- 1. Change the hydraulic oil and clean the suction strainers.
- 2. Change the hydraulic oil tank breather filter.
- 3. Change the oil in the pump drive gearbox and the wheel gear reducers.
- 4. Lubricate the control cables.
- 5. Drain the engine cooling system (every 2000 hours).
- 6. Check the engine governor (every 2000 hours). See the 150 Hour Service.
- 7. Check the engine valve lash. See the AVSpare 3204 Operation and Maintenance Manual for procedures.
Changing The Hydraulic Oil
When changing the hydraulic oil, cleanliness must be kept in mind at all times. Perform the work in a clean area, use clean tools, keep your hands clean and clean up the outside of the hydraulic oil tank before starting.
THE HYDRAULIC OIL AT OPERATING TEMPERATURE CAN CAUSE SERIOUS BURNS. LET THE MACHINE STAND IDLE UNTIL THE HYDRAULIC OIL HAS COOLED AND THE TANK IS COMFORTABLE TO TOUCH.
- 1. Open the drain valve at the bottom of the tank and allow the oil to drain.
- 2. Pump a gallon or two of oil from the replenishing tank to the hydraulic oil tank and allow it to drain from the oil tank in order to remove any water present in the replenishing tank.
- 3. Remove the bolts from the tank cover and pull the cover from the tank.
- 4. Remove the suction strainers from the pipe nipples.
- 5. Clean the strainers in clean solvent and blow dry with filtered air.
- 6. Thoroughly clean the tank cover and gasket.
- 7. Thoroughly clean the hydraulic oil tank.
- 8. Install the clean strainers on the pipe nipples.
- 9. Install the tank cover and gasket. Use a new gasket, if necessary.
- 10. Close the drain valve and refill the tank with hydraulic oil. by pumping the oil from the replenishing tank and adding oil to the replenishing tank as needed. Use only hydraulic oil that conforms to the specification on page 5-1.
- 11. Loosen the hose at the suction port of each pump until air-free hydraulic oil flows from the connection.
- 12. Loosen the outlet connection on the accessory pump and crank the engine with the starter until air-free hydraulic oil flows from the connection. Tighten the connection.
- 13. Start the engine and run at a low idle for several minutes. Check for leaks and check the hydraulic oil level. Add oil as necessary.
Cleaning The Oil Tank Suction Strainers
See "Changing the Hydraulic Oil" above.
Changing The Hydraulic Oil Tank Breather Filter
The hydraulic oil tank breather filter element is a spin-on type element.
THE HYDRAULIC OIL AT OPERATING TEMPERATURE CAN CAUSE SERIOUS BURNS. LET THE MACHINE STAND IDLE UNTIL THE HYDRAULIC OIL HAS COOLED AND THE FILTER ELEMENT IS COMFORTABLE TO TOUCH.
To change the element:
- 1. Unscrew the filter element from the filter head. Be sure the gasket comes off with the filter element.
- 2. Coat the gasket of the new element with clean hydraulic oil.
- 3. Screw the element onto the filter head until the gasket contacts the head.
- 4. Turn the element about 1/2 turn more.
Changing The Oil In The Pump Drive Gearbox
INADVERTENT ENGAGEMENT OF THE PUMP DRIVE GEARBOX CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.
- 1. Remove the drain plug and allow the oil to drain.
- 2. Reinstall the drain plug.
- 3. Remove the check plug and breather.
- 4. Add oil through the breather port until it reaches the check plug level.
- 5. Reinstall the check plug and breather.
Changing The Oil In The Wheel Gear Reducers
- 1. Move the machine so that a drain plug in a gear reducer is at the bottom of the case.
INADVERTENT ENGAGEMENT OF THE WHEEL DRIVE SYSTEM CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FRON THE IGNITION SWITCH.
- 2. Shut the engine down, remove the drain plug and allow the oil to drain. Install the plug.
- 3. Move the machine so the check plug is at the bottom of the case.
- 4. Remove the check plug and fill plug.
- 5. Add oil through the fill plug until check plug level is reached.
- 6. Install the check plug and fill plug.
- 7. Repeat steps 1 through 6 for the other wheel.
Lubricating The Throttle, Travel And Steering Indicator Control Cables
- 1. Disconnect both ends of the cable being lubricated.
- 2. Remove and discard the rod and sleeve seals from both ends of the cable.
- 3. Lubricate from the uppermost end of the cable until clear lubricant comes out the lowermost end. Stroke the cable while lubricating.
- 4. Install new seals on the cable.
- 5. Reconnect the cable and check the operation of the cable.
Draining The Engine Cooling System
IF THE ENGINE IS WARM, STEAM MAY SPRAY OUTWARD UNDER HIGH PRESSURE WHEN THE RADIATOR CAP IS LOOSENED. SERIOUS BURNS MAY RESULT. REMOVE THE RADIATOR CAP ONLY WHEN THE ENGINE IS STOPPED AND THE CAP IS COOL ENOUGH TO TOUCH.
- 1. Slowly turn the pressure cap until the pressure is fully released.
- 2. Open the radiator drain cock.
- 3. Remove the cylinder block drain plug.
- 4. Allow the coolant to drain, then close the radiator drain cock and install the drain plug.
- 5. Add the correct amount of cooling system conditioner to the cooling system to maintain a 3% to 6% concentration (approximately 2 pints).
- 6. Fill the cooling system with coolant.
USE A 50% ANTIFREEZE AND 50% CLEAN MINERAL-FREE WATER MIXTURE. DO NOT USE SOFTENED WATER.
DO NOT USE DOWTHERM 209 FULL-FILL COOLANT WITH AVSpare COOLING SYSTEM CONDITIONER.
- 7. Start and run the engine until the coolant level stabilizes. Shut the engine down.
- 8. Add coolant as necessary to fill the system.
- 9. Inspect the radiator cap gaskets. Replace the cap if the gaskets are damaged.
- 10. Install the radiator cap.