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MAINTENANCE INTERVALS - Safety

1. D R p EL IZ ELEC mms e GREEN p EL ER E ccce puc frr p a LEE EN R3 or MC EL i LEE C Le LL See E EEG crm ea KI SS L Illustration 145 g00928025 location of the drain plug for the 247 and the 257 y Illustration 146 900928088 location of the drain plug for the 287 2 The fuel tank drain plug for the 287 machine is located on the side of the tank Remove the access panel in the bottom of the machine in order to access the drain plug Loosen the drain plug The fuel tank drain plug for the 247 and 257 machines is located underneath the machine at the left rear corner Loosen the plug 3 Allow the water and the sediment to drain into a suitable container 4 Install the fuel tank drain plug Note Apply 5P 3413 Pipe Sealant to the threads on the drain plug 5 Install the fuel tank cap 101962605 Hydraulic System Oil Change SMCS Code 5095 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 a
2. WA A LIES j 2 amp 0 ia 0 i A t g01393193 Illustration 101 Use an appropriate floor jack in order to lift the machine off the ground Use appropriate jack stands 1 in order to block up the machine Raise the machine until tracks are approximately 50 mm 2 0 inches A off the ground Loosen the track in order to work on the bogies and idlers Refer to Operation and Maintenance Manual Track Inspect Adjust for the procedure Note The track may be removed in the illustrations for clarity Idler wheels Illustration 102 g01393325 2 Outer idler wheel 3 Bolts and washers for the wheels 1 Remove the bolts 3 and the washers for the outer idler wheel 2 2 Remove the outer idler wheel 3 If necessary remove the bolts and the washers for the inner idler wheel and remove the wheel 4 Install the wheels Tighten the bolts to a torque of 50 5 N m 37 3 7 Ib ft Turn the bolts an additional 45 degrees 5 degrees in the same star pattern SEBU8386 03 119 Maintenance Section Bucket Cutting Edges Inspect Replace Bogie wheels Illustration 103 g01393304 4 Bogie Wheel 5 Bolts and washers for the wheels 1 Remove the bolts 5 and the washers for the outer bogie wheel 4 2 Remove the outer bogie wheel 3 If necessary remove the bolts and the washers for the inner bogie wheel and remove the wheel 4 Install
3. Illustration 120 g01018412 C2 2 PA D Ad 7 Z LA Illustration 121 901210045 C3 4 3 Loosen the hose clamp 1 and remove the hose from the thermostat housing assembly 2 4 Remove the two bolts 3 from the thermostat housing assembly Remove the thermostat housing assembly 5 Remove the seal and the thermostat from the thermostat housing assembly 6 Install a new thermostat and a new seal Install the thermostat housing assembly on the engine cylinder head 7T Install the hose Tighten the hose clamp 128 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU8386 03 8 Refill the cooling system Refer to Operation and Maintenance Manual Capacities Refill Refer to Operation and Maintenance Manual Cooling System Coolant ELC Change for information about refilling the cooling system Refer to Special Publication SEBU6250 Caterpillar Machine Fluid Recommendations for coolant information 9 Close the engine access door 103880059 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Never service the air cleaner when the engine is run ning to avoid engine damage NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedure
4. Illustration 127 900101864 2 Unlatch the air cleaner housing cover 1 Rotate the cover counterclockwise and remove the cover 3 Remove the primary filter element 2 Illustration 128 900038606 4 Clean the inside of the air cleaner housing with a damp cloth Do not use compressed air to clean the housing 5 Remove the secondary filter element 6 Cover the air inlet opening 7 Clean the inside of the air cleaner housing with a damp cloth if necessary Do not use compressed air to clean the housing 8 Uncover the air inlet opening 9 Install a new secondary element 10 Install the primary element 11 Install the cover for the filter housing SEBU8386 03 131 Maintenance Section Engine Compartment Inspect Clean Illustration 129 g01433098 12 Rotate the cover clockwise and latch the cover 13 Close the engine access door 102772835 Engine Compartment Inspect Clean SMCS Code 1000 040 CPA 1000 070 CPA Inspect the engine compartment for dirt buildup or debris Remove any dirt or debris from the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 130 g01264593 2 Remove any debris or dirt from the engine compartment If necessary remove the access panel in order to clean out the engi
5. Illustration 142 901017292 Fuel Filter Water Separator that is located on the left side of the engine compartment 2 Open the drain on the fuel filter water separator 3 Allow the water and fuel to drain into a suitable container 138 Maintenance Section Fuel System Priming Pump Operate SEBU8386 03 3 Close the drain valve by hand Do not tighten the drain valve with a tool Damage to the valve or to the seals may occur 4 Support the fuel filter water separator and rotate the locking ring 1 counterclockwise Remove the fuel filter water separator 5 Rotate the locking ring 2 counterclockwise Remove the bowl assembly 6 Clean the mounting base for the fuel filter water separator 7 Clean the bowl assembly for the fuel water separator 8 Install the bowl assembly onto the new fuel water separator and rotate the locking ring clockwise 9 Install the new fuel filter water separator onto the mounting base Rotate the locking ring clockwise in order to fasten the fuel filter water separator to the mounting base 10 Prime the fuel system in order to fill the fuel filter water separator with fuel Refer to Operation and Maintenance Manual Fuel System Priming Pump Operate 11 Close the engine access door 102781099 Fuel System Priming Pump Operate SMCS Code 1258 548 The fuel priming pump is located on top of the fuel filter water separator Illustration 143
6. sssssssss 114 Backup Alarm Test 2 ccecceeeeeeeeeeeteeseeaeees 114 Bogie and Idler Inspect Replace 117 Cooling System Level Check 126 Engine Compartment Inspect Clean 131 Engine Oil Level Check ssssssss 131 Equipment Lowering Control Valve Check 134 Fuel System Primary Filter Water Separator ring 137 Hydraulic System Oil Level Check 142 Lift Arm and Cylinder Linkage Lubricate 142 Quick Coupler Clean Inspect 144 Radiator Core Clean ssesseeesss 144 Seat Belt Inspect sss 146 Sprocket Inspect eiiiai piini 147 Tilt Cylinder Bearings and Bucket Linkage Bearings L bricate at deii t et eR 149 Track Rubber Inspect Adjust 149 Work Tool Lubricate sssessssssssss 153 Work Tool Mounting Bracket Inspect 155 Initial 250 Service Hours Final Drive Oil Change eese 135 Every 250 Service Hours Final Drive Oil Level Check 135 Every 250 Service Hours or Monthly Belts Inspect Adjust Replace 115 Every 500 Service Hours Cooling System Coolant Sample Level 1 Obtain zt eto reto ees 124 Final Drive Oil Change eessen 135 Hydraulic System Oil S
7. The fuel system water separator is located in the left side of the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers a Illustration 141 901023095 2 Loosen the drain valve on the bottom of the water separator Allow the water and the sediment to drain into a suitable container 3 Tighten the drain valve by hand Do not tighten the drain valve with a tool Damage to the valve or to the seals may occur 4 Close the engine access door 102867255 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 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 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 Note This unit has a dual purpose The element Serves as a water separator and a fuel filter 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers
8. SEBU8386 03 133 Maintenance Section Engine Oil and Filter Change 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting Illustration 133 g01022394 Note The crankcase drain is located on the right side of the oil pan 3 Pull the drain hose for the crankcase through the opening in the rear of the machine and remove the plug in the end of the drain hose Open the crankcase drain valve and drain the oil into a suitable container Close the crankcase drain valve Install the plug in the drain hose Illustration 134 g01022354 4 Remove the filter element with a 187 2718 Filter Wrench Refer to Operation and Maintenance Manual Oil Filter Inspect in order to inspect the used filter for debris 5 Apply a thin film of clean engine oil to the sealing surface of the new filter element 6 Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 7 Tighten the filter according to the instruc
9. Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended to 3000 hours S O S services may extend the oil change even longer Consult your Cat dealer for details When Required Battery or Battery Cable Inspect Replace 115 Blade Frame Adjust sseseseess 116 Bucket Cutting Edges Inspect Replace 119 Bucket Tips Inspect Replace 119 Cab Air Filter Clean Replace 119 Circuit Breakers and Fuses Reset Replace 120 Engine Air Filter Primary Element Clean Replace aaia ox ete lds EAR EO 128 Engine Air Filter Secondary Element Replace 130 Fuel System Priming Pump Operate 138 Fuel Tank Cap Clean ssssss 138 Fuel Tank Water and Sediment Drain 138 Lower Machine Frame Clean 143 Oil Filter Inspect ssssseeseseese 143 Track Rubber Remove Replace 151 Window Washer Reservoir Fill 152 Window Wiper Inspect Replace 152 Windows Clean eem 152 Every 10 Service Hours or Daily Air Cleaner Dust Valve Clean Inspect 114 Axle Bearings Lubricate
10. 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 The normal oil change interval for the machine is Every 500 Service Hours or every year when the following conditions are met e Use an engine oil in the Operation and Maintenance Manual Lubricant Viscosities e Caterpillar filters are used e The altitude does not exceed 2300 m 7545 ft e Sulfur content in the fuel is between 0 05 and 0 50 An oil change interval of Every 250 Service Hours or every six months is required when the following conditions occur e Use an engine oil in the Operation and Maintenance Manual Lubricant Viscosities e The altitude exceeds 2300 m 7545 ft e Sulfur content in the fuel is between 0 50 and 1 0096 An oil change interval of Every 125 Service Hours is required when the following condition occurs e Sulfur content in the fuel is above 1 00 Refer to the results of the S O S oil analysis in order to determine if the oil change interval should be decreased Consult your Caterpillar Dealer for detailed information regarding the optimum oil change interval
11. 901019689 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Push down on the top of the fuel priming pump plunger and release the fuel priming pump plunger in order to operate the fuel priming pump Operate the fuel priming pump plunger in order to fill the new filter element with fuel Continue to pump until increased resistance is felt This resistance will indicate that the filter element is full of fuel 3 Attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate the engine at low idle until the engine runs smoothly If the engine fails to start or if the engine continues to misfire or smoke repeat the priming procedure 4 Close the engine access door 101819309 Fuel Tank Cap Clean SMCS Code 1273 070 Z2 1 Remove the fuel cap Illustration 144 900104238 2 Inspect the cap Replace the cap if the cap is damaged 3 Wash the fuel cap in a clean nonflammable solvent and dry the fuel cap 4 Put a light coating of fuel on the cap gasket 5 Install the fuel cap 101989211 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Note Drain the water and the sediment from the fuel tank when the tank is almost empty SEBU8386 03 139 Maintenance Section Hydraulic System Oil Change 1 Slowly remove the fuel tank cap in order to relieve the tank pressure
12. Open the engine access door Illustration 122 g00101864 2 Unlatch the air cleaner housing cover 1 Rotate the cover counterclockwise and remove the cover 3 Remove the primary filter element 2 4 If itis appropriate clean the primary filter element Use air pressure to clean the primary filter elements Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Note When the primary filter elements are cleaned always begin with the inside in order to force dirt particles toward the 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 filter element 5 nspect the cleaned 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 confirm the result compare the primary air filter element to a new primary air filter element that has the same part number SEBU8386 03 129 Maintenance Section Engine Air Filter Primary Element Clean Replace Note Do not use a primary air filter ele
13. for the coupler engagement pins Apply lubricant to the grease fitting 4 for the pivot pin of the quick coupler assembly There are a total of 8 grease fittings 102970641 Track Rubber Inspect Adjust SMCS Code 4197 4198 025 4198 040 Periodic adjustment of the track tension is necessary in order to avoid damage to the tracks Maintaining the tracks at the proper tension will maximize the service life of the undercarriage components The undercarriage components include the sleeves of the drive sprocket the rings of the drive sprocket the wheels and the track 150 Maintenance Section Track Rubber Inspect Adjust SEBU8386 03 NOTICE Do not overtighten the tracks Tracks that are too tight can cause premature failure of the tracks Tracks that are too tight can cause power loss and bearing fail ures Tracks that are too loose increase the possibility of the track derailing or the drive lugs mis feeding on the drive sprocket In aggressive operating conditions oc casional mis feeding is normal If consistent mis feed ing is observed ensure that the track tension is set to the recommended specification If the track tension is set to the recommended specification and mis feed ing is still observed then your application may require a tighter track tension Increase the track tension until consistent mis feeding is no longer observed The intervals for track tension vary depending on the following cond
14. muddy or sandy will cause accelerated wear on the sprocket and other undercarriage components It is important to clean the undercarriage of the machine daily in order to maximize component life Sleeves that do not meet the minimum thickness or sleeves that do not turn freely may cause unnecessary wear on the drive lugs on the rubber track Remove the Sprocket Illustration 165 1 Drive motor 2 Bolts and washers Note In order to service the sprocket the tracks must be loosened Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust for the procedure 1 Remove the 12 bolts and the 12 washers that hold the sprocket assembly to the drive motor 2 Slide the sprocket assembly off the drive motor 901394413 3 Sprocket assembly 148 Maintenance Section Sprocket Sleeve Inspect SEBU8386 03 Sleeves and Rings Illustration 166 g01394415 4 Sprocket mounting ring 5 Washers and Locknuts 6 Outer sleeve 7 Inner sleeve The sprocket is equipped with two types of sleeves e Inner Sleeves 6 Outer sleeves 5 The outer sleeves are free to rotate on the inner sleeves The sleeves are held in position by the sprocket mounting ring Note There are many parts in the sprocket assembly Remove the sprocket completely from the machine in order to work on the sprocket Use a clean flat surface in order to disassemble the sprocket and assemble the sprocket 1 Remov
15. of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 102429594 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 elie moe 4 901152685 Illustration 164 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension SEBU8386 03 147 Maintenance Section Sprocket Inspect 103890329 Sprocket Inspect SMCS Code 4164 040 Note Operating the machine in conditions that are
16. over time For cleaning your polycarbonate top window use a soft cloth a sponge or a chamois Use any of the following cleaners e soap and water e isopropyl alcohol kerosene e denatured alcohol e commercially available window cleaning solutions Apply the cleaning solution liberally Wipe the surface SEBU8386 03 153 Maintenance Section Work Tool Lubricate 102728710 Work Tool Lubricate SMCS Code 6700 086 Multipurpose Bucket Illustration 176 900534457 Apply lubricant to the grease fitting 1 for the pivot pin of the apron Apply lubricant to the grease fitting 2 for the rod end of the multipurpose bucket cylinder Apply lubricant to the grease fitting 3 for the head end of the multipurpose bucket cylinder Repeat for the other side of the bucket There are six grease fittings Utility Grapple Tools Illustration 177 900647980 Apply lubricant to the four grease fittings for the grapples Illustration 178 900647988 Apply lubricant to the two fittings for the grapple cylinder There are six grease fittings Industrial Grapple Tools Illustration 179 900645995 Apply lubricant to the four grease fittings for the fork cylinders g00646004 Illustration 180 Apply lubricant to the four grease fittings for the two forks 154 Maintenance Section Work Tool Lubricate SEBU8386 03 There are eight grease fittings Grapple
