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MAINTENANCE INTERVALS - Safety

1. Illustration 162 g01095177 1 Open the access panel on the left side of the machine Illustration 163 g01097860 2 Loosen breather outlet hose clamp 3 and remove the hose from breather cover 1 238 SEBU7892 09 Maintenance Section Engine Crankcase Breather Clean 3 Remove bolt 2 that holds the breather assembly onto breather cover 1 Remove the breather 4 Check the condition of the cover seal Replace the seal if the seal is damaged 5 Wash the breather cover and the element in a clean nonflammable solvent Shake the element dry or use pressure air 6 Inspect the hose Replace the hose if the hose is damaged 7 Install the breather assembly breather cover 1 and bolt 2 8 Install the hose and breather outlet hose clamp 3 9 Close the engine access panel SEBU7892 09 239 Maintenance Section Engine Oil Level Check 102145934 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 1 Open the engine access door on the left side of the machine Ba RR rr ri g01089197 Illustration 164 2 Maintain the engine oil within the marks on the correct side of oil level dipstick 1 Check the oil level while the engine is stopped Illustration 165
2. p Illustration 236 g01135488 16 Pull out the extendable oil filler tube for easier access and fill the transmission with oil Reference Refer to Operation and Maintenance Manual Capacities Refill for the correct amount 17 Remove the transmission breather from the top of the dipstick tube Wash the breather in a clean nonflammable solvent Install the breather SEBU7892 09 309 Maintenance Section Transmission Oil Change Illustration 237 g01115803 18 Open the access panel on the left side of the machine Illustration 238 g01119039 19 Remove the transfer gear housing breather Wash the breather in a clean nonflammable solvent Install the breather Note The photo shows a machine that is equipped with a secondary steering arrangement 20 Start the engine and run the engine at low idle 21 Disengage the parking brake Apply the service brakes 310 SEBU7892 09 Maintenance Section Transmission Oil Filter Replace 22 Move the transmission control to FORWARD and to REVERSE in order to circulate the oil 23 Move the transmission control to the NEUTRAL position and engage the parking brake 24 Check for leaks under the machine 25 Check the transmission oil
3. Illustration 136 g01097787 2 Maintain the coolant level between the FULL and the LOW marks on the coolant reservoir 3 Note If it is necessary to add coolant daily check for leaks 3 If more coolant is needed open engine access door 2 214 SEBU7892 09 Maintenance Section Cooling System Coolant Sample Level 1 Obtain 4 Open the cap on the top of the coolant reservoir 3 and add coolant until the coolant level is between the FULL and LOW marks on the coolant reservoir 3 102251419 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 Note It is not necessary to obtain a Coolant Sample Level 1 if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC This includes the following types of coolants e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat Diesel Engine Antifreeze Coolant DEAC e Commercial heavy duty coolant antifreeze 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
4. ri a F _ an 1 ee a Ogle oy See Illustration 217 g01088315 The hydraulic system is equipped with a sampling valve The sampling valve 1 is located on the base of the hydraulic oil filter Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample SEBU7892 09 293 Maintenance Section Hydraulic Tank Breaker Relief Valve Clean 102156875 Hydraulic Tank Breaker Relief Valve Clean SMCS Code 5118 070 Illustration 218 g01094645 1 Open the access door on the top of the engine enclosure Illustration 219 g01093924 2 Slowly loosen the hydraulic tank filler cap 1 in order to relieve the pressure in the hydraulic tank 3 Tighten the hydraulic tank filler cap 1 Remove the hydraulic tank breaker relief valve 2 294 SEBU7892 09 Maintenance Section Oil Filter Inspect 3 Clean the hydraulic tank breaker relief valve 2 in a clean nonflammable solvent Shake the relief valve 2 dry or use pressure air 4 Install the hydraulic tank breaker relief valve 2 5 Close the access door 102161948 Oil Filter Inspect SMCS Code 1308 507 3067 507 5068 507 5177 507 Inspect a Used Filter for Debris Illustration 220 901096266 The element is shown with de
5. Ee _ i TT TOS Illustration 240 g01135506 Use an oil filter strap wrench to remove the transmission oil filter Dispose of the used filter properly Clean the filter base Make sure that all of the used gasket is removed Apply a light coat of clean transmission oil on the new gasket Install the gasket on the new filter 312 SEBU7892 09 Maintenance Section Transmission Oil Level Check 6 Install a new transmission oil filter When the filter contacts the filter base tighten the filter by an additional 3 4 turn 7 Start the engine Apply the service brakes 8 Disengage the parking brake 9 Move the transmission direction control switch to FORWARD and to REVERSE in order to circulate the transmission oil 10 Move the transmission direction control switch to the NEUTRAL position and engage the parking brake 11 Inspect the filter for leaks Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure 12 Reinstall the step assembly 102254945 Transmission Oil Level Check SMCS Code 3030 535 FLV W i Illustration 241 g01135465 SEBU7892 09 313 Maintenance Section Transmission Oil Sample Obtain gt Illustration 242 g01135568 1 Open the access
6. Illustration 132 g01118819 1 Remove bolts 1 and the access door 2 on the top front part of the machine 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 212 SEBU7892 09 Maintenance Section Cooling System Coolant Extender ELC Add g01118820 Illustration 133 2 Slowly remove the cooling system pressure cap 3 in order to relieve system pressure Illustration 134 g00671272 3 If necessary drain enough coolant into a suitable container in order to allow the addition of the Extender to the cooling system Open the engine access door on the left side of the machine The coolant drain valve is located at the bottom of the radiator on the left side of the machine 4 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe 5 Install the cooling system pressure cap Close the access door SEBU7892 09 213 Maintenance Section Cooling System Coolant Level Check 102164357 Cooling System Coolant Level Check SMCS Code 1350 535 FLV N FWD E7 ZI eal i ya rr a A Ll Illustration 135 g01097780 1 Open the engine access door 1
7. Illustration 178 g01118968 1 Open the engine access door on the left side of the machine The primary fuel filter and water separator 1 is located on the left side of the machine 2 Loosen drain valve 2 on the bottom of the water separator bowl Allow the water and the sediment to drain into a suitable container 252 SEBU7892 09 Maintenance Section Fuel System Primary Filter Water Separator Element Replace 3 Tighten drain valve 2 Note The water separator is under suction during normal engine operation Tightening the drain valve prevents air leakage into the fuel system 4 If the engine fails to start or if there is a power loss change the fuel filter Reference Refer to Operation and Maintenance Manual Fuel System Primary Filter Water Separator Element Replace for the correct procedure 5 Close the engine access door Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 1263 510 FQ Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters SEBU7892 09 253 Maintenance Section Fuel System Primary Filter Water Separator Element Replace NOTICE Care must be taken to ensure that fluids ar
8. Illustration 180 g01098027 1 Open the left front engine access door The secondary fuel filter is located on the left side of the engine Illustration 181 g01099064 2 Use a strap type wrench to remove the secondary fuel filter 3 Clean the filter mounting base Make sure that all of the used seal is completely removed SEBU7892 09 257 Maintenance Section Fuel System Secondary Filter Replace Illustration 182 g01099018 4 Install the new filter element by hand After the gasket contacts the filter mounting base tighten the filter elements by an additional 3 4 turn 5 Prime the fuel system Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure 6 Close the engine access door 258 SEBU7892 09 Maintenance Section Fuel Tank Cap and Strainer Clean 102145893 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 Z2 1273 070 STR The fuel tank cap is located on the right side of the machine Illustration 183 g00702968 1 Lift lever 5 and turn the lever counterclockwise until the lever stops Lift the cap straight up in order to remove the cap 2 Inspect seal 4 for damage Replace the seal if necessary 3 Remove screws 1 filter assembly 2 valve 3 and the gaskets 4 Wash the fuel tank cap in a clean nonflammable solvent 5 Install the new cap filter kit Install the compon
9. 242 SEBU7892 09 Maintenance Section Engine Oil and Filter Change Engine Oil and Filter Change SMCS Code 1318 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 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 167 g00698957 535C and 545C 102340757 SEBU7892 09 243 Maintenance Section Engine Oil and Filter Change Illustration 168 g01096085 535C and 545C Illustration 169 g01207506 525C The drain valve is located on the left side of the machine 244 SEBU7892 09 Maintenance Section Engine Oil and Filter Change Illustration 170 g01230416 525C 1 Remove the plug from the drain valve in order to drain the oil from the engine 2 Attach an elbow and hose to the drain valve Open the drain valve and allow the oil to drain into a suitable container 3 Close the drain valve Remove the elbow and the hose from the drain valve 4 Clean the plug and reinsta
10. 7 Reduce the engine speed to low idle Move the transmission direction control to NEUTRAL Lower the decking blade Lower the grapple 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 i02408600 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Note When you are operating the machine in dusty conditions clean the cab air filters more often g00584743 Illustration 124 1 Open the access door on the rear of the cab 2 Remove the filter element 3 Replace the filter element The filter element is disposable 204 SEBU7892 09 Maintenance Section Cab Air Filter Clean Replace 4 Close the access door on the rear of the cab g00584744 Illustration 125 5 Remove four bolts and the filter cover behind the seat inside the cab Remove the filter element 6 Clean the filter element with pressure air or wash the filter elements in warm water with a nonsudsing household detergent Rinse the filter element with clean water and allow the filter elements to air dry thoroughly 7 Install the filter element Install the filter cover SEBU7892 09 205 Maintenance Section Circuit Breakers Reset 102205736 Circuit Breakers Reset SMCS Code 1420 529 Illustration 12
11. Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters 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 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 256 SEBU7892 09 Maintenance Section Fuel System Secondary Filter Replace
