1000 Horas

1000-hour service
Overview, 1000-hour service

Consumables
Adjust valve play
855, 855.1, 865, 895
Intended for
Personal protection equipment
Equipment
Tools (special tools)
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Clean/replace the air filter in the engine
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Function check
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Tightening of wheel nuts
Intended for
561307
GB / 1000 h service_(1.11) 1
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Function check
Lubricate the platform
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Function check
Oil change, gearbox
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Function check
Changing the filter in the AdBlue®/DEF pump
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
561307
2 GB / 1000 h service_(1.11)
Safety
Overview
Execution
Function check
Hydraulic filter replacement
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Replacement of insert filter
Function check
Drain the water from the tank
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Function check
Control the stabilising and steering cylinders
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Function check
Oil change, slew motor, crane.
561307
GB / 1000 h service_(1.11) 3
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Function check
Lubricate the bogie bearings
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Lubricate universal joints in the front and back frame
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Lubricate support bearings for the universal shaft
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
561307
4 GB / 1000 h service_(1.11)
Safety
Overview
Execution
Tightening of load bunks
Intended for
Equipment
Consumables
Spare parts
Conditions
Environment
Safety
Overview
Execution
Function check
Checking decals
561307
GB / 1000 h service_(1.11) 5
561307
6 GB / 1000 h service_(1.11)
1000-hour service
1000-hour service
Overview, 1000-hour service

The service points that must be carried out on the machine after 1000 machine
hours are shown in the figure below. The table lists the consumables that are
necessary for performing the complete service.
Use this overview for planning work.
Engine Tank Crane

Change air filter and safety filter. Replacing the hydraulic filter, Changing the oil in the slewing motor
Valve adjustment, Tier 2/3B, non-recurring. return and fine filter Check for play and cracks
Drain the fuel tank.
Front frame Under cab Chassis, articulated Rear frame

Changing the oil in the gearbox joint Tightening the wheel nuts
Tightening the wheel nuts Control the stabilising and
Lubricate bogie seals. Changing the filter in the steering cylinders Lubricate bogie seals.
AdBlue®/DEF pump Check for play and cracks Check for play and cracks
Check for play and cracks
Check for play and cracks
Lubricate universal joints and
Lubricate universal joint support bearings.
Lubricate the platform Tightening the load bunks
561307
GB / 1000 h service_(1.11) 7
1000-hour service
Consumables
835
Designation Wheel Part Quantity Total Description
operation
FKS-F/FKE-F 1 1 Filter kit
LUB Grease
GO Gearbox 4.5 litres 4.5 litres Transmission oil
GO Slew motor 13 litres 13 litres Transmission oil
500 hours
EO Diesel engine 11 litres 11 litres Engine oil
OSK 1 1 Oil testing kit
HM/HE 20 litres 20 litres Hydraulic oil
AO 8WD 20 litres 20 litres Transmission oil
GO 8WD 20 litres 20 litres Transmission oil
Hydraulic and transmission oils are brought along in case filling is necessary after inspection.
845
operation
LUB Grease
500 hours
EO 11 litres 11 litres Engine oil
HM/HE 20 litres Hydraulic oil
AO 8WD 20 litres Transmission oil
GO 8WD 20 litres Transmission oil
* Comfort bogie
855, 855.1
operation
LUB Grease
500 hours
561307
8 GB / 1000 h service_(1.11)
1000-hour service

855.2
operation
LUB Grease
500 hours
EO 24 litres Engine oil
HM/HE 20 litres Hydraulic oil
Hydraulic and transmission oils are brought along in case filling is
necessary after inspection.
561307
GB / 1000 h service_(1.11) 9
1000-hour service
865
operation
LUB Grease
500 hours
875
operation
LUB Grease
GO Gearbox 5 litres 5 litres Transmission oil
500 hours
895, 895.1
operation
LUB Grease
GO Gearbox 5 litres 5 litres Transmission oil
500 hours
561307
10 GB / 1000 h service_(1.11)
1000-hour service

561307
GB / 1000 h service_(1.11) 11
1000-hour service
Adjust valve play
855, 855.1, 865, 895
Total persons: 1
Time required: 120 minutes
Intended for
Machine model Serial number
855 8550000137
855.1 8550011011
865 8650001137
895 8950000141
Equipment
Quantity Designation Description Specification

