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MAINTENANCE INTERVALS - Safety

1. do 2 z Gd 2 D l l a o H o L jio o o 9 eC isi o fe iz OEE I o ig J mj 9 KU a O 8 1A Tmt 6 Uy ie T_T Illustration 244 g01000083 3 Open the side access panels on each side of the radiator AY AS yy ANN Illustration 245 g00101939 172 Maintenance Section Receiver Dryer Refrigerant Replace SEBU7879 15 4 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 5 Swing the hydraulic oil cooler and the air conditioner condenser if equipped back into the operating position 6 Close the radiator grill 102894326 Receiver Dryer Refrigerant Replace SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face
2. Illustration 178 g01387239 Rear Magnetic Oil Filter 8 Remove the magnetic plug on the front filter Clean the magnetic plug with a clean nonflammable solvent Install the magnetic plug Repeat the process for the rear magnetic filter 9 Operate the machine for a few minutes and recheck the oil level The oil level should reach the bottom of the filler plug opening If the oil level is higher than the filler plug opening do not allow the oil to drain to the level of the filler plug opening SEBU7879 15 141 Maintenance Section Differential and Final Drive Oil Level Check Rear Differential and Rear Final Drives O O Illustration 179 g00760167 1 Position the rear wheels so that final drive drain plugs 2 are facing downward Remove the final drive drain plugs and allow the oil to drain into a suitable container Clean the drain plugs and install the drain plugs Illustration 180 g00864019 Front view 2 Remove rear differential drain plug 4 and allow the oil to drain into a suitable container Clean the drain plug and install the drain plug 3 Remove rear differential filler plug 3 Fill the rear differential to the bottom of the filler plug opening Reference For the correct amount of oil refer to Operation and Maintenance Manual Capacities Refill 4 Clean the filler plug and install the filler plug 5 Position each rear whee
3. Illustration 160 g00759048 1 Remove the filter cover behind the seat Two threaded knobs 1 are used in order to remove the cover Remove the filter element 2 2 Open the access door 3 on the left side of the cab Remove the filter element 3 Clean the filter elements with pressure air or wash the filter elements in warm water with a nonsudsing household detergent 4 If water and detergent are used to clean the filter elements rinse the filter elements in clean water and allow the filter elements to air dry thoroughly Note If either filter element is damaged install a new filter element 5 Install the filter elements Install the filter cover and close the access door 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 SEBU7879 15 133 Maintenance Section Case Drain Screen Strainer Steering Pump Hydraulic Fan Pump Motor Clean Display _ _______4 FEES VODSOSG Illustration 161 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 162 g01223051 The WAVS camera is located on the rear of the machine in the center
4. Illustration 165 g01051679 The circuit breakers are located in the engine compartment on the left side of the machine Engine Shutdown 1 50 amp Electrical Circuits in Cab 2 20 amp Tilt Hood Actuator 3 60 amp Main Circuit 4 80 amp Alternator 5 105 amp S P Illustration 166 g00879750 Two circuit breakers are also located in the cab behind the operator seat These breakers are both 15 amperes i01709233 Cooling System Coolant ELC 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 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 SEBU7879 15 135 Maintenance Section Cooling System Coolant ELC Change NOTICE Topping off or mixing Cat ELC with ot
5. The Automatic TWIN Greasing System Reference Refer to System Operation RENR 6331for more information on the Automatic TWIN Greasing System A pressure hazard is present Severe personal in jury or death can result from removing hoses or fittings that are under pressure Relieve the pres sure in the system before you remove hoses or fittings Illustration 136 g01068678 Grease reservoir 1 is located near the rear fender on the right side of the machine Filling the Reservoir 1 Remove the dust cap 2 from the grease reservoir 1 2 Clean the filler tube assembly 3 and the coupling on the filler assembly 3 Install the filler assembly onto the filler tube assembly 3 4 Fill the grease reservoir 1 with grease to the maximum level which is indicated on the grease reservoir 1 Reference For the correct type of grease refer to Operation and Maintenance Manual Lubricant Viscosities 5 Remove the filler assembly and install the dust cap 2 If pumping becomes difficult the filter behind the coupling of the pump may be clogged Also check the coupling of the filler pipe Remove the clogged parts and clean the clogged parts Clean the filter in the coupling on a regular basis Air may be pumped into the reservoir Air can accumulate under the piston In order to remove the air fill the reservoir slightly above the maximum level mark Air and grease can escape through the
6. Replace the water temperature regulator Reference Refer to Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the correct procedure Add the Extended Life Coolant Reference Refer to Operation and Maintenance Manual Capacities Refill for the refill capacity of the cooling system Start the engine Run the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes Maintain the coolant level in sight gauge 2 on the upper right side of the radiator tank Install the cooling system pressure cap Close the engine hood 136 Maintenance Section Cooling System Coolant Extender ELC Add SEBU7879 15 101920332 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 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 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 conta
7. Dispose of all fluids according to local regulations and mandates SEBU7879 15 159 Maintenance Section Fuses Replace Illustration 219 g00761041 The fuel tank drain valve is located at the left side of the machine under the fuel tank 1 Open the fuel tank drain valve Allow the water and sediment to drain into a suitable container 2 Close the fuel tank drain valve 102283060 Fuses Replace SMCS Code 1417 510 NOTICE Replace fuses with the same type and size only Oth erwise electrical damage can result If itis necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer system from a circuit that has been overloaded Change a fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary Fuses The fuses protect the electrical Illustration 220 g01000750 Illustration 221 g01078009 The fuses are located in the cab on the right side of the operator seat 1 HVAC Blower nsise 20 Amperes 2 Neutralizer Override Switch 10 Amperes 3 Axle Oil Cooler and Switched Autolube POWST iee e eeen aisean 10 Amperes 4 Autodig Audible Alert 0 10 Amperes 5 Rear Ca
8. Illustration 140 Open the battery compartment on the right rear side of the machine Over time the vibration of an operating machine can cause the battery hold downs to loosen To help to prevent loose batteries and the possibility of loose cable connections tighten the nut on the hold down to a torque of 14 3 3 N m 10 5 2 2 Ib ft Repeat for the battery compartment on the left rear side of the machine g01058475 Illustration 139 Open the battery compartment on the right rear side of the machine 124 Maintenance Section Battery or Battery Cable Inspect Replace SEBU7879 15 103657099 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 Personal injury may occur from failure to properly service the batteries Batteries give off flammable fumes that can ex plode Electrolyte is an acid and can cause per sonal injury if it contacts the skin or eyes Prevent sparks near the batteries Sparks could cause vapors to explode Do not allow jumper ca ble ends to contact each other or the engine Im proper jumper cable connections can cause an ex plosion Always wear protective glasses when working with batteries 1 Turn the engine start switch key OFF Turn all of the switches OFF 2 Turn the battery disconnect switch OFF Remove the key 3 Disconnect the negative battery cable from the disconnect switch Note Do not allow the disconnecte
9. Install for the correct procedure for installing the pins in the linkage Apply lubricant through fitting 1 at the rod end of each tilt cylinder Apply lubricant through fitting 2 at the center pivot point of the linkage Apply lubricant through fitting 3 at the bottom of the linkage SEBU7879 15 129 Maintenance Section Bucket Lower Pivot Bearings Lubricate Illustration 148 g01125651 4 Rod End of LH Lift Cylinder 5 LH Upper Lift Arm Bearing 6 Head End of LH Tilt Cylinder 7 Head End of RH Tilt Cylinder 8 RH Upper Lift Arm Bearing 9 Rod End of RH Lift Cylinder 10 Rod End of RH Steering Cylinder 11 Head End of RH Lift Cylinder 12 Head End of LH Lift Cylinder Apply lubricant through the remote grease fittings for the upper lift arm bearings the head ends of the tilt cylinders the rod ends of the lift cylinders and the head end of the RH lift cylinder Apply lubricant through grease fitting 12 for the head end of the LH lift cylinder 103700100 Bucket Lower Pivot Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD Wipe all fittings before you apply lubricant Illustration 149 g0 1000649 Apply lubricant to each fitting There are a total of two fittings Note If necessary the work tool may need to be tilted forward in order to apply lubricant to the lower pivot bearing 103657242 Bucket Tips Inspect Replace SMCS Code 6805 040 680
10. 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 Caterpillar 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 5 Prime the fuel filters Reference Refer to Operation and Maintenance Manual Fuel System Prime for the proper procedure i04798701 Fuel Tank Breaker Relief Valve Replace If Equipped SMCS Code 5118 510 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Illustration 216 g01121947 1 Remove the fuel tank breaker relief valve from the top of the fuel tank 2 Install a new fuel tank breaker relief valve 158 Maintenance Section Fuel Tank Cap and Strainer Clean SEBU7879 15 102877628 Fuel Tan
11. and allow the oil to drain into a suitable container Clean the drain plug and install the drain plug 3 Remove front differential filler plug 4 Fill the front differential to the bottom of the filler plug opening Reference For the correct amount of oil refer to Operation and Maintenance Manual Capacities Refill 4 Clean the filler plug and install the filler plug 5 Position each front wheel so that front final drive filler plugs 1 are flush with the centerline of each front wheel Remove the front final drive filler plugs 6 Fill the front final drives to the bottom of the filler plug opening Reference For the correct amount of oil refer to Operation and Maintenance Manual Capacities Refill Note If the specified amount of oil will not fit in the front final drives install the filler plugs and operate the machine on level ground for a few minutes This will equalize the oil level in the front differential and in the front final drives Then add the remaining oil 7 Clean the filler plugs and install the filler plugs Note If your machine is equipped with the axle oil cooler there are 2 magnetic filters that need to be cleaned If your machine is not equipped with the axle oil cooler skip the next step Illustration 177 g01387238 Front Magnetic Oil Filter ees Z em O oa oa e AAAA eyo Go Woe F B wy
