MAINTENANCE INTERVALS - Safety
Contents
1. 9 Wipe the area around the oil filler cap Remove the oil filler cap Fill the crankcase with new oil Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Clean the oil filler cap and install the oil filler cap 10 Start the engine and allow the oil to warm Check for leaks Note After you stop the engine you must wait for ten minutes before you check the oil level This is done in order to allow the oil to drain back into the oil pan 11 Stop the engine and wait for ten minutes in order to allow the oil to drain into the oil pan Maintain the oil level in the crosshatched region of the engine oil dipstick Add oil if necessary 12 Close the engine hood i00664189 Engine Valve Lash Check SMCS Code 1105 025 Refer to the Service Manual for the complete adjustment procedure for the engine valve lash A qualified mechanic should adjust the engine valve lash and the fuel injector timing because special tools and training are required SEBU8458 01 i03005669 Fuel System Filter and Water Separator Replace SMCS Code 1261 510 1263 510 The fuel system filter water separator element is located in the engine compartment on the left side 1 Open the engine access door f CLI Illustration 138 g01355125 1 Electric fuel priming pump 2 Fuel filter base 3 Quick release collar 4 Fuel filter 5 Sediment bowl 62. Intermittent Windshield Wiper 42 Intermittent Windshield Wiper Main Fuses Illustration 147 g01357092 43 80 Amp Fuse 44 60 Amp Fuse There are 2 main fuses in the engine compartment on the right side under the battery If the element of either one of these fuses is separated investigate the cause before operating the machine 01416931 Hinges Lubricate SMCS Code 7000 086 HNG Use dry film lubricant for the following applications all moving door latches hinges door locks lock for the hood hinges for the hood and throttle pedal linkage y 2 SEBU8458 01 103751352 Hydraulic System Oil HYDO Advanced 10 Change SMCS Code 5095 044 Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic and hydrostatic transmission systems when ambient temperature is between 20 C 4 F and 50 C 122 F Cat HYDO Advanced 10 has an SAE viscosity grade of 10W Cat HYDO Advanced 10 has a 50 increase in the standard oil drain interval up to 3000 hours for machine hydraulic systems over second and third choice oils when you follow the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual 6000 hour oil drain intervals are possible when using S O S Services oil analysis When you switch to Cat HYDO Advanced 10 cross contamination with the previous oil should be kept to less than 10 Consult
3. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpil All Rights alana CATERPI LLAR CATERPILLAR cee LL Operation and Maintenance Manual 906H 907H and 908H Compact Wheel Loaders SDH1 Up 906H Machine SJM1 Up 907H Machine LMD1 Up 908H Machine SAFETY CAT COM 106 Maintenance Section Maintenance Interval Schedule 03704302 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 is extended to 3000 hours S O S services may extend the oil change even
4. Drain valve for fuel filter 2 Open the drain on the water separator bowl Allow the water and fuel to drain into a suitable container 3 Support the water separator element and rotate the locking ring counterclockwise Remove the locking ring 4 Remove the water separator bowl from the bottom of the fuel filter water separator element Note The water separator bowl is reusable Do not discard the water separator bowl 5 Inspect the O ring seal of the water separator bowl for damage Replace the O ring seal if necessary SEBU8458 01 6 Lubricate the O ring seal with clean diesel fuel or lubricate the O ring seal with motor oil Place the seal in the water separator bowl 7 Spin the water separator bowl onto the new filter element by hand until the fuel filter water separator is snug Do not use tools to tighten the fuel filter water separator element to the bowl 8 Clean the filter mounting base 9 Install the new element Rotate the locking ring clockwise in order to fasten the filter to the mounting base 10 In order to activate the electric fuel priming pump turn the ignition switch to the START position and release the ignition switch This process will activate the relay for the electric fuel priming pump which allows power to reach the electric fuel priming pump The electrically operated fuel pump will fill the water separator element with fuel 129 Maintenance Section Fuel System Water Separator Dr
5. There is a grease fitting for each side of the machine 101409489 Tire Inflation Check SMCS Code 4203 535 Al Measure the tire pressure on each tire Consult your Caterpillar dealer for the correct load rating and for the correct operating pressures These correct load ratings and correct operating pressures can also be obtained from your tire dealer Inflate the tires if necessary See Operation and Maintenance Manual Tire Inflation with Air or Operation and Maintenance Manual Tire Inflation with Nitrogen i02699169 Transfer Drive Hydrostatic Oil Change SMCS Code 3159 044 OC The transfer drive is located underneath the machine in front of the rear axle There are 2 styles of transfer drive e Standard Drive e Speeder Drive 146 Maintenance Section Transfer Drive Hydrostatic Oil Level Check 1 Illustration 172 Standard Drive 1 Level Fill Plug 2 Drain Plug g01358806 rey F g01358807 Illustration 173 Speeder Drive 1 Level Fill Plug 2 Drain Plug 1 Remove the drain plug 2 and allow the oil to drain into a suitable container 2 Clean the drain plug and install the drain plug SEBU8458 01 3 Remove the oil level fill plug 1 Add oil until the oil is level with the bottom of the plug threads Refer to the Operation and Maintenance Manual Lubricant Specifications and Operation and Maintenance Manual Refill C
