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MAINTENANCE INTERVALS - Safety

1. 184 Radiator Core Clean 184 Ride Control Accumulator Check 185 Window Washer Reservoir Fill 191 Window Wipers Inspect Replace 192 Every 10 Service Hours or Daily Backup Alarm 151 Bucket Tips Inspect Replace 155 Cooling System Coolant Level Check 161 Engine Oil Level Check 169 Hydraulic System Oil Level Check 182 Seat Belt Inspect 186 Transmission Oil Level Check 191 Windows Clean 192 Every 50 Service Hours or Weekly Bucket Lower Pivot Bearings Lubricate 155 Cab Air Filter Clean Replace 158 Tire Inflation Check 188 Every 100 Service Hours or 2 Weeks Axle Oscillation Bearings Lubricate 150 Bucket Linkage and Loader Cylinder Bearings L bricate sairin raen ee ot 154 Steering Cylinder Bearings Lubricate 187 Every 250 Service Hours Cooling System Coolant Sample Level 1 iiie dete ette EM seo stet er ebd 162 Engine Oil Sample Obtain
2. 169 Every 250 Service Hours or Monthly Belts Inspect Replace 152 Brake Accumulator Check 152 Braking System 153 Drive Shaft Spline Center Lubricate 164 Drive Shaft Support Bearing Lubricate 165 Every 250 Service Hours or 3 Months Steering Column Play 187 Initial 500 Service Hours Engine Valve Lash 173 Every 500 Service Hours Differential and Final Drive Oil Level Check 163 Differential and Final Drive Oil Sample Obtain 164 Engine Crankcase Breather Closed Circuit iecit eM 168 Hydraulic System Oil Sample Obtain 183 Transmission Oil Sample Obtain 191 Every 500 Service Hours or 3 Months Engine Oil and Filter Change 170 SEBU8354 07 149 Maintenance Section Maintenance Interval Schedule Fuel System Primary Filter Water Separator Element Replace Fuel System Secondary Filter Replace Transmission Oil Filter Replace Every 500 Service Hours or 1 Year Cooling System Coolant Sample Level 2 Obtain Un pe e tee Ee edet Every 1000 Service Hours Articulation Bearings
3. NOTICE Never service the air cleaner when the engine is run ning to avoid engine damage 166 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU8354 07 NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Cat dealers The Cat clean ing process uses proven procedures to assure consis tent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components Service the air cleaner filter element when the indicator light comes on Refer to Operation and Maintenance Manual Alert Indicators for information about the alert indicator Illustration 157 g00101864 1 Remove the air cleaner housing cover 1 2 Remove the primary filter element 2 from the air cleaner housing When you use pressure air the maximum air pressure is 207 kPa 30 psi a When you clean the inside ple
4. 10 Install the battery disconnect switch key Turn the battery disconnect switch to the ON position Recycle the Battery Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier An authorized battery collection facility e Recycling facility 02816216 Belts Inspect Replace SMCS Code 1397 040 1397 510 Serpentine Belt 1 Open the engine access door on the left side of the machine 2 Inspect the condition of the serpentine belt If the belt is worn or frayed replace the belt Note The serpentine belt is the self adjusting type There is no adjustment of the tension 3 Close the engine access door 102828865 Brake Accumulator Check SMCS Code 4263 535 5 y emm 209 e o Illustration 124 901411109 1 Turn the engine start switch to the ON position The alert indicator for brake oil pressure should come on if the braking system is not at normal operating pressure 2 Start the engine Run the engine at half speed for two minutes in order to increase the accumulator pressure The alert indicator for brake oil pressure should go off 3 Stop the engine Apply the service brake pedal and release the service brake pedal until the alert indicator for brake oil pressure comes on This will decrease the accumulator pressure A minimum of five applications of the service brake
5. Engage the parking brake 3 Move the transmission control lever to THIRD SPEED FORWARD to NEUTRAL and back to THIRD SPEED FORWARD This is done in order to override the transmission neutralizer for this test Note The parking brake indicator light should come on and the parking brake alarm should sound 4 Gradually increase the engine speed to high idle The machine should not move If the machine begins to move reduce the engine speed immediately and apply the service brake pedal 5 Reduce the engine speed Move the transmission to NEUTRAL Lower the blade to the ground Stop the engine 154 Maintenance Section Bucket Cutting Edges Inspect Replace SEBU8354 07 NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the parking brakes before returning the machine to oper ation 01920076 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Raise the bucket Place a block under the bucket 2 Lower the bucket to the blocking Do not block up the bucket too high Block up the bucket so that the bucket is high enough to remove the cutting edges and the end bits 3 Remove the bolts Remove the cutting edge and the end bits 4 Clean the contact surfaces 5 Use the
6. Remove the dipstick fill plug for the front differential Check the oil level 2 Maintain the oil level between the ADD mark and the FULL mark on the dipstick fill plug Add oil if necessary Replace the dipstick fill plug g00615943 Illustration 151 3 Remove the dipstick fill plug for the rear differential Check the oil level 4 Maintain the oil level between the ADD mark and the FULL mark on the dipstick fill plug Add oil if necessary Replace the dipstick fill plug Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4011 008 4070 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers g00614039 Illustration 152 In order to obtain a sample of the differential and final drive oil remove the filler plug Withdraw the oil through the filler opening Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining an oil sample Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining an oil sample 101700983 Drive S
7. 149 900615872 3 Remove the dipstick fill plug for the front differential and remove the dipstick fill plug for the rear differential 4 Add 0 5 L 53 qt of Hydraulic Oil Additive to each axle 5 Fill the axles with oil Maintain the oil between the ADD mark and the FULL mark on the dipstick fill plug of each differential See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Note Install the dipstick fill plug completely before you check the oil level If the dipstick fill plug is not installed completely an incorrect oil level reading can occur 6 Replace the dipstick fill plugs for each differential Operate the machine for a few minutes and allow the oil to flow completely through the axles Remove the dipstick fill plugs and recheck the oil level Add oil if necessary 7 Clean the dipstick fill plugs and install the dipstick fill plugs for each differential Differential and Final Drive Level Check SMCS Code 3278 535 FLV 4011 535 FLV Before you measure the oil level operate the machine for a few minutes This will allow all of the oil to reach a common level Park the machine on level ground Lower the bucket and apply slight downward pressure Engage the parking brake Stop the engine 164 Maintenance Section Differential and Final Drive Oil Sample Obtain SEBU8354 07 Illustration 150 g00615872 1
8. charge in the ride control accumulator Note Special tools and equipment are required to test the accumulator Reference For more information refer to Testing and Adjusting RENR6078 or consult your Caterpillar dealer N E TAL g01037257 Illustration 199 1 Remove the access covers from both sides of the ROPS 2 Inspect the ROPS for loose bolts or for damaged bolts Replace any damaged bolts or missing bolts with original equipment parts only Note Apply oil to all ROPS bolt threads before you install the bolts Failure to apply oil to the bolt threads can result in improper bolt torque Tighten the bolts that hold the platform to the frame to a torque of 530 70 N m 400 50 Ib ft Tighten the bolts that hold the ROPS to the platform to a torque of 460 60 N m 340 45 Ib ft Once you have torqued all the bolts torque the bolts again 3 Operate the machine on a rough surface Replace the ROPS mounting supports if the ROPS emits a noise Replace the ROPS mounting supports if the ROPS rattles 4 Install the access covers Do not straighten the ROPS Do not repair the ROPS by welding reinforcement plates to the ROPS Consult your Caterpillar dealer for repair of cracks in any welds in any castings or in any metal section of the ROPS 186 Maintenance S