1 Part no. Socket Hub nut, crankshaft
902455800
1 Feeler gauge
1 Torque spanner
Consumables
1 Gasket, preheater and intake
2 Cylinder head cover gasket
1 Dosage module gasket
8 O-rings
Spare parts
Conditions
• Machine parked on firm, flat ground.
• Diesel engine off.
• Diesel engine, cold
• Main power switch off.
561307
12 GB / 1000 h service_(1.11)
1000-hour service
Environment
Follow local environmental rules and regulations.
Safety
Important!
When removing the gas tube for the fire extinguishing equipment, observe
caution so that the activation button with the safety does not activate fire
extinguishing.
Important!
Foreign matter must not enter the motor. Observe caution when removing and
fitting ducts and openings for the motor.
561307
GB / 1000 h service_(1.11) 13
1000-hour service
Overview
1
295921
Execution
1. Opening the engine hood.
2. Tilt the cab up. See the instructions in Instruction Manual – Basic.
Disassembly
1. Remove the main panel.
855, 855.1, 865, 895
2
294972
1. Pin
2. Main panel
2. Remove the rear engine hood

3. Remove the hose clip and air hose from the filter housing.
561307
14 GB / 1000 h service_(1.11)
1000-hour service
298089
4. Remove the connector from the filter housing.

5. Remove the screws holding the filter housing on its back edge.
Two screws, socket 15.

298091
6. Remove the filter housing.

7. Remove the platform.
561307
GB / 1000 h service_(1.11) 15
1000-hour service
8. If the machine is equipped with an automatic fire extinguishing system,

dismantle the fire extinguishing hose.
855, 865, 895 Early models.
295608
1. Fire extinguishing hose
9. Remove the gas cylinder, complete with mounting and electronic unit.
Place alongside the washer fluid tank.
10. Remove the cabling for aftertreatment equipment by loosening connector
X248 (under the catalytic converter).
Remove the cabling and clip (note the spacing) connected to aftertreatment
injector XY66.
Remove the bracket for connector X248 (M8 screws).
Move all the cables to one side.

11. To loosen the aftertreatment injector, first remove the plate on the wall of
the engine compartment nearest the cab. When the injector is loose, wrap it
in something suitable.
12. Loosen the intake pipe near the grille. Move the pipe to one side, cover the
grille to avoid dirt and foreign particles entering the engine’s intake ducts.
13. Remove the two clips on the exhaust pipe.
14. Remove the sensor on the exhaust pipe.
15. Remove the exhaust pipe mounting by firstly removing the screws between
the SCR catalytic converter’s mounting and rack (4 x M10).
Then use the screw hole for the fire extinguisher clip to mount a belt to
hold up the aftertreatment equipment.
Then loosen the exhaust pipe mounting from the SCR rack mounting (three
screws with nuts).
561307
16 GB / 1000 h service_(1.11)
1000-hour service
16. Remove the SCR rack mounting by first loosening the two front screws and
removing the two rear screws.
Then guide the mounting forwards so that it can be removed.
Remove the exhaust pipe.

17. Remove the upper radiator mounting.
18. Remove the cylinder head covers.
Checking the valve play

1. Loosen the protected bolts (x3, 13-mm socket).
Remove the guard.
1. Screw
2. Protective guard
4-cylinder engines
561307
GB / 1000 h service_(1.11) 17
1000-hour service
2. Rotate the crankshaft in its normal direction of rotation (clockwise) until

the fourth cylinder’s exhaust valves begin to close, and the intake valves
are just beginning to open (top dead centre is achieved in cylinder one). In
this position, check the valve play of the first cylinder, and adjust the play if
necessary.
3. The next cylinder to check is the second cylinder. Rotate the crankshaft
another half turn in its direction of rotation so that the third cylinder’s
exhaust valves are starting to close while the intake valves are just
beginning to open. Then check the valve play on the engine’s second
cylinder, and adjust the play if necessary.
4. Repeat the procedure for cylinder four, and finally three.
6-cylinder engines
2. Rotate the crankshaft in its normal direction of rotation (clockwise) until

the sixth cylinder’s exhaust valves begin to close, and the intake valves are
just beginning to open (top dead centre is achieved in cylinder one). In this
position, check the valve play of the first cylinder, and adjust the play if
necessary.
3. The next cylinder to check is the fifth cylinder. Rotate the crankshaft
another half turn in its direction of rotation so that the second cylinder’s
exhaust valves are starting to close while the intake valves are just
beginning to open. Then check the valve play on the engine’s fifth cylinder,
and adjust the play if necessary.
4. Repeat the process for cylinders three, six, two, and finally four.
561307
18 GB / 1000 h service_(1.11)
1000-hour service
Valve adjustment
1. Loosen the lock nuts.
1. Lock nut
2. Adjuster screw
2. Use a feeler gauge between the arm and valve, and adjust the play (0.35
mm) with the adjustment screw.
1. Exhaust valve
2. Intake valve
3. Injector
3. Tighten the lock nuts.