6. Final Drive Oil Level Check SMCS Code 3278 535 FLV 4050 535 FLV Differential I et ITT TS E TTT MEA Illustration 122 g01357818 Front Differential 1 Level Fill Plug 2 Drain Plug T ILLL i ia pence os 1 2 Illustration 123 g01357819 Rear Differential 1 Level Fill Plug 2 Drain Plug 121 Maintenance Section Differential and Final Drive Oil Level Check 1 Remove the differential level fill plugs 1 for the front axle and the rear axle 2 The oil level should be at the bottom of the threads for the plug 3 Add oil if necessary 4 Clean the plugs and install the plugs Wheels Illustration 124 g01357831 Wheel in the position for checking Note Work on one wheel at a time 1 Move the machine so that the plug on the wheel is in the horizontal position 2 Remove the level fill plugs for the wheel 3 The oil level should be at the bottom of the threads for the plug 4 Maintain the oil level at the bottom of the threads for the plug 5 Add oil if necessary 6 Clean the plug and install the plug 7 Repeat steps 1 through 6 for each wheel 122 Maintenance Section Differential and Final Drive Oil Sample Obtain 102699139 Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4050 008 4070 008 7542 Ay WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact
7. Open the engine hood The coolant tank is located on the right side above the battery Illustration 114 g01357729 1 Remove the cap 1 from the coolant tank 2 Maintain the coolant level between the marks on the side of the tank when the cooling system is cool If you need to add coolant daily check the cooling system for leaks 3 Replace the cap if the seal is damaged 4 Install the cap on the tank 102699199 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 analysis 118 Maintenance Section Cooling System Coolant Sample Level 2 Obtain Illustration 115 g01357744 Coolant Drain Valve 1 Open the engine hood 2 Open the coolant drain valve that is located on the side of the engine in order to sample the coolant 3 Submit the sample for Level 1 analysis 102699201 Cooling System Coolant Sample Level 2 Obtain SMCS Code 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
8. SEBU8458 01 ee N Illustration 113 g01380076 5 Open the drain and allow the coolant to drain from the radiator into a suitable container 6 Close the drain 7 Replace the access panel 8 Replace the thermostat See Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the process for replacing the thermostat 9 Add the coolant solution directly to the coolant tank Refer to Operation and Maintenance Manual Capacities Refill Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Note Premix the coolant solution before filling the cooling system The coolant solution should contain 50 percent coolant and 50 percent distilled water Note Add the coolant solution at a maximum rate of five liters per minute This will reduce the chance of trapping air inside the engine block A large amount of trapped air can cause localized heating to occur upon start up Localized heating may result in engine damage which may lead to failure of the engine 10 Start the engine Run the engine without the radiator cap for 30 seconds Stop the engine Allow the engine to sit for 1 minute Check the coolant level If necessary add coolant 11 Check the coolant level in the coolant tank Maintain the coolant level to the top mark on the tank SEBU8458 01 12 Stop the engine Inspect the cap for the coolant tank and the gasket Replace the
9. any accumulated debris 4 Close the engine hood 102699187 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD Wipe the grease fittings before you lubricate the grease fittings SEBU8458 01 Illustration 100 g01355727 g01355731 Illustration 101 Apply lubricant to the grease fittings for the upper and lower bearing and for the oscillation bearing 101390799 Backup Alarm Test SMCS Code 7406 081 The backup alarm is mounted below the radiator in the engine compartment The backup alarm has one sound level The sound level is not adjustable SEBU8458 01 Turn the engine start switch key to the ON position in order to perform the test Apply the service brake Move the direction control switch to the REVERSE position The backup alarm should immediately sound The backup alarm will continue to sound until the direction control switch is moved to the NEUTRAL position or to the FORWARD position 103704739 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 The battery is located under the hood on the right side of the machine Open the hood g01355762 Illustration 102 Battery on Right Side 1 Positive Battery Terminal 2 Battery Hold Down 3 Negative Battery Terminal Ay WARNING To avoid personal injury fr
10. 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 SEBU8458 01 E n Pea ia P a Ya Pa H ECO Tone JESO z5 Illustration 116 g01357744 1 Open the engine hood 2 Open the coolant drain valve that is located on the side of the engine in order to sample the coolant Submit the sample for Level 2 analysis i02998149 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Failure to replace the engine s thermostat on a regularly scheduled basis could cause severe engine damage The thermostat should be replaced after the cooling system has been cleaned Replace the thermostat while the cooling system is completely drained or while the coolant is drained to a level that is below the thermostat housing Caterpillar engines incorporate a shunt design cooling system It is mandatory to always operate the engine with a thermostat SEBU8458 01 7 Se ea amp AWC gt 19 TH NE ee aa H gt Leech eee A GA Sie Res oy i a i TA Go aw F r P i ry lt p A f DIEN r RA DY Dw EAS D bgi 1 TEA p F Eii a vmi Illustration 117 g01520307 1 Loosen the hose clamp and remove the hose from the thermostat housing assembly 2 Remove the bolts from the assembly and remove the assembly 3 Remove the gasket the