12. automatically apply the correct amount of tension to the new belt SEBU7879 15 125 Maintenance Section Brake Accumulator Check 101709202 Brake Accumulator Check SMCS Code 4263 535 OOOO A T Illustration 142 1 g00883720 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 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 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 pedal are required 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 101732078 Brake Discs Check SMCS Code 4255 535 Reference For the correct procedure refer to the Testing and Adjusting Service Manual of the braking system for your machine or consult your Caterpillar dealer 101739721 Braking System Test SMCS Code 4251 081 4267 081 e Fasten the seat belt befo
13. damage If the components are damaged consult your Cat dealer Refer to Daily Inspection for additional information Blade Thickness Illustration 238 g01600073 170 Maintenance Section Pallet Fork Inspect SEBU7879 15 1 Measure the thickness of the shank Ensure that the measuring device is held square across the shank in order to acquire an accurate measurement Q Illustration 239 g01600074 2 Measure the blade of the fork tine near the heel Ensure that the measuring device is held square across the blade in order to acquire an accurate measurement 3 Compare the measurement of the blade and the measurement of the shank 4 If the difference in measurements is less than 10 the fork tine can remain in service 5 If the difference in measurements is greater than 10 the fork tine must be taken out of service Fork tine wear that is greater than 10 represents a 20 reduction in the capacity of the fork tine Consult your Cat dealer for additional information Angle of the Heel Q a N gt Illustration 240 g01600075 1 Place a measuring device in the top inside area of the heel on top of the blade Ensure that the measuring device is held flat against the blade in order to acquire an accurate measurement Illustration 241 g01600076 2 Move the upper arm of the measuring device toward the face of the shank Ensure that the measuring devi
14. equipped Wash polycarbonate windows with a mild soap or detergent Never use a cleaning solvent on polycarbonate windows Wash polycarbonate windows with warm water and a soft sponge or damp cloth Never use a dry cloth or paper towels on polycarbonate windows Rinse the windows with a sufficient amount of clean water
15. overflow passage in the piston guide Excess air and excess grease will be released from the pump at the overflow passage The overflow passage is located on the right side of the pump 102231817 Axle Oscillation Bearings Lubricate SMCS Code 3268 086 BD 3278 086 BD Wipe all fittings before you apply lubricant Illustration 137 g01125821 Apply grease to the two remote grease fittings that are located on the left side of the machine near the articulation joint Backup Alarm Test If Equipped SMCS Code 7406 081 The backup alarm is on the rear of the machine SEBU7879 15 123 Maintenance Section Battery Clean Clean the battery terminals and the surfaces of the batteries with a clean cloth Coat the battery terminals with petroleum jelly Make sure that the battery cables are installed securely Repeat for the battery compartment on the left rear side of the machine 102066363 Battery Hold Down Tighten SMCS Code 7257 527 Illustration 138 g01043892 Turn the engine start switch to the ON position in order to perform the test Apply the service brake Place the transmission into REVERSE The backup alarm should sound immediately The backup alarm will continue to sound until the transmission is placed into NEUTRAL or into FORWARD 102065247 Battery Clean SMCS Code 1401 070 g01058828
16. 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 HYDO Advance 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 e Caterpillar TDTO TMS e Caterpillar Diesel Engine Oil e Caterpillar Biodegradable Hydraulic Oils HEES e Caterpillar Multipurpose Tractor Oil 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 2000 oil change interval should be u
17. Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 201 g00761763 150 Maintenance Section Engine Oil Sample Obtain SEBU7879 15 1 Open the engine access door on the right rear side of the machine 2 Remove engine oil dipstick 2 and wipe the dipstick with a clean cloth Then insert the dipstick and remove the dipstick again This will ensure a more accurate measurement of the engine oil level 3 While the engine is stopped check the ENGINE STOPPED side of engine oil dipstick 2 Maintain the oil level between the marks on the dipstick While the engine is running check the ENGINE RUNNING side of engine oil dipstick 2 Maintain the oil level between the marks on the dipstick 4 If necessary remove oil filler plug 1 and add oil through the oil filler tube 5 Clean the oil filler plug and install the oil filler plug 6 Close the engine access door Engine Oil Sample Obtain SMCS Code 1348 008 7542 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin 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
18. Lower the attachment to the ground and apply slight downward pressure Engage the parking brake and stop the engine 178 Maintenance Section Transmission Oil Change SEBU7879 15 Illustration 257 g00763411 Note Remove the transmission guard from the bottom of the machine in order to access the magnetic screen assembly 3 Remove the transmission oil drain plug 2 Allow the transmission oil to drain into a suitable container Clean the drain plug and install the drain plug 4 Change the transmission oil filter Reference Refer to Operation and Maintenance Manual Transmission Oil Filter Replace for the correct procedure 5 Remove the bolts and the cover from the front left side of the transmission case 6 Remove magnetic screen tube assembly 3 and suction screen 4 from the housing Remove three magnets from the magnetic screen tube assembly 7 Wash the magnetic screen tube assembly and the suction screen in a clean nonflammable solvent NOTICE Do not drop or rap the magnets against any hard ob jects Replace any damaged magnets 8 Use a cloth a stiff bristle brush or pressure air to clean the magnets 9 Clean the cover and inspect the cover seal Replace the seal if the seal is damaged 10 Install three magnets on magnetic screen tube assembly 3 Insert suction screen 4 and magnetic screen tube assembly 3 in the housing 11 Install the cover and four bolts 12 R
19. Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Operate the machine for a few minutes before you obtain the fluid sample This will thoroughly mix the fluid for a more accurate sample Illustration 202 g01573337 1 Sampling port for the engine oil Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample 103649984 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 SEBU7879 15 151 Maintenance Section Engine Oil and Filter Change Abnormally harsh operating cycles or harsh environments c
20. The cooling system drain valve is located on the lower left side of the radiator 4 Add the Extender to the cooling system SEBU7879 15 137 Maintenance Section Cooling System Coolant Level Check Reference Refer to Operation and Maintenance Manual Capacities Refill for the correct amount 5 Maintain the coolant level in sight gauge 2 on the upper right side of the radiator 6 Install the cooling system pressure cap Close the engine hood 102561075 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 1 Open the engine hood Illustration 171 g00879763 2 Maintain the coolant level in the sight gauge when the cooling system is cool If you need to add coolant daily check the cooling system for leaks 3 Inspect the radiator core for debris Clean the radiator core if necessary 4 If the coolant level is low slowly remove cooling system pressure cap in order to relieve system pressure Add coolant in order to maintain the coolant level in the sight gauge Add the coolant until the coolant level reaches the bottom of the filler neck 5 Inspect the cooling system pressure cap and the cap seal for damage Replace the cap seal if necessary Clean the cooling system pressure cap 6 Install
21. a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises Illustration 198 g01001638 The air filter service indicator is located near the air filter housing 1 Observe the performance of the air filter service indicator The air filter element should be cleaned or the air filter element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position 2 If any component damage is present replace the service indicator 3 If air leaks are present replace the service indicator Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 101968211 Engine Air Filter Service Indicator Inspect Replace SMCS Code 7452 040 7452 510 Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element bec
22. and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system Illustration 246 g01107270 1 Refrigerant accumulator 2 Refrigerant dryer Access refrigerant accumulator 1 from the left side of the machine Access in line refrigerant dryer 2 from the right side of the machine Refer to Service Manual SENR5664 Refrigerant Accumulator Remove and Install for the replacement procedure of accumulator 1 Refer to Service Manual SENR5664 In Line Refrigerant Dryer Remove and Install for the replacement procedure of refrigerant dryer 2 Note When you operate the machine in a climate wit
23. and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Open the access doors that are located on both sides of the machine Illustration 203 g01030594 Earlier machine models Left side of machine 152 Maintenance Section Engine Oil and Filter Change SEBU7879 15 Illustration 204 g01572993 Newer machine models Location of crankcase drain valve 2 Open the crankcase drain valve 1 on the right side of the machine Allow the oil to drain into a suitable container Close the crankcase drain valve Illustration 205 3 g01572998 Remove the filter element 2 on the left side of the machine with a strap type wrench Inspect the filter Clean the filter mounting base with a clean cloth Make sure that the used filter gasket has been completely removed Illustration 206 5 6 g00101318 Apply a thin coat of clean engine oil to the seal of the new filter Install the new oil filter elements by hand Instructions for the installation of the filters are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Illustration 207 7 g01573016 Remove engine oil filler cap 3 Fill the cran
24. local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them The fuel will not be filtered and could be contaminated Contaminated fuel will cause accelerated wear to fuel system parts The fuel system should be primed prior to starting the engine Illustration 213 g01109758 1 The water separator bowl is located on the bottom of the primary fuel filter Open the drain valve on the water separator bowl Allow the water and the fuel to drain into a suitable container 156 Maintenance Section Fuel System Secondary Filter Replace SEBU7879 15 2 Use a strap type wrench to remove the filter from the filter mounting base 3 Remove the water separator bowl from the filter element Clean the water separator bowl and the O ring groove Note The water separator bowl is reusable Do not discard the water separator bowl 4 Inspect the O ring seal in the water separator bowl for damage Replace the O ring seal if necessary 5 Lubricate the O ring seal with clean diesel fuel or with engine oil Place the O ring seal in the water separator bowl 6 Install the water separator bowl onto the new filter element by hand Do not use tools to tighten the water separator bowl Illustration 214 g00101318 7 Lubricate the gasket of the new filter element with clean diesel fuel Install a new filter hand tight until the seal of the fuel filter contacts the base Note the pos
