Engine Air Intake System
Clean the Air Intake
Pressure air can cause personal injury.
When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes.
The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.
Check the air inlet screen for accumulation of trash and dirt.
- 1. Remove the screen and clean.
- 2. Inspect the precleaner tubes for accumulation of dust and dirt. Clean if dirty.
Change the Filter Elements
Service the air cleaner only with the engine stopped.
Service the air cleaner if the amber indicator lights with the engine running at high idle. Stop the engine.
Open the rear access door on the right side of the machine.
Service the Primary Element
- 1. Remove the air cleaner cover.
- 2. Remove the primary filter element from the air cleaner housing.
- 3. Clean the inside of the air cleaner housing.
- 4. Clean and inspect the primary element. See "Cleaning Primary Elements."
- 5. Install a clean primary element.
- 6. Clean and install the cover. Tighten the cover bolts finger tight. Do not use a tool to tighten the bolts.
If the amber air cleaner indicator light comes on shortly 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 six times. Replace the element once a year even though it has not been cleaned six times.
Change the Secondary Element
Always replace the secondary filter element. Never attempt to reuse it by cleaning.
The secondary filter element should be replaced at the time the primary element is serviced for the third time.
The secondary filter element should also be replaced if the amber indicator lights after installation of a clean primary element, or if the exhaust smoke is still black.
- 1. Remove the housing cover and the primary element.
- 2. Remove the eight nuts holding the secondary element. Remove the secondary element.
- 3. Cover the air inlet opening. 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 opening. Install a new secondary element.
- 6. Install the nuts and washers on the studs. Torque them to 27 ± 7 N·m (20 ± 5 lb ft).
- 7. Install the primary element. Install the cover. Tighten the cover bolts finger tight only. Do not use a tool to tighten the cover bolts.
- 8. Close and secure the access door.
Cleaning Primary Elements
Do not clean the filter elements by bumping or tapping them.
Filter elements can be cleaned with pressure air, pressure water, or detergent washing.
Direct air or water along pleats inside and outside of filter element.
Inspect the filter elements after cleaning. Do not use a filter element with damaged pleats, gaskets or seals.
Ether Starting Aid Cylinder (If Equipped)
Installing the Cylinder
Ether is poisonous and flammable.
Breathing ether vapors or repeated contact of ether with skin can cause personal injury.
Use ether only in well ventilated areas.
Use ether with care to avoid fires.
Do not smoke while changing ether cylinders.
Do not store ether cylinders in the operator's compartment or living areas.
Do not store ether cylinders in direct sunlight or at temperatures above 39°C (102°F).
Discard ether cylinders properly. Do not puncture or burn ether cylinders.
Keep ether cylinders out of the reach of unauthorized personnel.
Located in left rear of engine compartment.
- 1. Loosen the cylinder retaining clamp, unscrew and remove the empty ether cylinder.
- 2. Remove the used gasket. Install the new gasket provided with each new cylinder.
- 3. Install the new cylinder. Tighten the cylinder hand tight. Refasten the cylinder clamp securely.
Check Electrolyte Level
Batteries give off flammable fumes that can explode.
Do not smoke when observing the battery electrolyte levels.
Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.
Always wear protective glasses when working with batteries.
Tighten the battery retainers every 1000 hours on all batteries.
Check the following at least every 1000 hours, and more often as conditions require:
Clean the top of the batteries with a clean cloth.
Keep the terminals clean and coated with petroleum jelly.
At the proper charging rate, in a moderate climate, a battery should not require more than 30 cc (1 ounce) of water per cell per week. Check the cells weekly in extreme temperatures, cell water usage could be higher.
- 1. Open the rear access door on the left side of the machine.
- 2. Clean the battery surface with a clean cloth. Keep the terminals clean and coated with petroleum jelly. Install the post cover after coating.
- 3. Inspect the electrolyte level in each battery cell, except maintenance free. Maintain the level to the bottom of the fill openings with distilled water. If distilled water is not available, use clean drinking water.
- 4. Close the access door.
Radiator Pressure Cap
Clean or Replace the Cap
At operating temperature, the engine coolant is hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
- 1. Open the rear access door on the left side of the machine.
- 2. Pull the latch and open the radiator access cover.
- 3. Remove the radiator cap.
- 4. Inspect the cap for damage, deposits or foreign material. Clean the cap with a clean cloth or replace the cap as necessary.
- 5. Install the cap.
- 6. Close and secure access cover and door.
The fuse box is located inside the front access door on the left side of the machine.
Fuses - They protect the electrical system from damage caused by overloaded circuits. Change a fuse if the element separates. If the element of a new fuse separates, have the circuit checked and repaired.
Replace fuses with the same type and size only to prevent electrical damage.
Pull the cover open for fuse access.
The following circuits protected by each fuse includes the fuse amperage.
Boom Lights (1.) - 15A
Front Lights (2.) - 15A
Wiper and Washer (3.) - 10A
Heater and Dome Light (4.) - 5A
Defroster (5.) - 5A
Warning Circuit (6.) - 1A
Horn and Lighter (7.) - 15A
Start Switch and Electric Hydraulic Control (8.) - 5A
Air Conditioner (if equipped) (9.) - 30A
Windshield Wipers and Washer
Change Wiper Blades
Inspect the windshield wiper blades. Replace them if worn, damaged or streaking.
Fill Washer Solvent Bottle
The windshield washer bottle is located inside the rear access door on the left side of the machine.
Grease is under high pressure.
Grease coming out of the relief valve under pressure can penetrate the body causing injury or death.
Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened.
Loosen the relief valve one turn only.
Repeat the procedure on the opposite track after completion of the first track.
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
Do not adjust the track if the dimension shown is less than 9.5 mm (3/8 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.
Track Bolt Torque
The torque requirement for 5/8" track bolts is 170 ± 40 N·m (120 ± 30lb ft) plus an extra 1/3turn (120°), and for 3/4" track bolts it is 300 ± 50 N·m (220 ± 35 lb ft) plus an extra 1/3 turn (120°).
If the Track is too Tight
- 1. Be sure the idler can retract. Remove the relief valve access plate on the roller frame.
- 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.
Bucket Tips and Side Cutters
Change the Tip
Retainer pins, when struck with force, can fly out and cause injury to nearby people.
Make sure the area is clear of people when driving retainer pins.
To avoid injury to your eyes, wear protective glasses when striking a retainer pin.
Replace the bucket tip when worn close to shank. Too blunt of a tip will not penetrate properly.
- 1. Raise and support the bucket.
- 2. If the bucket tip is worn, drive the pin out. Remove the tip and the pin retainer.
- 3. Clean the shank pin retainer and pin.
- 4. Install the new tip and retainer.
- 5. Install the pin in from the side opposite of the retainer.
- 6. Raise the bucket and remove the support.
- 7. Lower the bucket to the ground.
- 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.
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.