12. I HEE j m 5 seni Gh a 9 ka 0 Bae ALN Illustration 139 g01097799 1 Open the right engine compartment 1 2 g01097811 Illustration 140 The water temperature regulator housing is located on the front right side of the engine Regulator housing 1 Water temperature regulator 2 2 Remove the bolts from regulator housing 1 Remove the regulator housing 1 Remove all of the used gasket from the regulator housing 1 3 Remove the water temperature regulator 2 SEBU7892 09 219 Maintenance Section Cooling System Water Temperature Regulator Replace NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a thermostat Depending on load failure to operate with a thermo stat could result in either an overheating or an over cooling condition NOTICE If the thermostat is installed incorrectly it will cause the engine to overheat 4 Install a new water temperature regulator 2 5 Install a new gasket and the two bolts on regulator housing 1 Install the thermostat housing on the engine cylinder head 6 Close the right engine compartment 7 Replace the coolant that was drained from the system Refer to Operation and Maintenance Manual Capacities Refill 220 SEBU7892 09 Maintenance Section Differential and Final Drive Oil Change 102338399 Differ
13. SMCS Code 7323 040 7325 040 Gey ad Illustration 224 g01133939 Remove the access panels from both sides of the machine Tighten the four cab mounting bolts to a torque of 850 100 N m 625 75 Ib ft Replace the mounting supports if the ROPS rattles during machine operation Inspect the ROPS for bolts that are loose damaged or missing Replace any bolts that are damaged or missing with original equipment parts only Note Apply oil to all bolt threads before installation Failure to apply oil may result in improper bolt torque Do not repair the ROPS by welding reinforcement plates to the ROPS Consult your Caterpillar dealer for repair of cracks in welds in castings or in any metal section on the ROPS SEBU7892 09 299 Maintenance Section Seat Belt Inspect 102429612 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 225 g00932801 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
14. 6 If the oil level is low open the access door on the top of the engine enclosure Illustration 216 g01093664 7 Slowly loosen the hydraulic cap 1 in order to release the pressure from the tank 2 SEBU7892 09 291 Maintenance Section Hydraulic System Oil Sample Obtain 8 Remove the hydraulic tank filler cap and add oil if necessary 9 Clean the filler cap and install the filler cap Close the access door 102127840 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 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 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 Operate the machine for a few minutes before you obtain the fluid sample This will thoroughly mix the fluid for a more accurate sample 292 SEBU7892 09 Maintenance Section Hydraulic System Oil Sample Obtain
15. 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 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 Operate the machine for a few minutes before you obtain the fluid sample This will thoroughly mix the fluid for a more accurate sample SEBU7892 09 333 Maintenance Section Winch Wire Rope Install Illustration 264 g00697412 The winch is not equipped with a sampling valve Obtaining a sample of the winch oil will require a vacuum pump or an equivalent Remove the filler plug from the left side of the winch and withdraw the oil sample Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample 100947128 Winch Wire Rope Install SMCS Code 5154 012 Personal injury or death can result from improper wire rope use Always wear
16. Maintenance Section Transmission Oil Change g00701384 Illustration 233 g00586353 7 Remove the magnetic strainer cover Note The first photo shows a machine that is equipped with a secondary steering pump and electric motor The second photo shows a machine that is not equipped with a secondary steering pump and electric motor SEBU7892 09 307 Maintenance Section Transmission Oil Change Illustration 234 g00585943 8 Remove suction screen 2 and tube 4 from the housing Remove three magnets 3 from the tube 9 Wash the tube and the suction screen in a clean nonflammable solvent 10 Use a cloth a stiff bristle brush or pressurized air to clean the magnets NOTICE Do not drop or rap the magnets against any hard ob jects Replace any damaged magnets 11 Clean the cover and inspect cover seal 1 Replace the seal if necessary 12 Install three magnets 3 on the tube Insert suction screen 2 and tube 4 in the housing 13 Install the cover and the cover bolts 14 Replace the transmission oil filter Reference Refer to Operation and Maintenance Manual Transmission Oil Filter Replace for the correct procedure 308 SEBU7892 09 Maintenance Section Transmission Oil Change j W i Illustration 235 g01135465 15 Open the access door on the right side of the machine wey
17. SEBU7892 09 327 Maintenance Section Winch Oil Change Illustration 255 g01231645 1 Remove the cover plate on the right side of the winch Illustration 256 g01225969 2 Remove drain plug 1 on the right side of the winch Attach a hose to a suitable drain adapter Install the adapter in the drain valve and allow the oil to drain into a suitable container 328 SEBU7892 09 Maintenance Section Winch Oil Change Illustration 257 g01231535 3 Remove drain plug 2 on the center of the winch Attach a hose to a suitable drain adapter Install the adapter in the drain valve and allow the oil to drain into a suitable container 4 After you have drained the oil remove the adapters from the drain openings 5 Clean the drain plugs and install the drain plugs Illustration 258 g01231657 6 Remove vent plug 3 on the left side of the winch Clean the vent plug in a clean nonflammable solvent Install the vent plug SEBU7892 09 329 Maintenance Section Winch Oil Change Note Do not replace the vent plug with a solid plug Do not apply paint over the vent plug Either condition may cause oil leaks due to increased internal pressure during operation of the winch Illustration 259 g01231668 7 Remove filler plug 4 and fill the winch with oil through the opening Reference Refer to Operation and Maintenance Manua
18. Water Cleaning System Pressurized Test 0 317 Winch Drive Shaft Support Bearing Lubricate 0 ceeeee 318 Winch Drive Shaft Universal Joint Lubricate cccccseeeeeeeeees 319 Winch Fairlead Rollers Lubricate cccccceceeeeeeeeeeeecceeeeeeeeeeeees 321 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtain 0ee 216 Every 500 Service Hours Differential and Final Drive Oil Sample Obtain eeeeeees 225 Hydraulic System Oil Sample Obtain c cccccceceeeeeeeeeeeeneteeeees 291 Transmission Oil Sample Obtain cece cccccccceeceseeeeaeaeseseseaeeeeeeees 313 Winch Oil Sample Obtain cece cece ceeecceceeceeeeeeeeeeeeeeeenneaeeeeeeeeenees 332 Every 500 Service Hours or 3 Months Engine Crankcase Breather Clean ececeeeeeeeeeteeeeeeeeeneeeeeetnneeeeereeas 237 Engine Oil and Filter Change eeceeeeceeeeeeeeeeeeeeeeeeceeeeeetneeeeereeee 242 Fuel System Primary Filter Water Separator Element Replace 252 Fuel System Secondary Filter Replace eccceeeeeeeeeeeeeeenteeeeeeeeee 255 Fuel Tank Cap and Strainer Clean cecccceeeeeeeeeteeeeeeeteneeaeeees 258 Grapple Head Rotator Continuous Rotation Lubricate 272 Hydraulic System Oil Filter Replace ccc eeeeeeeeeeeteeeeeeeeteeee
19. 10 Amp 20 Spare Fuse 15 Amp O O SEBU7892 09 265 Maintenance Section Grapple Boom and Arch Dual Function Lubricate 102461972 Grapple Boom and Arch Dual Function Lubricate SMCS Code 6302 086 6308 086 Illustration 189 g01228503 Wipe off the fittings before you apply any lubricant Apply lubricant through six fittings on each side of the grapple arch There is a total of twelve fittings 266 SEBU 7892 09 Maintenance Section Grapple Boom and Arch Single Function Lubricate 102462104 Grapple Boom and Arch Single Function Lubricate SMCS Code 6302 086 6308 086 ras Illustration 190 g01228518 Wipe off the fittings before you apply any lubricant Apply lubricant through three fittings on each side of the grapple arch There is a total of six fittings SEBU7892 09 267 Maintenance Section Grapple Head Bunching Lubricate 102462202 Grapple Head Bunching Lubricate SMCS Code 6307 086 Illustration 191 g00954439 Wipe off the fittings before you apply any lubricant Apply lubricant through seven fittings on the grapple head i01906178 Grapple Head Continuous Rotation Lubricate SMCS Code 6307 086 S N 5351 Up S N 5451 Up Wipe off the fittings before you apply any lubricant 268 SEBU7892 09 Maintenance Section Grapple Head Continuous Rotation Lub
20. 208 901095187 8 Route hose 5 through door 6 9 Remove plug 4 from hose 5 al g U 2 n pe g01093617 Illustration 209 10 Open drain valve 7 Allow the oil to drain into a suitable container 11 Close drain valve 7 12 Install plug 4 into hose 5 13 Return hose 5 to the original position and install the bolt and the retainer 3 SEBU7892 09 285 Maintenance Section Hydraulic System Oil Change 14 Replace the hydraulic oil filters Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Replace for the correct procedure 15 Remove the strainer from the hydraulic oil filler tube Clean the strainer and install the strainer 16 Fill the hydraulic tank with oil Reference Refer to Operation and Maintenance Manual Capacities Refill for the correct amount of oil 17 Inspect the filler cap gasket If the gasket is damaged replace the gasket 18 Install the hydraulic tank filler cap 19 Start the engine and check for leaks Check the hydraulic oil level Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check for the correct procedure Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction line for leaks 286 SEBU7892 09 Maintenance Section Hydraulic System Oil Filter Replace 102156638 Hydraulic System Oil Filter Re
21. 216 SEBU7892 09 Maintenance Section Cooling System Coolant Sample Level 2 Obtain For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102471396 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 138 g01195489 1 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 Reference Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant SEBU7892 09 217 Maintenance Section Cooling System Water Temperature Regulator Replace 2 Submit the sample for Level 2 analysis Reference For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 104333314 Cooling System Water
22. 3956 Shim 4 Reaction plate 5 Friction plate 1 Install pin 8 g00992715 11 12 13 14 Lip seal Pin Spring Retaining ring 22S 2 Install one reaction plate 4 and one friction plate 5 Note All friction plates should be dipped in 8T 9579 Oil for five minutes before assembly Note A total of five friction plates are required for proper operation 280 SEBU7892 09 Maintenance Section Hydraulic System Oil Change 3 Insert the pin 12 with retaining ring 14 to the back of the clutch housing 4 Insert shims 6 7 at the back of the clutch housing lug and pass pin 12 through the shims until retaining ring 14 touches the first friction plate 5 Use the shims as needed 6 204 9606 Shim 000 cceceeeeeeceeeteeees 2 29 mm 090 inch 7 204 9607 Shim cccccecceeeeesteeeeeeenee 1 52 mm 060 inch 5 Install the rest of the parts Note Install cap 2 with the reversed grease zerk at the top 6 Apply 5P 0960 Molybdenum Grease on the bearings and the clutch housing through the grease fittings that are on the bearing Apply the grease to the clutch housing until grease comes out of the reversed grease zerk 7 Repeat Step 6 again after one hour of operation after the initial fill 102156191 Hydraulic System Oil Change SMCS Code 5056 044 Personal injury can result from hydraulic oil pres sure and hot oil Hydraulic oil pressure can remain in the hydrau