9. cleaning agent to flush the cooling system After you drain the cooling system thoroughly flush the cooling system with clean water All of the cleaning agent must be removed from the cooling system 102839787 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Excessive additive greater than the recommended 6 initial fill together with concentrations of antifreeze greater than 60 cause deposits to form and can re sult in radiator tube blockage and overheating 1 Open the engine access panel on the right side of the machine g01416399 Illustration 145 2 Maintain the coolant level between the ADD and the FULL marks on the overflow tank when the cooling system is cool Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage Yr g01416397 Illustration 146 3 Open the access panel on the top of the engine compartment 4 If additional coolant is necessary remove the cap on the overflow tank and add the appropriate coolant mixture If you need to add coolant daily check the cooling system for leaks 162 Maintenance Section Cooling System Coolant Sample Level 1 Obtain SEBU8354
10. lever to NEUTRAL and engage the parking brake Inspect the transmission for leaks 190 Maintenance Section Transmission Oil Filter Replace SEBU8354 07 Illustration 213 g00627269 8 Maintain the transmission oil level between the LOW mark and the HIGH mark in the sight gauge when the transmission is warm and the engine is running Maintain the transmission oil level to the top of the sight gauge when the transmission is cool and the engine is not running Add transmission oil through the transmission filler tube if necessary Note Check the transmission oil level by using the dipstick if the sight gauge is blocked You may need to take more than one reading in order to achieve a consistent reading on the dipstick The oil level should be maintained in the crosshatched area of the dipstick The dipstick is attached to the oil fill cap 9 Stop the engine 01734082 Transmission Filter Replace SMCS Code 3067 510 Illustration 214 900627316 1 The transmission filter is located on the left side of the machine under the steps Remove the transmission oil filter element with a strap type wrench 2 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 3 Apply a light coat of oil to the gasket of the new filter element 4 Install the new filter element by hand When the gasket contacts the mo
11. opposite side of the cutting edge if this side is not worn 6 Install a new cutting edge if both edges are worn 7 Install the bolts Tighten the bolts to the specified torque 8 Raise the bucket Remove the blocks 9 Lower the bucket to the ground 10 After a few hours of operation check the bolts for proper torque 102814805 Bucket Linkage and Loader Cylinder Bearings Lubricate SMCS Code 5102 086 BD 5104 086 BD 6107 086 BD Illustration 125 900873076 Z Bar Illustration 126 900930756 VersaLink Grease fittings 1 2 3 and 4 are greased at the remote grease fitting on the left side of the front frame Wipe off the fittings before you apply any lubricant Apply lubricant to the grease fittings The grease fittings are located on each side of the bucket and loader linkage Note The lower bucket pivot bearing needs to be greased at every 50 hour interval SEBU8354 07 155 Maintenance Section Bucket Lower Pivot Bearings Lubricate 102814823 Bucket Lower Pivot Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD Illustration 127 900891053 Z Bar Illustration 128 900891056 VersaLink Wipe off the fittings before you apply any lubricant Apply lubricant to the grease fittings The grease fittings are located on both sides of the bucket 103657242 Bucket Tips Inspect Replace SMCS Code 6
12. other When you tighten the hydraulic oil filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter You may need to use a filter strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter Illustration 190 g01403318 8 Maintain the hydraulic oil level between the top and the bottom mark on the sight gauge Add oil if necessary 9 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary 10 Install the hydraulic tank filler cap 102830758 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV Note Check the hydraulic system oil level with the machine on a level surface Illustration 191 g01403318 1 Maintain the hydraulic oil level between the top and the bottom mark on the sight gauge Add oil if necessary X Illustration 192 901412231 SEBU8354 07 183 Maintenance Section Hydraulic System Oil Sample Obtain 2 The hydraulic tank filler cap is located on the top of the engine compartment Remove the hydraulic
13. pedal are required 4 If the alert indicator comes on after less than five applications of the brake measure the accumulator precharge pressure An authorized Caterpillar dealer can measure the nitrogen gas pressure in the accumulator Use only dry nitrogen gas for recharging SEBU8354 07 153 Maintenance Section Braking System Test 100058445 Braking System Test SMCS Code 4251 081 4267 081 Service Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles Make sure that the steering frame lock link is in the stored position Test the brakes on a dry level surface Fasten the seat belt before you test the brakes The following tests are used to determine if the service brake is functional These tests are not intended to measure the maximum brake holding effort The brake holding effort that is required to sustain a machine at a specific engine rpm varies depending on the machine The variations are the differences in the engine setting in the power train efficiency and in the brake holding ability etc 1 Start the engine Raise the bucket slightly 2 Apply the service brake Release the parking brake 3 Press the top of the transmission neutrali
14. tank filler cap and add hydraulic oil if necessary 3 Clean the hydraulic tank filler cap Install the hydraulic tank filler cap 103732588 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 008 7542 Illustration 193 902014215 The sampling valve is located on the base of the hydraulic oil filter Use the sampling valve in order to obtain a sample of the hydraulic oil The engine must be running in order to take a sample of the hydraulic oil Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 5 0 5 Oil Analysis for information that pertains to obtaining and oil sample Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining an oil sample 103001622 Hydraulic Tank Breather Replace SMCS Code 5056 510 BRE The hydraulic tank breather is located on the top side of the machine next to the hydraulic tank cap behind the cab Illustration 194 901412231 Remove the hydraulic tank breather Replace the old breather with a new breather 102106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 195 900100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspe
15. the transmission drain plug 2 Change the transmission oil filter element Refer to Operation and Maintenance Manual Transmission Oil Filter Replace 3 Clean the transmission magnetic screen 900627182 Illustration 210 a Remove the magnetic strainer cover b Remove the magnets from the housing c Remove the screen from the housing d Wash the tube and the screen in a clean nonflammable solvent NOTICE Do not drop or rap the magnets against any hard ob jects Replace any damaged magnets e Clean the magnets with a cloth with a stiff bristle brush or with pressure air f Install the magnets and the tube assembly into the magnetic screen g Install the magnetic screen h Clean the cover and inspect the seal Replace the seal if the seal is damaged i Install the cover Tighten the cover bolts Illustration 211 900627264 4 Fill the transmission with transmission through the transmission filler tube Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities 900627267 Illustration 212 5 Remove the transmission breather that is located on the top of the transmission case Install a new transmission breather 6 Start the engine and run the engine at low idle Apply the service brake Slowly operate the transmission controls in order to circulate the oil T Move the transmission control
