Removing the Engine Multi-Belt

Standard Operating Procedure

Removing the Engine Multi-Belt

Removing the Engine Multi-Belt

Prepare and Position the Machine

  1. 1.
    Park the machine on a dry and level surface.
  2. 2.
    Apply the parking brake.
  3. 3.
    Stop the machine.
  4. 4.
    Stop the battery isolation switch to the OFF position.
  5. 5.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  6. 6.
    Block the wheels with the wheel chocks in accordance with the procedure.

    NOTE

    Extra requirements can apply. Refer to local regulations.

  7. 7.
    Insert the articulation lock bar (Figure 1, item A) to the pins on the machine frames.
    Figure 1

    A

    Articulation lock bar

    B

    Locking clip

  8. 8.
    Install the locking clips (item B) to attach the articulation lock bar (item A) with the pins.
  9. 9.

    WARNING

    Energized Machine

    Can cause serious injury.

    1. The machine must be fully energized and the engine must be switched on to complete this procedure.

    2. Be careful around moving parts and pinch points.

    Inform the supervisor, lead hand, and all other persons who are concerned of the intent to restart the machine for testing purposes.

    NOTE

    Make sure that all personnel and bystanders are clear of the machine before start-up.

  10. 10.
    Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
  11. 11.
    Set the battery isolation switch to the ON position.
  12. 12.
    Start the machine.
  13. 13.

    WARNING

    Accidental Movement

    Unexpected movement of the machine can cause serious injury or death.

    1. Examine the unwanted machine movements with a spotter while working on the machine.

    2. All persons who are involved in this task must be aware of hazards on and around the machine.

    3. Use the correct personal protective equipment.

    Extend the front jack support legs fully from the jack beam (Figure 2).
    Figure 2
  14. 14.
    Lower the front and the rear support legs onto the ground (Figures 3A and 3B).
    Figure 3A
    Figure 3B
  15. 15.
    Put the boom and the Feed Assembly in the rest position.
  16. 16.
    Stop the machine.
  17. 17.
    Set the battery isolation switch to the OFF position.
  18. 18.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  19. 19.

    WARNING

    High-Pressure System

    Working with pressurized systems can cause personal injury.

    1. Do not do the maintenance work when you operate the machine.

    2. Make sure that the hydraulic, water, and air systems are depressurized before you start to work on these systems.

    3. Put on the applicable gloves.

    Release the stored energy from the hydraulic brake system.

    NOTE

    Make sure that there is no pressure in the system.

  20. 20.
    Release the stored energy from the hydraulic oil tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  21. 21.
    Release the stored energy from the air tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  22. 22.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Open the side hatch (Figures 4A, 4B, and 4C, item A) and secure it in the open position.
    Figure 4A Boltec M and Cabletec M
    Figure 4B Boltec E, EC, Boomer M, E, Simba M, E
    Figure 4C Cabletec E and LC

    A

    Side hatch

Isolation of the Component

  1. 1.

    DANGER

    Electric Shock Hazard

    Electric shock while working with the electrical systems cause serious personal injury.

    1. Only authorized personnel can do the work involving cables, electrical cabinets, fuses, and connectors.

    2. Attach safety locks and tags to the electrical switches of the specific components before working.

    3. Do not use a high-pressure washer to clean the electrical components.

    Label and disconnect the sensor connection (Figure 5, item A) from the filter. Cap the connectors immediately.
    Figure 5

    A

    Sensor connection

  2. 2.

    WARNING

    Slipping Hazard

    Fluid leaks or spills can cause personal injury.

    1. Cover all of the open ports.

    2. Wipe off any spilled fluid immediately.

    Put an oil container or oil absorbent material below the filters.
  3. 3.

    WARNING

    Hot Fluids or Components

    Working with hot fluids or components can cause personal injury.

