(50)Air Intake System
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Service air cleaner with engine stopped. |
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Service filter elements when RED indicator locks in the visible position.
Primary Element
- 1. Remove cover and primary element.
- 2. Clean inside of body and cover.
NOTE: 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.
- 3. Clean and inspect element. See Cleaning Air Cleaner Elements.
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Always inspect primary element, before and after cleaning, with a light bulb inside the element. Discard if any tears, rips or damage is evident. |
- 4. Install clean element and cover.
Secondary Element
| NOTICE |
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Always replace the secondary element. Do not attempt to reuse by cleaning. |
NOTE: Replace the secondary element at the time the primary element has been cleaned for the third time.
NOTE: If indicator still shows RED after installation of a clean primary element, install a new secondary element.
- 1. Remove cover and primary element.
- 2. Remove and discard secondary element.
- 3. Cover air inlet opening with heavy tape.
- 4. Clean entire air cleaner, including precleaner, if necessary.
- 5. Remove tape from air inlet opening.
- 6. Inspect gaskets between filter housings and air intake manifolds. If gaskets are damaged, or if housings were separated from manifolds, remove gaskets, clean mounting surfaces and install new gaskets.
NOTE: If indicators still show RED after installation of a new secondary element, install other clean primary element.
- 9. Reset filter indicator.
Cleaning Air Cleaner Elements
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When using pressure air, wear safety face shield and protective clothing. Use 30 psi (205 kPa) maximum pressure air for cleaning purposes. |
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Do not clean elements by bumping or tapping. Do not use elements with damaged pleats, gaskets or seals. |
NOTE: Have spare elements on hand to use while cleaning used elements.
Pressure Air - 30 psi (205 kPa) Maximum
- 1. Direct air inside element along length of pleats.
- 2. Direct air outside element along length of pleats. Direct air inside element along length of pleats. Inspect element.
Water-40 psi (280 kPa) Maximum
- 1. Direct water inside element along length of pleats.
- 2. Direct water outside element along length of pleats. Rinse, air dry thoroughly and inspect.
Detergent
- 1. Wash element in warm water and non-sudsing household detergent.
- 2. Rinse with clean water. See above.
- 3. Air dry thoroughly and inspect element.
Inspecting Element
- 1. Insert light inside clean and dry element and inspect. Discard element if rips or tears are found.
- 2. Wrap and store good elements in a clean, dry place.
(51)Final Drives
Remove fill plug on each side. Observe oil level. Oil should be up to the fill plug openings. Add oil as required. Install fill plugs.
(52)Seat Belts
Inspect condition of seat belts. Replace if damaged.
NOTE: Replace seat belts every 3 years regardless of appearance.
(53)Transmission
Measure oil level with engine running at low idle and transmission in NEUTRAL. Maintain oil level at FULL mark on gauge.
(54)Cable Control Gear Case
Remove fill plug. Inspect oil level. Maintain oil level at fill plug opening. Add oil as required. Install plug.
(55)Winch
Start engine and run at low idle. Maintain oil level so it is visible in sight gauge.
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If cable has frayed or worn spots, install new cable. Always wear gloves when handling cable. |
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NOTE: Make certain winch mounting bolts are secure and no oil leakage is observed.
(52)Ripper-Tip Replacement
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The pin, when struck, may fly out and cause injury to nearby personnel. |
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- 1. Drive pin out and remove tip.
- 2. Check plug. Metal part of plug must be toward pin hole.
- 3. Clean ripper shank.
- 4. Install tip in either digger or runner position. Align pin holes and install pin.
(57)Cutting Edge And End Bits
Change cutting edge and use new end bits before wear starts on blade support.
- 1. Raise and block blade before changing cutting edge or end bits.
- 2. Remove bolts.
- 3. Remove cutting edge or bit. Clean contact surfaces.
- 4. Use opposite cutting edge if not worn. Use new section if both edges are worn.
- 5. Install new end bits.
- 6. Install bolts and tighten to specified torque. See G.E.T. BOLT TORQUE CHART.
- 7. After a few hours of operation retighten bolts to proper torque.
(58)Sprocket Hub Bearings
- 1. Remove guards. Place a 5 foot (1.5 m) bar between the track roller frame and the sprocket.
- 2. Pry on bar. If side movement is noticeable, consult your AVSpare dealer.
(59)Cooling System Relief Cap
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Always inspect cooling system with engine stopped. Remove filler cap slowly to relieve pressure. Steam can cause personal injury. Inhibitor contains alkali, avoid contact with skin and eyes to prevent personal injury. |
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Clean or replace relief cap when cooling system does not maintain pressure, or coolant loss is experienced.
(60)Cable Control
- 1. Stop engine. Loosen locknut.