17. pressure Remove the radiator cap 4 If necessary drain enough coolant from the radiator in order to allow the addition of the coolant additive 5 Add 0 17 L 0 18 qt of cooling system additive 6 Inspect the radiator cap and the gasket If the cap or the gasket is damaged replace the cap Install the radiator cap UUU D D g00956179 Illustration 114 Typical Example Note The sight gauge for the coolant level is located on the right side of the engine compartment on machines that are equipped with the C2 2 engine The sight gauge for the coolant level is located on the left side of the engine compartment on machines that are equipped with the C3 4 engine 7 Check the coolant level in the sight gauge on the radiator Maintain the coolant level to the top of the sight gauge with the radiator in the LOWERED position 8 Tilt the radiator guard downward 9 Close the engine access door For additional information on the addition of extender see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 103880003 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 anal
18. the hydraulic tank filler cap Ld I PENES ENS is pup N E Et E g01021146 Illustration 149 2 Remove the access panel in the belly guard underneath the machine Illustration 150 g01030411 3 Remove the plug from the end of the drain hose Pull the drain hose through the access panel in the belly guard Open the drain valve and drain the oil into a suitable container 4 Close the drain valve and pull the drain hose back into the machine Install the drain plug into the drain hose 5 Change the hydraulic system filter Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Change 6 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 7 Maintain the hydraulic oil level approximately in the middle of the sight gauge Check the oil level with the loader arms in the fully lowered position Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction hoses and hose clamps 8 Install the hydraulic tank filler cap SEBU8386 03 141 Maintenance Section Hydraulic System Oil Filter Replace 103880895 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
19. the wheels Tighten the bolts to a torque of 150 20 N m 110 15 Ib ft 101743875 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket cutting edge is accessible 2 Place blocks under the raised edge of the bucket 3 Remove the bolts Remove the cutting edge and the end bits 4 Clean the contact surfaces 5 Use the opposite side of the cutting edge if this side is not worn 6 Install a new cutting edge if both edges are worn T Install the bolts 8 Remove the blocks that are under the bucket 9 After a few hours of operation check the bolts for proper torque 101764331 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket tips are accessible 2 Place blocks under the raised edge of the bucket 3 Remove the mounting bolts Remove the bucket tips 4 Clean the mounting surface 5 Replace the bucket tips 6 Install the bolts 7 Remove the blocks that are under the bucket 8 After a few hours of operation check the bolts for proper torque 101962545 Cab Air Filter Clean Replace If Eq
20. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A Q O SEBUB8386 03 CATERPILLAR january 20 Operation and Maintenance Manual 247B2 and 257B2 Multi Terrain Loaders 112 Maintenance Section Maintenance Interval Schedule SEBU8386 03 104193489 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
21. Operation and Maintenance Manual Access Doors and Covers for the location of the service points 126 Maintenance Section Cooling System Level Check SEBU8386 03 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 Obtain the sample of the coolant from the radiator When the system is cool slowly remove the radiator cap Note The radiator cap is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The radiator cap is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine Note Do not take the sample from the Coolant Overflow Reservoir Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 103880033 Cooling System Level Check SMCS Code 1350 040 HX 1350 535 FLV 1382 070 1382 510 Pressurized system Hot coolant can cau
22. Rake Illustration 181 g01368386 Apply lubricant to the four grease fittings for the grapple cylinders Apply lubricant to the four grease fittings for the two grapples There are eight grease fittings Angle Blade g00648033 Illustration 182 Apply lubricant to the grease fitting on the rod end of the angle cylinder Illustration 183 g00648037 Apply lubricant to the grease fitting on the horizontal pivot point of the blade Illustration 184 g00648038 Apply lubricant to the grease fitting on the vertical pivot point of the blade Repeat for opposite side of the blade Illustration 185 g00677570 This is a bottom view of the angle blade Apply lubricant to the grease fitting on the pivot point of the cylinder There are five grease fittings SEBU8386 03 155 Maintenance Section Work Tool Mounting Bracket Inspect Dozer Blade Illustration 186 g01073259 Apply lubricant to the grease fitting on both ends of the right hand angle cylinder 1 Repeat for opposite side of the blade Apply lubricant to the grease fitting on the pivot points on each end of the tilt cylinder 2 There are six grease fittings 101809997 Work Tool Mounting Bracket Inspect SMCS Code 6700 040 BK Illustration 187 900925058 Inspect upper angled plate 1 and ensure that the plate is not bent or otherwise
23. a damaged plug 5 Position the final drive so that the oil fill drain plug 1 is at the top 6 Add oil through the opening for the oil fill drain plug 1 that is now at the top 7T Fill the final drive to the bottom of the opening for the oil plug 2 Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 8 Install the oil plugs Tighten the oil plugs to a torque of 27 1 N m 20 0 7 Ib ft 9 Perform Step 1 to Step 8 on the other final drive 10 Completely remove any oil that has spilled 11 Start the engine and allow the final drives to operate through several cycles 12 Stop the engine 13 Check the oil level 14 Maintain the oil level to the bottom of the opening for the oil check plug 2 102939714 Final Drive Oil Level Check SMCS Code 4050 535 FLV Illustration 139 901457026 1 Oil fill drain plug 2 Oil check plug 1 Position one final drive so that the oil fill drain plug 1 is at the top Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 136 Maintenance Section Fuel Injection Timing Check SEBU8386 03 2 Use an 8 mm 5 16 inch allen wrench Remove the oil check plug 2 3 Check the oil level The oil should be near the bottom of the opening for the oil check plug 2 4 Add oil through the opening for the o
24. ample Obtain 142 Every 500 Service Hours or 6 Months Fuel System Filter In Line Replace 136 Fuel System Primary Filter Water Separator Element Replace sssssssssssss 137 Hydraulic System Oil Filter Replace 141 Every 500 Service Hours or 1 Year Engine Oil and Filter Change 132 Every 1000 Service Hours Engine Valve Lash Check susssse 134 SEBU8386 03 113 Maintenance Section Maintenance Interval Schedule Every 1000 Service Hours or 6 Months Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 145 Every 1000 Service Hours or 1 Year Sprocket Sleeve Inspect sssusssss 148 Every 2000 Service Hours Refrigerant Dryer Replace 145 Every 2000 Service Hours or 1 Year Fuel Injection Timing Check 136 Hydraulic System Oil Change 139 Every Year Cooling System Coolant Sample Level 2 Obtalht tet etr rio ertt 125 Every 3000 Service Hours or 2 Years Cooling System Water Temperature Regulator teo f 1e c Em 127 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccccceeceeetceeeeeesereeees 146 Every 6000 Service Hours or 3 Years Cooling System Coo