16. the engine valve lash A qualified mechanic should adjust the engine valve lash because special tools and training are required Ether Starting Aid Cylinder Replace If Equipped SMCS Code 1456 510 CD 1 Illustration 172 1 Open the engine hood on the right side The ether starting aid cylinder is mounted on the frame of the machine next to the air cleaner 2 Loosen retaining clamp 1 and unscrew ether starting aid cylinder 2 3 Remove the gasket Install the new gasket that is provided with each new ether starting aid cylinder 4 Install new ether starting aid cylinder 2 hand tight Tighten retaining clamp 1 securely 5 Close the engine hood 104422151 Fuel System SMCS Code 1250 548 This machine is equipped with a fuel transfer pump that is electric Two examples that may cause the fuel System to lose prime are listed here The machine runs out of fuel The Fuel System Filter Water Separator Element is replaced Follow the steps below in order to prime the fuel system 1 Ensure that the battery disconnect switch is in the ON position 174 Maintenance Section Fuel System Primary Filter Water Separator Drain SEBU8354 07 2 The primary fuel filter is located in the right side of the machine by the radiator Examine the clear bowl 3 The bowl must be full of fuel If the bowl is not full of fuel use the switch on the filter base to tur
17. 07 5 Install the cap for the overflow tank Close the cover on top of the engine compartment 6 Close the engine compartment 02161416 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Level 1 results may indicate a need for Level 2 Analysis Reference See Operation and Maintenance Manual Cooling System Level Check in order to access the overflow tank for coolant sample Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the inform
18. 805 040 6805 510 Personal injury or death can result from the bucket falling Block the bucket before changing bucket tips Bucket Tips g00101352 Illustration 129 1 Usable 2 Replace the tip 3 Replace the tip Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip 1 Remove the pin from the bucket tip The pin can be removed by one of the following methods e Use a hammer and a punch from the retainer side of the bucket to drive out the pin Use a Pin Master Follow Step 1 a through Step 1 c for the procedure 156 Maintenance Section Bucket Tips Inspect Replace SEBU8354 07 e 2 ZA lt 0 A cei b Illustration 130 a Place the Pin Master on the bucket tooth 900590670 4 Back of Pin Master 5 Extractor b Align extractor 5 with the pin c Strike the Pin Master at the back of the tool 4 and remove the pin Illustration 131 900590819 6 Retainer 7 Retaining washer 8 Adapter 2 Clean the adapter and the pin 3 Fit retainer 6 into retaining washer 7 Install this assembly into the groove that is in the side of adapter 8 Illustration 132 900101359 4 Install the new bucket tip onto the adapter Note The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration 5 Drive the pin through the buc
19. 878977 Engine Oil and Filter Change SMCS Code 1318 510 Selection of the Oil Change Interval NOTICE A 500 hour engine oil change interval is available pro vided that the operating conditions and recommend ed multigrade oil types are met When these require ments are not met shorten the oil change interval to 250 hours or use an S O S Services oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine The normal engine oil change interval is listed in this Operation and Maintenance Manual Maintenance Interval Schedule Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals Also refer to Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Poor maintenance of air filters or of fuel filters requires reduced oil change intervals Consult your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Cat oil filters are recommended Program A Verification for an Oil Change Interval of 500 Hour
20. Lubricate Engine Valve Lash Hydraulic System Oil Filter Replace Every 1000 Service Hours or 6 Months Rollover Protective Structure ROPS Inspect Transmission Oil Change Every 2000 Service Hours or 1 Year Axle Oil Cooler Screen Clean Replace Differential and Final Drive Oil Change Hydraulic Tank Breather Replace Every 3000 Service Hours Hydraulic System Oil Change Every 3 Years Seat Belt Replace Every 6000 Service Hours Hydraulic System Oil Change Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 150 Maintenance Section Articulation Bearings Lubricate SEBU8354 07 01698389 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD Wipe the grease fittings before you lubricate the grease fittings 900614530 Illustration 118 Apply lubricant to one grease fitting on the upper pivot bearing 1 Apply lubricant to one grease fitting on the lower pivot bearing 2 02154820 Axle Cooler Screen Clean Replace SMCS Code 1365 070 Z3 1365 510 Z3 Reference For information about containing fluid spillage refer to Operation and Ma
21. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR Pita 2012 LL Operation and Maintenance Manual 924H 924HZ 928HZ and 930H Wheel Loaders RCB1 Up Machine WLB1 Up Machine DHC1 Up Machine HXC1 Up Machine BYD1 Up Machine FTD1 Up Machine PED1 Up Machine CXK1 Up Machine JRL1 Up Machine JTM1 Up Machine KLN1 Up Machine RRS1 Up Machine JZZ1 Up Machine SAFETY CAT COM 148 Maintenance Section Maintenance Interval Schedule SEBU8354 07 104784644 Maintenance Interval Schedule SMCS Code 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance All adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging are included Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Refer to the maintenance procedure for any other exceptions that may change the main
22. The ladder and the platform are located on the right side of the machine 1 Empty the precleaner bowl whenever the dirt reaches the FULL mark 104571790 Engine Crankcase Breather Closed Circuit Replace SMCS Code 1317 510 FQ Yr Illustration 163 901521425 2 Loosen the wing nut on the cover and remove the cover 3 Empty the precleaner bowl Wash the precleaner bowl and wash the cover 4 Install the precleaner bowl and install the cover Tighten the wing nut until the wing nut is only finger tight Do not use a tool to tighten the wing nut Illustration 164 901300560 Illustration 165 900927676 1 Breather Cap 2 O Ring 3 O Ring for the Breather Element 4 Breather Element 5 Housing for the Breather 1 Open the engine access door that is located on the right side of the machine SEBU8354 07 169 Maintenance Section Engine Oil Level Check 2 Turn the cover 1 for the filter housing counterclockwise for one quarter of a turn in order to remove the cover 3 Remove the filter element 4 by pulling the filter element out of the housing 5 4 Clean the inside of the housing for the breather 5 5 Lubricate the O ring 3 with clean engine oil If necessary fit a new O ring 3 to the housing for the breather 6 Install a new filter element 4 7 Install the cover 1 for the filter housing and turn one quarter of a turn clockwise in o
23. Use the pry bar in order to remove retainer 5 from bucket tip 4 3 Remove bucket tip 4 from adapter 6 with a slight counterclockwise rotation 4 Clean adapter 6 Installation 1 Clean the adapter and the area around the latch if necessary 2 Install the new bucket tip onto the adapter with a slight clockwise rotation Illustration 136 g01124736 3 Install the retainer Make sure that the retainer s latch catches under the tip pocket 4 Make sure that the latch is properly seated by trying to remove the bucket tip 102003771 Bucket Wear Plates Inspect Replace SMCS Code 6120 040 6120 510 Personal injury or death can result from falling bucket When working under or around the bucket or link age with the bucket raised proper support must be provided for the bucket and or the linkage Replace the wear plates before damage to the bottom of the bucket occurs 1 Raise the bucket and block up the bucket 2 Loosen bolts and remove wear plates 3 Install new wear plates Tighten the bolts to the specified torque 158 Maintenance Section Cab Air Filter Clean Replace SEBU8354 07 Reference For more information refer to Specifications SENR3130 Torque Specifications Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Clean Filters Note Clean the filter elements more often in dusty conditions If there is a noticeable reduction in the airflow
24. aterpillar Machines Reference Special Publication PEDP7035 Optimizing Oil Change Intervals Reference Special Publication PEDP7036 5 0 5 Fluid Analysis Reference Special Publication PEDP7076 Understanding the S O S Oil Analysis Tests SEBU8354 07 171 Maintenance Section Engine Oil and Filter Change Drain the Oil Method with Drain Hoses If Equipped Illustration 168 g01507438 8 Bolts 9 Access Panel for the Oil Drain Valve Illustration 169 g01506895 1 Oil Filler Cap 2 Dipstick 3 Oil Filter 4 Oil Separator Filter 5 Drain Valve on the Oil Filter 6 Oil Drain Valve 7 Plugs The crankcase drain is on the right side of the oil pan 1 Open the engine access door on the right side of the machine 2 Loosen the two bolts on the access panel for the oil drain valve on the right side of the machine 3 Swing the access panel open 4 Remove the plastic plug in the bottom of the drain hose for the crankcase 5 Remove the plastic plug in the bottom of the hose for the drain for the oil filter 6 Place the ends of the hoses into a suitable container 7 Open the crankcase drain 8 Open the drain on the oil filter base 9 Allow the oil to drain completely from the engine 10 Close the crankcase drain 172 Maintenance Section Engine Oil and Filter Change SEBU8354 07 11 Swing the access panel back into the closed positio