25. 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 102050852 Case Drain Screen Strainer Steering Pump Hydraulic Fan Pump Motor Clean SMCS Code 4304 070 Z3 5057 070 Z3 The screen is located in the case drain line near the hydraulic oil tank g00999347 Illustration 163 Top view of case drain line for the implement pump Illustration 164 g00999352 Side view of case drain line Disconnect the line from the hydraulic oil tank Remove the screen from the hydraulic line Wash the screen in a clean nonflammable solvent Dry the screen by using pressure air Inspect the screen for damage Replace the screen if necessary Install the screen and connect the hydraulic oil line 134 Maintenance Section Circuit Breakers Reset SEBU7879 15 102050226 Circuit Breakers Reset SMCS Code 1420 529 button in order to reset the circuit breakers If the circuit is functioning properly the button will remain depressed If the button will not remain depressed check the appropriate electrical circuit C Circuit Breaker Reset Depress the
26. 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 NOTICE Do not fill fuel filters with fuel before installing them The fuel will not be filtered and could be contaminated Contaminated fuel will cause accelerated wear to fuel system parts The fuel system should be primed prior to starting the engine SEBU7879 15 157 Maintenance Section Fuel Tank Breaker Relief Valve Replace Illustration 215 g01109780 1 Use a strap type wrench to remove the secondary fuel filter The secondary fuel filter is located on the right side of the machine in the engine compartment Dispose of the used filter properly 2 Clean the filter mounting base Remove all of the used seal from the filter mounting base 3 Lubricate the seal of the new fuel filter with clean diesel fuel Install a new secondary fuel filter hand tight until the seal of the secondary fuel 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 fuel filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the fuel filter use the rotation index marks as a guide 4
27. pump is difficult to prime in order to aid pump priming refer to Illustration 225 and 226 Install the 5P 3415 Adapter 1 after removing the fitting 2 on the end of the 5P 2413 Air Regulator 3 The hydraulic tank breaker relief valve 4 is removed and the air regulator 3 is installed in order to regulate air pressure Air pressure of less than 10 psi can be applied in order to aid pump priming Illustration 225 g01662555 1 Adapter 2 Fitting 3 Air Regulator Illustration 226 g0 1660894 4 Hydraulic Tank Breaker Relief Valve 10 Add hydraulic oil to the tank until the oil level is at the FULL mark on the sight gauge 11 Stop the engine Top off the hydraulic tank so that the oil level is at the FULL mark on the sight gauge Install the filler cap Note The oil must be free of air bubbles If air bubbles are present in the hydraulic oil air is entering the hydraulic system Inspect the hydraulic suction line and the hose clamps 12 If necessary tighten any loose clamps or any loose connections Replace any damaged hoses 104004038 Hydraulic System Oil Filter Replace SMCS Code 5068 510 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
28. the bottom of the screen group 3 Wash the screens in a clean nonflammable solvent Dry each screen by using pressure air Inspect each screen for damage Replace the screens if necessary 4 Install the screens Install the two lines 3 and 4 102305841 Tire Inflation Check SMCS Code 4203 535 Al N eS Illustration 256 g01160201 Always obtain proper tire inflation pressures and maintenance recommendations for the tires on your machine from your tire supplier Measure the tire pressure on each tire Inflate the tires with nitrogen if necessary Reference Refer to the Tire Inflation Information section of the Operation and Maintenance Manual for more information i04004110 Transmission Oil Change SMCS Code 3030 044 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes in order to warm the transmission oil 2 Park the machine on a level surface
29. the cooling system pressure cap Close the engine hood 103697922 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 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 Note Level 1 results may indicate a need for Level 2 Analysis Illustration 172 g01058055 The sampling valve for the cooling system is located on the left side of the engine compartment near the water temperature regulator 138 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU7879 15 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 information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags
30. the load 9 Flanks The side faces of the blade and the shank 10 Blade Bevel The upper and lower surfaces of the tip on the blade that are tapered for easy insertion of the fork tines 11 Tip Flanks The side surfaces of the tip on the blade that are tapered for easy insertion of the fork tines 12 Top of Shank The upper surface on the shank 13 Shaft The tubes that are mounted on the fork tines for mounting the fork tines to the carriage Dimensions GTS BH A T e 3 em XX A A Section A A Illustration 237 T Thickness The thickness of the blade at the closest point to the heel W Width The width of the blade at the closest point to the heel BH Back Height The distance from the bottom of the blade to the top of the shank BL Length The length of the blade is measured from the front face on the shank to the tip on the blade A Angle The angle from the upper surface of the blade to the front face of the shank Inspection of the Fork Tines Check the fork tines daily for any twisting or bending of the fork tines If any twisting or bending is observed the fork tines should be changed prior to any lifting operation If the fork tines are damaged consult your Cat dealer g01598405 Check the fork tines for wear or for damage Inspect the welds the locks the shafts and the fork tines for
31. 4 Start the engine Raise the bucket Release the parking brake Reposition the machine in a straight direction without articulation 5 Lower the bucket to the ground Apply a slight down pressure Engage the parking brake Stop the engine 102407821 Drive Shaft Support Bearing Lubricate SMCS Code 3267 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Wipe off the fitting before any lubricant is applied 144 Maintenance Section Electronic Unit Injector Inspect Adjust SEBU7879 15 s mp a as Illustration 187 g00879770 Apply lubricant through one remote fitting on the support in the front loader frame 102061807 Electronic Unit Injector Inspect Adjust SMCS Code 1251 025 1251 040 1290 025 1290 040 The Electronic Control module produces high voltage To prevent personal injury make sure the Electronic Control Module is not powered and the unit injector solenoids are disconnected NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the unit injector lash is made The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result The operation of Caterpillar engines wi
32. 5 510 Personal injury or death can result from the bucket falling Block the bucket before changing bucket tips Bucket Tips g00101352 Illustration 150 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 e Use a Pin Master Follow Step 1 a through Step 1 c for the procedure 130 Maintenance Section Bucket Tips Inspect Replace SEBU7879 15 6 2 aN lt RNI CE A B b a Place the Pin Master on the bucket tooth MA Illustration 151 g00590670 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 152 g00590819 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 153 g00101359 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 bucket tip The p
33. Check the hydraulic oil level Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Level Check 162 Maintenance Section Hydraulic System Oil Change SEBU7879 15 103267620 Hydraulic System Oil Change SMCS Code 5056 044 Selection of the Oil Change Interval 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 2000 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 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
34. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR aon 2012 Operation and Maintenance Manual 980H Wheel Loader SEBU7879 15 119 Maintenance Section Maintenance Interval Schedule 104876432 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 maintenance 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 perform
35. 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 e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102196476 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 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 Illustration 173 g01058055 The sampling valve for the cooling system is located on the left side of the engine compartment near the water temperature regulator 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 Operati
36. Shims Inspect Adjust Replace SMCS Code 6001 025 CLR 6001 040 CLR 6001 510 24 6119 025 CLR 6119 040 CLR 6119 510 24 Inspect the Linkage Illustration 145 g03003577 1 Lift Arm 2 Bucket 3 Inspection Points for the Bucket Hinge Periodically inspect the bucket linkage The gap between the bucket and the linkage should not exceed the thinnest shim that is available for the bucket assembly 1 Lower the lift arm assembly 1 to suitable blocking Rest the bucket 2 on the ground 2 Use a gauge to measure the gap at the hinge 3 If the measurement exceeds the required amount new shims must be installed Installing Shims for the Hinge on the Bucket Note Refer to the Disassembly and Assembly Manual Bucket Remove for the correct procedure for removing the pins in the linkage 128 SEBU7879 15 Maintenance Section Bucket Linkage and Loader Cylinder Bearings Lubricate 102231274 Bucket Linkage and Loader Cylinder Bearings Lubricate SMCS Code 5102 086 BD 5104 086 BD 6107 086 BD Illustration 146 g01345720 2 Bucket 4 Install washers on lift arm Install washers and pin assembly to the bucket When possible use washers on both sides of the lift arm to reduce the gap between the lift arm and the hinges on the bucket illustration 147 g01063586 Note Refer to the Disassembly and Assembly Wipe off all fittings before any lubricant is applied Manual Bucket
37. an 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 Hours This program consists of three oil change intervals of 500 hours Oil 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 Maint
38. an two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 191 g00281692 Note When the primary air filter elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air filter element Dirt could be forced further into the pleats 146 Maintenance Section Engine Air Filter Secondary Element Replace SEBU7879 15 Vacuum Cleaning Vacuum cleaning is another method for cleaning primary air filter elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Inspecting the Primary Air Filter Elements Illustration 192 g00281693 Inspect the clean dry primary air filter element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air filter element Rotate the primary air filter element Inspect the primary air filter element for tears and or holes Inspect the primary air filter element for light that may show through the filter material If it is necessary in order to
