- 1. Check the following and service as required:
- a. Engine oil level.
- b. Engine coolant level.
- c. Fuel level.
- d. Spray system water level.
- e. Moldboard.
- f. Cutter bits, bit holders and flighting.
- g. Cutter drum water level.
- b. Engine coolant level.
Checking The Engine Oil Level
The dipstick is stamped on both sides of the blade. One side is marked and to be read when checking the oil level with the ENGINE STOPPED. The other side is marked and to be read with the ENGINE IDLING - HOT OIL. Each side is stamped to remind you not to OVERFILL the crankcase with oil.
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BE SURE TO READ THE CORRECT SIDE OF THE DIPSTICK. THE ADD AND FILL LEVELS ARE NOT THE SAME WHEN CHECKING THE OIL WHILE STOPPED OR WHILE IDLING. |
Checking The Engine Coolant Level
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AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER PRESSURE. STEAM CAN CAUSE PERSONAL INJURY. DRAIN COOLING SYSTEM ONLY WHEN ENGINE IS STOPPED AND FILLER CAP IS COOL ENOUGH TO TOUCH WITH YOUR HAND. REMOVE THE FILLER CAP SLOWLY TO RELIEVE PRESSURE. COOLING SYSTEM CONDITIONER CONTAINS ALKALI. AVOID CONTACT WITH SKIN AND EYES TO PREVENT PERSONAL INJURY. |
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Check the engine coolant with the engine stopped and cool.
- 1. Slowly turn the pressure cap to the first stop and release any pressure.
- 2. Push the cap down and turn it until it is released.
- 3. Maintain the coolant level at the base of the fill pipe. If a loss of coolant is noticeable, check for leaks in the system. After filling the system, start the engine and recheck the coolant level after normal operating temperature is reached. Running the engine at operating temperature will permit the temperature regulator to open and allow the coolant to circulate through the entire system and purge air from the engine.
Make up coolant should be water that is free as possible of scale forming minerals (not softened water), a permanent type antifreeze and AVSpare Corrosion Inhibitor. Follow the recommendations given on the container.
Maintain a 3% concentration of AVSpare Corrosion Inhibitor. Makeup water added without the proper proportions of coolant corrosion inhibitor can cause excessive lime deposits and corrosion.
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DO NOT USE AVSpare CORROSION INHIBITOR WITH DOWTHERM 209 FULLFILL COOLANT. DO NOT ADD COOLANT TO AN OVERHEATED ENGINE, ALLOW THE ENGINE TO COOL FIRST. ADD COOLANT SLOWLY TO A HOT ENGINE TO PREVENT POSSIBLE CRACKING OR DISTORTING OF THE CYLINDER HEAD. |
If a loss of coolant is noticeable, check for leaks in the system. After filling the system, start the engine and recheck the coolant level after normal operating temperature is reached. Running the engine at operating temperature will permit the temperature regulator to open and allow the coolant to circulate through the entire system and purge air from the engine.
If a permanent antifreeze solution is used in the cooling system without coolant conditioner elements, either renew the rust inhibitor every three months by adding AVSpare Corrosion Inhibitor, or drain the entire cooling system annually and refill with fresh coolant solution.
Checking The Fuel Level
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DIESEL FUEL IS VOLATILE AND COULD IGNITE OR EXPLODE, CAUSING SERIOUS BURNS AND INJURIES FROM FLYING OBJECTS. NEVER SMOKE OR HAVE AN OPEN FLAME WHILE WORKING ON THE FUEL SYSTEM. |
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The fuel tank has a sight gauge for easy checking of the fuel level. The tank should be filled at the end of each workday to reduce the amount of water condensed out of the air as the tank cools during the night.
Before filling the fuel tank the last time for the day, open the drain valve under the tank. Allow any accumulated water and sediment to drain, then close the valve. In cold weather, drain the water immediately after stopping the engine, to prevent the water from freezing in the bottom of the tank.
Checking The Spray System Water Level
The water level can be checked by looking at the sight gauge located on the outer face of the water tank. Fill the tank with clean water before starting operation. To fill the tank from ground level, connect a water supply hose with a 3-inch (7.6 cm) female, automatic check, quick connect coupling half to the fitting on either side of the machine. The tank can also be filled through the uncapped top fill opening. Use the cleanest water possible to avoid rapid clogging of the filters.
If the machine is to be parked overnight or left idle for a period of time, the water tank, lines, filter and pumps should all be drained to avoid damage from freezing water.
Draining The Water System
If the water system must be drained to avoid damage from freezing water:
- 1. Open the water tank drain valve and check that the gate valves near the lower conveyor spray bar are not closed.
- 2. Remove the filter bowls, remove the filter elements from the bowls, dump the water from the bowls and reinstall the bowls. Store the filter elements in a warm place.
- 3. Disconnect one end of each hose loop at the water filters and drain the water from the loops.
- 4. Open the petcocks near the optional high pressure water pump, near the lower conveyor spray bar and on the spray system pump.
- 5. With the engine running, use the spray bar control to turn the spray system pump momentarily to clear any water from the pump, then return the control to "Off". If a high pressure water pump is installed, clear any water from it also. Shut the engine down.
- 6. With the engine shut down, move the spray bar control to "Spray Bar" and leave it for two or three minutes to open the solenoid valve and allow any water to drain. Move the spray bar control to "Off".
Checking The Moldboard
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INADVERTENT ENGAGEMENT OF THE CUTTER COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN, LOCK THE CUTTER CONTROL AT "OFF", AND REMOVE THE KEY FROM THE IGNITION SWITCH. THE MAINFRAME COULD FALL AND CAUSE PERSONAL INJURY. LOWER THE SUPPORT LEGS INTO POSITION WHENEVER WORKING UNDER THE MACHINE. |
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The moldboard blade sections should be checked for excessive wear and for loose connecting bolts. Tighten any loose bolts and replace the blade sections as necessary. Replace all the blade sections at the same time or loose material will pass underneath the worn sections. Use the mechanical stops to adjust the amount of moldboard downward travel possible.