25. ation on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system Submit the sample for Level 1 analysis Level 1 analysis is a test of the properties of the coolant For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102161468 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local reg
26. ats and the outside pleats direct the air along the pleats b Inspect the filter elements after you clean the filter elements Do not use a filter if the pleats the gaskets or the seals are damaged Note Replace the primary element after the primary element has been cleaned six times Also replace the primary element if the primary element has been in service for 1 year 3 Install a clean filter element and install the cover Alternator Guard and Filter If Equipped If your machine is equipped with the heavy duty alternator perform the following procedure Illustration 158 902346203 At the same time that the primary filter element is cleaned check and clean the alternator filter Visibly inspect cover and filter to determine if excessive debris buildup has occurred Remove the three fasteners holding the cover to the alternator Remove the filter and clean or replace as needed Clean debris buildup from the cover Insert the filter and install the cover and filter with the original fasteners Torque the bolts to 2 5 0 5 N m 1 8 0 4 Ib ft Note If the turbo hose is removed keep the area clean Ensure that all hoses and clamps are properly installed before operating the engine SEBU8354 07 167 Maintenance Section Engine Air Filter Secondary Element Replace 102839331 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary filter element N
27. cleaner The cleanliness should be monitored by particle count analysis The levels of contamination should not exceed the normal by more than two ISO codes Action should be taken in order to determine the cause of the contamination The system should be returned to the original levels of contamination There should not be significant changes in sodium silicon copper and potassium The allowable level of oxidation is 40 percent 0 12 Abs units The kinematic viscosity of 100 212 F oil should not exceed a change of more than 2 cSt from new oil Procedure for Changing the Hydraulic Oil Operate the machine for a few minutes in order to warm the hydraulic system oil 180 Maintenance Section Hydraulic System Oil Change SEBU8354 07 The machine should be level Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine B Illustration 183 901403313 1 Remove the hydraulic tank filler cap Note Some parts are removed for clarity in the following illustrations Illustration 184 901403288 924H g01403292 928H Illustration 186 901403296 930H 2 The hydraulic tank drain valve is located on a manifold near the articulation hitch on the right side for the 924H The hydraulic tank d
28. ct the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure 184 Maintenance Section Quick Coupler Check SEBU8354 07 If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 03657277 Quick Coupler Check If Equipped SMCS Code 6129 535 When you install a work tool on the quick coupler inspect the engagement of the coupler pins If there is play between the coupler pins and the corresponding bores inspect the coupler pins and the bores for damage or wear If there is play between the quick coupler and the hooks of the work tool inspect the q
29. e is stopped flush the system with water Flush the system until the draining water is transparent 8 Close the drain valve 9 Add the coolant solution See the following topics e Operation and Maintenance Manual Cooling System Specifications e Operation and Maintenance Manual Refill Capacities Note If you are using Caterpillar antifreeze do not add the supplemental coolant additive at this time 10 Start the engine Run the engine without the cap for the overflow tank until the thermostat opens and the coolant level stabilizes g01416399 Illustration 144 11 Maintain the coolant level between the ADD and FULL marks on the overflow tank 12 Install the cap for the overflow tank 13 Stop the engine 14 Replace the access panel Close the access door SEBU8354 07 161 Maintenance Section Cooling System Coolant Level Check Flushing the Extended Life Coolant From the Cooling System Some engines utilize Extended Life Coolant See the Operation and Maintenance Manual Maintenance Interval Schedule in order to determine the service interval If a Extended Life Coolant was previously used flush the cooling system with clean water No other cleaning agents are required Flushing a Standard Coolant From the Cooling System If you change the coolant of a machine to Extended Life Coolant from another type of coolant use a Caterpillar
30. ection Seat Belt Inspect SEBU8354 07 104423622 Seat Belt Inspect SMCS Code 7327 040 Always inspect the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 200 902620101 Typical example Inspect buckle 1 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect seat belt 2 for webbing that is worn or frayed Replace the seat belt if the webbing is worn or frayed Inspect all seat belt mounting hardware for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension Contact your Cat dealer for the replacement of the seat belt and the mounting hardware Note The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts 104421974 Seat Belt Replace SMCS Code 7327 510 The seat belt should be replaced within 3 years of the date of installation A da
31. electrical system from damage that is caused by overloaded circuits Replace the fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary NOTICE Replace the fuses with the same type and size only Otherwise electrical damage can result If itis necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer EX os e 22s sa LE o f jT 7 A Illustration 179 901412169 1 Console 2 Fuse Panel The fuse panel is located on the console at the right side of the cab Fuses Illustration 180 g01412164 Blowers 3 This space contains 20 Amp Breaker Reset the breaker by pushing Window Wipers 4 15 Amp 24 Volt to 12 Volt Converter 5 10 Amp Beacon Heated Seat 6 15 Amp Turn Signals 7 10 Amp Ride Control 8 10 Amp Air Suspension Seat 9 15 Amp Secondary Steering and Reversing Fan 10 10 Amp Spare 11 20 Amp Hydraulics 12 10 Amp Transmission 13 10 Amp Flood Lights 14 20 Amp Rear Window Wipers and Washer 15 10 Amp Work Lights and Lighter 16 15 Amp Rear Defrost 17 20 Amp 178 Maintenance Section Hydraulic System Oil Change SEBU8354 07 Air Conditioner 18 This space con
32. element by hand until the filter element is snug Do not use tools to tighten the filter element 8 Install the new water separator element Rotate the locking ring clockwise in order to fasten the filter to the mounting base 9 Prime the fuel system in order to fill the water separator element with fuel Refer to Operation and Maintenance Manual Fuel System Prime 102833836 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts The fuel filter is located in the engine compartment on the right side of the machine 1 Open the engine access door on the right side of the machine 901413118 Illustration 175 1 Primary Fuel Filter 2 Water Separator 3 Drain 4 Secondary Fuel Filter 2 Remove the fuel filter Inspect the fuel filter for debris by cutting the filter open Discard the filter properly 3 Clean the mounting base of the fuel filter Remove any part of the old seal that remains on the mounting base of the fuel filter 4 Coat the seal of the new fuel filter with clean diesel fuel 5 Install the new fuel filter by hand When the seal contacts the base tighten the filter for an additional three quarters of a turn 6 Prime the fuel system Refer to Operation and Maintenance Manual Fuel Sy
33. ever at tempt to reuse the secondary filter element by clean ing the element When the primary filter element is replaced the sec ondary filter element should be replaced The secondary filter element should also be replaced if the restricted Air Filter indicator comes on after the installation of a clean primary filter element or if the exhaust smoke is still black 1 Open the engine access door on the right side of the machine Illustration 159 900101864 2 Remove the air cleaner housing cover 1 3 Remove the primary filter element 2 from the air cleaner housing Illustration 160 900038606 4 Remove the secondary filter element Illustration 161 900101865 5 Cover the air inlet opening Clean the inside of the air cleaner housing 6 Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged 7 Uncover the air inlet opening Install a new secondary element 8 Install the primary element and the air cleaner housing cover Fasten the clips in order to secure the air cleaner housing cover 9 Close the engine access door 103001668 Engine Air Precleaner Clean If Equipped SMCS Code 1055 070 Illustration 162 901521423 168 Maintenance Section Engine Crankcase Breather Closed Circuit Replace SEBU8354 07 Use the ladder and the platform in order to access the precleaner bowl