Brake Adjustment
- 2. Turn adjusting nut to align center of roller and small hole in brake lever. Tighten locknut.
Clutch Adjustment (Adjust brake before adjusting clutch)
- 1. Stop engine. Loosen clamp bolt.
- 2. Turn adjusting screw counter-clockwise until retainer is tight and clutch is engaged.
- 3. Loosen locknut and turn bolt until it contacts pressure plate retainer. Back bolt out 1 turn.
- 4. Turn adjusting screw until pressure plate retainer contacts bolt. Tighten clamp bolt.
- 5. Loosen bolt 5 turns. Tighten locknut.
Cable Replacement
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If cable has frayed or worn sports, install new cable. Always wear gloves when handling cable. |
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- 1. Stop engine. Loosen wedge and remove old cable.
- 2. Thread new cable.
- 3. Loop end of cable around wedge. Pull cable to tighten wedge.
The recommended cable is: 1/2", 6 × 25 Filler Wire, Right Lang Lay, Independent Wire Rope Center, Preformed, Improved Plow Steel Type.
(61)Bulldozer - Diagonal Arm and Tilt Brace Ball and Socket Adjustment
- 1. Remove cap bolts. Shorten brace and remove shims.
- 2. Clean grease from ball and socket. Clean shims.
- 3. Lengthen brace. Install and tighten bolts evenly.
- 4. Measure clearance between cap and socket with shims.
- 5. Remove bolts and shorten brace. Install shims equal to measured clearance plus 1 shim.
- 6. Lengthen brace and install bolts. Tighten bolts to 150 ± 20 lb. ft. (205 ± 5 N·m).
- 7. Lubricate ball and socket.
(62)Fuel System-Primary Filter
Clean element when fuel pressure gauge registers OUT with engine running.
- 1. Close fuel supply valve.
- 2. Loosen primary filter bowl retaining clamp nut. Remove bowl and element.
- 3. Wash element in clean non-flammable solvent.
- 4. Clean bowl.
- 5. Install element and bowl.
- 6. Open fuel supply valve.
- 7. Start engine and check for leaks.
NOTE: If fuel pressure gauge still registers OUT with engine running, change secondary element.
Secondary Filter Element
- 1. Close fuel supply valve and remove filter with a strap type wrench.
- 2. Clean filter base gasket surface. Be sure all of old gasket is removed.
- 3. Lubricate new filter gasket with clean diesel fuel.
- 4. Install new element by hand. When gasket contacts base, tighten 1/2 turn more.
- 5. Prime fuel system
- 6. Start engine and check for leaks. Install guard.
Priming Fuel System (Scroll-type)
- 1. Move governor control to OFF position. Open system vent valve.
- 2. Unlock priming pump plunger.
- 3. Operate plunger until...
...flow of fuel from drain line is free of air bubbles. Close pump and lock plunger.
- 4. Close vent valve.
(Sleeve Metering)
- 1. Move governor control to OFF position. Open fuel system bleed valve.
- 2. Unlock priming pump plunger and operate pump until...
...flow of fuel from drain line is free of air bubbles.
- 3. When fuel flows free of bubbles, close pump and lock plunger.
- 4. Close bleed valve.
- 5. Start engine and inspect for leaks.
(63)Water Separator-If Equipped
NOTE: When inside of water separator becomes contaminated enough that water level cannot be seen through transparent cover, install new element.
- 1. Stop engine and close fuel supply valve.
- 2. Clean separator and surrounding area. Open separator drain valve (A) and vent valve (B). Allow to drain. Close drain and vent valves.
- 3. Depress extended tab on cover retaining clamp with heel of hand and lift slotted tab from locking slot. Pull off and discard used element assembly.
- 4. Clean three sealing surfaces on separator base before installing new element assembly.
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Make sure new seals are in seal recesses of new element assembly. |
- 5. Insert locating pin (A) into outlet passage (B) at bottom of new element and push into place on element base.
- 6. Engage lower tab of clamp in slot at bottom of separator base. While depressing clamp with heel of hand, push upper tab into locking slot at top of base.
NOTE: Clamp must always be installed with hand and finger tabs in the UP position.
Make sure clamp is securely engaged in top and bottom locking slots.
(64)Cooling System-Cleaning
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Always inspect cooling system with engine stopped. Remove filler cap slowly to relieve pressure. Steam can cause personal injury. Inhibitor contains alkali, avoid contact with skin and eyes to prevent personal injury. |
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Never add coolant to an overheated engine, allow engine to cool first. If machine is to be stored in, or shipped to, an area with below freezing temperatures, the cooling system must either be protected to the lowest expected ambient temperature, or drained completely. Do not use AVSpare Cooling System Inhibitor with Dowtherm 209 coolant. |
Machine level, blade lowered with slight down pressure, engine stopped and cool.