11. clean the windows Clean the outside windows from the ground unless handholds are available SEBU8458 01 102608161 Work Tool Lubricate SMCS Code 6700 086 Apply lubricant to the grease fitting for all pivot pins Apply lubricant to the grease fitting for the rod end of all cylinders Apply lubricant to the grease fitting for the head end of all cylinders i01809997 Work Tool Mounting Bracket Inspect SMCS Code 6700 040 BK Illustration 179 g00925058 Inspect upper angled plate 1 and ensure that the plate is not bent or otherwise damaged Inspect holes 2 for wear and for damage Inspect lower angled plate 3 and ensure that the plate is not bent or otherwise damaged If any wear is suspected or any damage is suspected consult your Caterpillar dealer before you use the work tool 149 Maintenance Section Work Tool Lubricate
12. hydraulic system oil tank with hydraulic oil Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Note Observe the sight gauges for the hydraulic oil level as you fill the hydraulic system oil tank Do not overfill the tank 7 The sight gauges for the hydraulic oil level are located on the side of the tank below the filler cap Maintain the hydraulic oil level in the center of the top sight gauge Add oil if necessary Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction hoses and hose clamps 8 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary 9 Install the hydraulic tank filler cap 10 Close the engine hood SEBU8458 01 102699150 Hydraulic System Oil Filter Return Replace SMCS Code 5068 510 RJ 1 Open the engine hood 2 Remove the hydraulic tank filler cap a Illustration 152 g01358262 3 The hydraulic oil filter is located in the engine compartment 4 Remove the filter element with a strap type wrench 5 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element base 6 Apply a light coat of oil to the gasket of the new filter element 7 Install a new filter hand tight until the seal of the filter contacts the base
13. longer Consult your Caterpillar dealer for details Note After the initial 250 hours the hystat system needs to be calibrated A Caterpillar dealer must perform the calibration Consult your Caterpillar dealer for information about the calibration When Required Battery or Battery Cable Inspect Replace 109 Bucket Cutting Edges Inspect Replace 112 Bucket Tips Inspect Replace cccceeeeees 113 Cab Air Filter Clean c ccccccceccceeceeeeeeeeeeeeeees 113 Engine Air Filter Primary Element Clean RODIACE is tiene ties Cicte E 122 Engine Air Filter Secondary Element Replace 123 Engine Compartment Clean ccccccceeee eee 125 Fuel Tank Water and Sediment Drain 130 Fuses Replace cccceccecceccceeceeceeceeeeeeeeseeees 131 Hinges Lubricate ccccccecceeceeceeeeeseeeseeees 134 Oil Filter Inspect 0 eee ceeeeceeeceeeseeeeeeeseeens 138 Radiator Core Clean cccccceeecseeeeeeeseeeeaees 140 Window Washer Reservoir Fill cece 148 Window Wiper Inspect Replace 008 148 Every 10 Service Hours or Daily Air Cleaner Dust Valve Clean Inspect 108 Articulation Bearings Lubricate 08 108 SEBU8458 01 Backup Alarm Test ccccccsecceeeeeeeseeeeeeeeeeees 108 Brake System Fluid Level Check 00 111 Coolin
14. of any cracks in the ROPS 102429589 Seat Belt Inspect SMCS Code 7327 040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine 142 Maintenance Section Seat Belt Replace Illustration 162 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 is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 101970036 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation 2 or within five years of the date of manuf
15. thermostat and the seal from the assembly 4 Install a new seal in the assembly Install a new thermostat and a new gasket Install the assembly 5 Install the hose Tighten the hose clamp 6 Refill the cooling system See Operation and Maintenance Manual SEBU6250 Cooling System Specifications and Operation and Maintenance Manual Refill Capacities 102699128 Differential and Final Drive Oil Change SMCS Code 3278 044 4050 044 Wipe the covers and surfaces around openings before you check the oil Wipe the covers and surfaces around openings before you add oil 119 Maintenance Section Differential and Final Drive Oil Change Differential Oil IND a STTIE TS iM HITET LP wh ie Illustration 118 g01357818 Front Differential 1 Level Fill Plug 2 Drain Plug ig lt H 7 T ILLL i ii IEA INO Illustration 119 g01357819 Rear Differential 1 Level Fill Plug 2 Drain Plug 1 Remove the drain plugs 2 from both differentials Allow the oil to drain into a suitable container 2 Clean the drain plugs and reinstall the drain plugs 3 Remove the differential level fill plug 1 from both differentials 120 Maintenance Section Differential and Final Drive Oil Change 4 Fill the differentials with oil See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities 5 Main
16. Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 8 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter SEBU8458 01 Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 9 Maintain the hydraulic oil level at the middle of the top sight gauge Add oil if necessary 10 inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary 11 Install the hydraulic tank filler cap 12 Close the engine hood 102699152 Hydraulic System Oil Level Check SMCS Code 5095 535 FLV Note Check the hydraulic system oil level with the machine on a level surface 1 Lower the work tool to the ground Turn off the engine 2 Open the engine hood 3 Wait for about five minutes before checking the level of the hydraulic oil The hydraulic tank is located on the right side of the engine compartment 137 Maintenance Section Hydraulic System Oil L
17. acture 1 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 each seat belt SEBU8458 01 TITTIE Wani g01022746 Illustration 163 1 Date of Manufacture 2 Date of Installation Contact your Caterpillar dealer for the replacement of the seat belt i03589859 Steering Column Play Check SMCS Code 4310 535 Illustration 164 g01408466 1 Hold the steering wheel with both hands 2 Try to move the steering wheel from one side to the other side The maximum allowed movement in the steering column should not exceed 25 mm 1 0 inch If the value is not within the limit perform the following steps a Inspect the pivot joint for loose bolts b Tighten the bolts if the bolts are loose SEBU8458 01 Note Apply 9S 3263 Thread Lock Compound to the bolts before tightening c Inspect the pivot joint for excessive wear d Replace the bushings if there is excessive wear Ay WARNING Failure to perform this inspection and repair may cause loss of steering control which may result in personal injury or death Do not operate the machine until the inspection and repair are completed Contact your Caterpillar dealer for any other required service 102934544 Steering Column Spline HMU Steering Lubricate SMCS Code 4310 086 JF 4343 086 JF The metering pump is located under the cab Crus
18. ain 103005672 Fuel System Water Separator Drain SMCS Code 1263 543 2 3 Cott Illustration 139 g01355125 1 Electric fuel priming pump 2 Fuel filter base 3 Quick release collar 4 Fuel filter 5 Sediment bowl 6 Drain valve for fuel filter 1 Open the engine hood 2 Pull the drain hose outside the engine compartment 3 Loosen the drain valve on the bottom of the water separator Allow the water and the sediment to drain into a suitable container 4 Tighten the drain valve and put the drain hose inside the engine compartment 5 Close the engine hood 130 Maintenance Section Fuel Tank Cap and Strainer Clean 102724242 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 Z2 1273 070 STR Illustration 140 g01366657 The fuel cap is located in the center on the left side of the machine Illustration 141 g0 1366659 1 Lift the lever 1 and turn the lever counterclockwise until the lever stops Remove the cap 2 2 Inspect the seal for damage Replace the seal if necessary SEBU8458 01 3 Remove the strainer that is located in the filler opening 4 Wash the strainer and the fuel tank cap in a clean nonflammable solvent 5 Install the strainer into the filler opening 6 Install the fuel tank cap Close the engine access door 102699147 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Release the pressure in the
19. allation of a clean primary element or if the exhaust smoke is still black NOTICE Service the air cleaner only with the engine stopped Engine damage could result if the air cleaner is ser viced while the engine is running Illustration 128 g01379338 1 Release the 3 clips on the air cleaner housing cover Remove the air cleaner housing cover 124 Maintenance Section Engine Air Filter Service Indicator Inspect Replace Illustration 129 2 g01379340 Remove the primary filter element Illustration 130 3 4 g01379368 Remove the secondary filter element Cover the air inlet opening Clean the inside of the air cleaner housing Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged Uncover the air inlet opening Install a new secondary element Install the primary element SEBU8458 01 8 Install the air cleaner housing cover and install the clip 9 Reset the engine air filter service indicator 102699207 Engine Air Filter Service Indicator Inspect Replace SMCS Code 7452 040 7452 510 Illustration 131 g01357913 Location of the engine air filter 1 Engine Air Filter Service Indicator 2 Engine Air Filter 1 Mount the machine 2 Fasten the seat belt and start the engine Run the engine at high idle ie oN Stop the engine 5 Open the engine hood 6 Inspect the indicator If t
20. apacities 4 Clean the oil level fill plug and install the oil level fill plug 102708167 Transfer Drive Hydrostatic Oil Level Check SMCS Code 3159 535 OC The transfer drive is located underneath the machine in front of the rear axle There are 2 styles of transfer drive e Standard Drive e Speeder Drive Illustration 174 g01358806 Standard Drive 1 Level Fill Plug 2 Drain Plug SEBU8458 01 147 Maintenance Section Transfer Drive Hydrostatic Oil Sample Obtain g01358807 Illustration 175 Speeder Drive 1 Level Fill Plug 2 Drain Plug 1 Remove the oil level fill plug The oil should be level with the bottom of the plug threads 2 Add oil if necessary Refer to the Operation and Maintenance Manual Lubricant Specifications and Operation and Maintenance Manual Refill Capacities 3 Clean the oil level fill plug and install the oil level fill plug 102708170 Transfer Drive Hydrostatic Oil Sample Obtain SMCS Code 3159 008 7542 The transfer drive is located underneath the machine in front of the rear axle There are 2 styles of transfer drive e Standard Drive e Speeder Drive g01358806 Illustration 176 Standard Drive 1 Level Fill Plug 2 Drain Plug rey FG g01358807 Illustration 177 Speeder Drive 1 Level Fill Plug 2 Drain Plug Remove the filler plug for the transfer drive Sample the