4. Check that the play is correct (0.35 mm).
Assembly
Replace in reverse order, using new gaskets. However, there are several things
to be aware of during assembly:
Use gasket adhesive on the valve covers so that the gaskets remain in place
when fitting.
561307
GB / 1000 h service_(1.11) 19
1000-hour service
Tighten the valve cover screws to 25 Nm screw.
To avoid damage due to high tension in the exhaust system, it is extremely

important that components are replaced carefully.
Assembling the lower parts of the SCR system.
3 1
1
429773
1. Pipe
2. DOC
3. SCR
During reassembly, the maximum angular adjustment should never exceed 2

mm between pipes and DOC, and between pipes and SCR.
Installation of Adblue®/DEF dosage module

429765
1. Screw in the screws gently according to the order shown in some of the
figures, until the sealing plate is lying evenly against the surface.
2. The screws should then be tightened to a torque of 8±2 Nm following the
same order.
561307
20 GB / 1000 h service_(1.11)
1000-hour service

Total persons: 1
Intended for
855 8550000137
855.1 8550011011
865 8650001137
895 8950000141
Equipment

Consumables
Spare parts
1 AF-MM Air filter
1 AF-MS Air filter, safety filter
Conditions
• Main power switch in 0 position
Environment
Safety
561307
GB / 1000 h service_(1.11) 21
1000-hour service
Overview
1
295921
1. Air filter
Execution
1. Opening the engine hood.
2. Remove the main panel.
855, 855.1, 865, 895
2
294972
1. Pin
2. Main panel
3. Remove the cover from the filter housing (4 catches).

561307
22 GB / 1000 h service_(1.11)
1000-hour service
295943
1. Catches
2. Collector
4. Dismantle the air filter by pulling it backward and out.
1
295948
1. Air filter
5. Remove the safety filter by pulling it backwards and out.

561307
GB / 1000 h service_(1.11) 23
1000-hour service
297860
6. Remove the collector and empty it of debris. (855, 855.1, 865, 895)
7. Refit in the reverse order.
Function check
561307
24 GB / 1000 h service_(1.11)
1000-hour service

Total persons: 1
Intended for
901 9010053267
901XC 9013050237
911 9110062167
911 9112062167
931 9310021067
931XC 9313021208
951 9510004367
835 8350000171
845 8450000262
855.2 8550022010
875 8750000010
Equipment

Consumables
Spare parts
1 AF-MM Air filter
1 AF-MS Air filter, safety filter
Conditions
• Engine hood open.
561307
GB / 1000 h service_(1.11) 25
1000-hour service
Environment
Safety
561307
26 GB / 1000 h service_(1.11)
1000-hour service
Overview
485065
523309
1. Air filter
Execution
1. Remove the cover from the filter housing (4 catches).
1. Catches
561307
GB / 1000 h service_(1.11) 27
1000-hour service
1. Air filter
3. Shake the air filter.

After 1,000 hours of operation, the air filter must be replaced along with the
safety filter within.
1. Safety filter
5. Refit in the reverse order.

561307
28 GB / 1000 h service_(1.11)
1000-hour service
Tightening of wheel nuts

Total persons: 1
Intended for
835 8350000171
845 8450000262
855 8550000137
855.1 8550011311
855.2 8550022010
865 8650001137
875 8750000010
895 8950000141
Equipment

1 TW800 Torque spanner 800 Nm
1 Extension 250 mm
Consumables
Spare parts
Conditions
Environment
Safety
561307
GB / 1000 h service_(1.11) 29
1000-hour service
Overview
291136
1. Wheel
Execution
1. Tighten the wheel nuts crosswise to 650 Nm.
291141
2. Repeat on each rim.
Function check
561307
30 GB / 1000 h service_(1.11)
1000-hour service
Lubricate the platform

Total persons: 1
Intended for
835 8350000171
845 8450000262
855 8550000137
855.1 8550011311
865 8650001137
895 8950000141
Equipment

1 Grease gun
Consumables
1 Grease
Spare parts
Conditions
Environment
Safety
561307
GB / 1000 h service_(1.11) 31
1000-hour service
Overview
1
298007
Execution
Wipe clean the lubrication points.
Lubricate (2 lubrication points) until you see grease emerge.

