,250 hours of operation on a new machine. Also, check and adjust the engine valve clearance to ensure proper performance. For routine maintenance, inspect and clean or replace air filter elements, clean the internal cooling system, check and tighten track shoe bolts, adjust track tension, inspect the intake air heater, replace worn teeth, adjust bucket clearance, check the windshield washer fluid level, and service the air conditioning system. Clean the cab floor and replace the crusher filter if equipped. When cleaning the cooling system, make sure the engine is fully cooled before opening the radiator cap to release pressure. Never work on a running engine, as high-speed fans can be dangerous. Always park the machine on level ground when handling coolant, and follow standard procedures for mixing antifreeze with water.
Before starting the engine, check the coolant level, engine oil, fuel, and hydraulic oil levels. Ensure the air filter is not clogged, check all wiring, test the horn, lubricate the bucket, and inspect the water separator for sediment. Every 100 hours, check the boom cylinder pins, connecting pins, and rod ends, lubricate the slewing ring, and drain water from the fuel tank. At 250 hours, check the final drive gear oil, battery electrolyte, change engine oil and filter, lubricate the slewing ring, and adjust belt tensions.
At 500 hours, perform all previous tasks plus replace the fuel filter, check and grease the slewing pinion, clean radiator fins, replace the hydraulic filter, and clean the air conditioner’s internal and external filters. At 1,000 hours, repeat all prior checks, replace the slewing gear oil, check the damper oil level, inspect turbocharger fasteners, check rotor clearance, and replace the generator belt. At 2,000 hours, complete all previous maintenance, clean the hydraulic tank strainer, inspect the turbocharger, check the generator and starter motor, adjust valve clearance, and inspect the shock absorbers.
For machines operated over 4,000 hours, increase pump inspections and replace hydraulic oil every 5,000 hours. When storing the machine long-term, place the working equipment on the ground to prevent cylinder rod rust. Wash and dry the machine, store it in a dry indoor area, or on a well-drained concrete surface if outdoors. Fill the fuel tank, lubricate all parts, replace hydraulic oil, apply a thin layer of grease to exposed metal, disconnect the battery, and add antifreeze to the cooling system based on ambient temperature. Start the engine monthly to keep components lubricated and the battery charged, and run the air conditioner for 5–10 minutes periodically.
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