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Daily Maintenance Task
Greasing all Points - Mainly

Bearing Seal Belt Tensioner

Steering Front/Rear
Bearing

Guide Columns
Scrapper door
Brgs.
Column
suspension
Daily Maintenance Task
Ensure all Anti Slip Surfaces Ladders are kept Clean and free from
grease/oil and dirt.
Daily Maintenance Task
Water System
• Check Water Tank Level
• Check Water Filter Mesh
• Check Nozzles
Daily Maintenance Task
Engine Check
Check Engine oil level.
Check Fuel Level.
Check Engine Coolant level.
Check Air Filters / Dirt indicators.
Check Engine Air intake hoses for damage/squeezing.
Air Filter dirt indicator

Fuel Level
1500L (max)
Coolant Level Engine Oil Level
Daily Maintenance Task
Hydraulic System Check
Check for Hydraulic oil leakages from components/hoses etc.
Check Hydraulic/PTO Gear Box Oil Level
Check Hydraulic Filters Dirt Indicators
Check Hydraulic Hoses leakages/abrasion
Check Hydraulic/PTO Gear Box Cooler Fins Leakages
Daily Maintenance Task
Milling Drum Unit
Check / Change
Cutting Tools Visual Check for Leakages – Gear Box &
Free Bearing End
Daily Maintenance Task
Advance Drive System

Check Track Hoses

Clean Undercarriage

Check Track Rollers for leakages

Weekly Maintenance
DAILY MAINTENANCE +
Clean Cooler Fins.
Clean out advance drive motor
protective cover.
Check all bolts for tightness.
Drum mtg. Bolts, Overlay, Track pads,
Engine mtg. PTO G.box mtg.

Inspect Electrical ‘X1’ cabinet use

blower to clean.
Milling Drum Maintenance.
250 Hrs Schedule Maintenance
1. Engine Maintenance
Change Engine oil with Filters
Change Fuel Filters and water Separator
Inspect Air Filter Elements in Dark Room

Check Coolant
Check coolant
additive
concentration with
test strip.
Nitrite concentration
1600 – 2000 ppm
250 Hrs Schedule Maintenance
contd.
Check Battery acid level,
clean cover breather holes
and grease terminals.

Clutch Greasing

Check all Drive Belts

 500 Hrs Schedule Maintenance
250 Hrs Engine maintenance

+ Replace Hyd. Filters

Milling Drum Gbox OilPTO Gbox Oil Track Gbox Oil

Free Brg. Oil
500 Hrs Schedule Maintenance
… contd.
Replace Water Pump Lube Oils

5 Bar ?
1000 Hrs Maintenance
1. 250 Hrs Engine Maintenance.
2. 500 Hrs G.Box Maintenance.
3. Replace Hyd oil + Filters
Machine monitoring System
= General Fault !!! In case of fault, RED pilot light will glow, warning
Horn will sound and symbol will appear in CGC.

On pressing key text message

will appear. Fault message can be
acknowledged by pressing
The error message will disappear and warning sound will go off.

= Diesel Engine fault!!RED warning light indicates fault has been

recognized by engine monitoring system.

YELLOW light blinking indicates error code. Engine operating manual to be

referred to analyse diagnosis code.
STOP Engine
FAULT ! Stop, check and Rectify

= Diesel engine fault indication – SPN/FMI read flash code

= Engine Oil pressure Oil

= Engine coolant Level Low

= Engine coolant Temperature High.

= Engine Fault
Engine Troubleshooting

•Follow Fault Messages from CGC.

•Follow Flash Code message from diagnostic lamp example flash code 27 = 2
short flashes followed by hesitation followed by 7 short flashes
•Check external wiring connection of engine/sensors/ECM.

• CONTACT : CATERPILLAR SERVICE/WIRTGEN

FAULT MESSAGES ON CGC DISPLAY
= Machine general fault indication on control panel. Also Service Due
Indication.

= Milling drum open – Drum will not start.

= Maximum height limit switch activated.

= Not enough water in tank-water pumps will not work.

= Battery Voltage < 23.5V – Check battery.

= Air intake temperature high.

= Air intake filter contaminated.

Stop ! Check ! Rectify ! and
Acknowledge

= Emergency Stop activated.

= Engine / general Can Bus fault-’subscriber missing’

= Hydraulic Oil Temperature High

= Cooling Fan Error

= Hydraulic Filter Contamination.