298008
Function check
561307
32 GB / 1000 h service_(1.11)
1000-hour service
Oil change, gearbox

Total persons: 1
Intended for
835 8350000171
845 8450000262
855 8550000137
855.1 8550011311
855.2 8550022010
865 8650001137
875 8750000010
895 8950000141
Equipment
1 Collection vessel
1 Funnel with flexible tube. 50-cm hose

Consumables
835, 845, 855, 855.1, 855.2, 865
4.5 litres GO Transmission oil Gear oil, GO 80W-90
875, 895
5 litres GO Transmission oil Gear oil, GO 80W-90
Spare parts
561307
GB / 1000 h service_(1.11) 33
1000-hour service
Conditions
• The machine’s transmission warmed up.
• The machine may not tilt to the rear since this would cause the oil from the gearbox to run into the frame.
Environment
• Properly dispose of waste oil.
• Properly dispose of rags and paper.
• Properly dispose of packaging materials.
Safety
Caution!
Oil is hazardous to health. Wash skin if splashed with oil. Change
clothes that have been splashed with oil.
561307
34 GB / 1000 h service_(1.11)
1000-hour service
Overview
2
297326
1. The rear service cover, located under the front frame.

2. The gearbox is located in the front frame.
Execution
Preparations prior to opening service cover

1. Tilt up the cab and tank (see the instruction in the user manual Basic).
2. Check for liquid in the front frame.
If any liquid is present in the frame, it must be drained via the service cover.
Use collection vessels to collect the liquid.
Drain oil
1. Remove the rear service cover on the front frame.
2 bolts, 18-mm socket.

294953
1. Service cover
561307
GB / 1000 h service_(1.11) 35
1000-hour service
2. Place the collection vessel under the service cover.

3. Remove the oil plug.
1, 12-mm Allen key.
294955
1. Oil plug
4. Let all of the oil drain and be observant of the old oil's quality, colour,
particles, etc.
5. Clean the oil plug.
6. Fit the oil plug.
7. Fit the service cover.
Filling oil
1. Remove the filler plug.
18-mm socket.
294957
561307
36 GB / 1000 h service_(1.11)
1000-hour service
1. Filler plug
2. Place the funnel in the oil filling hole.

3. Fill with oil.
4. Wait to ensure that the oil has run down to the right level before checking
the dip stick.
5. Check the level on the dipstick. The level should be between the dipstick's
markings.
294959
1. Dipstick
1. Upper line, dip stick (max. oil level).
6. Fit the oil filling plug.

7. Tilt down the cab and tank.
8. Secure the tank with the bolt.
Function check
561307
GB / 1000 h service_(1.11) 37
1000-hour service
Changing the filter in the AdBlue®/DEF pump

Total persons: 1
Intended for
835 8350000171
845 8450000262
855 8550000137
855.1 8550011311
865 8650001137
895 8950000141
Equipment

Consumables
Spare parts
1 AB-PF AdBlue pump filter
Conditions
Environment
• Clean up spills.
• Properly dispose of filter.
Safety
561307
38 GB / 1000 h service_(1.11)
1000-hour service
Caution!
Oils, greases, coolants and engine fuel are hazardous to health. Use
protective gloves and protective eyewear, as well as suitable clothing.
Important!
Because AdBlue®/DEF corrodes metal, spills on metal couplings and electrical
equipment must be avoided. Clean immediately if spills occur.
Note!
The AdBlue®/DEF system is sensitive to contaminants due to the risk
of the system becoming clogged. Cleanliness must therefore be kept in
mind with all handling of these fluids.
561307
GB / 1000 h service_(1.11) 39
1000-hour service
Overview
1
296729
Execution
1. Position the collection vessels under the rear service covers on the front
frame.
2. Remove the rear service covers.
4. Remove the Adblue®/DEF pump from its mount.
Three bolts, 13 mm socket
1
297799
1. Adblue®/DEF pump
5. Rotate the Adblue®/DEF pump so that the filter is pointing upwards.

6. Remove the filter cover.
561307
40 GB / 1000 h service_(1.11)
1000-hour service
297804
1. Filter cover
7. Remove the rubber insert.
1. Rubber insert
8. Loosen the filter using universal pliers and remove it.

561307
GB / 1000 h service_(1.11) 41
1000-hour service
1. Time filter
9. Fit a new filter.

10. Fit a new rubber insert.
11. Fit the filter cover.
12. Fit the Adblue®/DEF pump to its mount.
13. Rinse under the cab with water, preferably lukewarm.
14. Fit the rear service covers.
15. Tilt cab down
Function check
After changing the filter the machine should be started as follows:
1. Start the engine and let it idle.