23. A total of five friction plates are required for proper operation 2 Insert the pin 12 with retaining ring 14 until the retaining ring touches the first friction plate 5 3 Install the rest of the parts 278 SEBU7892 09 Maintenance Section Grapple Snubber Inspect Adjust Note Install cap 2 with the reversed grease zerk at the top 4 Retract the pin 8 far enough in order to slide shims 6 7 between the lug edge and the clevis end Insert the shims and assemble pin 8 Use the shims as needed 6 204 9606 SHIM 0 eesccessecssseeesseesseteeseeeee 2 29 mm 090 inch 7 204 9607 Shim cide ccscvestesveerisstece 1 52 mm 060 inch 5 Apply 5P 0960 Molybdenum Grease on the bearings and the clutch housing through the grease fittings that are on the bearing Apply the grease to the clutch housing until grease comes out of the reversed grease zerk 6 Repeat Step 5 again after one hour of operation after the initial fill Lower Joint Assembly B Illustration 202 g00956278 SEBU7892 09 279 Maintenance Section Grapple Snubber Inspect Adjust 45 9 3 21 AZION 10 14 13 Illustration 203 View B B 1 Bolt 2 Cap 3 203
24. Do not puncture or burn cylinders Keep ether cylinders out of the reach of unautho rized personnel To avoid possible injury be sure the brakes are ap plied and all controls are in Hold or Neutral when starting the engine NOTICE Do not manually apply the ether into the intake The heating element will incur damage if ether is sprayed directly into the intake SEBU7892 09 249 Maintenance Section Ether Starting Aid Cylinder Replace EA Illustration 175 g01095177 1 Open the access panel on the left side of the engine enclosure t 2 1 y N AAN s a i o 9 S A z a aa Illustration 176 g01225878 2 Loosen cylinder retaining clamp 1 Unscrew ether starting aid cylinder 2 3 Remove the ether starting aid cylinder and the used gasket Install the new gasket that is provided with the new ether starting aid cylinder 4 Install the new ether starting aid cylinder Tighten the ether starting aid cylinder and the cylinder retaining clamp by hand 5 Install the access panel 250 SEBU7892 09 Maintenance Section Fairlead Rollers Lubricate 102755946 Fairlead Rollers Lubricate SMCS Code 6306 086 Wipe off all fittings before any lubricant is applie
25. Move the transmission direction switch to the NEUTRAL position Lower all attachments to the ground Apply the parking brake and stop the engine Operate the machine in order to warm the oil Then park the machine on a level surface 282 SEBU7892 09 Maintenance Section Hydraulic System Oil Change aa ae Illustration 204 g01093673 4 Open the access door on the top of the engine enclosure g01093664 Illustration 205 5 Slowly loosen the hydraulic tank filler cap 1 in order to release the pressure from the hydraulic tank 2 283 Maintenance Section SEBU7892 09 Hydraulic System Oil Change Illustration 206 g01095177 6 Open the access door on the left side of the engine enclosure ee IN g01093612 Illustration 207 7 Remove the bolt and the retainer 3 so that hose 5 can be moved 284 SEBU7892 09 Maintenance Section Hydraulic System Oil Change Illustration
26. Steering Cylinder Bearings Lubricate 4 Release the test switch for the secondary steering Spring force will return the test switch for the secondary steering to the OFF position This will deactivate the secondary steering motor Do not run the secondary steering motor longer than 12 seconds while you are testing the secondary steering NOTICE Do not operate the machine if the secondary steering is not operating correctly 102252283 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD 1 Wipe off the fittings before you apply lubricant There is a total of four fittings g00725258 Illustration 228 2 Apply lubricant through the fitting at the rod end of each steering cylinder SEBU7892 09 303 Maintenance Section Steering Cylinder Bearings Lubricate j Illustration 229 g01093280 3 Open the engine access door on right side of the machine Illustration 230 g01133957 4 Apply lubricant through the remote fittings 1 and 2 for the head end of each steering cylinder 5 Close the engine access door on right side of the machine 304 SEBU7892 09 Maintenance Section Tire Inflation Check 101110218 Tire Inflation Check SMCS Code 4203 535 Al g00585803 Illustration 231 Remove the valve caps on each tire Measure the tire pressure on each tire Inflate the tires if necessary Reference Refer to the Tire Inflation Informat
27. Temperature Regulator Replace SMCS Code 1355 510 1393 010 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 Replace the thermostat on a regular basis per the maintenance interval schedule This action reduces the chance of unscheduled downtime and of problems with the cooling system A new thermostat should be installed after the cooling system has been cleaned Install the thermostat while the cooling system is drained completely Or install the thermostat while the cooling system coolant is drained to a level that is below the thermostat housing NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age 218 SEBU7892 09 Maintenance Section Cooling System Water Temperature Regulator Replace Note If you are only installing a new thermostat drain the cooling system coolant to a level that is below the thermostat housing
28. be moved for better access 3 Remove primary element 2 from the air filter housing Reference Refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace Z Illustration 156 g00882913 4 Clean the inside of the air filter housing Then remove the secondary element from the air filter housing SEBU7892 09 233 Maintenance Section Engine Air Filter Service Indicator Inspect 5 Install a new secondary element Note A secondary element should never be cleaned Always install a new secondary element filter 6 Install a clean primary element 7 Install cover 1 8 Make sure that the air filter housing is secure 9 Close the engine access panel 102212237 Engine Air Filter Service Indicator Inspect SMCS Code 7452 NOTICE Service the air cleaner only with the engine stopped Engine damage could result i e A j Illustration 157 g01095177 1 Open the engine access door on the LH side of the machine The air filter service indicator 1 is located in the engine compartment on the LH side of the machine 234 SEBU7892 09 Maintenance Section Engine Air Filter Service Indicator Inspect Replace Illustration 158 g01116980 2 If the yellow piston in the air filter service
29. door on the right side of the machine 2 Remove the dipstick and wipe off the dipstick with a clean cloth This will ensure a more accurate measurement of the oil level 3 Reinsert the dipstick and remove the dipstick again Check the oil level The oil level should be between the marks on the dipstick while the engine is running at low idle and the transmission is in neutral 4 If the oil level is low remove the oil filler cap and add transmission oil through the oil filler tube as needed Reinstall the oil filler cap 5 Install the dipstick and close the access door 102255100 Transmission Oil Sample Obtain SMCS Code 3080 008 7542 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin 314 SEBU7892 09 Maintenance Section Transmission Oil Sample Obtain 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 Operate the machine for a few minutes before you obtain the flui
30. is fully seated on the pulleys SEBU7892 09 199 Maintenance Section Brake Accumulator Check 102173659 Brake Accumulator Check SMCS Code 4263 535 1 Start the engine and run the engine at low idle Illustration 123 g01101739 Note The brake oil pressure indicator light 1 should come on when the engine is started The indicator light should turn off when the braking system reaches normal operating pressure 2 Allow the engine to idle for at least 30 seconds in order to fully charge the accumulators 3 Turn the engine start switch to the OFF position 4 Turn the engine start switch to the ON position but do not start the engine 5 Depress the service brake pedal for at least eight applications until the indicator light comes on 6 If the indicator light comes on after less than eight applications check the nitrogen precharge pressure of the brake accumulator Consult your Caterpillar dealer for the proper tools Note To completely discharge the brake accumulator depress the service brake pedal for at least 30 applications 200 SEBU7892 09 Maintenance Section Brake Discs Check 102127658 Brake Discs Check SMCS Code 4255 535 Personal injury or death can result if two persons are not used in the following procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting
31. machine can cause the battery retainers to loosen To help to prevent loose batteries and the possibility of loose cable connections tighten the three locknuts to a torque of 8 2N m 71 18 lb in Note Do not operate the blade while the radiator door is open 196 SEBU7892 09 Maintenance Section Battery or Battery Cable Inspect Replace 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 disconnected 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 n
32. 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 SEBU7892 09 215 Maintenance Section Cooling System Coolant Sample Level 1 Obtain g01195489 Illustration 137 1 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 Complete the information on the label for the sampling bottle before you begin to take the samples Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system 2 Submit the sample for Level 1 analysis
33. 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 element can be reused up to six times when the element is properly cleaned and inspected after each use 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 SEBU7892 09 229 Maintenance Section Engine Air Filter Primary Element Clean Replace NOTICE Do not clean the air filter elements by bumping or tap ping This could damage the seals Do not use ele ments with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air filter element before cleaning Inspect the air filter element 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 the primary air filter element e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean a primary air filter element that has not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum press
34. plate Raa The amount of drag of the snubber is set with shims 3 In order to increase the drag of the snubber remove shims In order to decrease drag of the snubber add shims 1 To adjust the snubber loosen bolts 1 from cap 2 Note Each shim goes halfway around cap 2 Therefore the shims are removed in pairs The machine is shipped with 5 shim thicknesses 2 Add or remove shims until the desired swing of the grapple is achieved Use the shims as needed 3 203 3956 Shim ceee 1 21 mm 048 inch 276 SEBU7892 09 Maintenance Section Grapple Snubber Inspect Adjust 3 Replace the reaction plates and the friction plates if the drag of the snubber is not high enough Installation Procedure Upper Joint Assembly Illustration 200 g00956218 6 204 9606 Shim 7 204 9607 Shim 8 Pin SEBU7892 09 277 Maintenance Section Grapple Snubber Inspect Adjust KSN 15 Illustration 201 g00956219 View A A 1 a 2 C 3 203 3956 Shim 4 Reaction plate 5 Friction plate 9 O ring seal 10 Bushing 11 Lip seal 12 Pin 13 Spring 14 Retaining ring 15 Bushing 1 Install one reaction plate 4 and one friction plate 5 Note All friction plates should be dipped in 8T 9579 Oil for five minutes before assembly Note
