Air Cleaner - Changing Filter Elements
Service the air cleaner if the indicator light does on with the engine running at high idle. Stop the engine.
Open the right rear door for air cleaner access.
Servicing the Primary Element
- 1. Remove the air cleaner cover (1). Remove the primary filter element (2) from the air cleaner housing.
- 2. Clean the inside of the air cleaner housing. Remove a tab from the secondary element. Change the secondary element when the third tab is removed.
- 3. Clean and inspect the primary element. See "Cleaning Primary Elements."
- 4. Install a clean primary element.
- 5. Clean and install the cover. Tighten the cover bolts finger tight to 4 N·m (3 lb. ft.).
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Do not use a tool to tighten the bolts. |
If the amber light comes on shortly after installation of a primary element that has been cleaned 6 times, change to another clean element.
If the amber light still comes on 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 6 times. Replace the element once a year even though it has not been cleaned 6 times.
Replacing the Secondary Element
Change the secondary element at the time the primary element is cleaned for the third time, or at the time the third tab is removed from the element.
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Always replace the secondary element. Never attempt to reuse it by cleaning. |
- 1. Remove the housing cover and the primary element.
- 2. Remove the 6 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.).
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Do not use a tool to tighten the cover bolts. |
- 8. Close and secure all access doors.
Cleaning Primary Elements
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When using pressure air, wear a face shield and protective clothing. Use a maximum air pressure to 205 kPa (30 psi) for cleaning purposes. |
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To prevent element damage when cleaning with pressure water, use 280 kPa (40 psi) maximum pressure. |
Pressure Air-205 kPa (30 psi) Maximum
- 1. Direct air inside the element along the length of the pleats.
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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.
- 2. Direct air outside along the length of the pleats. Direct air inside along the length of the pleats. Inspect the element.
Water-280 kPa (40 psi) Maximum
- 1. Direct water inside the element along the length of the pleats.
- 2. Direct water outside along the length of the pleats. Air dry and inspect the elements.
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
- 1. Insert a light inside a clean, dry element. Discard the element if rips or tears are found.
- 2. Wrap and store good elements in a clean, dry place.
Cooling System-Clean
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At operating temperature, engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only when the engine is stopped and the radiator cap is cool enough to touch with your hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury. |
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- 1. Open the radiator cap access door. Remove the cap slowly to relieve pressure.
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All water is corrosive at engine operating temperature. Use AVSpare Cooling System Conditioner to treat either plain water or an ethylene glycol solution. Do not use AVSpare Cooling System Conditioner with Dowtherm 209 Full-Fill coolant. Follow the recommendations with the Dowtherm 209 Full-Fill. If the machine is shipped to or stored in an area with temperatures below 0°C (32°F), the cooling system must be protected to the lowest expected outside temperature, or drained completely. |
Clean the cooling system if it overheats, if it is contaminated, or if foaming is observed in the radiator.
- 2. Open the drain valve and allow the coolant to drain.
- 3. Close the drain valve. Fill the system with cleaning solution. Use a commercially available cleaner or 1 kg. (2 lb.) sodium bisulfate (NaHSO4) per 38 liters (10 gal.) of water as a cleaner.
- 4. Start and operate the engine for 1/2 hour. Stop the engine and drain the cleaning solution.
- 5. Flush the system, with the engine stopped, with water until the draining water is clear.
- 6. Close the drain valve. Fill the system with a neutralizer. Use a commercially available neutralizer or 250 grams (1/2 lb.) sodium carbonate crystals (Na2Co3·10H2O) per 38 liters (10 gal.) of water
- 7. Operate the engine for 10 minutes. Stop the engine and drain the neutralizer.
- 8. Flush the system, with the engine stopped, until the draining water is clear. Close the drain valve.
- 9. Fill the system with clean water and operate the engine for 5 minutes. Stop the engine and drain the water.
- 10. Repeat step 9 several times, if necessary, until the drained water is clear.
- 11. Mix antifreeze solution to provide protection to the lowest expected outside temperature.
- 12. Add .9 liter (1 qt.) of AVSpare Cooling System Conditioner, or equivalent, to the coolant.
- 13. To avoid air locks, add coolant slowly at 19 liters (5 U.S. gal.) per minute or less. See "Refill Capacities."
- 14. With the radiator cap off, start and operate the engine. When the coolant level stabilizes, add coolant, if necessary, to within 1 cm (1/2inch) of the bottom of the fill pipe.
- 15. Replace the cap if the gasket is damaged. Install the cap.
Radiator Pressure Cap-Clean or replace the cap
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At operating temperature, engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only when the engine is stopped and the radiator cap is cool enough to touch with your hand. Remove the radiator cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury. |
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- 1. With the engine stopped and cool, open the radiator cap access door. Remove the radiator cap.