21. ation 137 g01520314 1 Oil Filler Cap 2 Oil Dipstick 3 Oil Filter 4 Oil Drain Valve 5 Oil Sample Port 2 Open the crankcase drain valve and drain the oil into a suitable container 3 Close the crankcase drain valve 4 Remove the filter element with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect 5 Clean the filter mounting base with a clean cloth Make sure that the old filter gasket has been removed 128 Maintenance Section Engine Valve Lash Check 6 Apply a thin film of clean engine oil to the sealing surface of the new filter element 7 Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 8 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter
22. bucket so that the bucket tips are accessible 2 Place blocks under the raised edge of the bucket 3 Remove the mounting bolts Remove the bucket tips 4 Clean the mounting surface 5 Replace the bucket tips 6 Install the bolts 7 Remove the blocks that are under the bucket 8 After a few hours of operation check the bolts for proper torque 113 Maintenance Section Bucket Tips Inspect Replace 102708467 Cab Air Filter Clean SMCS Code 7342 070 Clean Internal Filter Element Illustration 105 g01359738 1 Screws 2 Internal Filter Element The internal filter element is located in the cab on the left side There may be a cover panel over the filter If your machine has a storage box in the cab the filter is behind the storage box 1 Remove the cover panel or remove the storage box 2 Remove the 2 screws that hold the filter in place 3 Remove the filter element Clean the filter element with compressed air You can also wash the filter elements with a solution of warm water and of a nonsudsing household detergent Do not wash the filter element while the filter element is installed on the machine Replace the filter element if the filter element is damaged 4 Rinse the filter element in clean water Air dry the filter element thoroughly 5 Install the filter element and replace the screws 6 Install the cover panel or install the storage box 114 Maintenance Section Cab A
23. cap if the cap or the gasket is damaged Install the cap 13 Close the engine hood 01389522 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loose the cap slowly to relieve the pressure When a Caterpillar Extended Life Coolant is used an extender must be added to the cooling system See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval The amount of extender is determined by the cooling system capacity Table 29 RECOMMENDED AMOUNT OF EXTENDER BY COOLING SYSTEM CAPACITY Recommended Amount Cooling System Capacity of Extender 22 to 30 L 6 to 8 US gal 0 57 L 60 qt 30 to 38 L 8 to 10 US gal 0 71 L 75 qt 38 to 49 L 10 to 13 US gal 0 95 L 95 at 49 to 64 L 13 to 17 US gal 1 18 L 1 25 qt For additional information on the addition of extender see Operation and Maintenance Manual SEBU6250 Cooling System Specifications or consult your Caterpillar dealer 102699202 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure 117 Maintenance Section Cooling System Coolant Extender ELC Add
24. cceeeees 142 Every 250 Service Hours or 6 Months Brake Pads Check cccccceccsseceeeteeeeneeeeeees 109 Braking System Test ccccscccsseceseeceeeseeeeeees 111 Differential and Final Drive Oil Level Check 121 Transfer Drive Hydrostatic Oil Level Check 146 Initial 500 Service Hours Differential and Final Drive Oil Change 119 Engine Valve Lash Check ccccecceeeeeeeeees 128 Transfer Drive Hydrostatic Oil Change 145 Every 500 Service Hours Differential and Final Drive Oil Sample Obtain 122 Hydraulic System Oil Sample Obtain 138 Transfer Drive Hydrostatic Oil Sample ODIA arinean e e A lee tude uablteeh ci 147 SEBU8458 01 Every 500 Service Hours or 3 Months Cooling System Coolant Sample Level 1 OBAIN orasta ayes ticcidawil T 117 Fuel Tank Cap and Strainer Clean 130 Every 500 Service Hours or 1 Year Engine Oil and Filter Change ccccceee 127 Fuel System Filter and Water Separator FRE DIAC oani nea eN ide tdceuentei sania Remmmnelantss 128 Hydraulic System Oil Filter Return Replace 136 Every 1000 Service Hours or 6 Months Differential and Final Drive Oil Change 119 Transfer Drive Hydrostatic Oil Change 145 Every 1000 Service Hours or 1 Year Brake System Fluid Change c scccseeeeeees 110 Engine Crankcase Breat
25. draulic Oil Cooler 2 Radiator 141 Maintenance Section Rollover Protective Structure ROPS Inspect NOTICE When you are using compressed air or high pressure water to clean the radiator fins ensure that the air or water is directed parallel to the fins If the compressed air or high pressure water is not directed parallel to the radiator fins the radiator fins could be bent or dam aged 4 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator fins However the use of compressed air is preferred 5 Clean the hydraulic oil cooler and the radiator 6 Move the lever to the right in order to lower the hydraulic oil cooler to the original position Note Ensure that the hydraulic oil cooler is returned to the original position Failure to return the hydraulic oil cooler may cause overheating of the hydraulic oil 7 Close the side access doors 8 Close the engine hood 102293385 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 Inspect the ROPS for loose bolts or for damaged bolts Replace any damaged bolts or missing bolts with original equipment parts only Tighten the bolts that hold the ROPS to the frame to a torque of 460 60 N m 339 44 Ib ft There are twelve ROPS retaining bolts Do not straighten the ROPS Do not repair the ROPS by welding reinforcement plates to the ROPS Consult your Caterpillar dealer for repair
