- 1. Check the following items and service as required.
- a. Hydraulic oil level.
- b. Fuel tank level.
- c. Engine coolant level.
- d. Engine oil level.
- e. Wheel gear reducer oil levels.
- f. General machine for missing or damaged shields and guards, leaks, loose bolts, loose connectors, etc.
- b. Fuel tank level.
- 2. Clean the radiator and oil cooler cores.
- 3. Flush the spray system Y-strainer.
- 4. Check the main cutter and auxiliary cutter bits.
Checking The Hydraulic Oil Level
The hydraulic oil tank and replenishing tank are each equipped with a sight gauge for easy checking of the oil level. The sight gauge at the rear of the tanks displays the replenishing tank level and the gauge at the front displays the main tank level. The level of the tanks should be maintained within 1 inch of the "Hi" mark. If the main tank oil level is low, use the replenishing hand pump to pump oil from the replenishing tank into the main hydraulic oil tank. Refill the replenishing tank with new water-free hydraulic oil conforming to the specification on page 5-1. The replenishing tank should be kept full at all times to ensure that hydraulic oil is available if needed and to keep condensation to a minimum. Do not overill either tank, allow for expansion of the oil.
Checking The Fuel Level
The fuel tank is equipped with sight gauges for easy checking of the fuel level. The tank should be filled at the end of each work day to reduce the amount of water condensed out of the air as the tank cools during the night.
Checking The Engine Coolant Level
IF THE ENGINE IS WARM, STEAM MAY SPRAY OUTWARD UNDER HIGH PRESSURE WHEN THE RADIATOR CAP IS LOOSENED. SERIOUS BURNS MAY RESULT. CHECK THE COOLANT LEVEL ONLY WHEN THE ENGINE IS STOPPED AND THE RADIATOR CAP IS COOL ENOUGH TO TOUCH. COOLING SYSTEM CONDITIONER CONTAINS ALKALI AND CAN CAUSE CHEMICAL BURNS. WEAR EYE PROTECTION AND AVOID LETTING THE CONDITIONER TOUCH YOUR SKIN. |
- 1. Slowly turn the pressure cap to the first stop and release the pressure fully before proceeding.
- 2. Push the cap down and turn it until released.
- 3. Maintain the coolant level at 3/4 inch below the top of the radiator. If a loss of coolant is noticeable, check for leaks in the system. After filling the system, leave the pressure cap off, start the engine and recheck the coolant level after normal operating temperature is reached. Running the engine at operating temperature will permit the thermostat to open and allow the coolant to circulate through the entire system and purge air from the engine.
- 4. Install the pressure cap.
Make-up coolant should be water that is free as possible of scale forming minerals (not softened water), a permanent type antifreeze and AVSpare Cooling System Conditioner. Follow the recommendations given on the container.
Maintain a 3% concentration of AVSpare Cooling System Conditioner. Make-up water added without the proper proportions of cooling system conditioner can cause excessive lime deposits and corrosion.
NOTICE |
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DO NOT USE AVSpare COOLING SYSTEM CONDITIONER WITH DOWHTERM 209 FULL-FILL COOLANT. DO NOT ADD COOLANT TO 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. |
Checking The Engine Oil Level
INADVERTENT STARTING OF THE ENGINE CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
- 1. If the engine is running, shut the engine down and wait 10 minutes before checking engine oil level to allow the oil to drain into the crankcase.
- 2. Remove the pump cowling.
- 3. Remove the dipstick from the engine. The oil level should be between the marks on the dipstick.
- 4. If necessary, add oil conforming to the specification on page 5-1. Do not overfill.
Checking The Wheel Gear Reducer Oil Levels
- 1. Position the machine so that the check plug in a gear reducer is at the bottom of the case.
INADVERTANT ENGAGEMENT OF THE WHEELS CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
- 2. Shut the engine down, allow time for the oil to settle to the bottom of the gear reducer, then remove the check plug.
- 3. If the oil does not trickle from the check plug port, remove the fill plug and add oil until check plug port level is reached.
- 4. Install the check plug and fill plug.
- 5. Repeat steps 1 through 4 for the other wheel.
Cleaning The Radiator And Oil Cooler Cores
In order for the radiator and oil cooler to operate properly, cooling air must be able to flow through the cores. Remove any rags, paper or other debris that would impede air flow. A high pressure water hose or steam cleaner should be used daily to clean the cores of mud, DUST, bugs, etc. After cleaning the radiator and oil cooler, visually check the cooling fins and straighten any that are bent.
Flushing The Y-Strainer
INADVERTENT STARTING OF THE ENGINE CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
- 1. Open the ball valve on the strainer.
- 2. Allow the water to flow out for a minute or two to flush the strainer screen.
- 3. Shut the ball valve.
- 4. Fill the water tank.
Checking The Cutter Bits, Bit Holders And Flighting
INADVERTENT STARTING OF THE MAIN CUTTER OR AUXILIARY CUTTER CAN RESULT IN PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
The cutter bits should be checked for excessive wear and 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 1/4inches (3.175 cm) or less.
At the same time the bits are checked, also check the cutter flighting, holder blocks and bit holders for breaks or cracks. Replace as necessary.
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 may be broken off or the bit holder damaged when the bit hits the concrete. Keep several worn bits on hand to replace any bits that break.
INADVERTENT STARTING OF THE MAIN CUTTER OR AUXILIARY CUTTER CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. HAMMERING ON METAL CAN RESULT IN FLYING PIECES OF METAL. EYE INJURIES CAN RESULT. WEAR EYE PROTECTION. |
To remove a bit:
- 1. Shut the engine down.
- 2. If necessary, turn the cutter by hand or by using a bar as a lever until the bit to be removed is accessible.
- 3. Insert the tip of the drive pin into the opening in the bit holder, then strike the pin sharply with a hammer to drive the bit out.
- 4. Position the new bit in the holder and drive it into place with a hammer. Be sure the keeper spring is engaged with the holder.
Replacing A Damaged Bit Holder
INADVERTENT STARTING OF THE MAIN CUTTER OR AUXILIARY CUTTER CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH. AFTER BEING CUT FREE THE BIT HOLDER AND CUTTER FLIGHTING WILL BE HOT ENOUGH TO CAUSE SERIOUS BURNS. ALLOW THE BIT HOLDER AND CUTTER FLIGHTING TO COOL BEFORE TOUCHING. |
- 1. Cut the 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. Slide the bit holder onto the mounting block so the bit holder is flush with the block.
NOTICE |
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IF THE BIT HOLDER WILL NOT MOUNT FLUSH ON THE MOUNTING BLOCK, DO NOT USE THE BIT HOLDER. |
- 4. Weld the bit holder to the holder mounting block. The welding process used should be CO-2 shielded fluxcored arc welding using an .052 E70T-1 electrode and electrode positive polarity. The contact tip to work distance should be 1", gas flow set at 30-40 CFH, voltage at 28V and amperage at 250A.