Maintain the fuel filter system by replacing the primary and secondary fuel filters after 1,250 hours of operation on a new machine. Check and adjust the engine valve clearance to ensure proper performance. For routine maintenance, inspect, 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, wait until the engine has cooled completely before loosening the radiator cap to release pressure. Never perform this task while the engine is running. High-speed rotating fans can be dangerous—always park the machine on level ground when working on cooling system fluids. Follow manufacturer guidelines for coolant and antifreeze mix ratios.
Before starting the engine, check the coolant level, engine oil, fuel, and hydraulic oil levels. Add fluids as needed. Inspect the air filter for blockage, check electrical connections, test the horn, lubricate the bucket, and check for water and sediment in the fuel water separator.
Every 100 hours, inspect and lubricate key pins and joints such as the boom cylinder head pin, boom pin, stick connecting pin, and other critical components. Check the oil level in the rotary mechanism box and drain water and sediment from the fuel tank.
At 250 hours, check the final drive gear oil level, battery electrolyte, and replace engine oil and the engine oil filter. Lubricate the slewing ring and check the tension of the fan and AC compressor belts.
At 500 hours, repeat all previous maintenance tasks and replace the fuel filter. Check and grease the slewing pinion, clean the radiator and oil cooler fins, replace the hydraulic filter, and change the final drive oil (only once at 500 hours; subsequent changes at 1,000 hours). Clean the air conditioner’s internal and external filters and replace the hydraulic oil vent filter.
At 1,000 hours, perform all prior maintenance tasks and replace the slewing gear oil. Check the damper housing oil level, inspect turbocharger fasteners, check rotor clearance, adjust generator belt tension, replace anti-corrosion filter elements, and change the final drive oil.
At 2,000 hours, complete all previous maintenance and clean the hydraulic tank strainer, inspect the turbocharger, check the generator and starter motor, recheck valve clearance, and inspect the shock absorbers.
For machines operating over 4,000 hours, increase pump inspections every 4,000 hours and replace hydraulic oil every 5,000 hours.
When storing the machine long-term, lower the work equipment to the ground to prevent cylinder rod rust. Wash and dry the machine, store it indoors in a dry area, or on a well-drained concrete surface if necessary. Fill the fuel tank, lubricate all parts, replace hydraulic oil, and apply a thin layer of grease to exposed metal surfaces. Disconnect the battery or remove it and store separately. Add the correct antifreeze mixture to the cooling system based on ambient temperature. Start the engine monthly to lubricate moving parts and charge the battery. Run the air conditioner for 5–10 minutes to maintain system functionality.
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