    1. Fluids must be at a safe working temperature when you disconnect the hoses.

    2. Do not touch hot fluids or components.

    3. Always wear personal protective equipment.

    Clean, label, and disconnect the hoses (Figure 6, item A) from the oil filter. Plug the hoses and cap the ports immediately.
    Figure 6

    A

    Hose

  4. 4.
    Clean, label, and disconnect the hoses (Figure 7, item A) from the fuel filters. Plug the hoses and cap the ports immediately.
    Figure 7

    A

    Hose

  5. 5.
    Clean, label, and disconnect the hoses (Figure 8, item A) from the filter. Plug the hoses and cap the ports immediately.
    Figure 8

    A

    Hose

  6. 6.

    CAUTION

    Environmental Contaminant

    Oil is an environmental contaminant and must be discarded correctly.

    1. Do not let the used oil drain onto the ground.

    2. Discard the used oil in accordance with local environmental regulations.

    Remove the oil container or oil absorbent material that is placed below the filters.
  7. 7.
    Remove the oil filler (Figure 9, item A) from the attachment. Secure it away from the attachment.
    Figure 9

    A

    Oil filler

  8. 8.
    Remove the screws (Figure 10, item A) and the washers (item B) that attach the attachment (item C) along with the filters to the engine frame. Discard the hardware.
    Figure 10

    A

    Screw

    B

    Washer

    C

    Attachment

  9. 9.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Remove the attachment (item C) along with the filters from the engine frame and put it in a safe location.
  10. 10.
    Remove the screw (Figures 11A and 11B, item A), washers (item B), and lock nut (item C) that attach the lower cover (item D) of the engine multi-belt to the engine frame. Discard the hardware.
    Figure 11A Boltec M, Cabletec M, Boomer M1 D, Simba E7 C, M6 C
    Figure 11B Boltec E, EC, Cabletec E, LC, Boomer E2 C

    A

    Screw

    B

    Washer

    C

    Lock nut

    D

    Lower cover

    E

    Screw

  11. 11.
    Remove the screw (item E) and the washer (item B) that attach the lower cover (item D) of the engine multi-belt to the engine. Discard the hardware.
  12. 12.
    Remove the lower cover (item D) from the engine and put it in a safe location.
  13. 13.
    Remove the hardware from the upper cover of the engine multi-belt as follows:
    1. Alternative step
      For Boltec M, Cabletec M, Boomer M1 D, Simba E7 C, M6 C Machine: Remove the screws (Figure 12A, items A and E) and the washers (items B and D) that attach the upper cover (item C) to the engine. Discard the hardware.
      Figure 12A

      A

      Screw

      B

      Washer

      C

      Upper cover

      D

      Washer

      E

      Screw

    2. Alternative step
      For Boltec E, EC, Cabletec E, LC, Boomer E2 C Machine: Remove the screws (Figure 12B, items A) and the washers (items B) that attach the upper cover (item C) to the engine. Discard the hardware.
      Figure 12B

      A

      Screw

      B

      Washer

      C

      Upper cover

  14. 14.
    Remove the upper cover (item C) from the engine and put it in a safe location.

Lifting and Removal

  1. 1.

    WARNING

    Pinch Points

    Can cause serious injury.

    1. Keep hands and fingers away from the moving parts during removal and installation of the component.

    2. Put on the applicable Personal Protective Equipment (PPE).

    Turn the tensioner (Figure 13, item A) in the clockwise direction using a ½ - inch drive breaker bar to release the engine multi-belt tension.
    Figure 13

    A

    Engine multi-belt tensioner

  2. 2.
    Lock the engine multi-belt tensioner (item A) in the position where the engine multi-belt is slack using a lockpin.

    NOTE

    Use 3/8-inch screw as a lockpin.

  3. 3.
    Remove the engine multi-belt (Figure 14, item A) from the engine and put it in a safe location.
    Figure 14

    A

    Engine multi-belt

  4. 4.
    Put a tag onto battery isolation switch stating that the engine multi-belt is removed from the machine.