34. from the air vents check the filter elements Illustration 137 900614999 1 Remove the filter cover The filter cover is located on the left side of the operator compartment under the steps 2 Remove the filter elements Clean the filter elements with compressed air You can also wash the filter elements with a solution of warm water and of a nonsudsing household detergent Do not wash the filter elements while the filter elements are installed on the machine 3 Rinse the filter elements in clean water Air dry the filter elements thoroughly 4 Install the filter elements and replace the cover 900447093 Illustration 138 5 Remove the filter cover and filter elements The filter elements are located near the left side of the operator seat Note Raise the operator seat in order to remove the filter elements 6 Clean the filter elements with compressed air You can also wash the filter elements with a solution of warm water and of a nonsudsing household detergent 7 Rinse the filter elements in clean water Air dry the filter elements thoroughly 8 Replace any filter elements that are worn or damaged 9 Face the seal toward the parking brake lever when you install the filter element 102816405 Camera Clean If Equipped SMCS Code 7348 070 In order to maintain sufficient vision keep the Work Area Vision System WAVS camera lens and the display clean SEBU8354 07 159 Mainte
35. gauge Add oil if necessary Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction hoses and hose clamps 11 Stop the engine 12 If necessary tighten any loose clamps and any loose connections Replace any damaged hoses 13 Close the engine access door 103732587 Hydraulic System Oil Filter Replace SMCS Code 5068 510 xd Illustration 188 g01412231 1 Remove the hydraulic tank filler cap 2 The hydraulic oil filter is located in the back of the machine behind the primary fuel filter Open the engine access door on the left side of the machine d Illustration 189 902014219 3 Remove the filter element with a strap type wrench 182 Maintenance Section Hydraulic System Oil Level Check SEBU8354 07 4 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 5 Apply a thin coat of oil to seal on the new filter Install a new hydraulic oil filter hand tight until the seal of the hydraulic oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base 6 There are rotation index marks on the hydraulic oil filter that are spaced 90 degrees or 1 4 of a turn away from each
36. haft Spline Center Lubricate SMCS Code 3253 086 SN Wipe the grease fitting before you lubricate the grease fitting NOTICE To prevent damage to the seal fully articulate the ma chine to the right or to the left before lubricating the spline SEBU8354 07 165 Maintenance Section Drive Shaft Support Bearing Lubricate 1 Start the engine Raise the bucket Release the parking brake Fully articulate the machine to the left or to the right 2 Lower the bucket to the ground Engage the parking brake Stop the engine ma Illustration 153 g00616221 3 Apply lubricant to the grease fitting that is on the drive shaft spline 4 Start the engine Raise the bucket Release the parking brake Articulate the machine until the machine is straight 5 Lower the bucket until the bucket exerts a slight downward pressure on the ground Stop the engine Engage the parking brake 02814810 Drive Shaft Support Bearing Lubricate SMCS Code 3267 086 BD Wipe the grease fitting before you lubricate the grease fitting Illustration 154 Illustration 155 924H and 924Hz 900616286 Illustration 156 928Hz and 930H Apply lubricant to the grease fitting that is on the drive shaft support bearing 104662871 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY The primary air filter element is located in the engine compartment
37. il MTO e Heavy duty diesel engine oils with a minimum zinc content of 900 ppm If Caterpillar oils cannot be used use heavy duty oils with the following classification Caterpillar ECF 1 API CG 4 API CF and TO 4 These oils must have a minimum zinc additive of 0 09 percent 900 ppm Note Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours Caterpillar s standard SOS Fluids Analysis or an equivalent oil sampling program should be used The current guidelines for cleanliness of the oil should be observed Refer to Measured Data If an oil sampling program is not available the standard 3000 oil change interval should be used Measured Data The following information should be monitored through sampling of the oil e Significant changes in wear metals should be monitored These metals include iron copper chromium lead aluminum and tin Significant changes in the following additives should be monitored zinc calcium magnesium and phosphorus Contaminants should not be present These contaminants include fuel and antifreeze Water content should be 5 percent or less The silicon level should not exceed 15 parts per million for new oil The particle counts should be monitored The recommended level of cleanliness for Caterpillar machines that are operated in the field is ISO 18 15 or
38. intenance Manual General Hazard Information Clean the screens after any maintenance on the brake system 2 lE Illustration 119 900916582 1 Make sure that there is no pressure in the lines for the axle oil Loosen the fitting on the hose and drain the oil from the line into a suitable container Dispose of the oil properly 2 Remove the screen from the rear of the axle housing Clean the screen in a clean nonflammable solvent 3 Install the screen and the hose 4 Check for leaks Make any necessary repairs 102814814 Axle Oscillation Bearings Lubricate SMCS Code 3268 086 BD 3278 086 BD Illustration 120 g00614728 924H and 924Hz SEBU8354 07 151 Maintenance Section Backup Alarm Test Illustration 121 900904205 928Hz and 930H Apply grease to the remote grease fittings for the trunnion bearings The grease fittings are located on the left side of the machine near the articulation joint 01698523 Backup Alarm Test SMCS Code 7406 081 Turn the engine start switch key to ON in order to perform the test Apply the service brake Move the transmission direction control lever to REVERSE position The backup alarm should immediately sound The backup alarm will continue to sound until the transmission direction control lever is moved to the NEUTRAL
39. ket tip The pin can be installed by using one of the following methods From the other side of the retainer drive the pin through the bucket tip the adapter and the retainer e Use a Pin Master Follow Step 5 a through Step 5 e for the procedure Note To correctly install the pin into the retainer the pin must be driven in from the right side of the tooth Improper installation of the pin can result in the loss of the bucket tip g00590666 Illustration 133 4 Back of Pin Master 9 Pin setter 10 Pin holder a Insert the pin through the bucket tooth b Place the Pin Master over the bucket tooth and locate the pin in the hole of holder 10 SEBU8354 07 157 Maintenance Section Bucket Wear Plates Inspect Replace c Strike the tool with a hammer at the back of the tool 4 in order to start the pin d Slide pin holder 10 away from the pin and rotate the tool slightly in order to align pin setter 9 with the pin e Strike the end of the tool until the pin is fully inserted 6 After you drive the pin make sure that the retainer fits snugly into the pin groove K Series Tip Removal Illustration 134 g01389463 Note Retainers are often damaged during the removal process Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced Illustration 135 g01175361 1 Use a pry bar in order to disengage retainer 5 2
