Air Cleaner
Change the Filter Elements
| NOTICE |
|---|
Service the air cleaner only with the engine stopped. |
Service the air cleaner if the amber indicator lights with the engine running at high idle. Stop the engine.
Open the right side rear access door.
Change the Primary Element
- 1. Remove the air cleaner cover.
- 2. Remove the primary filter element from the air cleaner housing.
- 3. Clean the inside of the air cleaner housing.
- 4. Clean and inspect the primary element. See "Cleaning Primary Elements."
- 5. Install a clean primary element.
- 6. Clean and install the cover. Tighten the cover bolts finger tight to 4 N·m (3 lb ft).
Do not use a tool to tighten the bolts.
If the amber air cleaner indicator light comes on shortly after the installation of a clean primary filter element, change the secondary element.
The primary element should be replaced after being cleaned a maximum of six times. Replace the element once a year even though it has not been cleaned six times.
Change the Secondary Element
| NOTICE |
|---|
Always replace the secondary filter element. Never attempt to reuse it by cleaning. The secondary filter element should be replaced at the time the primary element is serviced for the third time. The secondary filter element should also be replaced if the amber indicator lights after installation of a clean primary element, or if the exhaust smoke is still black. |
- 1. Remove the housing cover and the primary element.
- 2. Remove the six nuts and washers and the ground wire from the flange on the air inlet pipe. Remove the secondary element.
- 3. Cover the air inlet pipe. Clean the inside of the air cleaner housing.
- 4. Inspect the gasket between the air inlet pipe and the housing. Replace it if it is damaged.
- 5. Uncover the air inlet pipe. Install a new secondary element.
- 6. Install the nuts and washers on the studs. Torque them to 28 ± 6 N·m (20 ± 5 lb ft).
- 7. Install the primary element. Install the cover. Tighten the cover bolts finger tight to 4 N·m (3 lb ft).
Do not use a tool to tighten the cover bolts.
- 8. Close and secure the access door.
Cleaning the Primary Element
 |
Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes. |
 |
| NOTICE |
|---|
To prevent element damage when cleaning with pressure water, use 280 kPa (40 psi) maximum pressure. Do not use an element with damaged pleats, gaskets or seals. Do not clean elements by bumping or tapping them on hard objects. |
Inspect each element after cleaning.
Have spare elements on hand to use when cleaning used ones.
Pressure Air - 205 kPa (30 psi) Maximum
Direct air inside and outside the element along the length of the pleats.
Water - 280 kPa (40 psi) Maximum
Direct water inside and outside the element along the length of the pleats.
Detergent
- 1. Wash the element in warm water and nonsudsing household detergent.
- 2. Rinse it thoroughly with clean water.
- 3. Air dry and inspect the element.
Inspecting Elements
Insert a light inside a clean, dry element. Discard the element if rips or tears are found.
Storing the Filter Elements
Wrap and store good elements in a clean, dry place.
Radiator Pressure Cap
Clean or Replace the Cap
|
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. |
|
- 1. Open the radiator cap access door.
- 2. Remove the radiator cap.
- 3. Inspect the cap for damage, deposits or foreign material.
- 4. Clean the cap with a clean cloth or replace the cap as necessary.
- 5. Install the cap.
Swing Brake
Adjust
It should require a firm pull to snap the handle over center to apply the brake.
Turn the knob clockwise to tighten or counterclockwise to loosen the brake.
The brake is properly adjusted when it holds the boom from swinging against swing motor torque, when applied. The lining must be free when the brake is released.
If the brake cannot be adjusted, consult your AVSpare dealer.
Swing Gear
Lubricate Fitting
Fitting located in the cab.
If unusual swing gear noise develops, lubricate the gear through the left hand fitting.
- 1. The upper structure must be rotated 720° (two full rotations).
- 2. Stop at 90° intervals and lubricate through the fitting.
Undercarriage
Changing the Track Gauge
| NOTICE |
|---|
If the machine is equipped with track motor guards, prior to changing the track gauge, remove the two bolts attaching each guard to the track roller frame bracket. |
When in the wide gauge position, protect the eight unused tapped holes in the roller frames. Install AVSpare Part T-690 Plugs in the holes.
- 1. Position the machine on level ground.
- 2. Remove the six bolts from each car body leg of one roller frame.
- 3. Position boom over opposite roller frame and apply boom down pressure to raise the opposite track 10 to 12 cm (4 to 5 inches).
- 4. Use stick IN or OUT force to extend or retract the roller frame.
Turning the machine slightly in left or right turns may be necessary for bolt installation.
- 5. Install the six bolts and torque to 750 ± 80 N·m (555 ± 60 lb ft).
- 6. Repeat steps 1 through 5 for the opposite roller frame.
Tracks
Adjust
|
Grease is under high pressure. Grease coming out of the relief valve under pressure can penetrate the body causing injury or death. Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened. Loosen the relief valve one turn only. |
|
Operate the machine in the direction of the idlers. Stop with one track pin directly over the front carrier roller.
Correct adjustment allows 25 to 40 mm (1 to 1 1/2 inches) of sag midway between the front carrier roller and the idler.
Repeat the procedure on the opposite track after completion of the first track.