26. evel Check Illustration 153 g01358251 1 Filler Cap 2 Hydraulic Tank 3 Upper Sight Gauge 4 Lower Sight Gauge 4 Maintain the oil level to the middle of the upper sight gauge Do not overfill the hydraulic tank Never allow the hydraulic oil level below the center of the lower sight gauge 5 Remove the hydraulic tank filler cap and add hydraulic oil if necessary 6 Clean the hydraulic tank filler cap Install the hydraulic tank filler cap 7 Close the engine hood 138 Maintenance Section Hydraulic System Oil Sample Obtain i02998097 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 008 7542 Illustration 154 g01520287 Open the engine hood The sampling port for the hydraulic oil is located on the hydraulic oil filter base 102699155 Lift Arm and Cylinder Linkage Lubricate SMCS Code 5102 086 BD 6107 086 BD Wipe all of the grease fittings before you apply lubricant SEBU8458 01 Illustration 155 g01358346 Apply lubricant to the grease fittings 1 for the frame and for the lift arm There is a grease fitting for each side of the machine Apply lubricant to the grease fitting 2 for the head end of the lift cylinder There is a grease fitting for each side of the machine Apply lubricant to the grease fitting 3 for the rod end of the lift cylinder There is a grease fitting for each side of the machine 102106227 Oil Filter Inspect SMCS C
27. fuel tank by loosening the fuel tank cap The fuel tank drain valve is located in the center on the left side underneath the machine Illustration 142 g01358191 Remove the cover Open the fuel tank drain valve Allow the water and sediment to drain into a suitable container Close the fuel tank drain valve Replace the cover SEBU8458 01 102699211 Fuses Replace SMCS Code 1417 510 Fuses 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 NOTICE Replace the fuses with the same type and size only Otherwise electrical damage can result If itis necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer Illustration 143 g01356828 131 Maintenance Section Fuses Replace Illustration 144 g01356829 The fuse panel is located on the right side of the cab In order to access the fuse panel you must open the right side door 132 Maintenance Section Fuses Replace 15A S 12 x laa aN 10A tt 15A Dg 10A DS 10A 15 l 19 10A Min 10A MA PIES 20A A 10A Pd 27 1 4 10A A 104 10A 4 Pesta JJA 1w 4 10A 10A 18 22 26 29 30 Illustration 145 g01356830 1 Ride Control 10 Amp 2 Reverse Light 10 Amp 3 Diffe
28. g System Coolant Level Check 117 Engine Oil Level Check ccccceceseeeeeeeeees 126 Fuel System Water Separator Drain 129 Hydraulic System Oil Level Check 137 Lift Arm and Cylinder Linkage Lubricate 138 Quick Coupler Clean Inspect c0cccceeees 139 Quick Coupler Lubricate cccccceceeeeeeeeees 140 Seat Belt Inspect o oo ccccseeeceeeeeeeeeeeeeeees 141 Steering Cylinder Bearings Lubricate 144 Tilt Cylinder Bearings and Bucket Linkage Bearings PUD GOs ora n eh aces esd toda ented 144 Tire Inflation Check cccecceceseeeeeeeeeeneeeeeees 145 Wheel Nut Torque Check ccccceeeeeeeeeeees 148 Windows Clean jcsecc reine yobs coc eeidedeaasuadncteastehexs 148 Work Tool Lubricate cernes ai 149 Work Tool Mounting Bracket Inspect 149 Every 50 Service Hours or Monthly Cab Air Filter Clean Replace ccccceeee 114 Initial 250 Service Hours Cooling System Coolant Sample Level 2 OD TAIN sere de Sees Sess venetian te sate viwestvaeteescdistteasaesteees 118 Every 250 Service Hours Engine Oil Sample Obtain cc ceeeeeeee eee 126 Every 250 Service Hours or Monthly Engine Air Filter Service Indicator INSDECY REDIACE icoana cesses 124 Every 250 Service Hours or 3 Months Steering Column Play Check cccc
29. he machine moves consult your Caterpillar dealer Ay WARNING If the machine begins to move reduce the engine speed immediately and apply the service brake pedal 3 Lower the bucket to the ground Stop the engine SEBU8458 01 NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the parking brakes before returning the machine to oper ation 101743875 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Ay WARNING Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket cutting edge is accessible 2 Place blocks under the raised edge of the bucket 3 Remove the bolts Remove the cutting edge and the end bits 4 Clean the contact surfaces 5 Use the opposite side of the cutting edge if this side is not worn 6 Install a new cutting edge if both edges are worn 7 Install the bolts 8 Remove the blocks that are under the bucket 9 After a few hours of operation check the bolts for proper torque SEBU8458 01 101764331 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Ay WARNING Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the
30. he yellow piston in the indicator enters the red zone service the air cleaner Note See Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace see Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 7 Reset the indicator SEBU8458 01 Note To check the condition of the service indicator try resetting the service indicator This should require less than three pushes of the reset button Next check the movement of the yellow piston in the service indicator Start the engine and accelerate the engine to high idle for a few seconds After the governor control pedal is released the yellow piston should remain at the highest position that was achieved during acceleration If either of these conditions are not met replace the service indicator i 02708486 Engine Compartment Clean SMCS Code 1000 070 CPA Inspect the engine compartment for dirt buildup or debris Remove any dirt or debris from the engine compartment 1 Open the engine hood Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 132 g01359660 2 Remove any debris or dirt from the engine compartment If necessary remove the belly plate in order to clean out the engine compartment The belly plate is located under the rear of the machine on the left side Note Use care when you clean the engine compartment Damage to the machine may occur 3 Insta