40. lar Extender Note This machine is shipped with Extended Life Coolant Extended Life Coolant is recommended for use Drain the coolant whenever the coolant is dirty Drain the coolant whenever the coolant starts to foam Illustration 141 g01416397 160 Maintenance Section Cooling System Coolant ELC Change SEBU8354 07 The overflow tank is located under the access panel on the top of the engine compartment Use the steps and the handholds on the right side of the machine in order to reach the access panel 1 Open the access panel on the top of the engine compartment 2 Slowly lift the tab on the cap for the overflow tank in order to relieve system pressure Remove the cap for the overflow tank Illustration 142 900921567 3 Open the access doors on both sides of the engine compartment Remove five bolts 1 Remove plate 2 900921568 Illustration 143 4 The drain valve is located on the bottom left corner of the radiator Open the drain valve Allow the coolant to drain into a suitable container 5 Close the drain valve Fill the system with a solution which consists of clean water and of cooling system cleaner The concentration of the cooling system cleaner in the solution should be between 6 percent and 10 percent 6 Start the engine Run the engine for 90 minutes Stop the engine Drain the cleaning solution into a suitable container 7 While the engin
41. n 12 Tighten the bolts on the access panel 13 Close the drain on the oil filter base 14 Install the plugs in each hose Method Without Drain Hoses D Mi Illustration 170 901412276 The crankcase drain is on the right side of the pan 1 Open the crankcase drain and drain the oil into a suitable container Install the plug into the oil pan Install New Filters 1 Open the access door on the right side of the machine Illustration 171 901412248 1 Oil Filler 2 Dipstick 3 Oil Filter 4 Oil Separator Filter 2 Remove the filter element with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect 3 Clean the filter mounting base with a clean cloth Make sure that the old filter gasket has been removed Note Cat filters are designed to ensure a ready supply of oil with every engine start Use of approved Cat filters is recommended on this machine 4 Apply a thin film of clean engine oil to the sealing surface of the new filter element 5 Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a tu
42. n on the pump Run the pump until the clear bowl is full of fuel 4 Attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate the engine at low idle until the engine runs smoothly Note If the engine fails to start or if the engine continues to misfire or smoke stop the engine and repeat the procedure If the problem persists after repeating the procedure consult your Cat dealer 02833831 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 The water separator is located in the engine compartment on the right side of the machine Note This unit has a dual purpose The element serves as a water separator and a fuel filter NC NEN iw LA Illustration 173 901413118 1 Primary Fuel Filter 2 Water Separator 3 Drain 4 Secondary Fuel Filter 1 Loosen the drain valve on the bottom of the water separator Allow the water and the sediment to drain into a suitable container 2 Tighten the drain valve 3 If the engine fails to start change the fuel filter If there is a power loss change the fuel filter 4 Tighten the drain valve and close the engine access door Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 1263 510 FQ NOTICE Do not fill fuel filters with fuel before installing them The fuel will not be filtered and c
43. nance Section Cooling System Coolant ELC Change Display FEES VODSOSG Illustration 139 g01223034 WAVS display Use a soft damp cloth in order to clean the display The display has a soft plastic surface that can be easily damaged by an abrasive material The display is not sealed Do not immerse the display with liquid Camera Illustration 140 g01223051 The WAVS camera is located on the rear of the machine in the center of the fan guard Use a damp cloth or water spray in order to clean the camera lens The camera is a sealed unit The camera is not affected by high pressure spray The camera is equipped with an internal heater to help counteract the effects of condensation snow or ice Note For more information on WAVS refer to Operation and Maintenance Manual SEBU8157 Work Area Vision System 103739601 Cooling System Coolant Change SMCS Code 1350 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Mixing ELC with other products will reduce the effec tiveness of the coolant This could result in damage to cooling system compo nents If Caterpillar products are not available and com mercial products must be used make sure they have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants and Caterpil
44. ould be contaminated Contaminated fuel will cause accelerated wear to fuel System parts The fuel system should be primed prior to starting the engine Note This unit has a dual purpose The element serves as a water separator and a fuel filter The water separator element is located in the engine compartment on the right side of the machine 901413118 Illustration 174 1 Primary Fuel Filter 2 Water Separator 3 Drain 4 Secondary Fuel Filter SEBU8354 07 175 Maintenance Section Fuel System Secondary Filter Replace 1 Open the drain on the water separator bowl Allow the water and fuel to drain into a suitable container 2 Support the water separator element and rotate the locking ring counterclockwise Remove the locking ring 3 While the water separator bowl is attached remove the water separator element from the mounting base 4 Remove the water separator bowl from the filter element Clean the water separator bowl and clean the O ring groove Note The water separator bowl is reusable Do not discard the water separator bowl 5 Inspect the O ring seal of the water separator bowl for damage Replace the O ring seal if necessary 6 Lubricate the O ring seal with clean diesel fuel or lubricate the O ring seal with motor oil Place the O ring seal in the groove in the water separator bowl 7 Spin the water separator bowl onto the new filter
45. position or to the FORWARD position The backup alarm is mounted in the back of the machine behind the rear grill 104096831 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 Open the engine access door on the right side of the machine Illustration 122 901416250 3 Turn the battery disconnect switch to the OFF position Remove the battery disconnect switch key Illustration 123 901416255 4 Remove the access panel for the battery on the right side and on the left side of the machine NOTICE Do not allow the disconnected battery cable to contact the disconnect switch 5 Disconnect the negative battery cable at the battery 152 Maintenance Section Belts Inspect Replace SEBU8354 07 6 At the battery disconnect switch disconnect the negative battery cable that is connected to the frame 7 Perform the necessary repairs Replace the cable or the battery as needed 8 Connect the battery cable at the battery disconnect switch if equipped If the machine is not equipped with a battery disconnect switch connect the negative cable to the frame 9 Connect the negative battery cable at the battery Replace the battery cover
46. rain valve is located on a manifold under the right side of the cab on the 928H The hydraulic tank drain valve is located on a manifold under the left side of the cab on the 930H Open the drain valve and allow the hydraulic oil to drain into a suitable container 3 Close the drain valve 4 Open the engine access door on the right side of the machine SEBU8354 07 181 Maintenance Section Hydraulic System Oil Filter Replace 5 Change the hydraulic system filter and the hydraulic tank breather Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Change 6 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities 7 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary 8 Install the hydraulic tank filler cap 9 Start the engine and run the engine for a few minutes The cooling fan should be operating and the brake oil pressure indicator should go out If the cooling fan is not operating or the brake oil pressure indicator does not go out repeat steps 6 and 8 Illustration 187 g01403318 The hydraulic tank sight gauge is located behind the cab on the front of the hydraulic tank 10 Maintain the hydraulic oil level between the top and the bottom mark on the sight
47. rder to lock the cover in place 8 Close all access covers 102830922 Engine Oil Level Check SMCS Code 1000 535 FLV NOTICE Do not overfill the crankcase Engine damage can re sult 1 Open the engine access door on the right side of the machine TA f la RTT me Li JE G mre Ress Ww rcd b i gt Illustration 166 901412248 1 Cil Filler Cap 2 Dipstick 3 Oil Filter 4 Oil Separator Filter 2 While the engine is stopped maintain the oil level in the crosshatched region of the engine oil dipstick 1 3 If necessary remove the oil filler plug and add oil 4 Clean the oil filler plug and install the oil filler plug 5 Close the engine access door Engine Oil Sample Obtain SMCS Code 1348 008 7542 Illustration 167 g01507256 Oil Sample Port Use the sampling valve in order to obtain a sample of the engine oil The engine must be running in order to take a sample of the engine oil Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining an oil sample Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining an oil sample 170 Maintenance Section Engine Oil and Filter Change SEBU8354 07 103