If the Track is too Loose
| NOTICE |
|---|
Do not adjust the track if the dimension shown is less than 16 mm (5/8 inch) on the standard machine. Do not adjust the track if the dimension shown is less than 9.5 mm (3/8 inch) on the special application machine. Consult your AVSpare dealer for track service. |
- 1. Remove the adjustment access plate on the track roller frame. Add grease through the fill valve fitting until the adjustment is correct.
- 2. Operate back and forth to equalize pressure.
- 3. Recheck the adjustment.
If the Track is too Tight
- 1. Be sure the idler can retract. Remove the relief valve access plate on the roller frame.
- 2. Loosen the relief valve one turn only to allow grease to escape.
- 3. Tighten the valve when the adjustment is correct.
- 4. Operate the machine back and forth to equalize pressure. Remeasure the adjustment.
If the correct adjustment cannot be obtained, consult your AVSpare dealer.
Track Bolt Torque
The torque requirement for 5/8" track bolts is 170 ± 40 N·m (120 ± 30 lb ft) plus 1/3 turn (120°) and for 3/4" track bolts is 300 ± 50 N·m (220 ± 35 lb ft) plus 1/3 turn (120°).
Final Drives
Check Oil Level
|
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
|
Final drive oil plugs are located on the back side of the roller frames.
Remove the oil fill/level plug from each final drive. Maintain the oil level in each final drive to the bottom of the plug opening. Install the plugs.
Pump Drive
Check Oil Level
|
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
|
- 1. Open the right rear access door.
- 2. Remove the oil level plug (1).
- 3. Maintain the oil level to the bottom of the plug opening.
- 4. Remove the oil fill plug (2), if necessary to add oil.
- 5. Clean and install the plugs. Close the access door.
Swing Drive
Check Oil Level
|
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
|
Plug is located behind boom.
- 1. Remove the oil level plug.
- 2. Maintain the oil level to the bottom of the plug opening.
- 3. Clean and install the plug.
Clamshell Rotator Gear Drive
Check Oil Level
|
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
|
- 1. Remove the plug at the top of the rotator.
- 2. Maintain the oil level to the bottom of the plug opening.
- 3. Clean and install the plug.
Bucket Teeth and Side Cutters
Change or Rotate
|
Retainer pins, when struck with force, can fly out and cause injury to nearby people. Make sure the area is clear of people when driving retainer pins. To avoid injury to your eyes, wear protective glasses when striking a retainer pin. |
|
|
Block the bucket before changing bucket teeth or side cutters. |
|
|
Block the clamshell bucket in the open position. |
|
Change bucket teeth or side cutters before the mounting surfaces become worn.
Bucket Teeth
- 1. Drive the pin out of the tooth from the washer side of the tooth. Remove the tooth and the washer.
- 2. Clean the shank, pin and washer. Install the washer in the groove in the side of the shank.
- 3. Install the new or rotated tooth over the washer. The tooth may be rotated 180° for more or less penetration while digging.
- 4. Drive the pin through the tooth shank and washer from the same side of the washer.
Side Cutters
- 1. Remove the mounting bolts and remove the side cutters.
- 2. Some side cutters may be rotated for additional wear. Clean the mounting surfaces. Install the new or rotated cutters.
Fuses
Replace
The fuse box is located inside the left front access door.
Fuses - They protect the electrical system from damage caused by overloaded circuits. Change a fuse if the element separates. If the element of a new fuse separates, have the circuit checked and repaired.
| NOTICE |
|---|
Replace fuses with the same type and size only to prevent electrical damage. |
Pull the cover open for fuse access.
The following circuits protected by each fuse includes the fuse amperage.
Boom Light (1.) - 15A
Front Lights (2.) - 15A
Wiper and Washer (3.) - 3A MDX SLOW BLOW
Heater and Dome Light (4.) - 5A
Defroster (5.) - 5A
Fault Lights Warning Circuit (6.) - 1A
Horn and Lighter (7.) - 15A
Start Switch and Electric Hydraulic Control (8.) - 5A
Air Conditioner (if equipped) (9.) - 30A
Windshield Wiper and Washer
Change Wiper Blades
Inspect the windshield wiper blades. Replace them if worn, damaged or streaking.
Fill Washer Solvent Bottle
The windshield washer bottle is located inside the left side rear access door.
Fill the bottle when it is empty. Use a nonfreezing window washer solvent in freezing weather.
The washer nozzle may be turned to spray in the desired direction.
Starting Aid Ether Cylinder
Replace the Cylinder
|
Ether is poisonous and flammable. Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Use ether only in well ventilated areas. Use ether with care to avoid fires. Do not smoke while changing ether cylinders. Do not store ether cylinders in the operator's compartment or living areas. Do not store ether cylinders in direct sunlight or at temperatures above 49°C (102°F). Discard ether cylinders properly. Do not puncture or burn ether cylinders. Keep ether cylinders out of the reach of unauthorized personnel. |
|
Open the left rear access door.
- 1. Loosen the clamp and unscrew the ether cylinder.
- 2. Remove the used gasket and install the new gasket provided with each new cylinder.
- 3. Install the new cylinder. Tighten the cylinder hand tight.
- 4. Fasten the cylinder clamp securely around the cylinder.
- 5. Close the access door.