35. that the steering frame lock is in the unlocked position e Fasten the seat belt before you test the brakes 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 This test is performed when the service brakes are 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 decking blade slightly Apply the service brakes Release the parking brake 202 SEBU7892 09 Maintenance Section Braking System Test 2 Move the transmission control to THIRD SPEED FORWARD while the service brakes are applied 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 NEUTRAL Engage the parking brake Lower the decking blade to the ground Stop the engine If
36. the engine stopped En gine damage could result NOTICE Always change the air filter based on the Air Filter Ser vice Indicator Do not based service on the appear ance of the filter 1 The air filter is located on the left side of the machine Open the engine access panel Illustration 151 g01096335 2 Remove cover 1 3 Remove air filter element 2 To avoid personal injury always wear eye and face protection when using pressurized air 228 SEBU7892 09 Maintenance Section Engine Air Filter Primary Element Clean Replace 4 Clean the inside of the air filter housing 5 Install a clean primary air filter element For more information refer to Cleaning the Primary Air Filter Element 6 Install cover 1 7 Close the engine access panel Cleaning the Primary Air Filter Element NOTICE Caterpillar recommends certified air filter cleaning ser vices available at participating Caterpillar dealers The Caterpillar cleaning process uses proven procedures 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
37. 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 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 Engage the parking brake 2 Move the transmission direction control to the NEUTRAL position 3 Start the engine Apply the service brake Disengage the parking brake Press the upshift switch until the display shows 4N 4 Engage the parking brake Raise the decking blade slightly Raise the grapple slightly Release the service brake 5 Move the transmission direction control to FOURTH SPEED FORWARD Then move the transmission direction control back to NEUTRAL position Then move the transmission direction control back to FOURTH SPEED FORWARD The parking brake indicator should come on SEBU7892 09 203 Maintenance Section Cab Air Filter Clean Replace Note The transmission will be in FOURTH SPEED FORWARD Note This will cause a level 3 warning which will activate the alarm 6 Gradually increase the engine speed to high idle The machine should not move
38. 6 g01097660 The circuit breakers are located on the right side of the machine in the engine compartment Open the access panel on the right side of the machine Illustration 127 g01097663 Press the reset button in order to reset circuit breaker 1 Circuit breaker 1 is the breaker for the thermal starting aid The thermal starting aid is an air inlet heater 206 SEBU7892 09 Maintenance Section Cooling System Coolant ELC Change Press the reset button in order to reset circuit breaker 2 Circuit breaker 2 is for the breaker for the alternator Press the reset button in order to reset circuit breaker 3 Circuit breaker 3 is the main breaker for the electrical system Press the reset button in order to reset circuit breaker 4 Circuit breaker 4 is for the unswitched circuits If the button remains depressed the electrical circuit is functioning properly If the button does not remain depressed check the appropriate electrical circuit 102216952 Cooling System Coolant ELC Change SMCS Code 1350 044 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 F
39. Date of Manufacture Seat Belt Replace iadaa aeai ane t aade ieaie ani 300 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add n se 210 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change ccceeeeeeeeeeeeeeetteeeeeees 206 SEBU7892 09 189 Maintenance Section Air Cleaner Dust Valve Clean Inspect 103239585 Air Cleaner Dust Valve Clean Inspect SMCS Code 1051 571 VL 1 Open the right side engine compartment 2 The air filter housing is located on the right side of the machine The air cleaner dust valve is located below the air filter housing ge Illustration 112 g01645293 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 4 Close the engine compartment 190 SEBU7892 09 Maintenance Section Articulation Bearings Lubricate 102354839 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD Illustration 113 g01176013 Illustration 114 g01176016 Place the steering frame lock into the LOCKED position before lubricating the articulation bearings Wipe the fittings before you apply lubricant Apply lubricant through one fitting on the upper hitch and through one fitting on the lower hitch SEBU7892 09 191 Maintenance Section Axle Oscillation Bearings Lu
40. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A SEBU7892 09 AATERPILLAR Saath E Operation and Maintenance Manual 525C 535C and 545C Wheel Skidders 5251 Up 525C 5351 Up 535C 5451 Up 545C SAFETY CAT COM SEBU7892 09 185 Maintenance Section Maintenance Interval Schedule 104793508 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 including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging 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 Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced 10 hydraulic oil is used the hydraulic oil change interval will change The normal interval of 2000 hours is extended to 3000 hours S O S
41. U7892 09 273 Maintenance Section Grapple Snubber Inspect Adjust 101906192 Grapple Snubber Inspect Adjust SMCS Code 6307 025 6307 040 If the swing dampener snubber is not properly tightened the grapple can swing freely This could cause personal injury to nearby personnel Make sure that the area around the grapple is clear of personnel before you check the swing dampen er snubber In order to achieve the longest life of the components for the snubber the operation of the snubber should be monitored constantly The adjustment should be tight enough to avoid damaging contact with the arch or the boom while the grapple arms tongs are empty st mee JB Illustration 197 g00956113 SEBU7892 09 Grapple Snubber Inspect Adjust Maintenance Section 274 g00956038 Reaction plate Friction plate aan ne Upper Joint Assembly Illustration 198 View A A SEBU7892 09 275 Maintenance Section Grapple Snubber Inspect Adjust Illustration 199 g00956037 View B B Lower Joint Assembly 1 Bolt 2 Cap 3 Shims 4 Reaction plate 5 Friction
42. ailure to follow these recommendations can result in shortened cooling system component life 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 cooling system coolant ELC SEBU7892 09 207 Maintenance Section Cooling System Coolant ELC Change Illustration 128 g01118819 1 Remove bolts 1 and the access door 2 on the top front part of the machine 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 Illustration 129 g01118820 2 Slowly loosen the cooling system pressure cap 3 in order to relieve system pressure 208 SEBU7892 09 Maintenance Section Cooling System Coolant ELC Change Illustration 130 g01180997 3 Remove the bottom guard at the front of the machine Pull out the drain hose through the opening 4 Open the engine access door on the left side of the machine 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
43. 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 Brake service life can vary greatly because of the different applications The following conditions can lead to premature brake failure e The axle housing breather is damaged or plugged e Excessive heat is generated e Oil leaks at the yoke and the drive axles A leak can also allow contamination from water and debris to occur Water and debris can enter the axle through the lip seal at the drive yoke The water and debris can mix with the oil This water and debris can lead to premature brake failure Inspect wear on the brake discs in order to determine the remaining life of the brake discs SEBU7892 09 201 Maintenance Section Braking System Test Reference For the procedure refer to the Testing and Adjusting service manual of the braking system or consult your Caterpillar dealer 102391229 Braking System Test SMCS Code 4251 081 4267 081 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
44. bricate There is a total of two fittings 102155797 Axle Oscillation Bearings Lubricate SMCS Code 3278 086 BD Illustration 115 g01093280 Illustration 116 901097033 Open the engine access door on the right side of the machine Wipe off the fittings before you apply any lubricant Apply lubricant through two remote fittings 1 and 2 in order to grease the bearings for the oscillating axle 192 SEBU7892 09 Maintenance Section Backup Alarm Test 102261741 Backup Alarm Test SMCS Code 7406 081 1 Turn the engine start switch to the ON position Do not start the engine 2 Move the transmission direction control switch to the REVERSE position 3 The backup alarm should immediately sound The backup alarm will continue to sound until the transmission control is moved to the NEUTRAL position or to the FORWARD position Illustration 117 g00930005 The backup alarm is mounted on the rear of the machine A three position switch at the rear of the backup alarm regulates the sound of the alarm HIGH LOW and MEDIUM The alarm is set at the maximum sound level when the machine is shipped from the factory The setting should remain on HIGH unless the job site requires a lower sound level SEBU7892 09 193 Maintenance Section Battery Clean 102146969 Battery Clean SMCS Code 1401 070 Illustration 118 g01089244 Be
45. bris 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 SEBU7892 09 295 Maintenance Section Radiator Core Clean 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 102469270 Radiator Core Clean SMCS Code 1353 070 KO Before you can clean the radiator you must open the radiator grill The radiator grill is hinged in two places o B amp n Illustration 221 g01089244 Radiator Grill 1 Remove bolts 1 and 2 from t
46. d Illustration 177 g00586884 On the cable skidder apply lubricant through the fitting on the end of each fairlead roller There is a total of four fittings 102456550 Fuel System Prime SMCS Code 1258 548 1 Turn the engine start switch to the ON position Leave the engine start switch in the ON position for two minutes 2 Attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate at low idle until the engine is running smoothly If the engine cannot be started or if the engine continues to misfire or smoke repeat step 1 Note The electric fuel pump turns on when the key is turned on There is not a separate priming pump SEBU7892 09 251 Maintenance Section Fuel System Primary Filter Water Separator Drain 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 products Dispose of all fluids according to local regulations and mandates