25. ance Manual Access Doors and Covers for information about the rear door Raise the radiator Refer to Operation and Maintenance Manual Radiator Tilting for information about the radiator Illustration 154 900926177 1 Park the machine on level ground 2 Lower the work tool to the ground Turn off the engine 3 Wait for about five minutes before checking the level of the hydraulic oil 4 Maintain the oil level to the middle of the sight gauge Do not overfill the hydraulic tank Illustration 155 901280271 The sampling port for the hydraulic oil is located on the fan motor 101957078 Lift Arm and Cylinder Linkage Lubricate SMCS Code 5102 086 BD 6107 086 BD cU AQUI ADA Illustration 156 g01017352 Radial Lift SEBU8386 03 143 Maintenance Section Lower Machine Frame Clean Illustration 157 901017361 Extended Reach Apply lubricant to the grease fittings 1 for the lift arm linkage Apply lubricant to the grease fittings 2 for the lift cylinder bearings Repeat the process for the opposite side of the machine 101963869 Lower Machine Frame Clean SMCS Code 7050 070 1 Tilt the cab upward Refer to Operation and Maintenance Manual Cab Tilting Illustration 158 901020241 2 Remove the access panel in the frame t
26. and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Replace the fuel filter before the scheduled interval if any of the following occur e The filter screen is more than half obstructed e Engine performance is poor 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 901428665 Illustration 140 2 Loosen hose clamps 3 Remove the fuel filter and discard the fuel filter SEBU8386 03 137 Maintenance Section Fuel System Primary Filter Water Separator Drain 4 Replace the fuel filter Ensure that the arrow on the filter points upward 5 Tighten hose clamps 6 Start the engine 7 Check for leaks 8 Close the engine access door i02781090 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 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
27. 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 The hydraulic oil filter is located in the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers QOL VLEEEIEDEER ENEBEBBEBEREBER Illustration 151 900926534 2 Remove the hydraulic tank filler cap Illustration 152 901017252 3 Remove the filter with a strap type wrench Note Place a suitable nonconductive container under the hydraulic oil filter Use this container in order to catch any oil that may spill from the filter or the filter element mounting base 4 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 5 Apply a light coat of oil to the gasket of the new filter element gasket 6 Install a new filter hand tight until the seal of the filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on t
28. ar dealer Use the following guidelines for proper sampling of the coolant e Keep the unused sampling bottles stored in plastic bags e Keep the lids on empty sampling bottles until you are ready to collect the sample Complete the information on the label for the sampling bottle before you begin to take the samples Use a designated pump to collect the sample in order to avoid contamination Obtain coolant samples directly from the coolant tank You should not obtain the samples from any other location Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination 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 103880006 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 EEL SAE t Illustration 116 g00956151 Typical Example Refer to the
29. ch will lead to component failure Refer to Service Manual SENR5664 Air Conditioning and Heating R 134a For All Caterpillar Machines for the proper procedure to change the receiver dryer assembly and for the procedure to reclaim the refrigerant gas Note The receiver dryer must also be replaced when the air conditioning system is evacuated 102798931 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect SMCS Code 7323 040 7325 040 Ss Illustration 161 901022136 1 Front ROPS retaining bolt one bolt per side 2 3 oo oo 1400 eRe Ree SOLER SOBRE RRR RRRREB OOTOLO ODODUN e OTUNUN f ULLCLIULLLUCLICLCLICL TIO IIA WOO L3 900925477 Illustration 162 2 Rear ROPS retaining bolt one bolt per side 3 Retaining bolts for the FOPS 2 Note There is a total of four retaining bolts for the ROPS There is a total of eight retaining bolts for the FOPS 2 146 Maintenance Section Seat Belt Inspect SEBU8386 03 1 Inspect the ROPS and the FOPS for loose bolts Tighten the bolts 1 to the following torque 125 10 N m 92 7 Ib ft Tighten the bolts 2 to the following torque 55 5 N m 41 x 4 Ib ft Tighten the bolts 3 to the following torque 240 x 40 N m 177 x 30 Ib ft ROPS and the FOPS for damag
30. cover 8 Reset the air filter service indicator Refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect 9 Close the engine access door 130 Maintenance Section Engine Air Filter Secondary Element Replace SEBU8386 03 10 Start the engine The alert indicator for air filter restriction should turn off If the alert indicator continues to light replace the secondary air filter Refer to Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 102879321 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary filter element Nev er attempt to reuse the secondary filter element by cleaning the element When the primary filter element is cleaned for the third time the secondary filter element should be replaced The secondary filter element should also be replaced if the restricted Air Filter indicator comes on after the installation of a clean primary filter element or if the exhaust smoke is still black The air filter housing is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The air filter housing is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine Illustration 126 900891467 1 Open the engine access door
31. damaged Inspect holes 2 for wear and for damage Inspect lower angled plate 3 and ensure that the plate is not bent or otherwise damaged If any wear is suspected or any damage is suspected consult your Caterpillar dealer before you use the work tool
32. e gasket is damaged Install the radiator cap 6 Tilt the radiator guard downward SEBU8386 03 127 Maintenance Section Cooling System Water Temperature Regulator Replace Illustration 119 g01018341 7 The coolant reservoir is located on either the left side of the engine compartment or on the engine access door Maintain the coolant level in the coolant reservoir between the MIN and MAX lines 8 Close the engine access door 103880044 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system Failure to replace the engine s thermostat on a regularly scheduled basis could cause severe engine damage The thermostat should be replaced after the cooling system has been cleaned Replace the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing Caterpillar engines incorporate a shunt design cooling system It is mandatory to always operate the engine with a thermostat 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Drain the coolant from the machine See Operation and Maintenance Manual Cooling System Coolant ELC Change for the procedure to drain the cooling system
33. e the 12 locknuts and washers that hold the sprocket mounting ring in place 2 Remove the ring 3 Remove the outer sleeves and the inner sleeves 4 Measure thickness A for the outer sleeves If the thickness of the outer sleeves measures less than 3 mm 0 12 inch replace the sleeves Sleeves that do not meet the minimum thickness or sleeves that do not turn freely may cause unnecessary wear on the drive lugs on the rubber track 5 When you replace the outer sleeves rotate the inner sleeves for 180 If the inner sleeves have already been rotated replace the inner sleeves 6 Repeat steps 2 through 5 for each set of sleeves 7 The sprocket mounting rings of the drive sprocket will wear from the rotation of the outer sleeves Measure the thickness of the inner rings and outer rings If the thickness of the inner ring or outer ring measures less than 4 75 mm 0 19 inch replace the ring 8 Install the sleeves and the rings 9 Install the new locknuts Do not reuse the locknuts Tighten the locknuts to a torque of 70 5 N m 51 6 3 7 Ib ft in a star pattern Turn the nuts an additional 120 degrees 5 degrees in the same star pattern 10 Install the sprocket on the drive motor Tighten the bolts to a torque of 270 40 N m 199 30 lb ft Track Tighten the track to the proper tension Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust for the procedure 102790866 Sprocket Sl
34. ed bolts or missing bolts Replace any damaged bolts or missing bolts with original equipment parts only 2 Operate the machine on a rough surface Replace the ROPS mounting supports if the ROPS emits a noise Replace the ROPS mounting supports if the ROPS rattles Do not straighten the ROPS or the FOPS Do not repair the ROPS or the FOPS by welding reinforcement plates to the ROPS or the FOPS Consult your Caterpillar dealer for repair of any cracks in the ROPS or the FOPS Inspect the Flying Object Guard if equipped for damage Consult your Caterpillar dealer for repair of any cracks in the Flying Object Guard 102429589 Seat Belt Inspect SMCS Code 7327 040 Always check 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 163 900932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years