- 2. Inspect the cap for damage, deposits or foreign material.
- 3. Clean the cap with a clean cloth or replace the cap as necessary.
- 4. Observe the coolant level. Maintain the level to within 1 cm (1/2 inch) of the bottom of the fill pipe.
- 5. Install the cap.
Fuel System
Change the secondary filter and clean the primary filter element if plugging or power loss occurs. The normal fuel filter service interval is 500 Service Hours or 3 Months.
See Item (24) for fuel filter service instructions.
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 1 fitting
If unusual swing gear noise develops, lubricate the gear through the left hand fitting, located in the operator's compartment floor.
- 1. The upper structure must be rotated 720° (two full rotations).
- 2. Stop at 90° intervals and lubricate through the fitting.
Undercarriage-Change gauge
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If the machine is equipped with track motor guards, prior to changing the track gauge, remove the 2 bolts attaching each guard to the track roller frame bracket. |
When in the wide gauge position, protect the 8 unused tapped holes in the roller frames. Install AVSpare Part No. T-690 Plugs in the holes.
- 1. Position the machine on level ground.
- 2. Remove bolts (4 if extending gauge, 6 if retracting gauge) from each car body leg of one roller frame.
When not in use, the 4 extra bolts on each roller frame are stored on the idler recoil guard.
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The 4 bolts must be installed in their new location after gauge change. |
- 3. Position boom over opposite roller frame and apply boom down pressure to raise the opposite track 4 to 5 inches (10 to 12 cm).
- 4. Use stick IN or OUT force to extend or retract the roller frame.
- 5. Install the 4 or 6 bolts and torque to 575 ± 80 N·m (420 ± 60 lb. ft.)
Turning the machine slightly in left or right turns may be necessary for bolt installation.
- 6. Repeat steps 1 through 5 for the opposite roller frame.
Track-Adjust
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.
If the Track is too Loose:
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Do not adjust the track if the dimension shown is less than 16 mm (5/8 inch). 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.
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To prevent possible personal injury, never visually inspect the relief valve to see if grease is escaping. Always observe the track to see if it has loosened. Loosen the relief valve one turn only. |
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- 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.
Final Drives-Check oil level
Stop the machine on a level surface. Lower all equipment. Engage the hydraulic and anti-travel lock lever. Stop the engine.
Remove the 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
- 1. Open the right rear access door. Remove the level plug.
- 2. Maintain the level to the bottom of the plug opening.
- 3. Clean and install the plug. Close the access door.
Swing Drive-Check oil level
- 1. Remove the right front upper panel. Remove the level plug.
- 2. Maintain the oil level to the bottom of the plug opening.
- 3. Clean and install the plug. Install the panel.
Clamshell Rotator Gear Drive-Check oil level
- 1. Remove the plug at the top of the rotator.
- 2. Maintain the level to the bottom of the plug opening.
- 3. Clean and install the plug.
Bucket Teeth and Side Cutters-Change or rotate
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The pin, when struck, can fly out and cause personal injury. To avoid personal injury to eyes, wear protective glasses when striking a pin. |
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Block the bucket before changing bucket teeth or side cutters. |
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Block the clamshell bucket in the open position. |
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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 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 side of the tooth opposite 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.
- 1. Inspect the fuses if an electrical circuit does not function.
- 2. Replace a fuse if the element separates.
- 3. If the new fuse element separates again, have the circuit checked.
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Replace a fuse with the same size and type fuse. |
Windshield Wiper and Washer-Change wiper blades - Fill washer bottle
Inspect the windshield wiper blades. Replace them if worn, damaged or streaking.
The windshield washer bottle is located inside the right 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
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Ether is poison and flammable. Do not smoke while changing cylinders. Use it only in well ventilated areas. Use ether with care to avoid fires. Avoid breathing of vapors or repeated contact with skin. Do not store replacement ether cylinders in living areas or in the operator's compartment Keep cylinders out of the reach of children. Do not store cylinders at temperatures above 48.9°C (120°F) Do not use cylinders in environments above 93.3°C (200°F). Do not store cylinders in direct sunlight. Do not puncture or burn cylinders. Discard cylinders in a safe place. |
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- 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.
Hydraulic System-Check oil level
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At operating temperature, hydraulic oil is hot and under pressure. Hot oil can cause personal injury. Remove the hydraulic tank cap only when it is cool enough to touch with your hand. Remove the cap slowly to relieve pressure. |
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Position the backhoe machine on level ground with the stick cylinder fully extended and the bucket flat on the ground.
Position the clamshell machine on level ground with the stick cylinder fully extended and the bucket open on the ground.
- 1. Stop the engine. Open the right front access door.
- 2. Maintain the oil level to the FULL mark on the sight gauge.