39. and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Wipe the surfaces around any openings before you check the oil or before you add oil 142 Maintenance Section Differential and Final Drive Oil Sample Obtain SEBU7879 15 Differentials Illustration 181 g00535224 Front Differential Filler Plug Illustration 182 g00535225 Rear Differential Filler Plug 1 Remove the differential filler plug 2 Check the oil level The oil should be level with the bottom of the filler opening Add oil if necessary 3 Clean the differential filler plug and install the differential filler plug 4 Repeat the procedure for the remaining differential Final Drives O O SS YN Illustration 183 g00760182 1 Position the wheel so that the final drive filler plug is level with the centerline of the wheel Remove the final drive filler plug 2 Check the oil level The oil should be level with the bottom of the filler opening Add oil if necessary 3 Clean the final drive filler plug and install the final drive filler plug 4 Repeat the procedure for the remaining final drives 101920699 Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4050 008 4070 008 7542 Illustration 184 g00535224 Front Differential Filler Plu
40. ar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation 126 Maintenance Section Bucket Cutting Edges Inspect Replace SEBU7879 15 Parking Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move reduce the engine speed immediately and apply the service brake pedal This test is performed when the parking brake is engaged If the machine begins to move compare the engine rpm to the engine rpm of a prior test This will indicate the amount of system deterioration 1 Start the engine Raise the implement slightly Engage the parking brake 2 Move the transmission control to THIRD SPEED FORWARD Make sure that the autoshift control is in the OFF position The parking brake indicator light should come on 3 Gradually increase the engine speed to high idle The machine should not move 4 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation 103657238 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
41. ar 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 157 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 101922739 Bucket Upper Pivot Bearings Lubricate SMCS Code 6001 086 BD 6107 086 BD Wipe all fittings before you apply lubricant Illustration 158 g01000653 Apply lubricant to each fitting There are a total of two fittings 132 Maintenance Section Bucket Wear Plates Inspect Replace SEBU7879 15 101709216 Bucket Wear Plates Inspect Replace SMCS Code 6120 040 6120 510 Personal injury or death can result from the bucket falling Block the bucket before changing bucket wear plates Illustration 159 g00879740 Inspect the wear plates Replace the wear plates before damage to the bottom of the bucket occurs Consult your Caterpillar dealer for replacement of wear plates 101449996 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Note Clean the cab air filters more often if the machine is being operated in dusty conditions
42. are 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 SEBU7879 15 175 Maintenance Section Secondary Steering Test 103694709 Secondary Steering Test SMCS Code 4300 081 SE 4300 081 SST 4324 081 4324 The service brake must be checked in order to en sure proper operation before you test the supple mental steering system Personal injury death or property damage could occur if the supplemental steering system is test ed and the service brake is not operational Test the service brake before you test the supple mental steering system Perform the following procedure if your machine is equipped with a ground driven supplemental steering and if the procedure is required by local regulations Ensure that there are no hazards in the test area The test area must be unobstructed and level Operate the machine in second gear Ensure that all air tanks and accumulators are
43. b Floodlights 15 Amperes 6 Air Seat and Heated Seat 15 Amperes 7 Switched Autolube Power 10 Amperes 8 Engine ECM Switched Power 10 Amperes 9 Front Cab Floodlights 15 Amperes 10 Beacon and Heated Mirrors 10 Amperes 160 Maintenance Section High Intensity Discharge Lamp HID Replace SEBU7879 15 11 Turn Signal Flasher Front Flood Relays and Rear Flood Relays n se 10 Amperes 12 Machine Security System and Product LINK iaia seta linen 10 Amperes 13 LH Indicator Display and RH Indicator Display eere ta wetness 10 Amperes 14 Tilt Position Sensor and Lift Position SENSOR eeiiasseetictie ate eatadeeetaadicacntitlate 10 Amperes 15 Transmission ECM and LH Brake Pedal SENSOR aiaa e aee RAT 10 Amperes 16 Implement ECM and Lever SENSOMS i i e a a 10 Amperes 17 EMS Quad Gauge Speedometer Tachometer and Backlights cccceeeeeeeeees 10 Amperes 18 Wiper and Washer for the Front and the Rear WINdOWS 2 0 cecceceeeeeeeeeeeeeseteees 10 Amperes 19 Payload Control System PCS 10 Amperes 20 Voltage Converters and 24V Radio miners eee e a aa 10 Amperes 21 Center Indicator Display 10 Amperes 22 Engine ECM Unswitched Power 15 Amperes 23 Product Link ee 15 Amperes 24 Voltage Converter Memory Attachment 0 0 0 eceeeeeeeteeeeeeneee 10 Ampere
44. ce is held flat against the face of the shank in order to acquire an accurate measurement 3 Check the angle that was measured with the device for the angle of the heel 4 If the angle is between 87 degrees and 93 degrees the fork tine can remain in service 5 If the angle is less than 87 degrees or greater than 93 degrees the fork tine must be taken out of service The fork tines must be inspected for the following conditions e permanent deformation e stress cracks e other defects Consult your Cat dealer for additional information SEBU7879 15 171 Maintenance Section Pallet Fork Lubricate 103082842 Pallet Fork Lubricate SMCS Code 6136 086 Illustration 242 g01563105 typical example 1 Coat the shafts with grease Illustration 243 g01563115 typical example 2 Coat the mounting holes for the quick coupler with grease Reference Refer to Operation and Maintenance Manual SEBU6250 Caterpillar Machine Lubricant Recommendations for information on lubricants 104039309 Radiator Core Clean SMCS Code 1353 070 KO Ensure that the engine is off before you perform this procedure 1 Open the radiator grill at the rear of the machine 2 Swing the hydraulic oil cooler and the air conditioner condenser away from the radiator
45. cedures to assure consistent 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 The primary air filter element can be used up to six times if the element is properly cleaned and inspected When the primary air filter element is cleaned check for rips or tears in the filter material The primary air filter element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Visually inspect the primary air filter elements before cleaning Inspect the air filter elements for damage to the seal the gaskets and the outer cover Discard any damaged air filter elements There are two common methods that are used to clean primary air filter elements e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air filter elements that have not been cleaned more th
46. cesssteeeseseesseeeeeeees 177 Every 100 Service Hours or 2 Weeks Axle Oscillation Bearings Lubricate 122 Bucket Linkage and Loader Cylinder Bearings Lubricate secnieeteer ed eed nade iain wade dee 128 Logging Fork Clamp Lubricate eeeee 167 Steering Cylinder Bearings Lubricate 176 Initial 250 Service Hours Engine Valve Lash Check seisseen 153 Transmission Oil Filter Replace 06 179 Every 250 Service Hours Drive Shaft Support Bearing Lubricate 143 Engine Oil Sample Obtain a se 150 120 Maintenance Section Maintenance Interval Schedule SEBU7879 15 Every 250 Service Hours or Monthly Battery Clan orre arar EE TANARA 123 Belt Inspect Adjust Replace c cecceeees 124 Brake Accumulator Check ceceeeeeeeees 125 Braking System Test cceceseeeeeesteeeeeeenaes 125 Differential and Final Drive Oil Level Check 141 Drive Shaft Spline Center Lubricate 143 Engine Air Filter Service Indicator INSpect REPlACE cececeecceceeeeeeseeteeseenneaeeees 148 Every 250 Service Hours or 3 Months Engine Crankcase Breather Clean 08 149 Engine Oil and Filter Change n se 150 Pallet Fork Lubricate 2 0 ceceeeeeseeeeeeeenaes 171 Steering Column Play Check seeen 175 Initial 500 Hours for New Systems Refilled Systems and Converted Sys
47. confirm the result compare the primary air filter element to a new primary air filter element that has the same part number Do not use a primary air filter element that has any tears and or holes in the filter material Do not use a primary air filter element with damaged pleats gaskets or seals Discard damaged primary air filter elements Storing Primary Air Filter Elements If a primary air filter element that passes inspection will not be used the primary air filter element can be stored for future use Illustration 193 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An air flow restriction may result To protect against dirt and damage wrap the primary air filter elements in Volatile Corrosion Inhibited VCI paper Place the primary air filter element into a box for storage For identification mark the outside of the box and mark the primary air filter element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 103649902 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary filter element Never attempt to reuse it by cleaning The secondary filter element should be replaced at the time the primary element is serviced for the third time The secondary filter element should also be replaced if the yellow piston in the filter element indicat
48. d battery cable to contact the disconnect switch 4 Disconnect the negative battery cable at the battery 5 Disconnect the positive battery cable at the battery 6 Inspect the battery terminals for corrosion Inspect the battery cables for wear or damage 7 Make any necessary repairs If necessary replace the battery cables or the battery 8 Connect the positive battery cable at the battery 9 Connect the negative battery cable at the battery 10 Connect the battery cable at the battery disconnect switch 11 Install the key and turn the battery disconnect switch ON 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 e An authorized battery collection facility e Recycling facility i03700093 Belt Inspect Adjust Replace SMCS Code 1397 025 1397 040 1397 510 Your machine is equipped with a single serpentine belt Stop the engine Open the rear hood The belt is located at the front of the engine g00759275 2 3 Serpentine Belt 4 Square Drive Hole 5 Compressor 6 Drive Pulley Inspect the condition of the serpentine belt If the belt is cracked or frayed replace the belt Insert a ratchet with a square drive into the hole 4 of the tensioner Rotate the tensioner clockwise in order to relieve tension Remove the belt Install the new belt correctly as shown The tensioner will