31. her Closed Circuit RODIACE anann r waned esas eaecc tenses 125 Engine Valve Lash Check ccccecccseeeeeeeeees 128 Hydraulic System Oil Change ccc seeeeee 135 Rollover Protective Structure ROPS Inspect 141 Every 3000 Service Hours Hydraulic System Oil HYDO Advanced 10 CHANGE spueren ie er E 134 Steering Column Spline HMU Steering LUDICATG irrar oaa idectaate a 143 Every 3000 Service Hours or 2 Years Cooling System Coolant Extender ELC Add 117 Cooling System Water Temperature Regulator REDAC conre ied gaseal cede a aaas 118 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccccecccscccssecseeeeeeeseeens 142 Every 6000 Service Hours Hydraulic System Oil HYDO Advanced 10 GRANGE meei anceciet fe wee howeaee utes 134 Every 6000 Service Hours or 4 Years Cooling System Coolant ELC Change 115 107 Maintenance Section Maintenance Interval Schedule 108 Maintenance Section Air Cleaner Dust Valve Clean Inspect 102957879 Air Cleaner Dust Valve Clean Inspect SMCS Code 1051 571 VL 1 Open the engine hood 2 The air filter housing is located on the right side of the engine compartment Illustration 99 g01379352 3 Check the 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
32. hing Hazard Connect the steering frame lock between front and rear frames before servicing the machine in the articulation area Disconnect the steering frame lock and secure it in the stored po sition before resuming operation Failure to do so could result in serious injury or death Refer to Operation and Maintenance Manual Steering Frame Lock before entering the articulation joint Note Do not disconnect any hydraulic lines from the metering pump Use the following steps to lubricate the splines on the steering column 143 Maintenance Section Steering Column Spline HMU Steering Lubricate Illustration 165 g01358974 1 Open the access door on the front of the cab Refer to Operation and Maintenance Manual Access Doors and Covers for information about the access door Illustration 166 g01358589 2 Support the metering pump 1 Loosen the four bolts 3 that hold the pump Do not loosen the hose couplings 2 144 Maintenance Section Steering Cylinder Bearings Lubricate SEBU8458 01 Illustration 167 g01358591 3 Lower the pump in order to expose the splines 4 4 Clean the male splines on the steering column Clean the female splines in the pump 5 Apply proper grease to the splines Refer to Operation and Maintenance Manual Lubricant Viscosities for selecting the proper grease 6 Push the pump into position 7 Tighten the four bolts that hold the pump 8 Tes
33. ht gauge Add oil if necessary Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction hoses and hose clamps 8 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary 9 Install the hydraulic tank filler cap 10 Close the engine hood 135 Maintenance Section Hydraulic System Oil Change 102699149 Hydraulic System Oil Change SMCS Code 5095 044 Operate the machine for a few minutes in order to warm the hydraulic system oil The machine should be on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the Illustration 150 g01358251 1 Filler Cap 2 Hydraulic Tank 3 Upper Sight Gauge 4 Lower Sight Gauge 1 Open the engine hood 2 Remove the hydraulic tank filler cap 3 The hydraulic tank drain plug is located on the bottom of the hydraulic tank on the underside of the machine Remove the drain plug and allow the hydraulic oil to drain into a suitable container 4 Install the drain plug 136 Maintenance Section Hydraulic System Oil Filter Return Replace i rl Wi D ali il 7 y aw Illustration 151 g01358262 Hydraulic Oil Filter 5 Change the hydraulic system filter Refer to Operation and Maintenance Manual Hydraulic system Oil Filter Return Change 6 Fill the
34. ir Filter Clean Replace 102699198 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Note Clean the filter elements more often in dusty conditions If there is a noticeable reduction in the air flow from the air vents check the filter elements Clean External Filter Element Illustration 106 g01355651 1 Access Cover 2 Access Door 1 Open the access door 2 on the left side of the machine SEBU8458 01 Illustration 107 g01355653 Thumb screw for the access panel Note that the engine hood is removed for clarity 2 Remove the access cover 1 Ow Illustration 108 g01355920 3 Loosen the 2 top thumb screws 3 that hold the air duct 4 Remove the bottom thumb screw 5 SEBU8458 01 Illustration 109 g01355951 4 Remove the filter element Clean the filter element with compressed air 5 Install the filter element and replace the thumb screw 6 Tighten all of the thumb screws 7 Install the access panel 8 Close the access door 02754409 Cooling System Coolant ELC Change SMCS Code 1395 044 NL Ay WARNING 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 115 Maintenance Section Cooling System Coolant ELC Change NOTICE Mixing ELC with other products will reduce the effec tiveness of the coolant This could result in damage t