- 1. Turn filler cap slowly to relieve pressure, then remove cap.
- 2. Open drain valve and drain coolant.
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Use all cleaning solutions with care. |
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- 3. Close drain valve. Fill system with cleaning solution. (1)
NOTE: Most commercial cooling system cleaners may be used.
- 4. Start and run engine for 1/2 hour. Stop engine and drain cleaning solution.
- 5. Flush system with clean water until draining water is clean. Do not run engine while flushing.
- 6. Close drain valve. Fill system with neutralizing solution. (2)
- 7. Start and run engine for 10 minutes. Stop engine and drain neutralizing solution.
- 8. Flush system with clean water until draining water is clean. Do not run engine while flushing.
- 9. Close drain valve.
- 10. Mix antifreeze solution to provide protection to the lowest expected ambient temperature.
- 11. To help avoid air locks, add coolant slowly at 5 U.S. gallons (19 litres) per minute or less.
- 12. Add antifreeze solution. See REFILL CAPACITIES.
- 13. Add 2 pints (1 litre) of AVSpare Cooling System Inhibitor, or equivalent, so that the cooling system will have a 3% concentration of inhibitor.
- 14. Start and run engine with filler cap removed. Allow coolant to warm and level to stabilize.
- 15. Add coolant, if necessary, to bring level to bottom of pipe.
- 16. Observe condition of filler cap gasket. Replace if damaged. Install filler cap.
NOTE: Do not completely fill cooling system. Allow for addition of AVSpare Cooling System Inhibitor, or equivalent.
(1)2 lb. Sodium Bisulfate (NaHSO4) per 10 U.S. gallons (1 kilogram per 40 litres) water.
(2)1/2 lb. Sodium Carbonate Crystals (Na2 CO3 * 10 H2 O) per 10 U.S. gallons (250 grams per 40 litres) water.
(65)Track
If track was adjusted with sprocket teeth clean- readjust track if packing in the sprocket tooth area is present.
NOTE: Tracks should be adjusted under the same conditions in which the machine will be used. If packing conditions prevail on the job, the tracks should be adjusted with packing present.
(66)Fuel Tank
Open drain valve and drain off any sediment or water that may have accumulated. Close valve.
- 1. Remove fuel tank filler cap. Disassemble cap and wash cap in clean non-flammable solvent. Examine filler cap gasket and replace if damaged.
- 2. Oil elements lightly and assemble cap.
- 3. Install cap.
(67)Fuses
- 1. When electrical circuits do not function, remove and inspect fuses. Replace any fuse which has a broken element.
- 2. Reset circuit breaker if it has opened.
(68)Flywheel Clutch
| NOTICE |
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Measure and make adjustment with the engine stopped and the clutch cold. |
A properly adjusted clutch will require a clutch lever pull of approximately 55 lbs. (25 kg).
Slightly more effort may be required if the clutch is warm.
To Adjust:
- 1. Remove floor plate and clutch inspection cover. Turn flywheel until one of the locknuts is visible.
- 2. Loosen locknut 2 turns.
- 3. Tap plate to be sure it is free of stud.
- 4. Turn flywheel 180° and loosen other locknut.
- 5. Turn adjusting ring to obtain correct adjustment.
- 6. Tighten locknuts to 30 lb. ft. (40 N·m).
- 7. Install inspection cover.
Clutch Brake
With engine running, push the clutch control lever forward. If the clutch shaft is slow in stopping, adjust brake.
To Adjust:
- 1. Loosen locknut on lever linkage.
- 2. Hold control lever forward and ...
- 3. turn adjusting rod until lining contacts drum evenly.
- 4. Release control lever and turn adjusting rod in (clockwise) 2 turns.
- 5. Tighten locknut and install floor plate.
| NOTICE |
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Do not adjust brake too tight. Difficult shifting and rapid brake lining wear will result. |
(69)Air Conditioner-Cleaning Elements
Recirculating Filters
Change or clean filter elements if a reduction in air circulation is noticed.
- 1. Remove two recirculating filter cover screws and cover.
- 2. Remove two sponge-type filters.
- 3. Wash the filters in warm water and a household detergent.
- 4. Rinse and blow dry.
- 5. Install clean filters and cover.
Fresh Air Filters
- 1. Unlock the covers for air conditioner filters, located at the front and rear of the unit on top of the cab.
- 2. Remove and discard the two filter elements.
- 3. Install the two new filters.
- 4. Close and secure the two covers.
- 5. Inspect the condition of the fan blades. Make sure they are free of dirt and debris.