49. draulic oil tank is being drained or while the hydraulic oil tank is empty Excessive wear and damage to the hydraulic compo nents can occur 5 Remove the pipe nipple in order to close the drain valve Install the drain plug 6 Replace the hydraulic oil filter Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Replace for the correct procedure 7 Fill the hydraulic tank with clean oil Make sure that the oil level is at the FULL mark on the sight gauge 3 Install the filler cap Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 8 Start the engine and run the engine for at least ten seconds Then stop the engine and add hydraulic oil to the tank until the oil level is at the FULL mark on the sight gauge Install the filler cap 9 Start the engine and run the engine at low idle Cycle the implements so that all hydraulic systems are filled with oil Articulate the machine from left to right in order to fill the steering system with oil Note If the alert indicator for a low oil level comes on stop the engine and immediately add oil to the hydraulic tank The oil level should not be below the suction ports in the hydraulic tank while the engine is running 164 Maintenance Section Hydraulic System Oil Filter Replace SEBU7879 15 Note If the
50. eck for the correct procedure 101460230 Transmission Oil Level Check SMCS Code 3030 535 FLV The sight gauge for the transmission oil is located on the left side of the machine Illustration 260 g00763130 180 Maintenance Section Transmission Oil Sample Obtain SEBU7879 15 When the engine is off and the transmission oil is cold maintain the transmission oil level to FULL mark 1 When the engine is running at low idle and the transmission oil is warm maintain the transmission oil level between FULL mark 1 and LOW mark 2 Add oil if necessary 102065073 Transmission Oil Sample Obtain SMCS Code 3080 008 7542 Illustration 261 g01058363 Obtain a sample of the transmission oil from the sampling valve The sampling valve is located on the top of the transmission oil filter Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the engine oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil 101460367 Window Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solvent or equivalent System damage can result from freezing Illustration 262 g00763261 a Window Washer Reservoir The window washer reservoir i
51. ed 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 substantially S O S services may extend the oil change even longer Consult your Cat dealer for details The following guidlines shoud be followed if the service hours are not met Items listed between 10 and 100 service hours should be performed at least every 3 months Items listed between 250 and 500 service hours should be performed at least every 6 months Items listed between 1000 service hours and 2500 service hours should be performed at least every year When Required Automatic Lubrication Grease Tank Fill 121 Battery or Battery Cable Inspect Replace 124 Bucket Cutting Edges Inspect Replace 126 Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust Replace cceeeeesseseeeeeeees 127 Bucket Tips Inspect Replace e 129 Bucket Wear Plates Inspect Replace 132 Camera Clean 200 cececccccececeeeeeeeeeeeeeeneecaeeeeeeeeess 132 Circuit Breakers Reset eseeceeeeeeeeeees 134 Engine Air Filter Primary Element Clean Replaces neak eraai ee edeak Onah Eea ikee ia renint 144 Engine Air Filter Secondary Element Replace 146 Ether Starting Aid Cylinder Replace 153 Fuel System Prime 0 ccecceeeeeeeeeeeeeeeeeeeneeees 154 Fu
52. edges Illustration 143 g00764365 1 Bolts for Cutting Edge 2 Cutting Edge Check the cutting edges and the end bits for wear and for damage Use the following procedure to service the cutting edges and the end bits 1 Raise the bucket and place blocking under the bucket 2 Lower the bucket onto the blocking Stop the engine 3 Remove bolts 1 cutting edge 2 and the end bits 4 Clean all contact surfaces 5 If the opposite side of the cutting edge is not worn use the opposite side of the cutting edge The end bits are not reversible If both sides are worn install a new cutting edge 6 Install bolts 1 Tighten the bolts to the specified torque Reference Refer to Specifications SENR3130 Ground Engaging Tool G E T Fasteners 7 Start the engine Raise the bucket and remove the blocking Lower the bucket to the ground 8 After a few hours of operation check the bolts for proper torque SEBU7879 15 127 Maintenance Section Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust Replace Bucket Wear Plates Personal injury or death can result from the bucket falling Block the bucket before changing bucket wear plates Illustration 144 g00879740 Inspect the wear plates Replace the wear plates before damage to the bottom of the bucket occurs Consult your Caterpillar dealer for replacement of wear plates Bucket Hinge and Lift Arm Clearance
53. el Tank Breaker Relief Valve Replace 157 Fuses Replace it e a EE aT a 159 High Intensity Discharge Lamp HID Replace 160 Oil Filter InSpect 2 0 0 0 anane saa toekie aipat 167 Pallet Fork Inspect cecceeeeeeeeeeeeeeeteteeteeee 168 Radiator Core Clean oo eeeeeeeeeeeeeeeeeeeeenneeees 171 Ride Control Accumulator Check 2 055 173 Secondary Steering Test 0 ceeeeeeeeeeeeenees 175 Window Washer Reservoir Fill 000 180 Window Wiper Inspect Replace 6 180 Every 10 Service Hours or Daily Backup Alarm Test 2 ecceeceeeeeeeeeteeeeeees 122 Cooling System Coolant Level Check 137 Engine Air Filter Service Indicator Inspect 148 Engine Oil Level Check cceeeeeeeeeeeeeeeeeeees 149 Fuel System Primary Filter Water Separator DOAN EE E E cette ceeds O T E E 154 Hydraulic System Oil Level Check neses 166 Seat Belt Inspect oo eee eeeeeeeeteeteeeeeeeeees 174 Transmission Oil Level Check 179 Windows Clea isisisi ciinii tinei 181 Every 50 Service Hours or Weekly Bucket Lower Pivot Bearings Lubricate 129 Bucket Upper Pivot Bearings Lubricate 131 Cab Air Filter Clean Replace cee 132 Fuel Tank Water and Sediment Drain 158 Hydraulic System Oil Level Hood Tilt Check 165 Tire Inflation CHECK cccccece
54. emove transmission oil filler cap 1 on the left side of the machine Fill the transmission with oil through the transmission oil filler tube Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 13 Clean the filler cap and install the filler cap Illustration 258 g00763494 14 Remove the transmission breather from the top of the transmission Wash the transmission breather in a clean nonflammable solvent Allow the transmission breather to dry Then install the transmission breather 15 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 16 Move the transmission control to the NEUTRAL position Engage the parking brake and stop the engine Inspect the transmission for leaks 17 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check SEBU7879 15 179 Maintenance Section Transmission Oil Filter Replace 104004116 Transmission Oil Filter Replace SMCS Code 3004 510 3067 510 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 opening any compartment or disassembling any com pon
55. enance 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 SEBU6250 Caterpillar Machine Fluids Recommendations Reference Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Reference Special Publication PEDP7035 Optimizing Oil Change Intervals Reference Special Publication PEDP7036 S O S Fluid Analysis Reference Special Publication PEDP7076 Understanding the S O S Oil Analysis Tests Procedure for Changing the Engine Oil and the Filter 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 Dealer Service Tool Catalog for tools
56. ent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Open the engine hood The transmission oil filter is located on the right side of the machine Illustration 259 g01058312 2 Remove plug 2 and allow the oil to drain into a suitable container 3 Use a strap type wrench in order to remove the transmission filter housing 1 4 Remove the used transmission oil filter element Dispose of the used filter element properly 5 Clean the transmission filter housing in a clean nonflammable solvent Clean the filter housing base 6 Inspect the filter housing seal Replace the seal if the seal is damaged 7 Insert a new transmission oil filter element into the transmission filter housing 8 Install the transmission filter housing into the filter housing base Tighten the transmission filter housing by hand Install plug 2 9 Start the engine Apply the service brakes 10 Slowly operate the transmission controls in order to circulate the transmission oil Return the transmission to NEUTRAL 11 Engage the parking brake Inspect the transmission oil filter for leaks 12 Stop the engine 13 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Ch
57. er relief valve in a clean nonflammable solvent 3 Dry the breaker relief valve thoroughly by shaking or use compressed air 4 Install the hydraulic tank breaker relief valve Logging Fork Clamp Lubricate If Equipped SMCS Code 6113 086 BD 6410 086 BD 103657276 Wipe off all fittings before any lubricant is applied Illustration 233 g01962679 Apply lubricant through three fittings on each side of the logging fork There is a total of six fittings 102106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 234 g00100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure 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
58. g SEBU7879 15 143 Maintenance Section Drive Shaft Spline Center Lubricate Illustration 185 g00535225 Rear Differential Filler Plug The axles are not equipped with sampling valves Obtaining a sample of the differential and final drive oil will require a vacuum pump or an equivalent Withdraw the fluid through the filler opening on the right side of each axle Reference Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information about obtaining an fluid sample 103657243 Drive Shaft Spline Center Lubricate SMCS Code 3253 086 SN Wipe all of the fittings before you apply grease to the fittings NOTICE To prevent damage to the seal articulate the machine full right or left before lubricating the splines 1 Start the engine Raise the bucket Release the parking brake Articulate the machine to the right or to the left in order to properly lubricate the splined shaft 2 Lower the bucket to the ground Engage the parking brake Stop the engine Note Since the steering frame lock cannot be connected in this case remove the engine start switch key and turn the battery disconnect switch to the OFF position Illustration 186 g01106848 3 Apply grease to the fitting 1 Apply grease until the relief 2 overruns Note 5P 0960 Molybdenum Grease is preferred 1P 0808 Multipurpose Grease may be used
59. h high humidity replace the in line refrigerant dryer after every 1000 service hours or 6 months SEBU7879 15 173 Maintenance Section Ride Control Accumulator Check 101568401 Ride Control Accumulator Check SMCS Code 5077 535 R6 Beet COEN Illustration 247 g008 14351 G mM 22 p F 1 2 g00754724 Illustration 248 Travel at high speeds over rough terrain causes bucket movement and a swinging motion The ride control system acts as a shock absorber by dampening forces from the bucket This helps to stabilize the entire machine The ride control switch is located on the switch panel Manual Ride Control Press the bottom of the switch in order to turn on the ride control system at all travel speeds The indicator 1 for ride control will be illuminated Automatic Ride Control Press the top of the ride control switch in order to activate the automatic ride control system The ride control system will automatically turn on if the ground speed exceeds 9 6 km h 6 mph The ride control system will automatically turn off if the ground speed is less than 9 6 km h 6 mph and if the bucket is being operated The indicator for the automatic ride control 2 will be illuminated The activation speed for the automatic ride control can be adjusted by a qualified service technician Place the switch into the middle position in order to turn off the ride con