48. ring cylinders 928Hz and 930H Wipe all grease fittings before you apply any lubricant to the grease fittings Illustration 206 900913074 Left side steering cylinder Apply lubricant to the grease fitting for the head end of the steering cylinder 900913073 Illustration 207 Right side steering cylinder Apply lubricant to the grease fitting for the head end of the steering cylinder Illustration 208 900913018 Apply lubricant to the two remote grease fittings for the rod ends of both steering cylinders 102814798 Tire Inflation Check SMCS Code 4203 535 Al Measure the tire pressure on each tire Consult your Caterpillar dealer for the correct load rating and for the correct operating pressures Inflate the tires if necessary See Operation and Maintenance Manual Tire Inflation Information 103926633 Transmission Change SMCS Code 3030 044 Operate the machine for a few minutes in order to warm the transmission oil The machine should be level Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine SEBU8354 07 189 Maintenance Section Transmission Oil Change 8 z Z HN ume m 1 LES mu s LM oe wd X 900627260 Illustration 209 1 Remove the transmission drain plug Allow the transmission oil to drain into a suitable container Clean the transmission drain plug and install
49. rn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 6 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Cat strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter SEBU8354 07 173 Maintenance Section Engine Valve Lash Check Oil Separator Filter Crankcase Breather Use the same procedure in order to replace the Oil Separator Filter This filter must be replaced at the same time as the engine oil filter Fill with Oil 1 Remove the oil filler plug Fill the crankcase with new oil See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Clean the oil filler plug and install the oil filler plug 2 Start the engine and allow the oil to warm Check for leaks 3 Stop the engine and allow the oil to drain back into the oil pan Maintain the oil level in the crosshatched region of the engine oil dipstick Add oil if necessary 4 Close the engine access doors 103854660 Engine Valve Lash Check SMCS Code 1105 535 Refer to the Service Manual for the complete adjustment procedure for
50. s This program consists of three oil change intervals of 500 hours sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type in the Lubricant Viscosities for Ambient Temperatures Table in this Operation and Maintenance Manual Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each increment is an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above References Reference Special Publication SEBUG250 Caterpillar Machine Fluids Recommendations Reference Special Publication SEBU5898 Cold Weather Recommendations for All C
51. stem Prime 7 Close the engine access door 101793682 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 Z2 1273 070 STR The fuel tank cap is located on the right side of the machine 176 Maintenance Section Fuel Tank Water and Sediment Drain SEBU8354 07 Illustration 176 g00917717 1 Remove fuel tank cap 1 and strainer 3 from fuel tank 4 Remove seal 2 from the cap 2 Wash the strainer and the fuel tank cap in a clean nonflammable solvent 3 Install the strainer into the filler opening 4 Inspect the seal for damage Replace the seal if necessary Install the fuel tank cap 102830417 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Note If the water separator bowl is full on a daily basis drain the fuel tank on a daily basis The fuel tank drain is located at the rear of the machine underneath the machine on the right side Illustration 177 g01412141 Open the engine hood on the right side Slowly remove the fuel tank cap in order to relieve pressure Illustration 178 g01412142 Loosen the plug in the bottom of the fuel tank Allow the fuel and sediment to drain into a suitable container Tighten the plug Replace the fuel tank cap SEBU8354 07 177 Maintenance Section Fuses Replace 03640968 Fuses Replace SMCS Code 1417 510 Fuses Fuses protect the
52. t or equivalent System damage can result from freezing 192 Maintenance Section Window Wipers Inspect Replace SEBU8354 07 g00627905 Illustration 219 The window washer reservoir is located on the left side of the machine under the cab Fill the reservoir with window washer solvent 101740157 Window Wipers Inspect Replace SMCS Code 7305 040 7305 510 Inspect the condition of the window wiper blades Replace the window wiper blades if the window wiper blades are worn or damaged If the window wiper blades streak the window replace the window wiper blades 03732700 Windows Clean SMCS Code 7310 070 900627875 Illustration 220 Use commercially available window cleaning solutions in order to clean the windows Clean the outside of the windows from the ground unless handholds are available For machines that are equipped with debris screen guards unlatch the side screen guards and swing the guards to the open position in order to clean the glass behind the screen
53. tains a 20 Amp Breaker Reset the breaker by pushing 28 30 32 34 Illustration 181 901412166 Dome Light 20 10 Amp Electric Fuse 21 15 Amp Stop Lights 22 10 Amp Spare 23 10 Amp Spare 24 10 Amp Transmission 25 10 Amp Engine Stop 26 10 Amp Spare 27 25 Amp Front Lights 28 10 Amp Engine ECM 29 25 Amp Rear Lights 30 10 Amp Spare 32 10 Amp Product Link 33 10 Amp Spare 34 10 Amp Spare 35 10 Amp Relays Illustration 182 g01412168 Brake Lights 36 Relay Reversing Fan 36 Relay Ride Control 37 Relay Reverse Lights 38 Relay Secondary Steering 39 Relay 103739621 Hydraulic System Oil Change SMCS Code 5056 044 Selection of the Oil Change Interval The factory fills the hydraulic system with Cat HYDO Advanced 10 With continued use of Cat HYDO Advanced 10 and the recommended S O S Services oil analysis the maintenance interval for the oil change is 6000 hours Your machine may be able to use a 4000 hour interval for the hydraulic oil The hydraulic oil is in the system that is not integral to the service brakes the clutches the final drives or the differentials The standard change interval is 3000 hours The oil should be monitored during intervals of 500 hours The extended 4000 hour interval can be used if the following criteria are met SEBU8354 07 179 Maintenance Sec
54. te of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts 90 4 901152685 Illustration 201 Typical Example 1 Date of installation retractor 2 Date of installation buckle 3 Year of manufacture tag fully extended Web 4 Year of manufacture underside buckle Consult your Cat dealer for the replacement of the seat belt and the mounting hardware Determine age of new seat belt before installing on seat A manufacture label is on belt webbing and imprinted on belt buckle Do not exceed install by date on label Complete seat belt system should be installed with new mounting hardware Date of installation labels should be marked and affixed to the seat belt retractor and buckle Note Date of installation labels should be permanently marked by punch retractable belt or stamp non retractable belt If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension SEBU8354 07 187 Maintenance Section Steering Column Play Check 03589859 Steering Column Play Check SMCS Code 4310 535 4338 535 Illustration 202 901408466 1 Hold the steering
55. tenance intervals Note The aftertreatment system can be expected to function properly for the useful life of the engine emissions durability period as defined by regulation All prescribed maintenance requirements must be followed Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended to 3000 hours S O S services may extend the oil change even longer Consult your Cat dealer for details When Required Battery or Battery Cable Inspect Replace 151 Bucket Cutting Edges Inspect Replace 154 Bucket Wear Plates Inspect Replace 157 Camera Clean 158 Engine Air Filter Primary Element Clean Replace i niii td e eee aani 165 Engine Air Filter Secondary Element Replace 167 Engine Air Precleaner Clean 167 Ether Starting Aid Cylinder Replace 173 Fuel System Prime 173 Fuel System Primary Filter Water Separator BICI 174 Fuel Tank and Strainer Clean 175 Fuel Tank Water and Sediment Drain 176 Fuses Replace 177 Oil Filter 183 Quick Coupler
