Installing the Engine Multi-Belt

Standard Operating Procedure

Installing the Engine Multi-Belt

Installing the Engine Multi-Belt

Prepare and Position the machine

  1. 1.
    Make sure that the machine is isolated and, if necessary, isolate the machine with the battery isolation switch.

Lifting and Installation

  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).

    Install the engine multi-belt (Figure 15, item A) in position onto the engine.
    Figure 15

    A

    Engine multi-belt

  2. 2.

    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 engine multi-belt tensioner (Figure 16, item A) in the anti-clockwise direction using the ½-inch drive breaker bar to relieve the tension.

    NOTE

    The engine multi-belt is tensioned automatically when the lockpin is removed from the engine multi-belt tensioner.

    Figure 16

    A

    Engine multi-belt tensioner

  3. 3.
    Allow the engine multi-belt tensioner (item A) to freely tension the engine multi-belt.

    NOTE

    Make sure that the engine multi-belt tension is correct.

Preparation of the Component

  1. 1.
    Put the upper cover (Figure 17A and 17B, item C) of the engine multi-belt in position onto the engine.
    Figure 17A Boltec M, Cabletec M, Boomer M1 D, Simba E7 C, M6 C

    A

    Screw

    B

    Washer

    C

    Upper cover

    D

    Washer

    E

    Screw

    Figure 17B Boltec E, EC, Cabletec E, LC, Boomer E2 C

    A

    Screw

    B

    Washer

    C

    Upper cover

  2. 2.
    Insert the hardware to attach 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: Install the washers (items B and D) and insert the screws (items A and E) to attach the upper cover (item C) to the engine.
    2. Alternative step
      For Boltec E, EC, Cabletec E, LC, Boomer E2 C Machine: Install the washers (item B) and insert the screws (item A) to attach the upper cover (item C) to the engine.
  3. 3.
    Torque the screws of the upper cover as follows:
    1. Alternative step
      For Boltec M, Cabletec M, Boomer M1 D, Simba E7 C, M6 C Machine: Torque the screw (item E) to 69 Nm (51 ft-lb) dry.
    2. Alternative step
      For Boltec M, Cabletec M, Boomer M1 D, Simba E7 C, M6 C Machine: Torque the screws (item A) to 40 Nm (51 ft-lb) dry.
    3. Alternative step
      For Boltec E, EC, Cabletec E, LC, Boomer E2 C Machine: Torque the screws (item A) to 8.4 Nm (6.2 ft-lb) dry.
  4. 4.
    Put the lower cover (Figures 18A and 18B, item D) of the engine multi-belt in position onto the engine.
    Figure 18A Boltec M, Cabletec M, Boomer M1 D, Simba E7 C, M6 C
    Figure 18B Boltec E, EC, Cabletec E, LC, Boomer E2 C

    A

    Screw

    B

    Washer

    C

    Lock nut

    D

    Lower cover

    E

    Screw

  5. 5.
    Install the washer (item B) and insert the screw (item E) to attach the lower cover (item D) of the engine multi-belt to the engine.
  6. 6.
    Install the washers (item B), lock nut (item C), and insert the screw (item A) to attach the lower cover (item D) of the engine multi-belt to the engine bracket.
  7. 7.
    Torque the screws (items A and E) to 40 Nm (30 ft-lb) dry.
  8. 8.

    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.

    Put the attachment (Figure 19, item C) along with the filters in position onto the engine frame.
    Figure 19

    A

    Screw

    B

    Washer

    C

    Attachment

  9. 9.
    Install the washers (item B) and insert the screws (item A) to attach the attachment (item C) along with the filters to the engine frame.
  10. 10.
    Torque the screws (item A) to 69 Nm (51 ft-lb) dry.
  11. 11.
    Install the oil filler (Figure 20, item A) in position onto the bracket.
    Figure 20

    A

    Oil filler

  12. 12.

    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.
  13. 13.

    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.

    Connect the hoses (Figure 21, item A) to the filter as per the labels.
    Figure 21

    A

    Hose

  14. 14.
    Connect the hoses (Figure 22, item A) to the fuel filters as per the labels.
    Figure 22

    A

    Hose

  15. 15.
    Connect the hoses (Figure 23, item A) to the oil filter as per the labels.
    Figure 23

    A

    Hose

  16. 16.

    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.
  17. 17.

    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.

    Connect the sensor connection (Figure 24, item A) to the filter as per the label.
    Figure 24

    A

    Sensor connection

  18. 18.

    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.

    Close the side hatch (Figures 25A, 25B, and 25C, item A) and lock it in position.
    Figure 25A Boltec M and Cabletec M
    Figure 25B Boltec E, EC, Boomer M, E, Simba M, E
    Figure 25C Cabletec E and LC

    A

    Side hatch

  19. 19.

    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 concerned of the intent to restart the machine for testing purposes.
  20. 20.
    Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
  21. 21.
    Set the battery isolation switch to the ON position.
  22. 22.

    WARNING

    Energized Machine

    Can cause personal injury to the surrounding people.

    1. Warn the surrounding people that the machine is about to be started and operated.

    Start the machine.
  23. 23.
    Retract the front and the rear support legs (Figures 26A and 26B).
    Figure 26A
    Figure 26B
  24. 24.
    Retract the front jack support legs fully into the jack beam (Figure 27).
    Figure 27
  25. 25.
    Stop the machine.
  26. 26.
    Set the battery isolation switch to the OFF position.
  27. 27.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  28. 28.
    Put a tag onto battery isolation switch stating that the engine multi-belt is replaced.