60. her products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life Reference For information about adding Extender to your cooling system refer to Operation and Maintenance Manual Cooling System Coolant Extender ELC Add or consult your Caterpillar dealer If an Extended Life Coolant was previously used flush the cooling system with clean water No other cleaning agents are required Use the following procedure to change the Extended Life Coolant Illustration 167 g00759585 The cooling system pressure cap is located under the engine hood at the rear of the machine 1 Open the engine hood 2 Slowly loosen the cooling system pressure cap 1 in order to relieve system pressure Remove the cooling system pressure cap Illustration 168 3 g00879754 Open the drain valve The drain valve is located near the rear axle of the machine Allow the coolant to drain into a suitable container Flush the cooling system with clean water until the draining water is clean Close the drain valve
61. in can be installed by using one of the following methods e 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 154 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 SEBU7879 15 131 Maintenance Section Bucket Upper Pivot Bearings Lubricate 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 155 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 156 g01175361 1 Use a pry bar in order to disengage retainer 5 2 Use the pry b
62. in fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life When a Caterpillar Extended Life Coolant ELC is used an Extender must be added to the cooling system Use a 8T 5296 Coolant Test Kit to check the concentration of the coolant Reference For additional information about adding Extender refer to Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer Illustration 169 g00759585 The cooling system pressure cap is located under the engine hood at the rear of the machine 1 Open the engine hood 2 Slowly loosen cooling system pressure cap 1 in order to relieve any system pressure Remove the cooling system pressure cap Illustration 170 g00879755 3 If necessary drain enough coolant from the radiator in order to allow the addition of Extender to the cooling system
63. ing probe Install the sampling probe with the piece of bulk hose onto valve assembly 2 Note Consult your Caterpillar dealer for the proper tooling or refer to the parts manual for your machine 4 Position a suitable container under the hose 5 Turn toggle switch 1 to the ON position Toggle switch 1 is for the fuel priming pump 6 Allow the air fuel mixture to flow into the suitable container until the fuel flows in a steady stream 7 Turn toggle switch 1 to the OFF position 8 Remove the sampling probe with the piece of bulk hose from valve assembly 2 9 Start the engine The engine should start The engine should run smoothly Failure to tighten fittings could result in fuel leaks If the engine does not start or the engine misfires further priming is necessary 10 Clean residual fuel from the engine components 11 Close the engine access door 102197567 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 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 pr
64. 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 168 Maintenance Section Pallet Fork Inspect SEBU7879 15 104004068 Pallet Fork Inspect SMCS Code 6136 040 Descriptions of the Fork Tine Parts A aoo 4 we 2 Illustration 235 1 Blade The horizontal part of the fork tine that supports the load 2 Heel The radius on the fork tine that connects the blade to the shank 3 Shank The vertical part of the fork tine that has the hooks that support the fork tines attached 4 Hook or Hanger Carriers that mount the fork tines to the carriage 5 Tip The free end of the blade Surfaces g01598401 go a 13 d C Illustration 236 6 Upper Face of the Blade The upper surface of the blade that carries the load g01598403 7 Bottom of Heel The lower surface of the blade that includes the tapers SEBU7879 15 169 Maintenance Section Pallet Fork Inspect 8 Front Face of Shank The distance for the load center is measured from the front face of the shank and the face of the shank contacts
65. ition 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 fuel filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the fuel filter use the rotation index marks as a guide 8 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 Caterpillar 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 9 Tighten the drain valve on the water separator bowl Note The water separator element is under suction during normal engine operation The drain valve must be tightened in order to prevent air leakage into the fuel system 10 Prime the fuel system in order to fill the filter element with fuel Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure 102197586 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE 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
66. k Cap and Strainer Clean SMCS Code 1273 070 Z2 1273 070 STR Illustration 217 g01432143 1 Cap 2 Strainer 3 Fuel Tank The fuel tank is located on the left side of the machine 1 Remove the fuel tank cap and the strainer from the fuel tank 2 Inspect the seal for damage If the seal is damaged replace the cap 3 Wash the strainer in a clean nonflammable solvent 4 Install the strainer into the filler opening 5 Install the fuel tank cap Illustration 218 g01431287 6 Inspect the fuel cap boot if equipped If the fuel cap boot is damaged replace the fuel cap boot If your machine does not have a fuel cap boot contact your Caterpillar dealer for information about the fuel cap boot 7 Wash the fuel cap boot in a clean nonflammable solvent 8 Install the fuel cap boot and the fuel tank cap 101455356 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S 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
67. kcase with new oil Reference Refer to Operation and Maintenance Manual Capacities Refill Clean engine oil filler cap 3 Install the engine oil filler cap Start the engine and allow the oil to warm Check for leaks 10 Check the engine oil level with engine oil level gauge 4 Reference Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure SEBU7879 15 153 Maintenance Section Engine Valve Lash Check 11 Stop the engine Close the engine access door 104538255 Engine Valve Lash Check SMCS Code 1105 535 In order to perform the valve lash adjustment refer to Systems Operation Testing and Adjusting Engine Valve Lash Inspect Adjust Note A qualified mechanic should adjust the engine valve lash because special tools and training are required 102770364 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to prevent being burned by hot oil or spray Electrical shock hazard The electronic unit injec tor system uses 90 120 volts Illustration 208 g01372247 1 Start the engine Run the engine at low idle Illustration 209 g00038585 2 Watch the top surface of each valve rotator Whenever an inlet valve closes or an exhaust valve closes each valve rotator should turn 3 If a valve rotator fai
68. l so that rear final drive filler plugs 1 are flush with the centerline of each rear wheel Remove the rear final drive filler plugs 6 Fill the rear final drives to the bottom of the filler plug opening Reference For the correct amount of oil refer to Operation and Maintenance Manual Capacities Refill Note If the specified amount of oil will not fit in the rear final drives install the filler plugs and operate the machine on level ground for a few minutes This will equalize the oil level in the rear differential and in the rear final drives Then add the remaining oil 7 Clean the filler plugs and install the filler plugs 8 Operate the machine for a few minutes and recheck the oil level The oil level should reach the bottom of the filler plug opening If the oil level is higher than the filler plug opening do not allow the oil to drain to the level of the filler plug opening 101453263 Differential and Final Drive Oil Level Check SMCS Code 3278 535 FLV 4050 535 FLV 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
69. lectronic Unit Injector Inspect Adjust 144 Engine Valve Lash Check eessen 153 Engine Valve Rotators Inspect eee 153 Hydraulic System Oil Change eee 162 Hydraulic Tank Breaker Relief Valve Clean 166 Service Brake Wear Indicator Check 4 175 Steering Column Spline Command Control Steering U o ea IE EE E laa bbecseehiay 176 Every Year Cooling System Coolant Sample Level 2 Obtain ionin esee aiii i dee aSa aie 138 Receiver Dryer Refrigerant Replace 172 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace 22 00 0222 ccccceeeeeseceeceeeeeeeeeees 174 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 136 Cooling System Water Temperature Regulator Replace E EE aad EEA 138 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 134 SEBU7879 15 121 Maintenance Section Articulation Bearings Lubricate 103023062 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Wipe all fittings before applying grease OK Illustratio
70. ls to rotate consult your Caterpillar dealer for service Note Caterpillar recommends replacing valve rotators that are operating improperly An improperly operating valve rotator will shorten valve life because of accelerated wear on the valves Note If a damaged valve rotator is not replaced some valve face guttering could result Metal particles from the valve could fall into the cylinder This could cause damage to the piston head and to the cylinder head 102047267 Ether Starting Aid Cylinder Replace If Equipped SMCS Code 1456 510 CD Illustration 210 g00101192 154 Maintenance Section Fuel System Prime SEBU7879 15 1 Open the engine hood The ether starting aid cylinder is mounted in the center 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 102197564 Fuel System Prime SMCS Code 1250 548 The priming pump is located on the right side of the machine in the engine compartment 1 Turn the ignition switch to the OFF position 2 Open the engine access door Illustration 211 g01124747 3 Attach a piece of bulk hose to a sampl
71. ly The bulb is not removed separately from the lens assembly Replace the entire lens assembly on these HID lamps oo Remove the bulb from the HID lamp A Install the replacement bulb in the HID lamp If the bulb is an integral part of the lens assembly install the replacement lens assembly in the HID lamp Note In order to avoid failure to the bulb that is premature avoid touching the bulb s surface with your bare hands Clean any fingerprints from the bulb with alcohol prior to operation 5 Reassemble the housing for the HID lamp Ensure that any printing on the lens is oriented correctly with respect to the HID lamp s mounting position on the machine SEBU7879 15 161 Maintenance Section Hydraulic System Biodegradable Oil Filter Element Replace 6 Reattach the electrical power to the HID lamp 7 Check the HID lamp for proper operation Note Consult your Caterpillar dealer for additional information on HID lamps 104004021 Hydraulic System Biodegradable Oil Filter Element Replace SMCS Code 5068 510 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and s