47. d sample This will thoroughly mix the fluid for a more accurate sample 4 z 0 a JI Me ty Illustration 243 g01135571 The transmission is equipped with a sampling valve The sampling valve is located next to the transmission oil filter on the left side of the machine Remove the step assembly under the left door in order to gain access Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample SEBU7892 09 315 Maintenance Section Water Cleaning System Pressurized Purge 102393313 Water Cleaning System Pressurized Purge If Equipped SMCS Code 5612 542 5613 542 Illustration 244 g00868210 Water Cleaning System 1 Water Tank 2 Relief Valve 3 Filler Plugs 4 Air Valve 5 Ball Valve 6 Water Spray Nozzle 1 Open ball valve 5 2 Use water spray nozzle 6 to expel all of the water from water tank 1 Allow the compressed air to escape through the nozzle also 316 SEBU7892 09 Maintenance Section Water Cleaning System Pressurized Purge Do not remove the fill plug until the pressure in the water tank has been relieved Personal injury may result This fill plug has a cross drilled hole that allows the pressure to be relieved without d
48. e access doors 102392258 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV Illustration 212 g01196941 SEBU7892 09 289 Maintenance Section Hydraulic System Oil Level Check 1 Lower the decking blade to the ground Move the grapple tongs together so the tips of the grapple touch each other Lower the grapple to the ground This position is critical in order to obtain a proper reading of the hydraulic oil level Cable machines have only a decking blade that is hydraulic Therefore the decking blade is the only component that must be on the ground Illustration 213 g01094632 2 Open the access door on the top of the engine enclosure and open the access door on the right side of the engine enclosure 4 A Q NI T 2 Illustration 214 g01095207 290 SEBU7892 09 Maintenance Section Hydraulic System Oil Level Check 3 Slowly loosen the hydraulic filler cap 1 in order to release the pressure from the tank ee rer ee i Illustration 215 g01095177 4 Open the access door on the left side of the machine 5 Check the oil level sight gauge The oil level should be visible through the sight gauge
49. e 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 Mechanical Winch Note This procedure only pertains to machines that are equipped with a Caterpillar C 500 Series winch SEBU7892 09 323 Maintenance Section Winch Oil Change Illustration 249 g00694842 1 Remove drain plug 1 on the left side of the winch Attach a hose to a suitable drain adapter Install the adapter in the drain valve and allow the oil to drain into a suitable container g00672642 Illustration 250 2 Remove the protective cover from the right side of the winch 3 Disconnect the return line from the fitting 324 SEBU7892 09 Maintenance Section Winch Oil Change Illustration 251 Illustration 252 g00699155 4 Remove the four bolts and cover 2 on the lower right side of the winch Remove the strainer from the winch Remove the strainer from the suction tube Remove the metal band and the magnets from the strainer 5 Wash the strainer and the magnets in a clean nonflammab
50. e 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 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 179 g01119024 1 Open the engine access door on the left side of the machine The primary fuel filter 1 is a spin on type filter 254 SEBU7892 09 Maintenance Section Fuel System Primary Filter Water Separator Element Replace 2 Install a hose or a tube onto drain valve 3 Open drain valve 3 on the bottom of water separator bowl 2 Allow the water and the fuel to drain into a suitable container 3 Close drain valve 3 Remove the tube or the hose from the drain valve 4 Remove primary fuel filter 1 from the filter base 5 Remove water separator bowl 2 from primary fuel filter 1 Inspect the fuel filter element for debris by c
51. ecessary repairs If necessary replace the battery cables or the battery 8 Connect the positive battery cable at the battery SEBU7892 09 197 Maintenance Section Battery or Battery Cable Inspect Replace 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 198 SEBU7892 09 Maintenance Section Belt Inspect Adjust Replace 102216078 Belt Inspect Adjust Replace SMCS Code 1397 025 1397 040 1397 510 Illustration 122 g01090698 1 Air conditioner compressor 2 Alternator 3 Belt tensioner Your engine is equipped with a serpentine belt that drives the alternator 2 and the air conditioner compressor 1 For maximum engine performance and maximum utilization of your engine inspect the belt for wear and for cracking Replace the belt if necessary Insert a ratchet with a square drive into the square hole that is located in the belt tensioner 3 Rotate the belt tensioner 3 in order to relieve tension on the belt Remove the belt Install the new belt correctly as shown The correct tension will automatically be applied Be sure that the belt
52. eeeeee 286 Transmission Oil Filter Replace cccccecceceeeeeeseeeeecseeeeeeeeeeneees 310 Winch Oil Filter Replace 0 cceeeeeeeeeeccecceceeeeeeeeeseeeeeenncaeeeeeseeeeees 330 Every 1000 Service Hours Engine Valve Lash Check 0 cccccccceeeeeeceeeeeeeeeneeeeeesaaeeeeeetneeeeenenae 247 Every 1000 Service Hours or 6 Months Battery Hold Down Tighten 0 ccceceeeeseneeeeeeeeeneeeeeeetaeeeeeetneeeeeeeeee 194 Rollover Protective Structure ROPS Inspect seeen 298 Transmission Oil CHANGE eee ec eeeeeee eee eeenteeeeeeeenaeeeeeeeeaeeeeeseaaes 305 Winch Drum Bearing Lubricate 0 0 0 0 cee ccceeeeeeeeeeeeneeeeeeeeeneeeeeeeaaes 320 Winch Oil Change eis eea eT R 322 188 SEBU 7892 09 Maintenance Section Maintenance Interval Schedule Every 2000 Service Hours or 1 Year Brake Dis S Check ooien ea anachdes the aaaea ea ena 200 Cooling System Water Temperature Regulator Replace 217 Differential and Final Drive Oil Change cceeeeeseceeeeeeeeeeeeeeeeeeee 220 Hydraulic System Oil Change 2 ccc cece ec eeeeececeeceeeeeeeeeeeeeesstsenaeeees 280 Hydraulic Tank Breaker Relief Valve Clean cccceeeceeceeeeeetteeeeereeee 293 Refrigerant Accumulator With Desiccant Replace 0 0 0 297 Every Year Cooling System Coolant Sample Level 2 Obtain ee 216 Every 3 Years After Date of Installation or Every 5 Years After
53. eeeeeeeeeeeeeeeeeeseees 203 Differential and Final Drive Oil Level Check eceeeeteeeeeeeeeees 224 Fairlead Rollers Lubricate cccccecceeeceeeeeeceeceeeeeeeeeeeeeeesessnaeeees 250 Fuel Tank Water and Sediment Drain cccceceeeeeeeeeesenetteeeees 259 Steering Cylinder Bearings Lubricate 20 0 0 ceceeeeeeeeeeeteeeeeeeneeeees 302 Tire Inflation CHECK 2 4 oe eaer a n cue E A 304 Winch Drive Shaft Spline Lubricate 0 cccccccceeeeeeeeeeceeceeeeeeeeeeees 318 Initial 100 Service Hours Transmission Oil Filter Replace cccccecceeeeeeeeeeeeeeceeeeeeeeeeeeeees 310 Every 100 Service Hours or 2 Weeks Secondary Steering TeSt misiras ai eaa ae eieaa ead nests 301 Every 250 Service Hours Cooling System Coolant Sample Level 1 Obtain ee 214 Engine Oil Sample Obtain ee eeceeeeeeeceeeeeeeeeneeeeeeencaeeeeeeeneeeeeeaaas 240 SEBU7892 09 187 Maintenance Section Maintenance Interval Schedule Every 250 Service Hours or Monthly Battery Clean izciesicceacts socticdi stuees e a aE Beha 193 Belt Inspect Adjust Replace cccceceeeeeeseeeeeceeceeeeeeeeeeeeeeeeensaaeeees 198 Brake Accumulator Check ccccccecceeeeeeeeceeeaeceeeeeeeeeeeesessssnneaeeees 199 Braking System Test 2 0 cclsecceeceseeececeeeedieaceeeedeasceceeveasseeeeeddhenaeeeetees 201 Engine Air Filter Service Indicator Inspect Replace 234
54. engine access cover on the left side of the hood Fill the reservoir with window washer solvent 336 SEBU7892 09 Maintenance Section Window Wiper Inspect Replace 102143121 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 Inspect Inspect the front wiper blade and the rear wiper blade Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs The window wiper and or the wiper motor should be replaced under the following conditions e The wiper arm is worn or damaged e The wiper motor is faulty Replace Use the following procedure in order to install a new wiper and or a new wiper motor on the front window and the rear window 1 Move the transmission direction control switch to NEUTRAL 2 Engage the parking brake 3 Place the steering frame lock in the LOCK position 4 Remove the cover in order to access the wiper arm and the wiper motor 5 Remove the wiper arm and the wiper motor 6 Install the new wiper arm and or the new wiper motor 7 Reinstall the cover 8 Place the steering frame lock in the STORED position SEBU7892 09 337 Maintenance Section Windows Clean 101921569 Windows Clean SMCS Code 7310 070 Use commercially available window cleaning solutions in order to clean the windows Clean the outside windows from the ground unless handholds are available Note Use a damp cloth to clean the windows Using a dry cloth will damage the
55. ential and Final Drive Oil Change SMCS Code 3278 044 4011 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 Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note The axles on this machine are equipped with ecology drain valves Illustration 141 g01167201 Front Axle 1 Remove bolts 1 and plate 2 SEBU7892 09 221 Maintenance Section Differential and Final Drive Oil Change gt 2 N SOR _S 7 IO Og SE ie ie Illustration 142 g01167202 Front Axle 2 Remove the drain plug 3 near the bottom of the differential housing 3 Attach a hose to a suitable drain adapter Install the adapter in the drain valve and allow the oil to drain into a suitable container 4 Remove the adapter and the hose 5 Remove the ecology drain valve Inspect the magnet on the end for metal particles 6 Clean the metal particles from the magnet Install the valve g01231823 Illustration 143 Rear Axle 222 SEBU7892 09 Mainte
56. ents in reverse order 6 Remove the strainer from the tank filler opening Wash the strainer in a clean nonflammable solvent Install the strainer 7 Install the fuel tank cap SEBU7892 09 259 Maintenance Section Fuel Tank Water and Sediment Drain 101408020 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Illustration 184 g00741044 The fuel tank drain valve is located in the articulation joint near the drive shaft Note For better access turn the machine all the way to the right g00587858 Illustration 185 1 Pull the attached hose out of the opening in the hitch Remove the plug from the end of the hose 260 SEBU7892 09 Maintenance Section Fuses Replace g00585242 Illustration 186 2 Open the drain valve Allow the water and the sediment to drain into a suitable container for disposal 3 Close the drain valve Install the plug in the end of the hose and place the hose back into the rear frame 102206402 Fuses Replace SMCS Code 1417 510 NOTICE Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result Fuses Fuses protect the electrical system from damage that is caused by overloaded circuits Replace the fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary SEBU7892 09 261 Maintenance Section Fuse