35. eeve Inspect SMCS Code 4164 040 ZV Note Operating the machine in conditions that are muddy or sandy will cause accelerated wear on the sprocket and other undercarriage components It is important to clean the undercarriage of the machine daily in order to maximize component life Sleeves that do not meet the minimum thickness or sleeves that do not turn freely may cause unnecessary wear on the drive lugs on the rubber track SEBU8386 03 149 Maintenance Section Tilt Cylinder Bearings and Bucket Linkage Bearings Lubricate Illustration 167 g01394383 Check the outer sleeves in order to ensure that the sleeves rotate freely If the sleeves do not rotate freely refer to Operation and Maintenance Manual Sprocket Inspect for information about the inspection of the sprocket assembly Tilt Cylinder Bearings and Bucket Linkage Bearings Lubricate SMCS Code 5104 086 BD 6107 086 BD Wipe all of the grease fittings before you apply lubricant P Illustration 168 g00955895 Note Lubricate the fittings with the loader lift arms in the fully lowered position Apply lubricant to the grease fittings 1 for the upper bearings for the tilt cylinders Apply lubricant to the grease fittings 2 for the lower bearings for the tilt cylinders Apply lubricant to the grease fittings 3
36. enance Section Track Rubber Remove Replace 6 Recheck the track tension 7 Check the hoses Ensure that there is no tension in the hoses Ensure that the hoses are not kinked Tighten the hose clamps at the frame Note Too much slack in the hoses may allow the hoses to contact other components Not enough slack may strain hose connections at the drive motor 103880897 Track Rubber Remove Replace MTL SMCS Code 4197 4198 011 4198 510 Removing the Track 1 Position the machine on firm level ground 2 Remove any work tool that is attached to the quick coupler 3 Raise the loader arms and install the brace for the loader lift arm Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation 2 0 l VE 2 Zz LIES j i amp i n 0 i A i t g01393193 Illustration 172 4 Use an appropriate floor jack in order to lift the machine off the ground Use appropriate jack stands 1 in order to block up the machine Raise the machine until tracks are approximately 50 mm 2 0 inch A off the ground 5 Detension the track Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust Illustration 173 g01393194 6 Remove the front idler wheel Refer to Operation and Maintenance Manual Bogie and Idler Inspect Replace for the procedure to remove the idler wheels 7 If
37. ent System damage can result from freezing Illustration 174 901027404 The reservoir for the window washer solvent is located inside the cab on the left side Fill the reservoir with window washer solvent Note Window washer solvent with isopropyl alcohol is recommended 102810705 Window Wiper Inspect Replace If Equipped SMCS Code 7305 040 7305 510 Inspect the condition of the front window wiper blade Replace the window wiper blade if the window wiper blade is worn or damaged If the window wiper blade streaks the window replace the window wiper blade 103880915 Windows Clean SMCS Code 7310 070 Use commercially available window cleaning solutions in order to clean the windows The side windows of the cab can be removed for cleaning Refer to the following procedure in order to remove the side windows Illustration 175 901026875 1 Release the latch 2 in order to remove the window 1 Pull downward on the window in order to remove the window Pull outward on the window in order to remove the window 2 Release the latch 4 in order to remove the window 3 Pivot the channel for the window downward Pull the window outward in order to remove the window 3 Slide the window 5 forward Pull the window outward in order to remove the window Polycarbonate Front Door Note Do not wipe the window dry Do not use paper towels This may scratch the finish of the polycarbonate windows
38. fan can cause an imbalance 5 Tilt the radiator guard downward SEBU8386 03 145 Maintenance Section Refrigerant Dryer Replace 6 Close the engine access door 101968724 Refrigerant Dryer Replace If Equipped SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face 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 NOTICE If the refrigerant system has been open to the outside air without being plugged for more than 30 minutes the receiver dryer must be replaced Moisture will en ter an open refrigerant system and cause corrosion whi
39. hat is located underneath the machine 3 Remove any debris or dirt from the inside of the frame 4 Reinstall the access panel and tilt the cab downward 102106227 Oil Filter Inspect SMCS Code 1308 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 159 900100013 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 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 144 Maintenance Sec
40. he factory with Extended Life Coolant ELC in the cooling system For information about the addition of Extender to your cooling system see the Operation and Maintenance Manual Cooling System Coolant ELC Extender Add or consult your Caterpillar dealer Drain the coolant whenever the coolant is dirty or whenever the coolant is foaming The radiator cap is located under the radiator guard on the top of the engine compartment Allow the machine to cool before you change the coolant 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Raise the radiator guard Refer to Operation and Maintenance Manual Radiator Tilting ELLE SAE t Illustration 109 g00956151 Typical Example 3 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap Note The radiator cap is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The radiator cap is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine SEBU8386 03 123 Maintenance Section Cooling System Coolant ELC Change hy Sa Sor LH l ARDDA I lt 1 2 SS IE era Gs Illustration 110 Drain Valve for the C2 2 engine e ll gm E Illustrat
41. he filter base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide 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 8 Maintain the hydraulic oil level to the middle of the sight gauge Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check Do not overfill the hydraulic tank 9 Inspect the gasket on the hydraulic tank filler cap for damage Replace the hydraulic tank filler cap if necessary Install the hydraulic tank filler cap 10 Close the engine access door 142 Maintenance Section Hydraulic System Oil Level Check SEBU8386 03 101957050 Hydraulic System Oil Level Check SMCS Code 5095 535 FLV Illustration 153 900956818 Note This film is located near the hydraulic filler cap on machines that are filled with synthetic oil 102920120 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 7542 008 Open the rear access door Refer to Operation and Mainten
42. hed 7 Tighten the adjusting locknut Tighten the mounting bolt 8 Recheck the belt deflection If the amount of deflection is incorrect repeat step 4 to step 7 9 Install the guard for the V belt 10 Close the engine access door 102549571 Blade Frame Adjust SMCS Code 6060 025 BG Height Adjustment Illustration 99 901161532 1 Height Adjustment for the Frame 2 Adjusting Bolts 3 Frame The height of the frame may be adjusted in order to compensate for the wear on the cutting edge The front portion of the frame needs to be lowered as the cutting edge wears Remove the bolts 2 and lower the frame 3 Install the bolts This will keep the blade level with the ground and this will prevent the blade from digging into the ground Note In order to properly adjust the blade the work tool coupler needs to be vertical The position of the pivot point of the blade is perpendicular to the ground Follow this procedure in order to ensure that the cutting edge will remain flat on the ground during operation SEBU8386 03 117 Maintenance Section Bogie and Idler Inspect Replace Trunnion Joint Note The trunnion is a dry joint Adding grease to the trunnion simply attracts abrasive particles The tightness of the joint should be monitored Shims should be removed when the joint becomes too loose This may be indicated by excessive movement in the blade Illus