56. the HIGH mark on the sight gauge when the transmission is warm and the engine is running Maintain the transmission oil level to the top of the sight gauge when the transmission is cool and the engine is not running Note Check the transmission oil level by using the dipstick if the sight gauge is blocked You may need to take more than one reading in order to achieve a consistent reading on the dipstick The oil level needs to be maintained in the crosshatched area of the dipstick The oil fill cap is also the dipstick T gt v4 Illustration 217 900627264 2 Remove the transmission filler plug and add transmission oil if necessary 3 Clean the filler plug and install the filler plug 102092030 Transmission Oil Sample Obtain SMCS Code 3080 008 7542 Illustration 218 g00614038 Use the sampling valve in order to obtain a sample of the transmission oil The engine must be running in order to take a sample of the transmission oil Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining an oil sample Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining an oil sample 101706737 Window Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solven
57. tion Hydraulic System Oil Change HYDO Advanced 10 Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic and hydrostatic transmission systems when ambient temperature is between 20 C 4 F and 40 C 104 F Cat HYDO Advanced 10 has an SAE viscosity grade of 10W Cat HYDO Advanced 10 has a 50 increase in the standard oil drain interval up to 3000 hours for machine hydraulic systems over second and third choice oils when you follow the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual 6000 hour oil drain intervals are possible when using S 0 S Services oil analysis When you switch to Cat HYDO Advanced 10 cross contamination with the previous oil should be kept to less than 10 Consult your Cat dealer for details about the benefits from the improved performance designed into Cat HYDO Advanced 10 Oil Filters Caterpillar oil filters are recommended The interval for changing the oil filter should be 500 hours Oil The 6000 hour interval for changing the oil is specific to Cat HYDO Advanced 10 The 4000 hour interval for changing the oil is for the following oil types e Caterpillar Hydraulic Oil HYDO e Caterpillar Transmission and Drive Train Oil TDTO Caterpillar TDTO TMS Caterpillar Diesel Engine Oil Caterpillar Biodegradable Hydraulic Oils HEES Caterpillar Multipurpose Tractor O
58. uick coupler and the hooks for wear or for damage Make any necessary repairs before you operate the work tool 104164592 Radiator Core Clean SMCS Code 1353 070 KO Illustration 196 900914344 1 Open both of the engine access doors in order to open the radiator cooling fan housing Open the radiator cooling fan housing in order to expose the radiator core NN ASN NN RANI Illustration 197 g00101939 2 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator fins The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi However the use of compressed air is preferred Refer to Operation and Maintenance Manual General Hazard Information for Safety information about using pressurized air and water SEBU8354 07 185 Maintenance Section Ride Control Accumulator Check 102005410 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 Illustration 198 902356638 3 If equipped clean the air conditioner condenser on the top of the hood 102814826 Ride Control Accumulator Check SMCS Code 5077 535 R6 The ride control accumulator reduces the pitching of the machine If the machine seems to be bouncing excessively check the
59. ulations and mandates Reference See Operation and Maintenance Manual Cooling System Level Check in order to access the overflow tank for coolant sample Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis The Level 2 analysis is a comprehensive chemical evaluation of the coolant This analysis is also a check of the overall condition of the inside of the cooling system SEBU8354 07 163 Maintenance Section Differential and Final Drive Oil Change Reference For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 03024515 Differential and Final Drive Oil Change SMCS Code 3278 044 4011 044 Wipe the covers and surfaces around openings before you check the oil Wipe the covers and surfaces around openings before you add oil 900615911 Illustration 148 1 Remove the drain plugs for the front differential 1 and for the rear differential 2 Allow the oil to drain into a suitable container 2 Clean the drain plugs and install the drain plugs Illustration
60. unting base tighten the filter element for an additional three quarters of a turn 5 Start the engine and apply the service brake Slowly operate the transmission controls in order to circulate the transmission oil 6 Move the transmission control lever to NEUTRAL and engage the parking Inspect the filter element for leaks Illustration 215 900627269 7 Maintain the transmission oil level between the LOW mark and the HIGH mark on the sight gauge when the transmission is warm and the engine is running Maintain the transmission oil level to the top of the sight gauge when the transmission is cool and the engine is not running Add transmission oil if necessary Note Check the transmission oil level by using the dipstick if the sight gauge is blocked You may need to take more than one reading in order to achieve a consistent reading on the dipstick The oil level needs to be maintained in the crosshatched area of the dipstick The oil fill cap is also the dipstick 8 Stop the engine SEBU8354 07 191 Maintenance Section Transmission Oil Level Check 01734092 Transmission Oil Level Check SMCS Code 3030 535 FLV Check the transmission oil level while the machine is on a level surface The sight gauge for the transmission oil level is located on the left side of the machine under the steps Illustration 216 900627269 1 Maintain the transmission level between the LOW mark and
61. wheel with both hands 2 Try to move the steering wheel from one side to the other side The maximum allowed movement in the steering column should not exceed 25 mm 1 0 inch If the value is not within the limit perform the following steps a Inspect the pivot joint for loose bolts b Tighten the bolts if the bolts are loose Note Apply 98 3263 Thread Lock Compound to the bolts before tightening c Inspect the pivot joint for excessive wear d Replace the bushings if there is excessive wear Failure to perform this inspection and repair may cause loss of steering control which may result in personal injury or death Do not operate the machine until the inspection and repair are completed Contact your Caterpillar dealer for any other required service 102814818 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD 924H and 924Hz Wipe all grease fittings before you apply any lubricant to the grease fittings i 900626511 Illustration 203 Right side steering cylinder Apply lubricant to the grease fitting for the rod end of the steering cylinder g00626510 Illustration 204 Left side steering cylinder Apply lubricant to the grease fitting for the rod end of the steering cylinder 188 Maintenance Section Tire Inflation Check SEBU8354 07 Illustration 205 900626533 Apply lubricant to the two remote grease fittings for the head ends of both stee
62. zer override switch 4 Move the transmission control lever to THIRD SPEED FORWARD while the AUTO shift switch is in the OFF position 5 Gradually increase the engine speed to high idle The machine should not move 6 Reduce the engine speed to low idle Move the transmission to NEUTRAL Engage the parking brake Lower the blade to the ground Stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the service brake before returning the machine to operation Refer to the Operations and Maintenance Manual Disk Brakes Inspect for the requirements of the disc thickness Secondary Brake Holding Ability Test Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles Make sure that the steering frame lock link is in the stored position Test the brakes on a dry level surface Fasten the seat belt before you test the brakes The following tests are used to determine if the parking brake is functional These tests are not intended to measure the maximum brake holding effort The brake holding effort that is required to sustain a machine at a specific engine rpm varies depending on the machine The variations are the differences in the engine setting in the power train efficiency and in the brake holding ability etc 1 Start the engine Raise the bucket slightly 2

MAINTENANCE INTERVALS - Safety

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