57. eseesensaneeeees 192 Cooling System Coolant Level Check cccccecceeeeeeeeeeetneeeeeeeeneeees 213 Engine Air Filter Service Indicator Inspect eee eeeeeteeeeeeeeeteeeeeeeeee 233 Engine Oil Level Chek ccccceececceceeeeeccceeesetecceeeeeeeeceeeeenseeeeeeneeeees 239 Fuel System Primary Filter Water Separator Drain 0 0 0 251 Grapple Boom and Arch Dual Function Lubricate 0 eee 265 Grapple Boom and Arch Single Function Lubricate cee 266 Grapple Head Bunching Lubricate ee eeeeeeeeeeeeeeteeeeeeeneeeees 267 Grapple Head Continuous Rotation Lubricate ceeeeee 267 Grapple Head Sorting Lubricate 2 0 00 cecceeeeeeeeeeeeseeneeeeeeeeeneeees 271 Grapple Snubber Inspect AdjuSt 0 cccceeeeeeeeeeeeceeceeeeeeeeeeeeeeeseees 273 Hydraulic System Oil Level Check cececececeececeeeeeeeeeeeeseesneaeeees 288 Seat Belt INSPECt oinor e naiai anes eee aaa anaa aai ia aaa 299 Transmission Oil Level Check cc ceeceeeeceeeeeeeeeeeeeeneeeeeeeeneeeeeeeaaes 312 Winch Oil Level Chek 0 0 0 ccccccccceeeessecceeeeeneeeeeeeeeneneeeeeeneneeeteeeteneees 331 Every 50 Service Hours or Weekly Articulation Bearings Lubricate 0 0 0 0 eecccceeeeeeeeeeeeenneeeeeeeteaeeeeeeenaaes 190 Axle Oscillation Bearings Lubricate 00 cee eeeeeeeeneeeeeeeeneeeeeeenaas 191 Cab Air Filter Clean Replace ccccccceceeeeeeeeeeetc
58. fore you can clean the battery terminals you must open the radiator grill The radiator grill is hinged in two places in the front of the machine Use the following procedure to open the radiator grill Remove bolts 1 and 2 from the left side of the radiator grill This will allow you to open the grill Illustration 119 g01089245 194 SEBU7892 09 Maintenance Section Battery Recycle 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 102039199 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e A recycling facility 102467359 Battery Hold Down Tighten SMCS Code 7257 527 Illustration 120 g01089245 Before you can tighten the hold downs for the batteries you must open the radiator grill The radiator grill is hinged in two places in the front of the machine Use the following procedure to open the radiator grill SEBU7892 09 195 Maintenance Section Battery Hold Down Tighten Illustration 121 g01089244 Remove bolts 1 and 2 from the left side of the radiator grill This will allow you to open the grill Over time the vibration of an operating
59. g01089198 3 Add oil through oil filler tube 2 if necessary 4 Close the engine access door 240 SEBU7892 09 Maintenance Section Engine Oil Sample Obtain 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 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 102127839 SEBU7892 09 241 Maintenance Section Engine Oil Sample Obtain Illustration 166 g01095579 Operate the machine for a few minutes before you obtain the fluid sample This will thoroughly mix the fluid for a more accurate sample The sampling valve for the engine oil is located on the right side of the engine on the engine oil filter base Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample
60. gloves when handling wire rope 334 Maintenance Section Winch Wire Rope Install Note Ferrules are made in various sizes Make sure that you use the correct ferrule for the size of the wire rope Table 15 Caterpillar C 500 Series Winch Diameter of Wire Rope Ferrule Part Number 19 mm 3 4 inch 118 6273 22 mm 7 8 inch 118 6275 25 mm 1 inch 118 6276 4 Illustration 265 g00483393 1 Attach a ferrule to the end of the wire rope 2 Wrap the wire rope once around the drum and slide the ferrule into the slot in the drum Make sure that the wire rope is installed so that the wire rope will be reeled in over the top of the drum 3 Move the winch control lever to the REEL IN position in order to wind the wire rope onto the winch drum Note The wire rope will detach if the wire rope is unwound below one full turn Applying red paint to the last six coils of the wire rope will help to serve as a visual warning SEBU7892 09 335 Maintenance Section Window Washer Reservoir Fill 102176858 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 266 g01102225 The window washer reservoir is located inside the top
61. he left side of the radiator grill This will allow you to open the grill 296 SEBU7892 09 Maintenance Section Radiator Core Clean x WY ANN Illustration 222 g01096285 2 Use compressed air high pressure water or steam in order to remove dust and other debris from the radiator core However the use of compressed air is preferred DOSES pitta 5 the OOC EELO SSS SSO COS ES SEESE DO Illustration 223 g01231388 3 Remove the cover plates on the left side of the radiator and the right side of the radiator in order to expose the access hole for the radiator The holes will allow easier access in order to clean the radiator Reference For more information on cleaning the radiator core refer to Special Publication SEBD0518 Know Your Cooling System SEBU7892 09 297 Maintenance Section Refrigerant Accumulator With Desiccant Replace 101701441 Refrigerant Accumulator With Desiccant Replace SMCS Code 7322 510 DSS Reference For the correct procedure refer to Air Conditioning and Heating Service Manual SENR5664 or the Disassembly and Assembly Manual for your machine Note A qualified mechanic should replace the components of the refrigerant system since special tooling and training are required 298 SEBU7892 09 Maintenance Section Rollover Protective Structure ROPS Inspect 102252267 Rollover Protective Structure ROPS Inspect
62. indicator 1 enters the red zone service the air cleaner 3 Check the condition of the air filter service indicator If the air filter service indicator is damaged then replace the air filter service indicator 4 Close the engine access door 102212375 Engine Air Filter Service Indicator Inspect Replace SMCS Code 7452 040 7452 510 The air filter service indicator is an important inexpensive instrument The indicator is used to show air filter restriction The indicator can help prevent unnecessary servicing The indicator can also help avoid running the engine with an excessively plugged air filter The air filter service indicator should be the method for determining the filter s life A dirty filter can still maintain the required performance Only proper use of the air filter service indicator can determine if the filter can maintain the required performance SEBU7892 09 235 Maintenance Section Engine Air Filter Service Indicator Inspect Replace Illustration 159 g01116980 The air filter service indicator 1 is located in the engine compartment on the LH side of the machine In normal dust conditions the air filter service indicator should be tested for proper operation at 250 hours Also the indicator should be tested when the air filter elements are serviced In order to check the operation of the air filter service indicator do the following checks e Stop the engine Check for ease of resett
63. ing the indicator The indicator should reset within a maximum of three pushes e Check for movement of the yellow core when the engine is accelerated to high idle When the engine is accelerated to high idle the yellow core should latch near the highest position If the indicator will not easily reset replace the indicator When the engine is accelerated to high idle and the indicator does not latch at the highest position replace the indicator 236 SEBU7892 09 Maintenance Section Engine Air Precleaner Clean Engine Air Precleaner Clean If Equipped SMCS Code 1055 070 FITT cc 2 M jji ie Lae Z IHO DN ON fe Illustration 160 g01645019 The engine air precleaner is located on the top of the engine enclosure Empty the precleaner bowl whenever the dirt reaches the FULL mark Be Ja C j Tte M N M DDDDDDDDDDDDDDDDDDDD c I Illustration 161 g01645093 1 Loosen wing nut 1 on cover 2 Remove the cover 2 Empty precleaner bowl 3 Wash the precleaner bowl and the cover with water SEBU7892 09 237 Maintenance Section Engine Crankcase Breather Clean 3 Install precleaner bowl 3 and cover 2 Tighten wing nut 1 finger tight 102164487 Engine Crankcase Breather Clean SMCS Code 1317
64. ion section of the Operation and Maintenance Manual for more information or consult your Caterpillar dealer SEBU7892 09 305 Maintenance Section Transmission Oil Change 102786556 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 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 1 Operate the engine in order to warm the oil Park the machine on a level surface and lower the decking blade to the ground with slight down pressure 2 Engage the parking brake Stop the engine 3 Remove the access plate underneath the machine 4 Remove the transmission drain plug at the bottom of the transmission Drain the oil into a suitable container Note The transmission is equipped with an ecology drain valve 5 Clean the drain plug and install the drain plug Install the access plate 6 Remove the transmission guards The first guard weighs approximately 45 kg 95 Ib The second guard weighs approximately 20 kg 45 Ib 306 SEBU7892 09
65. is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your authorized dealer for the replacement of the seat belt and mounting hardware Note 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 300 SEBU7892 09 Maintenance Section Seat Belt Replace If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 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 1 2 elie mii 4 g01152685 Illustration 226 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 mounti
66. isengaging the threads Do not replace this fill plug with any other plug 3 Unscrew filler plugs 3 for two complete turns in order to relieve pressure 4 Once the pressure is relieved remove filler plugs 3 5 Close ball valve 5 Fill the tank with 60 L 16 US gal of water Note If the outside temperature is below freezing use a propylene glycol based antifreeze in the water tank The antifreeze should be a non toxic antifreeze that is used in recreational vehicles 6 When water tank 1 is full install filler plugs 3 7 Connect an air hose to air valve 4 Pressurize water tank 1 to 345 kPa 50 psi 8 Open ball valve 5 9 Expel the water from water spray nozzle 6 If the discharge is not strong repeat the purging process If there is still a problem remove the hose and the lines and check for an obstruction 10 Once the purging process is complete fill and pressurize the water tank SEBU7892 09 317 Maintenance Section Water Cleaning System Pressurized Test 102143406 Water Cleaning System Pressurized Test SMCS Code 5612 081 5613 081 Illustration 245 g00868210 Water Cleaning System 1 Water Tank 2 Relief Valve 3 Filler Plugs 4 Air Valve 5 Ball Valve 6 Water Spray Nozzle 1 Remove the water hose from behind the seat Open ball valve 5 2 Squeeze water spray nozzle 6 in order to expel the water There will be pressure as the water is expel
67. l Capacities Refill for the correct amount of oil 8 Clean the filler plug and install the filler plug Clean the vent plug and install the vent plug Illustration 260 g01231645 9 Install the cover plate on the right side of the winch 330 SEBU7892 09 Maintenance Section Winch Oil Filter Replace Winch Oil Filter Replace SMCS Code 5177 510 g00698328 Illustration 262 1 Remove the access panels on the right side of the machine in order to access the winch oil filter 2 Use a strap type wrench to remove the oil filter Clean the filter base and dispose of the used filter properly SEBU7892 09 331 Maintenance Section Winch Oil Level Check 3 Apply a thin coat of oil to the seal of a new filter and install the filter by hand When the filter contacts the filter base tighten the filter by an additional 3 4 turn 4 Install the access panels 101312912 Winch Oil Level Check SMCS Code 5163 535 FLV Note This procedure only pertains to machines that are equipped with a Caterpillar C 500 Series winch Illustration 263 g00694965 The sight gauge is on the left side of the winch Check the oil level of the winch when the engine is stopped Maintain the oil level within the sight gauge Add oil if necessary 332 SEBU7892 09 Maintenance Section Winch Oil Sample Obtain 102127842 Winch Oil Sample Obtain SMCS Code 5163 008 7542