43. il fill drain plug 1 if necessary Note Overfilling the final drive will cause the seals on the travel motor to allow hydraulic oil or water to enter the final drive This may contaminate the final drive 5 Clean the oil plugs 6 Install the oil plugs Tighten the oil plugs to a torque of 27 1 N m 20 0 7 Ib ft 7 Repeat the procedure for the other final drive 100916186 Fuel Injection Timing Check SMCS Code 1251 531 Note The correct fuel timing specification is found on the Engine Information Plate Fuel timing specifications may vary for different engine applications and or for different power ratings A qualified mechanic should adjust the fuel injection timing because special tools and training are required Refer to the Service Manual for the complete adjustment procedure for the fuel injection timing Refer to your Caterpillar dealer for the complete adjustment procedure for the fuel injection timing 102868096 Fuel System Filter In Line Replace SMCS Code 1261 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 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
44. ion 111 901018862 Drain Valve for the C3 4 engine 4 Remove the drain plug or open the drain valve if equipped and allow the coolant to drain into a suitable container 5 Install the drain plug or close the drain valve if equipped 6 Replace the thermostat See Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the process for replacing the thermostat 7 Add the coolant solution Refer to Operation and Maintenance Manual Capacities Refill Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Note Premix the coolant solution before filling the cooling system The coolant solution should contain 50 percent coolant and 50 percent distilled water Note Add the coolant solution at a maximum rate of five liters per minute This will reduce the chance of trapping air inside the engine block A large amount of trapped air can cause localized heating to occur upon start up Localized heating may result in engine damage which may lead to failure of the engine 8 Start the engine Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes YELLE gt amp g00956179 Illustration 112 Typical Example 9 Maintain the coolant level in the sight gauge Note The sight gauge is located on the right side of the engine compartment on machines that a
45. itions the machine application the op erator the soil conditions the climate and the condi tion of the undercarriage components Operators are responsible for basic visual inspections of the track tension on a daily basis Track Adjustment Illustration 169 g01393224 1 Place approximately 45 kg 100 Ib between the drive sprocket and the idlers Place a straight edge across the drive sprocket and idlers Measure the track sag between the bottom of the straight edge and the top of the track The track sag should be set at 12 mm 0 5 inch If the track needs adjustment proceed with the following steps Illustration 170 901393226 2 Loosen the jam nut 1 3 Turn the adjuster 2 in order to raise or lower the drive sprocket 4 Inspect the hoses Ensure that the hoses are not kinked If the hoses are kinked loosen the clamp and move the hoses so that the hoses are not kinked Note In order to detension the track for removal fully lower the drive sprocket t ofl Illustration 171 g01497493 Note that the rubber track is removed for clarity 1 Hoses at the frame 2 Fittings on final drive Note The hoses should not be under tension The fittings at the drive motor may leak if there is tension on the hoses 5 Tighten the jam nut to the following torque 270 40 N m 199 x 30 Ib ft SEBU8386 03 151 Maint
46. lant Extender ELC Add 124 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 122 114 Maintenance Section Air Cleaner Dust Valve Clean Inspect SEBU8386 03 103318742 Air Cleaner Dust Valve Clean Inspect SMCS Code 1051 571 VL Service the air filter elements when the alert indicator for air filter restriction lights Refer to Operation and Maintenance Manual Alert Indicators for information about the indicator 1 Open the engine access door 2 The air filter housing is located in the engine compartment Illustration 95 901433144 3 Check the air cleaner dust valve after every ten service hours or at the end of each day Actuate the valve by squeezing the lips of the valve in order to remove any accumulated debris 102772986 Axle Bearings Lubricate SMCS Code 3282 086 BD Illustration 96 901387575 Apply lubricant to the grease fittings for the rear axle bearings and the front axle bearings Repeat the process for the opposite side of the machine 101017495 Backup Alarm Test SMCS Code 7406 081 To prevent injury make sure that no people are working on the machine or near the machine To prevent injury keep the machine under control at all times 1 Get into the operator s seat Fasten the seat belt and pull the armrest downward 2 Start the engine 3 Disengage the parking brake 4 Move the speed direction contr
47. ment 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 6 Clean the inside of the air cleaner housing with a damp cloth Do not use compressed air to clean the housing 7 Install the primary filter element into the filter housing 8 Install the cover for the filter housing Illustration 123 g01433098 9 Rotate the cover clockwise and latch the cover 10 Close the engine access door 11 Start the engine The alert indicator for air filter restriction should turn off If the alert indicator continues to light replace the secondary air filter Refer to Operation and Maintenance Manual Engine Air Filter Secondary Element Replace Replace The primary filter element should be replaced at least one time per year You can clean the primary filter up to three times 1 Open the engine access door Illustration 124 900101864 2 Unlatch the air cleaner housing cover 1 Rotate the cover counterclockwise and remove the cover 3 Remove the primary filter element 2 4 Clean the inside of the air cleaner housing with a damp cloth Do not use compressed air to clean the housing 5 Install a new primary filter element into the filter housing 6 Install the cover for the filter housing Illustration 125 901433098 T Rotate the cover clockwise and latch the
48. n parts missing parts and cracked components 7 Inspect the hydraulic lines and the hydraulic fittings for damage or for wear Repair any worn components or replace any worn components Repair any leaking components 8 Inspect the steel material of the quick coupler for cracks Note Perform all repairs before placing the quick coupler back into operation 101488851 Radiator Core Clean SMCS Code 1353 070 KO The radiator is located at the rear of the machine above the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting NOTICE When you are using compressed air or high pressure water to clean the radiator fins ensure that the air or water is directed parallel to the fins If the compressed air or high pressure water is not directed parallel to the radiator fins the radiator fins could be bent or dam aged Note You can use compressed air high pressure water or steam to remove dust and other debris from the radiator fins However the use of compressed air is preferred 3 Clean the radiator core NOTICE Do not clean a running fan with high pressure water Fan blade failure can result 4 Remove any dirt or debris from the fan the fan hub the oil cooler the radiator guard and the fan guard Note Dirt or debris on the cooling
49. ne compartment Note Use care when you clean the engine compartment Damage to the machine may occur 3 Close the engine access door Air Conditioning Condenser The air conditioning condenser is located at the back of the engine compartment Cleaning the air conditioning condenser will maintain optimum performance of the air conditioning system Use low pressure water in order to clean the condenser 102781044 Engine Oil Level Check SMCS Code 1348 535 FLV NOTICE Do not overfill the crankcase Engine damage can re sult 1 Stop the engine and allow the oil to drain back into the oil pan 2 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 132 Maintenance Section Engine Oil and Filter Change SEBU8386 03 3 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting Illustration 131 901018561 900850465 Illustration 132 4 Maintain the oil level to the FULL mark 3 on the dipstick 1 5 f necessary remove the oil filler cap 2 and add oil 6 Clean the oil filler cap and install the oil filler cap 7 Tilt the radiator downward 8 Close the engine access door 103880121 Engine Oil and Filter Change SMCS Code 1308 510 1348 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing
50. necessary lubricate the remaining front idler wheel and the inside of the track in order to ease the removal of the track 8 Grasp the track on top of the front idler Pull the track forward and pull the track away from the frame Slide the drive lugs past the inside front idler wheels 9 Lift the track off the drive sprocket and pull the track away from the rear idler wheels Installing the Track 1 Slide the track onto the drive sprocket 2 Position the rear of the track so that the drive lugs are aligned between the rear idler wheels 3 Pull all of the slack forward and make sure that the drive lugs are properly meshed with the drive sprocket This will provide the maximum amount of slack to aid with installation across the front idler 4 Lubricate the idler wheels and the inside of the track in order to ease the installation of the track 5 Pull the track over the front idler wheel 6 Install the front idler wheel Refer to Operation and Maintenance Manual Bogie and Idler Inspect Replace for the procedure to install the idler wheel 152 Maintenance Section Window Washer Reservoir Fill SEBU8386 03 7 Tension the track Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust 103880912 Window Washer Reservoir Fill If Equipped SMCS Code 7306 544 KE NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solvent or equival
51. ny 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 Illustration 147 900956818 Note This film is located near the hydraulic filler cap on machines that are filled with synthetic oil Operate the machine for a few minutes in order to warm the hydraulic system oil Personal injury or death can result without releas ing all of the hydraulic pressure Release all the pressure from the hydraulic sys tem before any lines are disconnected 140 Maintenance Section Hydraulic System Oil Change SEBU8386 03 The machine should be on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine Keep the armrest lowered Turn the engine start switch key to the ON position Push the parking brake switch Move all of the hydraulic control levers while you press several times on each side of the auxiliary hydraulic control if equipped in order to relieve hydraulic pressure Move the engine start switch key to the OFF position Illustration 148 g00926534 1 Remove
52. ol lever to the REVERSE position The backup alarm if equipped should sound immediately The backup alarm should continue to sound until the speed direction control lever is returned to the HOLD position or to the FORWARD position SEBU8386 03 115 Maintenance Section Battery or Battery Cable Inspect Replace 103659214 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1401 561 1402 040 1402 510 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 The battery is located on the left side of the machine under the cab Raise the cab Refer to Operation and Maintenance Manual Cab Tilting for information on raising the cab 3 Disconnect the negative battery cable at the battery Note Do not allow the disconnected battery cable to contact the negative battery post 4 Disconnect the negative battery cable from the frame in order to inspect the cable 5 Disconnect the positive battery cable at the battery 6 Perform the necessary repairs Replace the cables or the battery as needed 7 Connect the positive battery cable at the battery 8 Connect the negative battery cable to the frame of the machine 9 Connect the negative battery cable at the battery 10 Lower the cab Refer to Operation and Maintenance Manual Cab Tilting for information on lowering the cab Recycle the Battery Always recycle a battery Never disca
53. rd 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 i01957641 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 If a new belt is installed check the belt adjustment after 30 minutes of operation A belt is considered to be used after 30 minutes of operation 1 Stop the engine in order to inspect the belt 2 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 97 901017605 3 Remove the guard for the V belt Illustration 98 901017632 4 Inspect the condition of the belt 1 and the adjustment of the belt The belt should deflect 10 mm 0 39 inch under a straight pull of 44 N 10 Ib This measurement should be taken between the alternator pulley and the crankshaft pulley Note A 144 0235 Borroughs Belt Tension Gauge may be used to measure belt tension This measurement should be taken between the alternator pulley and the crankshaft pulley Refer to the following table for belt tension 116 Maintenance Section Blade Frame Adjust SEBU8386 03 Table 31 Belt Tension Belt Tension Initial Used 534 22 N 120 5 Ib 400 44 N 90 10 Ib 5 Loosen the mounting bolt 2 Loosen the adjusting locknut 3 6 Move the alternator until the correct tension is reac
54. re equipped with the C2 2 engine The sight gauge is located on the left side of the engine compartment on machines that are equipped with the C3 4 engine 10 Stop the engine Inspect the radiator cap and the gasket Replace the cap if the cap or the gasket is damaged Install the radiator cap 11 Pull the radiator guard downward 12 Close the engine access door 124 Maintenance Section Cooling System Coolant Extender ELC Add SEBU8386 03 103879996 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 When a Caterpillar Extended Life Coolant is used an extender must be added to the cooling system periodically 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting EEL SAE D 900956151 Illustration 113 Typical Example Note The radiator cap is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The radiator cap is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine 3 Slowly loosen the radiator cap in order to relieve system
55. s 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 Service the air filter elements when the alert indicator for air filter restriction lights Refer to Operation and Maintenance Manual Alert Indicators The air filter housing is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The air filter housing is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine Clean The primary filter element can be used up to three times if the element is properly cleaned and if the element is properly inspected When the primary filter element is cleaned check for rips or tears in the filter material The primary filter element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings 1
56. se 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 access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting UUU D D Illustration 117 900956179 Note The sight gauge for the coolant level is located on the right side of the engine compartment on machines that are equipped with the C2 2 engine The sight gauge for the coolant level is located on the left side of the engine compartment on machines that are equipped with the C3 4 engine 3 Maintain the coolant to the top of the sight gauge with the radiator in the LOWERED position JEL oe D g00956151 Illustration 118 Note The radiator cap is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The radiator cap is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine 4 If you need to add coolant to the radiator remove the radiator cap slowly in order to relieve system pressure Note Inspect the cooling system hoses for any leaks cracks or signs of deterioration Replace any damaged hoses 5 Inspect the radiator cap and the gasket Replace the cap if the cap or th
57. separates If the element of a new fuse separates check the circuit Repair the circuit if necessary NOTICE Replace the fuses with the same type and size only Otherwise electrical damage can result If it is necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer m 7 d MESES d Illustration 106 901019673 The fuse panel is located behind the cover underneath the seat Remove the cover in order to access the fuse panel SEBU8386 03 121 Maintenance Section Circuit Breakers and Fuses Reset Replace Illustration 107 901430873 Fuses and Relays e Fuses e 19 Interlock ECM e 2 Finger Trigger for the Work Tool e 20 Beacon e 3 Front Work Lights e 21 Gauges e 4 Rear Work Lights e 22 The fan for the air conditioner condenser e 5 Left Tail Lamp e 23 Ignition Switch e 6 Right Tail Lamp e 24 Miscellaneous Power e 7 Spare e 25 Horn e 8 Backup Alarm e 27 Auxiliary Hydraulic C e 9 Cold Start e 28 Auxiliary Hydraulic C e 10 Radio e 29 Auxiliary Tools e 11 Spare e 30 Auxiliary Electrical Control C1 e 12 Spare e 33 Spare e 13 12 volt power socket 34 Auxiliary Electrical Control C2 e 14 Hydraulic Quick Coupler e Relays e 15 Wiper e 1 Finger Trigger for