Checking The Cutter Bits, Bit Holders And Flighting
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THE MAINFRAME OR CUTTER DOOR COULD FALL AND CAUSE PERSONAL INJURY. LOWER THE SUPPORT LEGS INTO POSITION AND INSTALL THE CUTTER DOOR CHAIN WHENEVER WORKING ON THE CUTTER. |
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- 1. Open the cutter belt cover.
- 2. Connect the cutter auxiliary drive system to the cutter (see page 5-6).
- 3. Check the cutter bits that are accessible for excessive wear. Also check the cutter flighting, mounting blocks and bit holders for breaks or cracks. Mark any parts that need replacement or repair.
- 4. Start the engine, use the cutter auxiliary drive control to turn the cutter until different cutter bits are accessible, then SHUT THE ENGINE DOWN.
- 5. Repeat the procedure until all the bits, holders, mounting blocks and flighting have been checked.
Parts can be repaired or replaced as soon as they are discovered to be defective, or after the entire cutter has been inspected. The cutter bits should be replaced anytime the distance from the holders to the tip of the bits (normal wear) or to the end of the supporting metal (carbide tip exposed) is 1 1/4 inches (3.2 cm) or less.
Replacing A Cutter Bit
When the bits get worn they should be changed as a group so that all the bits are approximately the same length. If a single bit is longer than the bits around it, the long bit will be broken off or the bit holder torn out when the bit hits the concrete. Keep several worn bits on hand to replace any bits that break.
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THE MAINFRAME OR CUTTER DOOR COULD FALL AND CAUSE PERSONAL INJURY. LOWER THE SUPPORT LEGS INTO POSITION AND INSTALL THE CUTTER DOOR CHAIN WHENEVER WORKING ON THE CUTTER. |
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An air operated hammer and a punch for the hammer are supplied with each machine. To remove a bit:
- 1. Connect the air hammer hose to the air system quick disconnect.
- 2. Insert the tip of the punch into the opening in the bit holder and use the air hammer to drive the bit out.
- 3. Position the new bit in the holder and drive it into place with a hammer or with the slide hammer supplied with the machine. Be sure the keeper spring is engaged with the holder.
A manual bit puller is also supplied with each machine. To remove a bit, hook the puller on the shoulder of the bit and strike the puller sharply with a hammer.
A drift pin and hammer can also be used to remove a bit, if necessary. Insert the drift pin into the opening in the bit holder and strike the drift pin sharply with a hammer.
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A METAL SPLINTER COULD FLY OFF AND BLIND YOU INSTANTLY. ALWAYS WEAR EYE PROTECTION WHEN HAMMERING ON METAL. |
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Replacing A Damaged Bit Holder
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THE MAINFRAME OR CUTTER DOOR COULD FALL AND CAUSE PERSONAL INJURY. LOWER THE SUPPORT LEGS INTO POSITION AND INSTALL THE CUTTER DOOR CHAIN WHENEVER WORKING ON THE CUTTER. METAL THAT HAS JUST BEEN GROUND OR CUT WITH A TORCH WILL BE HOT AND COULD CAUSE SERIOUS BURNS IF TOUCHED. DO NOT TOUCH THE BIT HOLDER OR CUTTER FLIGHTING UNTIL THEY HAVE COOLED. |
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- 1. Cut the bit holder free of the block and remove the holder.
- 2. Grind the surface of the holder mounting block smooth.
- 3. Position the new bit holder the same as the other bit holders, and slide the bit holder onto the dowels so the bit holder is flush with the block.
- 4. Weld the bit holder to the holder mounting block. The welding process used should be CO2 shielded fluxcored arc welding using a .052 E70T-1 electrode and electrode positive polarity. The contact tip to work distance should be 1 inch (2.54 cm), gas flow set at 30-40 cubic feet per hour (.85 to 1.1 cubic meters per hour), voltage at 28V, and amperage at 280A. Two passes.
Checking The Cutter Drum Water Level
- 1. Stop the cutter with the cutter teeth off the ground and open the cutter door.
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THE MAINFRAME OR CUTTER DOOR COULD FALL AND CAUSE PERSONAL INJURY. LOWER THE SUPPORT LEGS INTO POSITION AND INSTALL THE CUTTER DOOR CHAIN WHENEVER WORKING ON THE CUTTER. |
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- 2. Connect the auxiliary cutter drive motor to the cutter shaft and rotate the cutter to place the plug 5 inches (12.7 cm) above the centerline of the cutter.
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AT OPERATING TEMPERATURES THE WATER IN THE CUTTER DRUM CAN BE HOT ENOUGH TO CAUSE WATER AND STEAM TO SPRAY OUTWARD WHEN THE PLUG IS REMOVED. SERIOUS BURNS COULD RESULT. LET THE CUTTER DRUM COOL UNTIL IT IS COMFORTABLE TO TOUCH BEFORE REMOVING THE PLUG. |
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- 3. Remove the plug. If water does not flow from the port, add a 50% solution of water and ethylene glycol type permanent antifreeze until the liquid level reaches the port.
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THE MACHINE IS SHIPPED FROM THE FACTORY WITH A 50% SOLUTION OF WATER AND ETHYLENE GLYCOL TYPE PERMANENT ANTIFREEZE IN THE CUTTER DRUM. THIS SOLUTION MUST BE MAINTAINED IF THE CUTTER DRUM AND PLANETARY GEAR REDUCERS ARE TO BE PROTECTED. |