RENR8577

July 2005

AD45B Underground Articulated Truck

Service Sheet
SMCS Code: 7519

PIN: CXM1-Up

Use the following maintenance chart in conjunction with the machine Operation & Maintenance Manual
when performing machine service. For information on Specifications, Systems Operation and Testing and
Adjusting, make reference to the specific section of the machine Service Manual.

* First perform previous service hour items

Machine Model: Date Serviced:

Customer Unit No.: Job No.:
PIN No.: Serviced By:
Service Meter Reading:

When Required
SMCS Code: 7528

Item to Service Check Comments

1. Recycle battery.
2. Replace battery, battery cable or battery disconnect switch.
3. Check brake discs.
4. Clean brake oil cooler screen.
5. Reset circuit breakers.
6. Clean/replace engine air filter primary element.
7. Replace engine air filter secondary element.
8. Clean engine air precleaner.
9. Prime fuel system.
10. Replace fuses.
11. Clean hydraulic tank screens.
12. Inspect oil filter.
13. Clean radiator core externally from oil, film and dirt.
14. Inspect rims.
15. Clean torque converter screen.
16. Fill window washer bottle.
17. Inspect/replace window wiper.
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Every 10 Service Hours or Daily
SMCS Code: 7520

Item to Service Check Comments

1. Test indicators and gauges.
a) Check gauges and warning lights for operation. Check Caterpillar
Monitoring System for correct operation. Check the Caterpillar
Monitoring System functional test.
b) Check starter operation.
c) Inspect operation of dome lamp and dash lamps.
d) Inspect operation, adjustment and damage of lights. Clean if
required.
e) Check operation of window wipers and washer.
f) Inspect operation and adjustment of all controls. Lubricate pivot
points.
g) Check operation of cab air conditioning and heater.
2. Test backup alarm.
3. Inspect seat belt.
4. Service inspection.
a) Inspect the ground level controls for proper operation.
b) Inspect lights. Replace broken lamps and lenses.
c) Inspect cooling system for leaks, worn hoses and debris.
d) Check engine for oil and water leaks.
e) Check engine air precleaner for debris.
f) Inspect the hydraulic system for leaks, worn hoses and damaged
lines.
g) Inspect front suspension cylinders for leaks or damage.
h) Inspect fuel tanks for leaks and damage.
i) Inspect torque converter and transmission for leaks and damaged
lines.
j) Inspect steering system for leaks, worn hoses and damaged lines.
k) Inspect articulation area for damage and loose or missing bolts.
l) Inspect rear axle for leaks. Inspect rear lights for damage.
m) Inspect frame and body for damage.
n) Inspect automatic lubrication tank for leaks.
o) Inspect tires for damage and wear.
p) Inspect Rollover Protective Structure (ROPS) for cracks. Check
mounting bolts for damage.
5. Fill automatic lubrication grease tank.
a) Check all injectors are operative and all points are being lubricated.

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 Item to Service Check Comments
6. Lubricate hoist cylinder bearings (4 points).
7. Lubricate ejector cylinder bearings (6 points)
8. Lubricate oscillating hitch (4 points).
9. Lubricate steering cylinder bearings (4 points).
10. Lubricate suspension and suspension cylinder bearings (6 points).
11. Lubricate body pivot bearings (2 points).
12. Lubricat tailgate and tailgate cylinder bearings (6 points).
13. Check cooling system coolant level. Check coolant condition.
14. Check engine oil level.
15. Check hydraulic system oil level.
16. Check transmission oil level.
17. Drain fuel tank water and sediment.
18. Test braking system.
19. Check fire suppression system.
a) Refer to system manufacturer's service recommendations.
b) Check hand held fire extinguishers are installed and operational.
Check brackets are secure and usable.
20. Clean windows.

Every 50 Service Hours or Weekly*

SMCS Code: 7521

Item to Service Check Comments

1. Drain fuel system primary filter (water separator).
2. Clean automatic lubrication system filler filter.
3. Clean/replace cab air filter. Clean precleaner cup.
4. Check tire inflation. Inflate if necessary.

Initial 250 Service Hours (or at first oil change)

SMCS Code: 7524

Item to Service Check Comments

1. Inspect/adjust engine valve lash. Adjust electronic unit injector.
2. Adjust oscillating hitch.

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Every 250 Service Hours or Monthly*
SMCS Code: 7524

Item to Service Check Comments

1. Change engine oil and filter. Cut open filter and inspect for debris.
2. Clean/replace fuel system primary filter (water separator).
3. Replace fuel system secondary filter.
4. Inspect/adjust/replace belts.
5. Add cooling system coolant additive (DEAC).
6. Check battery electrolyte level. Clean terminals.
7. Test pressure sensor (transmission oil).
8. Check suspension cylinder.
9. Check wheel bolt torque.
10. Inspect/lubricate drive shaft universal joints, splines and bearings
(10 points).
a) Check all universal joints for wear and retaining bolt torque.
11. Lubricate fan drive bearing and belt tightener (2 points).
12. Inspect/clean exhaust purifier.
13. Inspect frame and body.
14. Check steering stop clearance.
15. Check differential and final drive oil level.

Initial 500 Service Hours*

SMCS Code: 7526

Item to Service Check Comments

1. Change differential and final drive oil.

Every 500 Service Hours or 3 Months*

SMCS Code: 7525

Item to Service Check Comments

1. Clean fuel tank cap and strainer.
2. Replace hydraulic system pilot oil filters. Cut open and inspect for
debris.
3. Replace steering system oil filters. Cut open and inspect for debris.
4. Replace transmission oil filters. Cut open and inspect for debris.

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Every 1000 Service Hours or 6 Months*
SMCS Code: 7526

Item to Service Check Comments

1. Check brake accumulator.
2. Change differential and final drive oil.
3. Clean/inspect frame and body support pads.
4. Change hydraulic system oil.
5. Replace hydraulic tank breather.
6. Adjust oscillating hitch.
7. Inspect Rollover Protective Structure (ROPS).
8. Change transmission oil.

Every 2000 Service Hours or 1 Year*

SMCS Code: 7527

Item to Service Check Comments

1. Check differential thrust pin clearance.
2. Inspect engine mounts.
3. Inspect/adjust engine valve lash. Adjust electronic unit injector.
4. Inspect engine valve rotators.
5. Inspect turbocharger. Check for bearing wear and oil leaks.

Every 3000 Service Hours or 2 Years*

SMCS Code: 7545

Item to Service Check Comments

1. Change cooling system coolant (DEAC).
2. Add cooling system coolant extender (ELC).
3. Clean/replace cooling system pressure cap.

Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture*
SMCS Code: 7546

Item to Service Check Comments

1. Replace seat belt.

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Every 6000 Service Hours or 4 Years*
SMCS Code: 7543

Item to Service Check Comments

1. Change cooling system coolant (ELC).
2. Replace cooling system water temperature regulator.
3. Inspect engine water pump.

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 Extra Repairs to be Done at Service

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Comments on Machine
List Repairs Found Necessary

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Note: Use Service Manual and Operation and Maintenance

Manual for correct repair and service procedures.