2. Automatic bleeding is performed, this takes approx. 5 minutes.
561307
42 GB / 1000 h service_(1.11)
1000-hour service
Hydraulic filter replacement

Total persons: 1
Intended for
835 8350000171
845 8450000262
855 8550000137
855.1 8550011311
865 8650001137
895 8950000141
Equipment
1 Collection vessel
1 Platform

Consumables
Spare parts
1 HF-6 Hydraulic filter 6 µm
1 HF-10 Hydraulic filter 10 µm
Conditions
• Let the machine stand for at least 15 minutes prior to service.
561307
GB / 1000 h service_(1.11) 43
1000-hour service
Environment
• Properly dispose of filter.
Safety
Caution!
Hydraulic oil is hazardous to health. Avoid breathing the vapour
from hydraulic oil, especially warm oil. Wash skin if splashed with
hydraulic oil. Change clothes that have been splashed with oil.
561307
44 GB / 1000 h service_(1.11)
1000-hour service
Overview
291232
1. Tank cover
2. Left side cover
3. Right side cover
4. Middle cover
5. Hydraulic filter
Note!
The fine filter and return filter differ. Be sure that you fit a filter of the
same type.
Execution
855, 855.1, 865, 895

1. Fold down the rear ladder on the left side of the hydraulic tank.
2. Open the tank cover.
3. Fold up the left side cover above the tank and lock it in the up position.
4. Pull out the lock catch for the right side cover.
291269
1. Lock catch
5. Move the ladder to the right side of the machine.

6. Fold up the right side cover and lock it in the up position.
561307
GB / 1000 h service_(1.11) 45
1000-hour service
7. Remove the two bolts with a 15-mm socket/ring spanner and fold up the
middle cover above the tank.
291271
1. Right side cover

2. Middle cover
8. Wipe clean.
9. Remove the three bolts that secure the filter cover by releasing alternately
with a socket/ring spanner 15 mm.
10. Remove the filter cover. Note the filter's location. Return filter (10 µm).
Fine filter (6 µm).
291273
1. Return filter
11. Remove the cover spring.

12. Carefully lift the filter and let it drain.
13. Lift the filter to a clean collection vessel.
14. Put the filter cover back over the hole to prevent entry of foreign matter.
855.2, 875
1. Open the tank covers and fit the ladder. See Basic User Manual.
561307
46 GB / 1000 h service_(1.11)
1000-hour service
2. Wipe clean.
3. Remove the three bolts that secure the filter cover by releasing alternately
with a socket/ring spanner 15 mm.
4. Remove the filter cover. Note the filter's location. Return filter (10 µm).
Fine filter (6 µm).
291273
1. Return filter
5. Remove the cover spring.

6. Carefully lift the filter and let it drain.
7. Lift the filter to a clean collection vessel.
8. Put the filter cover back over the hole to prevent entry of foreign matter.
Replacement of insert filter

1. Remove the nut for the bypass spring with a ring spanner 17 mm. Use a
vice to hold the filter. Remove the bypass spring.
561307
GB / 1000 h service_(1.11) 47
1000-hour service
295823
1. Bypass spring
561307
48 GB / 1000 h service_(1.11)
1000-hour service
291275
1. Fine screen (filter holder and insert)

2. Return filter (filter holder and insert)
3. Lock spring
4. Bypass spring
2. Remove the filter support.

3. Remove the filter element. Inspect the old filter for damage.
291277
1. Inner filter bracket

2. Time filter
3. Outer filter bracket
4. Wipe the magnetic rod clean with a rag.

561307
GB / 1000 h service_(1.11) 49
1000-hour service
291279
1. Magnetic rod
5. Carefully fit the new filter, being careful not to damage it.
6. Refit the bypass spring and pull it tight to the bottom.
291281
1. Bypass spring
561307
50 GB / 1000 h service_(1.11)
1000-hour service
7. Refit the cover spring.

8. Repeat the process with the other filter.
9. Fit the filter.
10. Fit the filter cover.
11. Hold down the filter cover and tighten the bolts alternately.
12. Repeat the process with the other filter.
13. Mount the middle cover above the tank.
14. Lower the side covers.
15. Close the tank cover.
Function check
After changing the filter the machine should be started as follows:
1. Bleed the hydraulic system by starting the engine and letting it idle for
about 5 minutes.
561307
GB / 1000 h service_(1.11) 51
1000-hour service
Drain the water from the tank

Total persons: 1
Intended for
835 8350000171
845 8450000262
855 8550000137
855.1 8550011311
865 8650001137
895 8950000141
Equipment

Consumables
Spare parts
Conditions
Environment
• Clean up spills.
Safety
561307
52 GB / 1000 h service_(1.11)
1000-hour service
Caution!
Oils, greases, coolants and engine fuel are hazardous to health. Use
protective gloves and protective eyewear, as well as suitable clothing.
561307
GB / 1000 h service_(1.11) 53
1000-hour service
Overview
1
297835
Execution
Preparations prior to opening service cover

1. Tilt up the cab and tank (see the instruction in the user manual Basic).
2. Check for liquid in the front frame.
If any liquid is present in the frame, it must be drained via the service cover.
Use collection vessels to collect the liquid.
Tilt the cab and tank to the fifth notch on the safety catch.
Drainage
1. Remove the rear service cover on the front frame.
2 bolts, 18-mm socket.

