Operation and maintenance manual

Section 110-0030
Engine - Engine and Mounting
SM 2121 Rev 1 11-03
12
MAINTENANCE
Numbers in parentheses refer to Fig. 1.
Note: Carry out the following maintenance procedures
in conjunction with additional procedures listed in
Section 300-0020, LUBRICATION SYSTEM.
Every 10 Hours (Daily)
Engine (1): Visually check engine for damage, loose or
frayed belts and listen for any unusual noises. Check
the turbocharger for leaks.
Engine (1) Oil Level: Check engine oil level and add
oil if low. To allow checking before starting as well as
immediately after shutting down the engine, the
dipstick is provided with two types of marks:
1. Dot Marks - Before starting up after a major shut
down period the oil level should be up to the top dot
mark (cold level).
2. Dash Marks - Upon shutting down the engine at low
idling (wait 1 to 2 minutes) the oil level should be up to,
but not over, the top dash mark (hot level).
Every 250 Hours
Engine (1): Drain engine oil and refill. Refer to Section
300-0020, LUBRICATION SYSTEM for oil
specification.
Engine Water Pump: Inspect water pump drain hole
and clean if required.
Engine Oil Filters (2): Replace oil filters as follows:
1. Using filter wrench, remove and discard both oil
filters (2) from engine (1). Inspect the sealing surface
of the filter to ensure that the seal ring stayed with the
filter. If not, remove it from the filter adaptor.
2. Clean the filter adaptor with a clean, lint free cloth.
3. Lightly coat new oil filter (2) seal with clean engine
oil as specified in Section 300-0020, LUBRICATION
SYSTEM.
4. Start a new oil filter (2) on the filter adaptor and
tighten it by hand until the seal touches the adaptor
filter head. Tighten an additional 2/3 of a turn after
contact.
Note: Mechanical tightening of oil filters (2) is not
16. Remove covers from air cleaner intake pipe and
rubber hose on the air cleaner inlet then slide air
cleaner assembly towards the hood locating the rubber
hose to the inlet pipe.
17. Secure air cleaner assembly to the right hand
fender and rubber hose to the inlet pipe with mounting
hardware removed during removal.
18. Connect battery positive connections to battery
terminals. Connect battery earth connections to battery
terminals.
19. Ensure all lines, harnesses and cables are secured
with clips and clamps as removed during removal.
Ensure no lines are chaffing on sharp edges or resting
against areas where heat will be evident.
20. Ensure shut-off valve at the bottom of the radiator
assembly, drain plugs in transmission oil cooler flanges
and drain cocks on engine (1) water jacket are securely
closed. Ensure shut off cocks at coolant filter (3) are
open to allow flow through the filter.
21. Fill the cooling system with coolant. Refer to
Section 210-0000, COOLING SYSTEM.
22. Fill the engine with lubricant through oil filler to the top
mark on dipstick (6). Refer to Section 300-0020,
LUBRICATION SYSTEM for oil specification.
23. Check all line and pipe connections for leaks prior
to starting the vehicle. Tighten as required.
24. Switch the battery master switch to the 'On'
position, start up the engine and check for leaks.
Tighten lines, pipes and fittings and top up all systems
as required.
25. Install hood assembly on the vehicle. Refer to
Section 100-0040, HOOD AND MOUNTING.
Note: Check that gap between hood and cowl is correct
(12 mm (0.5 in) maximum).
26. Using suitable lifting equipment position front guard
plate under the engine and secure to the frame with
mounting hardware removed during removal.
27. Using suitable lifting equipment position engine
sump guard under the engine and secure to the frame
with mounting hardware removed during removal.
28. Remove wheel blocks from all road wheels.