68. l Drive Oil Level Check Reference Refer to Operation and Maintenance Manual Differential and Final Drive Oil Level Check for the correct procedure 102338442 Differential and Final Drive Oil Level Check SMCS Code 3278 535 FLV 4011 535 FLV A Illustration 147 g01167247 Front Axle Right Side Illustration 148 g01167248 Rear Axle Left Side SEBU7892 09 225 Maintenance Section Differential and Final Drive Oil Sample Obtain 1 Remove the dipstick fill plug on the axle and wipe off the dipstick with a clean cloth This will ensure a more accurate measurement Reinsert the dipstick fill plug Note Make sure that the dipstick fill plug is installed tightly before you check the oil level Otherwise the oil level reading may be incorrect 2 Remove the dipstick fill plug again and check the oil level on the dipstick The oil level should be between the ADD mark and the FULL mark Add oil through the opening if necessary 3 Clean the plug and install the plug 102338440 Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4011 008 4070 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 c
69. lace 1 Park the machine on a level surface Lower all attachments to the ground Move the transmission direction switch to the NEUTRAL position Apply the parking brake and stop the engine Illustration 210 g01094632 2 Open the access door on the top of the engine enclosure and open the access door on the right side of the engine enclosure 4 A O NI T 2 Illustration 211 g01095207 3 Slowly loosen hydraulic tank filler cap 1 in order to release the pressure from the tank 288 SEBU7892 09 Maintenance Section Hydraulic System Oil Level Check 4 Use an oil filter strap wrench to remove the hydraulic oil filters 2 and 3 Dispose of the used filters properly 5 Clean both of the filter bases Make sure that all of the used gaskets are removed 6 Apply a light coat of clean hydraulic oil on the new gaskets 7 Install the new hydraulic oil filters 2 and 3 When the filter contacts the filter base tighten the filter by an additional 3 4 turn 8 Tighten hydraulic tank filler cap 1 9 Start the engine and operate the brakes the steering and the attachments Check the hydraulic oil level Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check for the correct procedure 10 Inspect the filters for leaks 11 Close th
70. le solvent Use compressed air to dry the parts 6 Inspect the strainer Replace the strainer if the strainer is damaged or plugged 7 Install the magnets and the metal band on the strainer Apply clean winch oil to the O ring seal and install the strainer on the suction tube SEBU7892 09 325 Maintenance Section Winch Oil Change 8 Inspect the cover seal for wear or for damage Replace the cover seal if necessary Install the cover and the four bolts 9 Reconnect the return line to the fitting 10 Reinstall the protective cover eo g00694843 Illustration 253 11 Remove vent plug 3 on the left side of the winch Clean the vent plug in a clean nonflammable solvent Install the vent plug Note Do not replace the vent plug with a solid plug Do not apply paint over the vent plug Either condition may cause oil leaks due to increased internal pressure during operation of the winch 326 SEBU7892 09 Maintenance Section Winch Oil Change g00694839 Illustration 254 12 Remove filler plug 4 and fill the winch with oil through the opening Reference Refer to Operation and Maintenance Manual Capacities Refill for the correct amount of oil 13 Clean the filler plug and install the filler plug Clean the vent plug and install the vent plug Hydraulic Winch Note The line for the hydraulic winch must be extended in order to expose the drain hole in the center of the winch
71. led If there is very little water pressure purge the water cleaning system 3 After you test the water cleaning system refill water tank 1 Water tank 1 must also be pressurized 318 SEBU7892 09 Maintenance Section Winch Drive Shaft Spline Lubricate Reference For information on purging and pressurizing the system refer to Operation and Maintenance Manual Water Cleaning System Pressurized Purge 102786672 Winch Drive Shaft Spline Lubricate If Equipped SMCS Code 5178 086 Note This procedure only pertains to machines that are equipped with a mechanical winch Wipe off the fitting before you apply any lubricant Apply lubricant through one fitting on the drive shaft spline 102786655 Winch Drive Shaft Support Bearing Lubricate If Equipped SMCS Code 5178 086 Note This procedure only pertains to machines that are equipped with a mechanical winch Wipe off the fitting before you apply any lubricant Apply lubricant through one fitting on the top of the support SEBU7892 09 319 Maintenance Section Winch Drive Shaft Universal Joint Lubricate 102216955 Winch Drive Shaft Universal Joint Lubricate If Equipped SMCS Code 5178 086 Note This procedure only pertains to machines that are equipped with a mechanical winch Illustration 246 g01118824 Top View Wipe the fittings before you apply any lubricant Appl
72. level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure 26 If transmission oil level is low add oil Recheck the transmission oil level 27 Close the access door 28 Stop the engine 29 Close the access panel on the left side of the machine Install the transmission guards underneath the machine 102254243 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 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 SEBU7892 09 311 Maintenance Section Transmission Oil Filter Replace Illustration 239 g01101509 1 Stop the engine Engage the parking brake 2 Remove the step assembly on the left side of the machine mA
73. lic system after the engine has been stopped Seri ous injury can be caused if this pressure is not re leased before any service is done on the hydraulic system Make sure all of the attachments have been low ered oil is cool before removing any components or lines Remove the oil filler cap only when the en gine is stopped and the filler cap is cool enough to touch with your bare hand SEBU7892 09 281 Maintenance Section Hydraulic System Oil Change 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 When you change the hydraulic oil be sure to clean the cover for the filter and the hydraulic filler cap before you remove these items Be sure to plug or cap any lines or hoses that are disconnected This will prevent foreign material from contaminating the hydraulic system Note The hydraulic tank supplies oil to the decking blade to the grapple to the differential lock to the brakes and to the steering system 1
74. ll the plug in the drain valve Illustration 171 g01096517 SEBU7892 09 245 Maintenance Section Engine Oil and Filter Change Illustration 172 g01095949 5 Open the front access door on the right side of the machine Use a strap type wrench to remove engine oil filter 1 6 Clean the housing base Make sure that the used gasket is completely removed 7 Apply a light coat of clean engine oil to the new gasket that is provided with the new filter Note There are rotation index marks on each engine oil filter that are spaced 90 degrees or 1 4 of a turn from each other When you tighten engine oil filters use the rotation marks as a guide 8 Install the engine oil filter hand tight until the seal contacts the base Note Note the position of the index marks on the filter in relation to a fixed point on the filter base 9 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide 246 SEBU7892 09 Maintenance Section Engine Oil and Filter Change Illustration 173 g01095976 Illustration 174 g01095975 10 Open the engine access door on the left side of the machine Fill the crankcase with oil through oil filler tube 3 Reference Refer to O
75. nance Section Differential and Final Drive Oil Change 7 Remove the plate 5 from the rear bottom guard in order to access the drain plug for the rear differential Note The plate is slotted Remove two bolts 4 and then loosen the remaining two bolts The plate will slide downward Remove the plate from the guard Illustration 144 g01231828 Rear Axle 8 Remove the drain plug 6 near the bottom of the differential housing Note Remove the dipstick on the right side of the axle in order to improve the oil flow while the oil is draining 9 Attach a hose to a suitable drain adapter Install the adapter in the drain valve and allow the oil to drain into a suitable container 10 Remove the adapter from the drain valve 11 Clean the drain plug and install the drain plug 12 Install the plate to the guard underneath the machine SEBU7892 09 Differential 223 Maintenance Section and Final Drive Oil Change Illustration 145 Front Axle Right Side g01167247 Phi D Illustration 146 Rear Axle Left Side g01167248 13 Remove the dipstick fill plugs on the right side of the axle Add oil through the opening Reference Refer to Operation and Maintenance Manual Capacities Refill for the proper amount of oil 14 Clean the plugs and install the plugs 15 Check the oil level 224 SEBU7892 09 Maintenance Section Differential and Fina
76. 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 SEBU7892 09 209 Maintenance Section Cooling System Coolant ELC Change Illustration 131 g01204097 5 Open the drain valve at the bottom of the radiator Allow the coolant to drain into a suitable container 6 Flush the cooling system with clean water until the draining water is clean Close the drain valve 7 Replace the water temperature regulator Reference For the correct procedure refer to Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace 8 Add the Extended Life Coolant ELC Reference For the capacity of the cooling system refer to Operation and Maintenance Manual Capacities Refill 9 Start the engine Run the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes 10 Stop the engine 11 Install the cooling system pressure cap 3 12 Install the access door 2 and the bolts 1 13 Check the cooling system coolant level 210 SEBU7892 09 Maintenance Section Cooling System Coolant Extender ELC Add Reference For the correct procedure refer to Operation and Maintenance Manual Cooli
77. ng System Coolant Level Check 14 Reinstall the bottom guard 102216953 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL 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 coolant test kit in order to check the concentration of the coolant solution SEBU7892 09 211 Maintenance Section Cooling System Coolant Extender ELC Add 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