294953
1. Service cover
2. Place the collection vessel under the service cover.

561307
54 GB / 1000 h service_(1.11)
1000-hour service
3. Loosen the drainage plug under the diesel tank until liquid comes out.
Remember to not loosen it completely.
297842
1. Drain plug (in the bottom of the tank)
4. Drain until pure diesel comes out.

5. Tighten the drainage plug.
6. Tilt down the cab and tank.
7. Fit the bolt securing the tank.
8. Fit the rear service cover.
Function check
561307
GB / 1000 h service_(1.11) 55
1000-hour service
Control the stabilising and steering cylinders

Total persons: 2
Intended for
835 8350000171
845 8450000262
855 8550000137
855.1 8550011311
865 8650001137
895 8950000141
Equipment

Consumables
Spare parts
Conditions
Environment
Safety
561307
56 GB / 1000 h service_(1.11)
1000-hour service
Overview
1
2
1
296486
1. Stabiliser cylinder
2. Steering cylinder
561307
GB / 1000 h service_(1.11) 57
1000-hour service
Execution
1. On the hydrostatic pump, disconnect the connector for forward and reverse
operation.
296558
2. Dismantle the steering cylinders’ protective plates.
2x2 screws, socket 16.
3. Start the machine

4. Fit the transport lock.
561307
58 GB / 1000 h service_(1.11)
1000-hour service
1
296574
1. Transport lock
296573
5. Activate the stabiliser lock.

6. Angle the crane straight out to the side and extend the crane fully.
7. One person should stand by the articulated joint on the opposite side from
the crane.
8. Operate the crane up and down so that the machine starts to sway.
9. The person at the side of the machine, checks that no apparent play occurs
on the stabilising cylinder.
10. Slew right and left.
11. The person at the side of the machine, checks that no apparent play occurs
on the steering cylinder.
12. Repeat on the other side.
13. Fit the steering cylinders’ protective plates.
561307
GB / 1000 h service_(1.11) 59
1000-hour service
Function check
561307
60 GB / 1000 h service_(1.11)
1000-hour service
Oil change, slew motor, crane.

Total persons: 1
Time required: 15 minutes (preparatory prior to oil drainage). Time for drainage and filling varies with
temperature and equipment.
Intended for
835 8350000171
845 8450000262
855 8550000137
855.1 8550011311
855.2 8550022010
865 8650001137
875 8750000010
895 8950000141
Equipment
1 Collection vessel 15 litres
1 Funnel with flexible tube. Max. Ø12 mm at tip
1 Work platform

Consumables
13 litres GO Transmission oil Gear oil, GO 80W-90
Spare parts
Conditions
561307
GB / 1000 h service_(1.11) 61
1000-hour service
Environment
Safety
Caution!
Oil is hazardous to health. Wash skin if splashed with oil. Change
clothes that have been splashed with oil.
561307
62 GB / 1000 h service_(1.11)
1000-hour service
Overview
291305
1. Drainage hose, slew motor

2. Breather and sight glass
Note!
Drainage takes a long time. It is preferable to begin the service with
this action.
Execution
Drain oil
835, 845, 855, 855.1, 865, 895
1. Remove the belt that holds the hydraulic hoses.

2. Remove the drainage hose from the adapter.
24-mm PU spanner.
294917
3. Fold down the hose and empty the oil into the collection vessel.
561307
GB / 1000 h service_(1.11) 63
1000-hour service
294921
particles, etc.
Drain oil
855.2, 875
1. Remove the plug.

522497
2. Fit the drainage hose.

3. Fold down the hose and empty the oil into the collection vessel.
particles, etc.
5. Remove the drainage hose from the adapter.
6. Refit the plug.
561307
64 GB / 1000 h service_(1.11)
1000-hour service
Filling oil
835, 845, 855, 855.1, 865, 895
1. Fold up the drainage hose; do not attach.

2. Remove the breather.
1, 19-mm socket.
3. Place the flexible funnel in the breather's opening and secure it.
4. Fill until the oil reaches the top of the sight glass.
294923
1. Ventilator
2. Sight glass
5. Remove the flexible funnel.