72. n 134 g00879717 Apply grease to one fitting on the upper pivot bearing and one fitting on the lower pivot bearing 103700085 Automatic Lubrication Grease Tank Fill If Equipped SMCS Code 7540 544 TNK The Lincoln Quicklub Lubrication System Reference Before any service work is performed on the lubrication system refer to Special Instructions REHS1396 or consult your Caterpillar dealer A pressure hazard is present Severe personal in jury or death can result from removing hoses or fittings that are under pressure Relieve the pres sure in the system before you remove hoses or fittings Illustration 135 g01067897 Filling the Reservoir 1 The Lincoln Quicklub pump 1 is located near the rear fender on the right side of the machine 2 Fill the reservoir 2 through the grease fitting 3 The grease fitting 3 is located at the base of the reservoir 2 Reference For the correct type of grease refer to Operation and Maintenance Manual Lubricant Viscosities 3 Refill the reservoir when the grease reaches the MIN mark on the reservoir 4 Fill the reservoir to the MAX mark on the reservoir Priming the System After the reservoir has been filled with the recommended lubricant loosen the fitting to the supply line Operate the pump until lubricant flows from the outlet Then tighten fitting 122 Maintenance Section Axle Oscillation Bearings Lubricate SEBU7879 15
73. ndicator annually regardless of the operating conditions Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 103091842 Engine Crankcase Breather Clean SMCS Code 1317 070 Illustration 200 g01573213 Engine crankcase breather 3 is located on the top of the valve cover 1 Loosen clamps 1 Remove hose 2 from engine crankcase breather 3 2 Loosen the hose clamp underneath the breather and remove the breather 3 Wash the breather in a clean nonflammable solvent Inspect the breather and the seal for damage Replace the seal if necessary 4 Use pressure air to dry the breather 5 Install the seal engine crankcase breather 3 hose 2 and clamps 1 101457076 Engine Oil Level Check SMCS Code 1000 535 FLV NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage 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
74. ny 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 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 ej 0 4 g01152685 Illustration 251 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 hardw
75. oducts Dispose of all fluids according to local regulations and mandates SEBU7879 15 155 Maintenance Section Fuel System Primary Filter Water Separator Element Replace Illustration 212 g01109758 1 Open the engine hood 2 The fuel filters are located on the right side of the machine in the engine compartment The water separator bowl is located on the bottom of primary fuel filter Attach a hose to the bottom of the drain valve in order to catch the fuel Open the drain valve on the bottom of the water separator bowl Allow the water and the fuel to drain into a suitable container 3 Close the drain valve Note The water separator is under suction during normal engine operation Tighten the drain valve securely in order to prevent air leakage into the fuel system 4 Close the engine hood 102197571 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1263 510 FQ 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
76. omes dirty the pressure differential rises Illustration 199 g01001638 The air filter service indicator is located near the air filter housing Inspect 1 Observe the performance of the air filter service indicator The air filter element should be cleaned or the air filter element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position 2 If any component damage is present replace the service indicator 3 If air leaks are present replace the service indicator Test 1 Check for ease of resetting The service indicator should reset in less than three pushes 2 Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained SEBU7879 15 149 Maintenance Section Engine Crankcase Breather Clean If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged Replace Replace the service indicator if the following conditions exist e The machine is used in a severely dusty environment e The engine is overhauled e Major components are replaced Note Replace the service i
77. on 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 For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 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 SEBU7879 15 139 Maintenance Section Differential and Final Drive Oil Change NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age NOTICE Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a ther mostat installed If the thermostat is installed wrong it will cause the engine to overheat Inspect gaskets before assembly and replace if worn or damaged Illustration 174 g01030547 Replace water temperature regulator 1 in order to reduce the chance of problems with the cooling system Replace the water temperature regulator and the seals while the cooling system is completely drained or while the coolant is drained to a level below the water temperature regulator housing Note If you are
78. only replacing the water temperature regulator drain the coolant to a level that is below the water temperature regulator housing Reference For the correct procedure for replacing the water temperature regulator refer to the Disassembly and Assembly manual for your machine s engine Differential and Final Drive Oil Change SMCS Code 3278 044 4050 044 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Front Differential and Front Final Drives O O Illustration 175 g00760167 1 Position the front wheels so that final drive drain plugs 2 are facing downward Remove the final drive drain plugs and allow the oil to drain into a suitable container Clean the drain plugs and install the drain plugs 140 Maintenance Section Differential and Final Drive Oil Change SEBU7879 15 Illustration 176 g00864014 Rear view 2 Remove front differential drain plug 3
79. opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Stop the engine 2 Drain the hydraulic oil Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Change Illustration 227 g00761222 SEBU7879 15 165 Maintenance Section Hydraulic System Oil Level Hood Tilt Check 3 The hydraulic oil filter is located on the right side of the machine in front of the hydraulic oil tank Use a strap type wrench to remove the filter element Dispose of the used filter element properly 4 Clean the filter mounting base Make sure that all of the used gasket is removed from the filter mounting base Illustration 228 g00101318 5 Apply a thin coat of hydraulic oil to the seal on the new filter 6 Install the new oil filter elements by hand Instructions for the installation of the filters are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter 7 Fill the hydraulic tank with clean oil Reference Fo
80. or en ters the red zone after installation of a clean primary element or if the exhaust smoke is still black SEBU7879 15 147 Maintenance Section Engine Air Filter Secondary Element Replace Illustration 194 1 Access the air cleaner from the right side of the machine Open the access door g01959139 Illustration 195 2 Loosen the clips which hold air cleaner housing cover 1 Remove the air cleaner housing cover 3 Remove primary filter element 2 from the air cleaner housing Reference For the correct procedure refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace g00281967 Z Illustration 196 g00882913 4 Remove the secondary filter element g00882914 Illustration 197 5 Cover the air inlet opening Clean the inside of the air cleaner housing Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged Uncover the air inlet opening Install a new secondary filter element Install the primary filter element and the air cleaner housing cover Fasten the clips in order to secure the air cleaner housing cover Close the engine hood 148 Maintenance Section Engine Air Filter Service Indicator Inspect SEBU7879 15 101968230 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 Some engines are equipped with
81. ove the hydraulic oil filler cap and add hydraulic oil i01920994 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 008 7542 g00274518 Illustration 231 Obtain a sample of the hydraulic oil from the sampling valve The sampling valve is located toward the front of the hydraulic oil tank on the right side of the machine Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the oil 104004058 Hydraulic Tank Breaker Relief Valve Clean SMCS Code 5118 070 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates SEBU7879 15 167 Maintenance Section Logging Fork Clamp Lubricate Illustration 232 g00761425 1 Remove the hydraulic tank breaker relief valve from the front of the hydraulic tank 2 Clean the break
82. properly charged Ensure that there is no load in the work tool Position the machine with the bucket or the work tool in the carry position with the machine in neutral Release the parking brake Apply the service brakes and put the engine at low idle Ensure that The area around the machine is clear of personnel Shift the transmission to second gear forward and slowly release the service brakes Moderately increase the engine speed to high idle Shift the transmission to neutral Turn the ignition to the OFF position Allow the machine to coast While the machine is in motion turn the machine to the left and to the right If the machine responds to the steering input the supplemental steering system is operating Stop the machine with the service brakes Apply the parking brake The machine can then be returned to normal operation If there is no response to the steering input the supplemental steering system is not operating Stop the machine immediately Repair the supplemental steering system before returning the machine to service 102197967 Service Brake Wear Indicator Check SMCS Code 4255 535 IND Reference For information about checking the service brake wear indicator refer to Testing and Adjusting Braking System for the machine that is being serviced or consult your Caterpillar dealer 103589859 Steering Column Play Check SMCS Code 4310 535 4338 535 Illustration 252 g01408466 1 Hold the
83. r the correct type of oil and for the correct amount of oil refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities 8 Start the engine and run the engine at low idle Inspect the hydraulic system for leaks 9 Check the hydraulic oil level Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Level Check 102085957 Hydraulic System Oil Level Hood Tilt Check SMCS Code 5050 535 HK 1 Lift the rear access cover on the left side of the machine Illustration 229 g01063820 2 Observe the level of oil in tank 2 The oil level should be about 2 54 cm 1 0 inch from the top of the tank 3 If necessary remove filler cap 1 and add oil through the top of the tank Refer to Operation and Maintenance Manual Lubricant Viscosities 4 Clean the filler cap and install the filler cap 5 Close the rear access cover 166 Maintenance Section Hydraulic System Oil Level Check SEBU7879 15 102214455 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV Illustration 230 g00761333 The hydraulic oil tank is located on the right side of the machine The lift arms must be lowered with the bucket flat in order to check the hydraulic oil Check the hydraulic oil level while the engine is stopped Maintain the oil level above the ADD COLD mark on the sight gauge If necessary rem