58. sonal injury or death can result from a work tool falling Keep personnel away from the front of the ma chine when lowering the work tool Before lowering any equipment clear the area around the equipment of all personnel 1 Lower arms to the fully lowered position Turn the keyswitch to the OFF position Illustration 137 g01272578 The bypass valve handle is located next to the operator seat on the right side 1 Seat 2 Armrest 3 Bypass valve handle 2 Pull up on the red handle in order to fully actuate the valve 3 Push the red handle to the original position Ensure that the handle is fully seated SEBU8386 03 135 Maintenance Section Final Drive Oil Change 102939717 Final Drive Oil Change SMCS Code 4050 044 OC Illustration 138 901291697 1 Oil fill drain plug 2 Oil check plug 1 Position one final drive so that the oil fill drain plug 1 is at the bottom Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage 2 Use an 8 mm 5 16 inch allen wrench Remove the oil plugs 1 and 2 Allow the oil to drain into a suitable container 3 Check the drained oil for metal chips or for particles If there are any chips or particles consult your Caterpillar dealer Note Dispose of drained fluids according to local regulations 4 Clean the plugs and inspect the plugs Replace a worn plug or
59. the Work Tool 16 Auxiliary Hydraulic ECM e 26 Auxiliary Hydraulic C Solenoid e 17 HVAC Blower Fan and the Solenoid for the e 31 Auxiliary Electric Control C1 Compressor e 32 Auxiliary Hydraulic C Solenoid e 18 Fuel Shutoff solenoid 122 Maintenance Section Cooling System Coolant ELC Change SEBU8386 03 e 35 ECM signal for the Auxiliary Hydraulic C and the Auxiliary Hydraulic C e 36 Auxiliary Electric Control C2 e Diodes e 37 C e 38 C Illustration 108 g01019607 Circuit Breaker The main circuit breaker is located in the engine compartment on the left side Press the switch and release the switch in order to reset the circuit breaker 103879985 Cooling System Coolant ELC Change SMCS Code 1395 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Mixing ELC with other products will reduce the effec tiveness of the coolant This could result in damage to cooling system compo nents If Caterpillar products are not available and com mercial products must be used make sure they have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants and Caterpillar Extender Note The machine was shipped from t
60. tion Quick Coupler Clean Inspect SEBU8386 03 102634143 Quick Coupler Clean Inspect SMCS Code 6129 040 6129 070 Personal injury or death can result from improp erly checking for a leak Always use a board or cardboard when checking for a leak Escaping air or fluid under pressure even a pin hole size leak can penetrate body tis sue causing serious injury and possible death If fluid is injected into your skin it must be treated immediately by a doctor familiar with this type of injury Note Do not weld on the quick coupler without consulting your Caterpillar dealer 1 Clean the quick coupler prior to inspection in order to properly inspect the quick coupler Illustration 160 901322438 This is the back side of the quick coupler The lift arm and the tilt cylinder are removed for clarity 2 Tilt the quick coupler all the way forward in order to clean the debris away from the pins 3 Move the quick coupler levers Ensure that the levers are not bent or broken 4 Make sure that the coupler pins extend through the bottom of the quick coupler assembly Check the pins for wear and check the pins for damage 5 Check the top edges ofthe quick coupler assembly for wear or for damage Check the face of the quick coupler assembly for wear or for damage 6 Inspect the components inside the quick coupler for the following problems loose bolts oil leaks broke
61. tions that are printed on the filter Use the index marks as a guide 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 Illustration 135 g01018561 8 Remove the oil filler cap 2 Fill the crankcase with new oil See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Clean the oil filler plug and install the oil filler plug 9 Start the engine and allow the oil to warm Check for leaks Illustration 136 g02126167 134 Maintenance Section Engine Valve Lash Check SEBU8386 03 10 Stop the engine and allow the oil to drain back into the oil pan Fill the crankcase to the FULL mark 4 on the oil level gauge 1 Do not exceed the FULL mark on the dipstick Add oil or drain oil if it is necessary 11 Tilt the radiator downward 12 Close the engine access door 101020861 Engine Valve Lash Check SMCS Code 1105 025 Refer to the Service Manual for the complete adjustment procedure for the engine valve lash A qualified mechanic should adjust the engine valve lash and the fuel injector timing because special tools and training are required 102793624 Equipment Lowering Control Valve Check SMCS Code 5147 MA Per
62. tration 100 g01173519 A Trunnion Joint B Bolts C Shims e Remove the four retaining bolts B and the cap e Remove the necessary shims e Replace the cap and bolts e The tightening sequence is shown in illustration 100 e Torque the bolts to 530 70 N m 391 52 Ib ft Note Some noise is typical and the noise does not indicate a problem 103318544 Bogie and ldler Inspect Replace SMCS Code 4159 040 4159 510 4192 040 4192 510 Inspect Clean the undercarriage before inspecting the bogies and the idlers Inspect the bogies and idlers for damage and wear Note Minor damage to the rubber on the bogies and idlers is acceptable Minor damage includes nicks cuts small pieces that are missing and small grooves This minor damage is normal and acceptable Minor damage will not adversely affect machine performance The bogies and the idlers should be replaced when the damage to the rubber wheels adversely affects machine performance Replace the bogies and the idlers when the rubber is worn beyond the minimum specifications that are listed below 118 Maintenance Section Bogie and Idler Inspect Replace SEBU8386 03 Table 32 Bogie Wheels and Idler Wheels Wear Limits Minimum Width Minimum Thickness 254 mm 10 inch 48 mm 1 9 inch 3 mm 0 12 inch 358 mm 14 inch 48 mm 1 9 inch 3 mm 0 12 inch Loosen the Track
63. uipped SMCS Code 7342 070 7342 510 Fresh Air Filter 1 Raise the loader lift arms Install the brace for the loader lift arm Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation 120 Maintenance Section Circuit Breakers and Fuses Reset Replace SEBU8386 03 Illustration 104 g01019732 2 Remove the filter cover 3 Remove the seal from the cover and inspect the seal If the seal is damaged replace the seal 4 Remove the air filter element from the cover and clean the filter element with low pressure air Replace the element if the element is damaged 5 Install the seal onto the filter cover and install the filter element 6 Install the filter cover on the machine 7 Remove the brace for the loader lift arms and return the brace to the stored position Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation Recirculation Filter Illustration 105 g01024691 1 Remove the cover in order to access the air filter element 2 Remove the air filter element and clean the element with soap and water Replace the element if the element is damaged 3 Install the element and replace the cover 102873702 Circuit Breakers and Fuses Reset Replace SMCS Code 1417 510 1420 529 Fuses Fuses protect the electrical system from damage that is caused by overloaded circuits Replace the fuse if the element
64. ysis 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 SEBU8386 03 125 Maintenance Section Cooling System Coolant Sample Level 2 Obtain EEL SAE D 900956151 Illustration 115 Typical Example Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of the service points 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 Obtain the sample of the coolant from the radiator When the system is cool slowly remove the radiator cap Note The radiator cap is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The radiator cap is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine Note Do not take the sample from the Coolant Overflow Reservoir 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 Caterpill

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