6. Fit the breather.
7. Fit the drainage hose.
8. Fit the belt.
Filling oil
855.2, 875
1. Remove the breather.
1, 19-mm socket.
2. Place the flexible funnel in the breather's opening and secure it.
3. Fill until the oil reaches the top of the sight glass.
561307
GB / 1000 h service_(1.11) 65
1000-hour service
294923
1. Ventilator
2. Sight glass
4. Remove the flexible funnel.

5. Fit the breather.
Function check
561307
66 GB / 1000 h service_(1.11)
1000-hour service
Lubricate the bogie bearings

Total persons: 1
Time required: 30–60 minutes
Intended for
Machine model Manufacturing number
855 8550000137
Equipment

1 Grease gun
Consumables
1 Grease
Spare parts
Conditions
Environment
Safety
Important!
Risk of machine damage. Carefully lubricate so that the seals do not break.
Important!
Risk of machine damage. Do not use compressed air powered grease guns!
561307
GB / 1000 h service_(1.11) 67
1000-hour service
Overview
2
297874
Execution
Without Bogie lift

1. Wipe clean around the lubrication points.
2. Remove the plastic plugs.
Two, one on top of and one under the outlet and two alongside the
lubrication points.
1
297876
561307
68 GB / 1000 h service_(1.11)
1000-hour service
1. Plastic plug
3. Remove the plug from one of the outlets.
1
297903
1. Removed plug from outlet.
4. Lubricate using a grease gun from both lubrication points until clean grease
comes out of the outlet.
1
297888
1. Outlet
5. Fit plug in outlet.

6. Remove the plug from the other outlet.
7. Lubricate using a grease gun from both lubrication points until clean grease
comes out of the outlet.
8. Fit plug in outlet.
9. Repeat on the other side of the bogie.
561307
GB / 1000 h service_(1.11) 69
1000-hour service
10. Repeat on each bogie axle.
With Bogie lift

If the machine is equipped with Bogie lift, the front bogie bearings must be
lubricated as follows:
1. Clean the area around the grease nipples (1, 2) and the drainage nipple (3),
then remove all the plastic plugs covering the nipples.
2. Loosen grease nipple (2) and lubricate at grease nipple (1) until grease
emerges through grease nipple (2). Retighten grease nipple (2).
3. Loosen drainage nipple (3) and lubricate at grease nipple (1) until grease
emerges through drainage nipple (3).
4. Lubricate grease nipple (2) until grease emerges from drainage nipple (3).
Retighten drainage nipple (3).
5. Lubricate again (1, 2) until grease emerges from around the entire bogie
bearing. Do not remove the surplus grease.
6. Refit all the plastic plugs.
561307
70 GB / 1000 h service_(1.11)
1000-hour service
Lubricate universal joints in the front and back frame

Total persons: 1
Intended for
Machine model Manufacturing number
855 8550000137
855.1 8550011311
865 8650001137
Equipment

1 Grease gun
Consumables
1 Grease
Spare parts
Conditions
Environment
Safety
Important!
Risk of machine damage. Carefully lubricate so that the seals do not break.
561307
GB / 1000 h service_(1.11) 71
1000-hour service
Overview
297956
2 1
Execution
Rear frame
1. Remove the bolts that secure the crane support.
8, M10, 24-mm socket.
1
295125
561307
72 GB / 1000 h service_(1.11)
1000-hour service
2.
297968
1. Rear universal joint, back frame

4. Remove the protective caps from the lubrication points.
5. Lubricate the universal joint (one grease nipple). Lubricate carefully; the
seal is destroyed if penetrated by grease and the universal joint will
then need to be replaced.
6. Fit the protective caps.
7. Check the condition of the universal joint and the support bearing after
noticeable damage.
8. Fit the crane support.
9. Remove the service cover on the back frame.
1
297969
1. Front universal joint, back frame

561307
GB / 1000 h service_(1.11) 73
1000-hour service

12. Lubricate the universal joint (one grease nipple). Lubricate carefully; the
seal is destroyed if penetrated by grease and the universal joint will
13. Lubricate the support bearing (one grease nipple). Lubricate until clean
grease comes out of the grease nipple.
noticeable damage.
16. Fit the service cover.
Front frame
1
297985
1. Rear universal joint, front frame

561307
74 GB / 1000 h service_(1.11)
1000-hour service
1
297986
1. Front universal joint, front frame
4. Lubricate the universal joints (two grease nipples). Lubricate carefully;

the seal is destroyed if penetrated by grease and the universal joint will
noticeable damage.
7. Tilt cab down
561307
GB / 1000 h service_(1.11) 75
1000-hour service
Lubricate support bearings for the universal shaft

Total persons: 1
Intended for
835 8350000171
845 8450000262
855 8550000137
855.1 8550011011
855.2 8550022010
865 8650001137
875 8750000010
Equipment

Consumables
Spare parts
Conditions
Environment
Safety
561307
76 GB / 1000 h service_(1.11)
1000-hour service
Overview
Execution
548653
1. Unscrew the 4 bolts that hold the cover in place.

