- 1. Check and service as required:
- a. Engine oil level.
- b. Engine coolant level.
- c. Engine radiator and hydraulic oil coolers.
- d. Engine air cleaner.
- e. Fuel level.
- f. Fuel filter gauge.
- g. Hydraulic oil level.
- h. Ground drive transmission oil level.
- i. Ground drive axle oil level.
- j. Rotor drive cooling oil reservoir oil level.
- k. Rotor bearing reservoir oil level.
- l. Rotor chaincase oil level.
- m. Rotor bits.
- n. Tire pressures.
- b. Engine coolant level.
- 2. Lubricate those points shown in the service chart.
Checking The Engine Oil Level
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CONTACT WITH ROTATING FAN OR HOT ENGINE COMPONENTS COULD CAUSE PERSONAL INJURY. STAY CLEAR OF FAN AND COMPONENTS WHEN CHECKING ENGINE OIL LEVEL. |
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- 1. Check the engine oil level with the engine running at low idle. The oil level must be between the "Add" and "Full" marks on the dipstick.
- 2. Add oil if necessary.
Checking The Engine Coolant Level
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AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER PRESSURE. STEAM CAN CAUSE PERSONAL INJURY. CHECK 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 level 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.
Makeup coolant should be water that is as free as possible of scale forming minerals (not softened water) and a permanent type antifreeze.
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DO NOT USE DOWTHERM 209 FULL-FILL COOLANT WITH AVSpare COOLING SYSTEM CONDITIONER. 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. |
Checking The Radiator And Hydraulic Oil Cooler Cores
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INADVERTENT STARTING OF THE ENGINE COULD CAUSE PERSONAL INJURY. STOP THE ENGINE AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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Check that the radiator and oil coolers are clear of any obstructions to air flow through the cooling fins. Any rags, paper, mud, DUST, bugs, etc. that may obstruct the air flow must be removed. Carefully straighten any bent fins.
Checking The Engine Air Cleaner
The engine air cleaner is equipped with an indicator that shows a red signal when the main element should be serviced. If the red signal is locked in view, the main element should be serviced as soon as possible to prevent possible engine damage. See "Changing the Engine Air Cleaner Elements" below for procedures.
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INADVERTENT STARTING OF THE ENGINE COULD CAUSE PERSONAL INJURY. STOP THE ENGINE AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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The air cleaner also has a dust cup that collects the dust from the pre-cleaner. Empty the dust cup when the dust builds up to within 1 3/4 inches (4.4 cm) from the top of the cup. Remove and inspect the dust cup daily until a regular service interval can be established. When replacing the dust cup, be sure a seal is made between the cup and the body to maintain high pre-cleaner efficiency. Replace the gasket if it is not smooth and clean.
| NOTICE |
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THIS IS A DRY TYPE AIR CLEANER - DO NOT USE OIL. |
Changing The Engine Air Cleaner Elements
The main element should be cleaned or replaced with a new element anytime the air cleaner red indicator is locked in view. Replace the main element after three cleanings or one year of use, whichever comes first. Change the secondary element every third time the main element is cleaned or replaced. (See the Service Manual for cleaning procedures.)
Although it is possible to clean the secondary element using the procedures described for the main element, it is not recommended except in an emergency situation. Maximum engine protection is achieved by replacing the plugged secondary element with a new element.
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INADVERTENT STARTING OF THE ENGINE COULD CAUSE PERSONAL INJURY. STOP THE ENGINE AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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To replace the main element:
- 1. STOP THE ENGINE, clean the dust off the access cover and unlatch it.
- 2. Remove the access cover and main element. DO NOT REMOVE THE SECONDARY ELEMENT.
- 3. Immediately inspect the main element for any dust streaks on the inside. If there are any dust streaks, the element is damaged. THROW IT AWAY.
- 4. Inspect the main element gasket. If the element gasket is not smooth and flat or is damaged in any way that might allow dust to get by, THROW THE GASKET AWAY.