78. ng hardware Determine age of new seat belt before installing on seat A manufacture label is on belt webbing and imprinted on belt buckle Do not exceed install by date on label Complete seat belt system should be installed with new mounting hardware SEBU7892 09 301 Maintenance Section Secondary Steering Test 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 102468987 Secondary Steering Test SMCS Code 4300 081 SE Use the following procedure to test the secondary steering system 1 Park the machine on a hard level surface Lower the implements and shut off the engine Leave the engine start switch in the ON position es ae ye LEE 6 A Vay es S ae 8 ae Illustration 227 2 Press and hold the top of the test switch for the secondary steering This will activate the secondary steering motor 3 Turn the steering wheel fully from left to right If the machine responds to the steering input the secondary steering is operating If the machine does not respond to the steering input the secondary steering is not working 302 SEBU7892 09 Maintenance Section
79. ollect 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 226 SEBU7892 09 Maintenance Section Differential and Final Drive Oil Sample Obtain Operate the machine for a few minutes before you obtain the fluid sample This will thoroughly mix the fluid for a more accurate sample pee es Illustration 149 g01167247 Front Axle Right Side Illustration 150 lustration 150 901167248 Rear Axle Left Side 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 Remove the dipstick fill plug on the right side of each axle and withdraw the oil through the filler opening Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample SEBU7892 09 227 Maintenance Section Engine Air Filter Primary Element Clean Replace 102468548 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Service the air filter only with
80. peration and Maintenance Manual Capacities Refill for the proper amount of oil 11 Start the engine and allow the oil to circulate Check for leaks 12 Check the engine oil level with oil dipstick 2 Reference Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure 13 If the oil level is correct close the engine access doors SEBU7892 09 247 Maintenance Section Engine Valve Lash Check 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 248 SEBU7892 09 Maintenance Section Ether Starting Aid Cylinder Replace 102391361 Ether Starting Aid Cylinder Replace If Equipped SMCS Code 1456 510 CD Breathing ether vapors or repeated contact of ether with skin can cause personal injury Person al injury may occur from failure to adhere to the following procedures Use ether only in well ventilated areas Do not smoke while changing ether cylinders Use ether with care to avoid fires Do not store replacement ether cylinders in living areas or in the operator s compartment Do not store ether cylinders in direct sunlight or at temperatures above 49 C 120 F Discard cylinders in a safe place
81. place SMCS Code 5056 510 Fl 5068 510 Personal injury can result from hydraulic oil pres sure and hot oil Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped Seri ous injury can be caused if this pressure is not re leased before any service is done on the hydraulic system Make sure all of the attachments have been low ered oil is cool before removing any components or lines Remove the oil filler cap only when the en gine is stopped and the filler cap is cool enough to touch with your bare hand 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 When you change the hydraulic filters be sure to clean the cover for the filter and the hydraulic filler cap before you remove these items Be sure to plug or cap any lines or hoses that are disconnected This will prevent foreign material from contaminating the hydraulic system SEBU7892 09 287 Maintenance Section Hydraulic System Oil Filter Rep
82. ricate Illustration 192 g00954439 Apply lubricant through six fittings on the grapple head SEBU7892 09 269 Maintenance Section Grapple Head Continuous Rotation Lubricate Illustration 193 g00956334 Grapple Rotator Apply lubricant through two fittings on the grapple rotator 270 SEBU7892 09 Maintenance Section Grapple Head Continuous Rotation Lubricate Illustration 194 g00992708 Grapple Snubber Apply 5P 0960 Molybdenum Grease through seven fittings on the grapple snubber Note Apply 5P 0960 Molybdenum Grease to the clutch housing until grease comes out of the reversed grease zerk SEBU7892 09 271 Maintenance Section Grapple Head Sorting Lubricate 102462227 Grapple Head Sorting Lubricate SMCS Code 6307 086 Illustration 195 g00954439 Wipe off the fittings before you apply any lubricant Apply lubricant through seven fittings on the grapple head 272 SEBU7892 09 Maintenance Section Grapple Head Rotator Continuous Rotation Lubricate i01878169 Grapple Head Rotator Continuous Rotation Lubricate SMCS Code 6307 086 Illustration 196 g00955879 Wipe off the fittings before you apply any lubricant Remove cover plate 1 in order to access fitting 2 Fill the rotator with lubricant through fitting 2 SEB
83. s Replace 0 ss DON A Aa Illustration 187 g01097733 The fuse panel is located on the left side of the cab 262 Maintenance Section Fuses Replace SEBU7892 09 15A 12 1 13 D gt 154 E on 11 15 D ne Illustration 188 3 Defroster Fan 15 Amp 1 Seat Adjustment Height 15 Amp 4 Rear Grapple Lights 15 Amp VARA 15A 18 ko 10A 19 nA 15A 20 g01099172 2 Voltage Converter 24 Volt Power Source 15 Amp SEBU7892 09 263 Maintenance Section Fuses Replace 5 Front Working Lights 15 Amp 6 Rear Working Lights 15 Amp 7 Engine Start Switch 10 Amp 8 Flood Lamp 15 Amp 9 Electronic Gauges 10 Amp 10 Engine 15 Amp 11 Fan Motor 15 Amp 12 Front Window Wiper and Washer 15 Amp 13 Engine 10 Amp 14 Transmission 15 Amp 00000000A 264 SEBU 7892 09 Maintenance Section Fuses Replace 15 Electronic Gauges 10 Amp 99 16 Spare Fuse 10 Amp 17 Interior Lights 10 Amp 18 Voltage Converter 24 Volt Power Source 15 Amp 19 Horn
84. services may extend the oil change even longer Consult your Cat dealer for details When Required Battery Recycle sc ha hais it ee ee ee 194 Battery or Battery Cable Inspect Replace 0 ecceeeceeeeeeeseteeeeereeee 196 Circuit Breakers Reset 20 c ceeeeceeeecteeeceeceeeeeesneneeeeeeeeneeedeeneeneeenes 205 Engine Air Filter Primary Element Clean Replace 227 Engine Air Filter Secondary Element Replace 231 Engine Air Precleaner Clean 00 2 ee cceceeecctceeeeeeeeteeeeeeeinneeeeeetneeeeereeee 236 Ether Starting Aid Cylinder Replace 0 eee ceecceeeeeeeeetteeeeeetnteeeeeeeeee 248 Fuel System Prime crs nnna ieis a eaa lian ka iiad 250 F se s Replace naen e e e e a a A 260 Oil Filter INSpeCt E ET E E AE 294 Radiator Core Cean seruirai aE AE EE ai 295 Water Cleaning System Pressurized Purge sisenes 315 Winch Wire Rope Install cceeeeeeeeeeceecceceeeeeeeeeseseecnncneeeeeeeeeeees 333 Window Washer Reservoir Fill 0 ccccccccecccceeccsseeceeeeeeeeeueeeeuaueeeeeaues 335 186 SEBU7892 09 Maintenance Section Maintenance Interval Schedule Window Wiper Inspect Replace cccecceceeeeeeeeeeeeccereeeeeeeeeeess 336 Windows Clean EE EEE EE E A E 337 Every 10 Service Hours or Daily Air Cleaner Dust Valve Clean INSpect cccccceeeeeeeeeeeeeeeeteeeees 189 Backup Alarm Test c ececececeececeeeeeeeeeeceaaeeeceeeeeeeeeee
85. surface of the window
86. ure of 207 kPa 30 psi Illustration 152 g01096212 Note When the primary air filter element is cleaned always begin with the inside of the filter in order to force dirt particles toward the outside 230 SEBU7892 09 Maintenance Section Engine Air Filter Primary Element Clean Replace 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 Vacuum Cleaning Vacuum cleaning is another method for cleaning a primary air filter element which requires 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 153 g01096213 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 confirm the result compare the primary air filter element to a new primary air filter element that has the same part number Do not
87. 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 SEBU7892 09 231 Maintenance Section Engine Air Filter Secondary Element Replace 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 154 g01096217 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow 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 102468628 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE 1 The air filter is located on the left side of the machine Open the engine access panel 232 SEBU7892 09 Maintenance Section Engine Air Filter Secondary Element Replace Illustration 155 g01096209 2 Remove cover 1 from the air filter housing Note If necessary unclamp the strap on the air filter housing so that the air filter housing can
88. utting the filter open Discard the used fuel filter element properly Clean water separator bowl 2 Note The water separator bowl is reusable Do not discard water separator bowl 2 6 Inspect the gasket on water separator bowl 2 Replace the gasket if necessary 7 Lubricate the gasket with clean diesel fuel or with engine oil Place the gasket in water separator bowl 2 8 Install water separator bowl 2 onto the new primary fuel filter 1 by hand until water separator bowl 2 is snug Do not use tools to tighten water separator bowl 2 Note Remove the cap from the new primary fuel filter before you install the water separator bowl Discard the cap 9 Clean the filter mounting base Make sure that all of the used seal is removed from the filter mounting base 10 Apply a thin coat of diesel fuel or engine oil to the seal on new primary fuel filter 1 11 Install the new fuel filter by hand When the seal contacts the filter base tighten primary fuel filter 1 by an additional 3 4 turn This will tighten primary fuel filter 1 sufficiently Do not use tools to tighten primary fuel filter 1 12 Prime the fuel system in order to fill the water separator element with fuel Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure SEBU7892 09 255 Maintenance Section Fuel System Secondary Filter Replace 13 Close the engine access door 102252246
89. y lubricant through fittings 1 and 2 on the rear drive shaft There is a total of two fittings 320 SEBU7892 09 Maintenance Section Winch Drum Bearing Lubricate 01367960 Winch Drum Bearing Lubricate SMCS Code 5159 086 BD Note This procedure only pertains to machines that are equipped with a Caterpillar C 500 Series winch Wipe off the fitting before you apply any lubricant g00721798 Illustration 247 Apply a small amount of lubricant through the fitting on the right side of the winch Excess lubricant may escape from the vent hole in the cover plate SEBU7892 09 321 Maintenance Section Winch Fairlead Rollers Lubricate 104794110 Winch Fairlead Rollers Lubricate SMCS Code 5163 086 5163 086 RLR Wheel Skidder with Mechanical Winch and Grapple Only Illustration 248 g02911616 Apply MPGM Grease lubricant to the fairlead grease fittings as shown 322 SEBU7892 09 Maintenance Section Winch Oil Change 102456564 Winch Oil Change SMCS Code 5163 044 Personal injury can result from winch oil pressure and hot oil Oil pressure can remain in the winch system after the engine has been stopped Serious injury can be caused if this pressure is not released before any service is done on the winch system Make sure the engine is stopped and the oil is cool before you remove any components or any lines NOTICE Care must be taken to ensure that fluids ar

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