- 1. Change the oil in the engine power take-off housing.
- 2. Change the engine coolant.
- 3. Change the oil in the pump drive gearbox.
- 4. Change the hydraulic oil.
- 5. Change the oil in the cutter sheaves.
- 6. Change the oil in the cutter and track gear reducers.
- 7. Change the oil in the optional high pressure water pump.
- 8. Clean the breathers, fill caps and screens for the fuel tank and hydraulic oil replenishing tank.
Changing The Oil In The Engine Power Take-Off Housing
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INADVERTENT STARTING OF THE ENGINE COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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- 1. Remove the drain plug and allow the oil to drain into a suitable container.
- 2. Replace the drain plug.
- 3. Remove the breather and the check plug.
- 4. Fill the housing through the breather port until check plug level is reached.
- 5. Replace the check plug and breather.
Changing The Engine Coolant
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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. THE MAINFRAME COULD FALL AND CAUSE PERSONAL INJURY. LOWER THE SUPPORT LEGS INTO POSITION WHENEVER WORKING UNDER THE MACHINE. |
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- 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. Remove the radiator drain plug.
- 4. Remove the engine block and oil cooler drain plugs.
- 5. Allow the coolant to drain, then flush the engine thoroughly.
- 6. Fill the cooling system with a solution of one pound (.45 kg) of oxalic acid or sodium bisulfate per five gallons (19 L) of water.
- 7. Run the engine at operating temperatures for one-half to one hour.
- 8. Repeat steps 1 through 5.
- 9. Fill the cooling system with a solution of 1/2 lb. (.23 kg) of sal soda per ten gallons (38 L) of water.
- 10. Run the engine for ten minutes.
- 11. Repeat steps 1 through 5.
| NOTICE |
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DO NOT USE AVSpare CORROSION INHIBITOR WITH DOWTHERM 209 FULL FILL COOLANT. ALL WATER IS CORROSIVE AT ENGINE OPERATING TEMPERATURE. USE EITHER AVSpare COOLING SYSTEM INHIBITOR LIQUID, OR THE COOLANT CONDITIONER ELEMENT TO TREAT EITHER PLAIN WATER OR EHTYLENE GLYCOL SOLUTION. DO NOT ADD BOTH THE LIQUID COOLING SYSTEM INHIBITOR AND THE COOLANT CONDITIONER ELEMENT AT THE SAME TIME. WHEN CHANGING ANTIFREEZE SOLUTION, REPLACE THE MAINTENANCE FILTER ELEMENT WITH THE CORRECT PRECHARGE ELEMENT (SEE PAGE 5-58 FOR PROCEDURES). THE NORMAL COOLANT CONDITIONER ELEMENT MUST NOT BE USED WITH DOWTHERM 209 COOLANT. |
- 12. Fill the cooling system with a solution of 50% antifreeze and 50% clean mineral-free water. Leave room to add corrosion inhibitor.
- 13. Add corrosion inhibitor to maintain a 3% concentration of inhibitor to coolant.
- 14. Run the engine until it reaches operating temperature, then SHUT THE ENGINE DOWN.
- 15. Allow the engine to cool, then check the coolant level. Add make-up coolant as necessary.
Changing The Oil In The Pump Drive Gearbox
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INADVERTENT STARTING OF THE ENGINE COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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- 1. Shut the engine down.
- 2. Remove the drain plug and allow the oil to drain.
- 3. Reinstall the drain plug.
- 4. Remove the check plug.
- 5. Add oil until it reaches check plug level.
- 6. Reinstall the check plug.
Changing The Hydraulic Oil
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AT OPERATING TEMPERATURES THE HYDRAULIC OIL AND OIL TANK CAN CAUSE SERIOUS BURNS. LET THE MACHINE STAND IDLE UNTIL THE HYDRAULIC OIL HAS COOLED AND THE OIL TANK IS COMFORTABLE TO TOUCH. |
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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 the outside of the hydraulic oil tank before starting.
- 1. Thoroughly clean around a hose connection at the pump suction shutoff valve, close the shutoff valve, disconnect a hose from the valve, and immediately cap or plug the hose.
- 2. Attach a clean hose long enough to reach a suitable container, place the other end of the hose in the container, then open the shutoff valve and allow the oil to drain.
- 3. While the oil is draining, use the replenishing pump to empty the replenishing tank.
- 4. After the oil has drained, disconnect the drain hose from the shutoff valve and connect the original suction hose to the valve.
- 5. Unbolt the replenishing pump from the tank cover and move the pump to a place where it will be out of the way and will not be damaged.
- 6. Thoroughly clean the tank cover and surrounding area of the tank, remove the bolts from the tank cover and pull the cover from the tank.
- 7. Remove the strainer from the pipe nipple.
- 8. If there is dirt or sediment in the tank or on the cover, thoroughly clean the tank and/or cover.
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DO NOT ALLOW ANY WATER, SOLVENT OR OTHER CLEANING AGENT TO ENTER ANY FITTINGS OR HOSES AND COMPLETELY REMOVE ANY FROM THE TANKS AND COVER. DO NOT USE RAGS THAT MAY LEAVE LINT OR THREADS IN THE TANK. |
- 9. Wash the strainer in clean nonflammable solvent and blow it dry with clean air or allow it to drain dry. Also clean off the flexible magnets.
- 10. Install the cleaned strainer on the pipe nipple.
- 11. Thoroughly clean the mating surfaces of the tank and cover, coat both surfaces with a liquid sealant such as Permatex, position the gasket and install the cover.
- 12. Install the replenishing pump.
- 13. Replace the elements in all the hydraulic oil filters (see pages 5-19, 5-20 and 5-22.