- 5. Install a new or cleaned main element and tighten the wing nut securely.
- 6. Install the access cover.
To replace the secondary element:
- 1. STOP THE ENGINE, clean the dust off the access cover and remove it.
- 2. Loosen the wing nut and remove the main element.
- 3. Remove the locking pin from the nut and remove the nut that secures the secondary element.
| NOTICE |
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DO NOT USE COMPRESSED AIR TO CLEAN THE AIR CLEANER BODY WHEN THE SECONDARY ELEMENT IS NOT IN PLACE. TO DO SO WILL FORCE DIRT INTO THE ENGINE. |
- 4. Remove the secondary element and clean out any dust dislodged into the cleaner outlet.
- 5. Install the new secondary element.
- 6. Inspect the gasket washer on the nut and replace it if a good air seal cannot be guaranteed.
- 7. Tighten the nut securely and replace the locking pin.
- 8. Install the main element and tighten the wing nut securely.
- 9. Install the access cover.
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 fuel gauge mounted in the control console 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.
Checking The Engine Fuel Gauge
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CONTACT WITH HOT OR ROTATING ENGINE COMPONENTS COULD CAUSE SERIOUS BURNS AND PERSONAL INJURY. STAY CLEAR OF HOT OR ROTATING COMPONENTS. |
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The engine is equipped with a fuel gauge which indicates the condition of the fuel filter elements. The gauge should be checked daily with the engine running. If the gauge registers "Out", clean the primary fuel filter and replace the final fuel filter (see below and page 3-16).
Cleaning The Primary Fuel Filter
- 1. Stop the engine and shut the fuel supply valve beneath the fuel tank.
- 2. Loosen the retaining nut on the filter cover.
- 3. Lower the filter case and element from the cover.
- 4. Remove the filter element from the case. Clean the element and case in clean nonflammable solvent.
- 5. Reinstall the element in the case.
- 6. Inspect the seal and replace if damaged.
- 7. Install the element and case on the housing and install the retaining nut.
- 8. Open the fuel supply valve.
Changing The Final Fuel Filter
- 1. Remove the filter.
- 2. Clean the gasket sealing surface on the filter base.
| NOTICE |
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BE SURE ALL OF THE OLD GASKET IS REMOVED. |
- 3. Lubricate the gasket of the new filter with clean fuel.
- 4. Install the filter and tighten it by hand until the gasket contacts the base, then tighten the element 1/2 to 3/4 turn more.
- 5. Prime the system (see below).
Priming The Fuel System
- 1. Unlock the fuel priming pump.
- 2. Operate the priming pump until resistance is felt.
- 3. Lock the fuel priming pump.
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CONTACT WITH HOT OR ROTATING ENGINE COMPONENTS COULD CAUSE SERIOUS BURNS AND PERSONAL INJURY. STAY CLEAR OF HOT OR ROTATING COMPONENTS. |
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If the engine continues to misfire or smoke, further priming is necessary. With the engine running, loosen the fuel line nuts one at a time and allow the fuel to run until free of air bubbles. Tighten the line nuts.
Checking The Hydraulic Oil Level
The hydraulic oil tank is equipped with two sight gauges for easy checking of the oil level. The oil level should be maintained between the two sight gauges. If the oil level is low, remove the tank cap and fill the tank with new water-free hydraulic oil conforming to the specification on page 3-1. Do not over-fill the tank, allow for expansion of the oil.
Checking The Ground Drive Transmission And Axle Oil Levels
- 1. Remove the check plug.
- 2. If lubricant does not flow from the plug port, add lubricant (see page 3-2 for specification) until check plug level is reached.
- 3. Replace the check plug.
Checking The Rotor Drive Cooling Oil Reservoir And Bearing Reservoir Oil Levels
ROTOR DRIVE COOLING OIL RESERVOIR
Remove the fill plug or fill cap and visually check the oil level. Add lubricant as necessary (see the specifications on page 3-2).