2. Remove the cover.
561307
GB / 1000 h service_(1.11) 77
1000-hour service
548654
3. Attach a grease gun and lubricate the support bearings.

4. Refit the cover and tighten the screws.
561307
78 GB / 1000 h service_(1.11)
1000-hour service
Tightening of load bunks

Total persons: 1
Intended for
835 8350000171
845 8450000262
855 8550000137
855.1 8550011311
855.2 8550022010
865 8650001137
875 8750000010
895 8950000141
Equipment

1 TW800 Torque spanner 800 Nm
Consumables
Spare parts
Conditions
• Calibrated torque spanner
Environment
Safety
561307
GB / 1000 h service_(1.11) 79
1000-hour service
Overview
1 1 1
291339
1. Load bunks
Execution
Torque the bolts that secure the load bunks. Tighten from the nut side.
Tightening torque 572 Nm.

295039
Function check
561307
80 GB / 1000 h service_(1.11)
1000-hour service
Checking decals
Total persons: 1 Time required: 10 minutes
All All
Personal protection
equipment
.
Equipment Quantity Designation Description Specification
.
Tools (special tools) Quantity Designation Description Specification
.
Consumables Quantity Designation Description Specification
.
Spare parts Quantity Designation Description Specification
.
Conditions Machine parked on firm, flat ground.
Diesel engine off.
Main power switch in 0 position
.
Environment Properly dispose of rags and paper.
Properly dispose of packaging materials.
.
Safety If possible, avoid climbing on the machine. Instead, use the machine's stepping
areas that have slip protection. Approved platforms should be used during
maintenance for all high work.
1. Check that all decals as stipulated in the Safety decals section of the Safety
chapter are at the correct locations on the machine and that they are legible.
2. Supplement with new decals if any are damaged or missing.
561307
GB / 1000 h service_(1.11) 81

1000 Horas

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1000-hour service

Overview, 1000-hour service

Overview, 1000-hour service

Use this overview for planning work.

Engine Tank Crane

Front frame Under cab Chassis, articulated Rear frame

AO 8WD 20 litres 20 litres Transmission oil

HM/HE 20 litres 20 litres Hydraulic oil

Adjust valve play

855, 855.1, 865, 895

Personal protection equipment

Tools (special tools)

855, 855.1, 865, 895

2. Remove the rear engine hood

4. Remove the connector from the filter housing.

Two screws, socket 15.

6. Remove the filter housing.

8. If the machine is equipped with an automatic fire extinguishing system,

855, 865, 895 Early models.

1. Fire extinguishing hose

Remove the bracket for connector X248 (M8 screws).

Move all the cables to one side.

Then guide the mounting forwards so that it can be removed.

Remove the exhaust pipe.

Checking the valve play

Remove the guard.

2. Rotate the crankshaft in its normal direction of rotation (clockwise) until

2. Rotate the crankshaft in its normal direction of rotation (clockwise) until

3. Tighten the lock nuts.

Tighten the valve cover screws to 25 Nm screw.

To avoid damage due to high tension in the exhaust system, it is extremely

Assembling the lower parts of the SCR system.

During reassembly, the maximum angular adjustment should never exceed 2

Installation of Adblue®/DEF dosage module

Clean/replace the air filter in the engine

Personal protection equipment

Tools (special tools)

855, 855.1, 865, 895

3. Remove the cover from the filter housing (4 catches).

4. Dismantle the air filter by pulling it backward and out.

5. Remove the safety filter by pulling it backwards and out.

Clean/replace the air filter in the engine

Personal protection equipment

Tools (special tools)

2. Dismantle the air filter by pulling it backward and out.

3. Shake the air filter.

4. Dismantle the air filter by pulling it backward and out.

5. Refit in the reverse order.

Tightening of wheel nuts

Personal protection equipment

Tools (special tools)

2. Repeat on each rim.

Lubricate the platform

Personal protection equipment

Tools (special tools)

Lubricate (2 lubrication points) until you see grease emerge.

Oil change, gearbox

Personal protection equipment

Tools (special tools)

1. The rear service cover, located under the front frame.

Preparations prior to opening service cover

2 bolts, 18-mm socket.

2. Place the collection vessel under the service cover.