84. re you test the brakes e Park the machine on a dry level surface e Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles e Make sure that the steering frame lock is in the unlocked position The following tests are used to determine whether the braking system is functional These tests are not intended to measure the maximum brake holding effort The required brake holding effort for sustaining a machine at a specific engine rpm varies from one machine to another machine The variations include differences in the engine setting the power train efficiency the brake holding ability etc 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 1 Start the engine Raise the implement slightly Apply the service brake Release the parking brake 2 Move the transmission control to THIRD SPEED FORWARD while the service brakes are applied Make sure that the autoshift control is in the OFF position 3 Gradually increase the engine speed to high idle The machine should not move 4 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Engage the parking brake Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpill
85. ring 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Operate the machine for a few minutes in order to warm the hydraulic oil Park the machine on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine Illustration 224 g00761267 The hydraulic tank is located on the right side of the machine Press hydraulic tank breaker relief valve 1 in order to relieve any tank pressure 1 Remove hydraulic tank filler cap 2 and the filler strainer Wash the filler cap and the strainer in a clean nonflammable solvent Install the strainer 2 Inspect the gasket on the filler cap for damage Replace the gasket if necessary 3 Remove the drain plug 4 from the bottom of the hydraulic tank Wash the drain plug in a clean nonflammable solvent 4 Install a 6B 3156 Pipe Nipple with a hose in order to unseat the internal drain valve Allow the hydraulic oil to drain into a suitable container NOTICE Never start the engine while the hy
86. s 25 ECAP and Unswitched Autolube POWST akae tensed iad ee a e 15 Amperes 26 LH Tail and Clearance Lights 10 Amperes 27 Hood Actuator aeeeeeee 10 Amperes 28 Stop Lamps ceeeeeeeeeeeeees 10 Amperes 29 HOM aeriene 10 Amperes 30 Voltage Converter Memory Standard iorsin 10 Amperes 31 Key Start Switch and Machine Security SYO a a E E 10 Amperes 32 Dome Lamps aasssseesssessssrrnseennn 10 Amperes 102245859 High Intensity Discharge Lamp HID Replace If Equipped SMCS Code 1434 510 HID lamps operate at very high voltages To avoid electrical shock and personal injury disconnect power before servicing HID lamps HID bulbs become very hot during operation Before servicing remove power from lamp for at least five minutes to ensure lamp is cool NOTICE Although HID bulb materials may change over time HID bulbs produced at the time of the printing of this manual contain mercury When disposing of this com ponent or any waste that contains mercury please use caution and comply with any applicable laws _ Remove the electrical power from the high intensity discharge lamp HID The electrical power must be removed from the HID lamp for at least five minutes in order to ensure that the bulb is cool N Disassemble the housing for the HID lamp in order to have access to the bulb Note On some HID lamps the bulb is an integral part of the lens assemb
87. s located under the access cover on the right cab platform Fill the window washer reservoir through the filler opening 101460440 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 Cip A HiT Illustration 263 g00763272 SEBU7879 15 181 Maintenance Section Windows Clean Inspect the condition of the wiper blades Replace the wiper blades if the wiper blades are worn or damaged If the wiper blades streak the window replace the wiper blades 104412316 Windows Clean SMCS Code 7310 070 Clean the outside of the windows from the ground unless handholds are available Illustration 264 g00566124 Typical example Cleaning Methods Commercial Window Cleaner Apply the cleaner with a soft cloth Rub the window with moderate pressure until all the dirt is removed Allow the cleaner to dry Wipe off the cleaner with a clean soft cloth Soap and Water Use aclean sponge or a soft cloth Wash the windows with a mild soap or with a mild detergent Also use plenty of lukewarm water Rinse the windows thoroughly Dry the windows with a moist chamois or with a moist cellulose sponge Stubborn Dirt and Grease Wash the windows with a good grade of naphtha of isopropyl alcohol or of Butyl Cellosolve Then wash the windows with soap and with water Polycarbonate Windows If
88. sed 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 e Contaminants should not be present These contaminants include fuel and antifreeze Water content should be 5 percent or less e The silicon level should not exceed 15 parts per million for new oil The particle counts should be monitored e The recommended level of cleanliness for Caterpillar machines that are operated in the field is ISO 18 15 or 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 e There should not be significant changes in sodium silicon copper and potassium SEBU7879 15 163 Maintenance Section Hydraulic System Oil Change e The allowable level of oxidation is 40 percent 0 12 Abs units e The kinematic viscosity of 100 C 212 F oil should not exceed a change of more than 2 cSt from new oil Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that fluids are contained du
89. steering 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 9S 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 176 SEBU7879 15 Maintenance Section Steering Column Spline Command Control Steering Lubricate AwaRNING 02231597 Steering Cylinder Bearings Failure to perform this inspection and repair may cause loss of steering control which may result Lubricate in personal injury or death SMCS Code 4303 086 BD Do not operate the machine until the inspection and repair are completed Contact your Caterpillar dealer for any other required service Steering Column Spline A a Command Control Steering vA PF Lubricate 1 a SMCS Code 4310 086 SN 4338 086 SN g01125801 Illustration 254 1 Rod End of RH Steering Cylinder 2 Head End of RH Steering Cylinder 3 Head End of LH Steering Cylinder Wipe all fittings before lubrication The head end of the steering cylinders are greased with a remote fitting Apply l
90. tems Cooling System Coolant Sample Level 2 Obtain vasten eis is eo 138 Every 500 Service Hours Cooling System Coolant Sample Level 1 OD al eas ietea ie eaa masta es i 137 Differential and Final Drive Oil Sample Obtain 142 Hydraulic System Oil Sample Obtain 166 Transmission Oil Sample Obtain 0 180 Every 500 Service Hours or 3 Months Engine Oil and Filter Change 150 Fuel System Primary Filter Water Separator Element Replace cccecceceeeeeeeeeeeeseees 155 Fuel System Secondary Filter Replace 156 Fuel Tank Cap and Strainer Clean 0 158 Hydraulic System Biodegradable Oil Filter Element ReplaCey is xeeF cee fi N E EA 161 Hydraulic System Oil Filter Replace 164 Every 1000 Service Hours or 6 Months Articulation Bearings Lubricate ceeee 121 Battery Hold Down Tighten asasen 123 Case Drain Screen Strainer Steering Pump Hydraulic Fan Pump Motor Clean 133 Rollover Protective Structure ROPS Inspect 173 Steering Pilot Oil Screen Command Control Steering Clean Replace ceeeeeeeeeees 177 Transmission Oil Change seese 177 Transmission Oil Filter Replace 0005 179 Every 2000 Service Hours or 1 Year Brake Discs Check cccecceseeeeeeeeesteeeeeeenaaes 125 Differential and Final Drive Oil Change 139 E
91. th improper adjustments of the electronic unit injector can reduce engine efficiency This reduced efficiency could result in excessive fuel usage and or shortened engine component life Adjust the electronic unit injector at the same interval as the valve lash adjustment Refer to your machine s Service Manual or your Caterpillar dealer for the complete adjustment procedure 103649895 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY Illustration 188 g01959139 1 Access the air cleaner from the right side of the machine The air cleaner is located directly under the precleaner Open the access door Illustration 189 g00281967 SEBU7879 15 145 Maintenance Section Engine Air Filter Primary Element Clean Replace 2 Loosen the clips which hold air cleaner housing cover 1 Remove the air cleaner housing cover 3 Remove primary filter element 2 from the air cleaner housing Illustration 190 g00101865 4 Clean the inside of the air cleaner housing 5 Inspect the primary element If the pleats the gaskets or the seals are damaged discard the element Replace the damaged primary element with a clean primary element 6 Close the engine hood Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven pro
92. trol system completely The ride control system should be in the automatic mode or in the off position during loading operations 101457460 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 Illustration 249 g00762107 Inspect the ROPS for bolts that are loose or damaged Use original equipment parts only to replace bolts that are damaged or missing Tighten the four cab mounting bolts to a torque of 850 100 N m 629 74 Ib ft Note Apply oil to all bolt threads before installation Failure to apply oil can result in improper bolt torque 174 Maintenance Section Seat Belt Inspect SEBU7879 15 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 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 250 g02620101 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 a
93. ubricant to the two fittings 2 and 3 that are located on the left side of the machine The rod end of the right steering cylinder is greased with a remote fitting Apply grease to the remote grease fitting 1 Q O O oii The rod end of the left steering cylinder is greased with a standard grease fitting oh iN There are a total of four fittings 6 7 8 g00812993 Illustration 253 1 Remove the steering shaft from the machine Reference Refer to Disassembly and Assembly Manual for the removal procedure and for the installation procedure 2 Wipe off all of the fittings before any lubricant is applied 3 Refer to Operation and Maintenance Manual Lubricant Viscosities for the proper grease to use Apply the grease through fittings 1 2 3 4 5 6 7 and 8 4 Install the steering shaft on the machine SEBU7879 15 177 Maintenance Section Steering Pilot Oil Screen Command Control Steering Clean Replace 101458229 Steering Pilot Oil Screen Command Control Steering Clean Replace SMCS Code 4304 070 Z3 4304 510 Z3 Illustration 255 g00762227 The screen for the pilot oil is located near the articulation joint below the steering neutralizer valves 1 1 Disconnect the two lines 3 and 4 from the bottom of the screen group 2 2 Use an allen wrench in order to remove the two screens from
94. upplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 1 Stop the engine 2 Drain the hydraulic oil Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Change Illustration 222 g00761222 3 The hydraulic oil filter is located on the right side of the machine in front of the hydraulic oil tank Use a strap type wrench to remove the filter element Dispose of the used filter element properly 4 Clean the filter mounting base Make sure that all of the used gasket is removed from the filter mounting base Illustration 223 g00101318 5 Apply a thin coat of hydraulic oil to the seal on the new filter 6 Install the new oil filter elements by hand Instructions for the installation of the filters are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter 7 Fill the hydraulic tank with clean oil Reference For the correct type of oil and for the correct amount of oil refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities 8 Start the engine and run the engine at low idle Inspect the hydraulic system for leaks 9

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