Checking The Rotor Chaincase Oil Level
- 1. Start the engine and lower the rotor to the ground, then stop the engine.
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CONTACT WITH THE ROTATING ROTOR COULD CAUSE PERSONAL INJURY. STOP THE ENGINE AND REMOVE THE KEY FROM THE IGNITION SWITCH. |
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- 2. Remove the check plug from one rotor chaincase.
- 3. If oil does not flow from the plug port, fill the chaincase to check plug level with 10-20-30 engine oil.
- 4. Replace the plug.
- 5. Repeat steps 2 through 4 for the other chaincase.
Checking The Rotor Bits And Bit Holders
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INADVERTENT ENGAGEMENT OF THE ROTOR COULD CAUSE PERSONAL INJURY. STOP THE ENGINE AND REMOVE THE KEY FROM THE KEY SWITCH. |
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The rotor bits should be checked for excessive wear and replaced anytime the distance from the holders to the tip of the bit (normal wear) or to the end of the supporting metal (carbide tip exposed) is 1 1/4 inches (3 cm) or less.
At the same time the bits are checked, also check the bit holders for breaks or cracks. Replace as necessary.
Replacing A Rotor Bit
When the bits get worn they should 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 surface being cut. Keep several worn bits on hand to replace any bits that break.
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INADVERTENT ENGAGEMENT OF THE ROTOR COULD CAUSE PERSONAL INJURY. STOP THE ENGINE AND REMOVE THE KEY FROM THE KEY SWITCH. |
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To remove a bit:
- 1. Clear all personnal from around the machine, start the engine, use the green rotor depth control to raise the hood and rotor, then rotate the rotor until the bit is accessible. Use the red rotor depth control to lower the hood and rotor to the ground, raise the door and securely prop it open, then STOP THE ENGINE.
- 2. Insert the tip of a drive pin into the opening in the bit holder. Strike the drive pin with a hammer to drive the bit out.
- 3. 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
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INADVERTENT ENGAGEMENT OF THE ROTOR COULD CAUSE PERSONAL INJURY. STOP THE ENGINE AND REMOVE THE KEY FROM THE KEY SWITCH. 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 ROTOR DRUM UNTIL THEY HAVE COOLED. |
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- 1. Cut the bit holder free of the rotor drum.
- 2. Grind the surface of the drum smooth.
- 3. Position the new bit holder on the rotor drum, then weld the bit holder to the drum.
Checking The Tire Pressures
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IF A TIRE WERE TO BLOWOUT, IT COULD CAUSE PERSONAL INJURIES. USED A CLIP-ON CHUCK AND A HOSE LONG ENOUGH TO ALLOW YOU TO STAND BEHIND THE TREAD WHEN INFLATING A TIRE. CALCIUM CHLORIDE SOLUTION MAY CAUSE SLIGHT BURNING IF IT CONTACTS SKIN. AVOID COMING IN CONTACT WITH THE SOLUTION. IF THE SOLUTION COMES IN CONTACT WITH SKIN, RINSE SOLUTION FROM SKIN WITH WATER. |
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| NOTICE |
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THE CALCIUM CHLORIDE SOLUTION USED IN THE REAR TIRES WILL DAMAGE A CONVENTIONAL TIRE GAUGE. USE A SPECIAL AIR-LIQUID PRESSURE GAUGE TO CHECK THE AIR PRESSURE IN THE REAR TIRES. |
The tires should be checked daily for proper inflation, abnormal wear, or loose wheel lug nuts. When checking the rear tire pressure make sure to position the valve stem near the top of the tire. Make repairs as necessary.
If the air pressure in a tire shows a decided drop, check for slow leaks and repair any leaks found. The inflation pressure for each front tire is 45 psi (310 kPa) and for each rear tire is 30 psi (207 kPa).