- 14. Refill the tank to 2 inches (5.1 cm) below the "Hi" mark on the sight gauge by pumping oil from the replenishing tank and refilling the replenishing tank as needed. Use only hydraulic oil conforming to the specification on page 5-2.
- 15. Open the pump suction shutoff valve.
- 16. Loosen the hose at the suction port of each pump until air-free hydraulic oil flows from the connection, then tighten the connection.
- 17. Loosen the outlet connection on the control (auxiliary) system pump, leave the ignition switch at "Off", and crank the engine with the starter until air-free hydraulic oil flows from the connection, then tighten the connection.
- 18. Start the engine and run it at low idle for several minutes. Check for leaks and check the hydraulic oil level. Add oil as necessary.
Cleaning The Hydraulic Oil Tank Strainer
See "Changing the Hydraulic Oil" on page 5-68.
Changing The Oil In The Cutter Sheaves
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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. |
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- 1. Loosen the four bolts on the takeup ONLY ENOUGH TO ALLOW THE TAKEUP TO SLIDE, then loosen the jam nuts on the takeup bolts and turn the bolts to loosen the belt band tension.
- 2. Remove the belt bands from the sheaves.
- 3. Attach a lifting device to the cutter sheave, remove the mounting nuts, then insert a 1/2-13 NC bolt into each of the three threaded holes in the sheave. Turn the bolts evenly and alternately to free the sheave, then move the sheave away.
- 4. Position a suitable container under the spindle, remove the drain plug and let the oil drain into the container.
- 5. Check the magnetic drain plug for metal particles. If there is an excessive amount of metal particles present, the drive shaft should be removed and the bearings inspected and/or replaced (see the Service Manual). Continued operation could lead to complete failure of the bearings which would cause damage to other components.
- 6. Install the drain plug, remove the check plug, disconnect the breather hose, then add SAE 90 gear lubricant until it reaches check plug port level.
- 7. Install the check plug and connect the breather hose.
- 8. Move the sheave onto the spindle and install the mounting nuts.
- 9. Position a suitable container under the upper sheave drain, remove the drain plug and let the oil drain into the container.
- 10. Check the magnetic drain plug for metal particles. If there is an excessive amount of metal particles present, the sheave should be removed and the bearings inspected and/or replaced (see the Service Manual). Continued operation would lead to complete failure of the bearings which would cause damage to other components.
- 11. Install the drain plug, remove the check plug and breather, then add SAE 90 gear lubricant until it reaches check plug port level.
- 12. Install the check plug and breather.
- 13. Slide the belt bands onto the sheaves and adjust the belt tension (see page 5-23).
Changing The Oil In The Cutter Planetary Gear Reducer
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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 BEFORE WORKING NEAR THE CUTTER. |
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- 1. Open the cutter belt drive cover and remove the two cover plates.
- 2. Rotate the cutter so that a gear reducer plug is centered in the lower cover plate opening and one plug is at the bottom of the reducer.
- 3. Remove both plugs and let the oil drain out.
- 4. Rotate the cutter to position the gear reducer check plug port 2 inches (5.1 cm) below the cutter centerline and the fill plug port in the upper cover plate opening.
- 5. Add oil through the fill plug port until it reaches check plug port level, wait several minutes for the oil level to even out throughout the reducer, then add more oil. Repeat until the oil remains at check plug port level.
| NOTICE |
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EXTREME CARE MUST BE TAKEN WHEN ADDING OIL TO ENSURE THAT THE PROPER OIL LEVEL IS REACHED. BE SURE TO ALLOW ENOUGH TIME FOR THE OIL TO FLOW THROUGH THE BEARINGS AND REACH THE CORRECT LEVEL IN ALL COMPARTMENTS. MORE TIME MUST BE ALLOWED FOR COLD OIL SINCE IT WILL NOT FLOW AS FAST AS WARMER OIL. |
- 6. After the correct oil level is assured, install the plugs and cover plates, and close the belt drive cover.
Changing The Oil In The Track Planetary Gear Reducers
- 1. Move the machine so that the drain (fill) plug in a planetary gear reducer is at the bottom of the case.
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INADVERTENT ENGAGEMENT OF THE TRACK DRIVE SYSTEM COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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- 2. Remove the drain plug and allow the oil to drain. Install the plug.
- 3. Move the machine so the fill plug is at the top 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 tracks.
Changing The Oil In The Optional High Pressure Water Pump
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THE MAINFRAME COULD FALL AND CAUSE PERSONAL INJURY. LOWER THE SUPPORT LEGS INTO POSITION WHENEVER WORKING UNDER THE MACHINE. |
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- 1. Remove the drain plug and allow the oil to drain.
- 2. Install the drain plug, remove the dipstick, and add oil through the dipstick port until the oil level reaches the full mark on the dipstick. USE ATF TYPE F HYDRAULIC OIL.
- 3. Install the dipstick.
Cleaning The Fuel Tank Breather, Fill Cap And Screen
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DIESEL FUEL IS VOLATILE AND COULD IGNITE OR EXPLODE, CAUSING SERIOUS BURNS AND INJURIES FROM FLYING OBJECT. NEVER SMOKE OR HAVE AN OPEN FLAME WHILE WORKING ON THE FUEL SYSTEM. |
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- 1. Remove the breather, fill cap and screen and wash them in clean nonflammable solvent.
- 2. Blow the components dry with clean air or allow them to drain dry.
- 3. Reinstall the components.
Cleaning The Breather, Fill Cap And Screen On The Hydraulic Oil Replenishing Tank
- 1. Remove the breather, fill cap and screen and wash them in clean nonflammable solvent.
- 2. Blow the components dry with clean air or allow them to drain dry.
- 3. Reinstall the components.