= Engine Service Due

= Machine maintenance Due

SAFETY DEVICES – CHECKING - 1
EMERGENCY STOP BUTTONS
“Press when Engine is at idling speed”
- Engine must stop-

Caution :
Ensure engine is stopped only during emergency
and for test purposes and NOT to generally stop
the engine.
SAFETY DEVICES – CHECKING - 2

ENGINE STOP BUTTON

When engine is idling - Press the Button

longer than 0.5 seconds.

- Engine must Stop

SAFETY DEVICES – CHECKING - 3

REVERSING HORN

Horn will sound at intervals as soon as the

machine moves in Reverse.
 SAFETY DEVICES – CHECKING - 4

WARNING HORN
Horn ‘A’ must sound when pressing the
button in the Main Control Panel

Horn ‘B’ must sound when pressing the

button on side Side Control Panel.
SAFETY DEVICES – CHECKING - 5

SAFETY RAILS

Do not operate the machine without the

Safety Rails. This safety device must be
correctly applied at all times.
SAFETY DEVICES – CHECKING - 6

SAFETY LATCH SCRAPER

Raise the Scraper until the safety latch

engages.
Ensure that the bolt securely engages in
the safety latch when scraper is raised.
SAFETY DEVICES – CHECKING - 7
LIMIT SWITCH SCRAPER

Raise the Scraper until the Limit Switch is

Activated within a movement of 150mm.
SAFETY DEVICES – CHECKING - 8

SIDE PLATE

Raise the Side Plate. After releasing the

switch the side plate will automatically
lower itself.
SAFETY DEVICES – CHECKING - 9

Check Anti Slip Surface

Check anti – slip surface

Clean or Change when necessary.
Safety - Important

Use High Pressure Cleaner only for machine cleaning purpose. DONOT
point jet cleaner towards sensitive Engine components, cables, electrical
or electronic components.
CAUTION: Do not point jet cleaner against eyes !!!
Clutch Assembly
 Clutch Repair
Without
tension = Pressurise 50 bar via
148mm Hyd hand pump. Max
minus 10% allowed 15mm
Replace disks
P T O / Splitter G. Box
Undercarriage

Leaking roller - Replace

Chain Wear

Permissible sweating of Seal

Under Carriage

Idler Roller

Sprocket Worn

Chain and Sprocket to be replaced as a Set.!

Track Chain Wear
 Milling drum

Maintain Ejector Blocks – replace when necessary –

Reduces load on engine and Traction. Replace Tool
holders when excessive play between Tool Shank and
Holder Bore.
Drum maintenance is dependent on Silica content of the milled material and
operating practises e.g. depth and speed of machine while milling. Hard facing
and Holder root weld should be planned at regular intervals
Milling drum
Inspect all Tool Holders welding, replace
worn tool holders wherever bores are oblong
resulting in lose of cutting tools. This is
dependent on experience with different
material characteristics.
Milling Drum G.Box

Follow scheduled maintenance, analyzing the oil carefully after every

maintenance for metal particles. G.Box is not to be opened without prior
consent of Wirtgen Service.
Guide / Steering Columns

Check Guide column Key way/ spline key

Gap Max 5mm. Between key and keyway.

Regular/sufficient guide column greasing and

avoid uneven raising of machine in undulated
terrain.
Guide / Steering Columns
Advance drive G.Box

G.Box without Brake G.Box with Brake

Carry out timely Schedule oil maintenance and requires no special

maintenance. Inspect oil after every change for wear. If necessary conduct
SOS every oil change.
List of Lubricants
Schedule
No Location Grade Quantity
(Hrs)

1 Milling drum Gear box PG220 39 L 500

Milling drum Gear box

2 (Support) PG220 1.2 L 500

3 Belt tensioner 85W90 5L 250

4 Fuel Tank HSD 1500 When Reqd

5 Eng Oil 15W40 CI4 70 L 250

6 Coolant CAT ELC 170 L 3000

List of Lubricants
Schedule
No Location Grade Quantity
(Hrs)
7 Hyd oil HVLP 68 500 L 1000
8 Splitter Gear BOX 85W90 14 L 500
9 Adv Drv GB –F 85W90 4.6 X 2 250
10 Adv Drv GB –R 85W90 5,2 X 2 250
11 Water tank Pottable 5000 When Reqd
12 Water filling pump 85W90 0.5 L 500
13 Sprinkler Pump 15W40 0.7 L 250
14 Grease EP3 - -
E.O.D

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