35. ll the belly plate Close the engine hood 125 Maintenance Section Engine Compartment Clean 102699208 Engine Crankcase Breather Closed Circuit Replace SMCS Code 1317 510 m 1 j N aie ae z TN VV a Illustration 133 g01357934 The engine crankcase breather is located inside the engine compartment 1 Loosen the three hose clamps and remove hoses 1 2 and 3 from the breather 2 Remove two bolts 4 and washers from the breather 3 Remove breather 5 from the bracket 4 Inspect the hoses for damage If the hoses are worn or damaged replace the hoses 5 Replace new breather 5 with washers and two bolts 4 6 Install hoses 3 2 and 1 to the breather and tighten the hoses 7 Close the engine hood 126 Maintenance Section Engine Oil Level Check 102998164 Engine Oil Level Check SMCS Code 1348 535 FLV NOTICE Do not overfill the crankcase Engine damage can re sult 1 Open the engine hood a reat a E mw HA U P E F i m N i ty i A ETN ike erases 2 x irae va tu eH rT b ge a h w at ae i NZ ens ap ee A Illustration 134 g01520314 1 Oil Filler Cap 2 Oil Dipstick 3 Oil Filter 4 Oil Drain Valve 5 Oil Sample Port SEBU8458 01 Illustration 135 g01277108 1 Oil level add mark 2 Full mark 2 Maintain the oil level between the mark 1 and the mark 2 on the dipstick Note After ten
36. minutes check the oil level on the dipstick 3 If necessary remove the oil filler cap and add oil 4 Clean the oil filler cap and install the oil filler cap 5 Close the engine hood 02998169 Engine Oil Sample Obtain SMCS Code 1348 008 7542 Open the engine hood SEBU8458 01 ae gp a 8 3 ae SEL eee yl i amp ga os a an TR Woes Ea mfp B os os SF fs OD Illustration 136 g01520314 1 Oil Filler Cap Oil Dipstick Oil Filter Oil Drain Valve 5 Oil Sample Port 2 3 4 5 The sampling port for the engine oil is located on the right side of the engine block next to the oil filter base 102998175 Engine Oil and Filter Change SMCS Code 1308 510 1348 044 The normal engine oil change interval is every 500 service hours or one year If the engine is operated under severe conditions or if the oil is not Caterpillar oil change the oil after every 250 service hours or after six months Severe conditions include the following factors high temperatures continuous high loads and extremely dusty conditions 127 Maintenance Section Engine Oil and Filter Change Refer to the results of the S O S oil analysis in order to determine if the engine oil change interval should be decreased Consult your Caterpillar dealer for detailed information regarding the optimum engine oil change interval 1 Open the engine hood wp fee ee OG WHOSE GAY oe O g Illustr
37. n components or replace any worn components Repair any leaking components 8 Inspect the steel material of the quick coupler for cracks Note Perform all repairs before placing the quick coupler back into operation 140 Maintenance Section Quick Coupler Lubricate 102998386 Quick Coupler Lubricate SMCS Code 6129 086 Vertical Pin Coupler Wipe the grease fittings before you apply lubricant to the grease fittings Illustration 158 g01520459 Apply lubricant to the grease fittings for the pins of the work tool coupler There is a grease fitting for each side of the machine Horizontal Pin Coupler Wipe the grease fittings before you apply lubricant to the grease fittings SEBU8458 01 Illustration 159 g01358390 Apply lubricant to the grease fittings for the pins of the work tool coupler There is a grease fitting for each side of the machine 102699162 Radiator Core Clean SMCS Code 1353 070 KO 1 Open the engine hood Refer to Operation and Maintenance Manual Access Doors and Covers SEBU8458 01 oN Ks ATA x alt VAN Illustration 160 g01358453 2 Move the lever to the left in order to move the hydraulic oil cooler away from the radiator 3 Open the side access doors The hydraulic oil cooler and the radiator may be reached from the left side and from the right side m f Us CH Y GY Illustration 161 g01358454 View From the Left Side 1 Hy
38. nents 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Brake fluid reservoirs are available only on standard machines Purge valves for the brake system are located on service brake cylinders The cylinders are located on the drive axle Access the purge valves below the machine 1 Park the machine on a hard level surface Stop the engine Allow the fluid to cool for five minutes However the brake fluid should be warm for this procedure 2 Thoroughly clean the outside of the purge valves Attach a line to the purge valve Drain the fluid from each purge valve into a suitable container SEBU8458 01 Illustration 104 g01355891 3 Remove the lid on the brake fluid reservoir The fluid reservoir is located in the compartment in front of the cab Add the correct type of brake fluid to the reservoir Refer to Operation and Maintenance Manual Lubricant Viscosities Chart for the correct fluid 4 Open the pu
39. o cooling system compo nents lf Caterpillar products are not available and com mercial products must be used make sure they have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants and Caterpillar Extender Note The machine was shipped from the factory with Extended Life Coolant ELC in the cooling system For information about the addition of Extender to your cooling system see the Operation and Maintenance Manual Cooling System Coolant ELC Extender Add or consult your Caterpillar dealer Drain the coolant whenever the coolant is dirty or whenever the coolant is foaming Allow the machine to cool before you change the coolant 1 Open the engine hood Refer to Operation and Maintenance Manual Access Doors and Covers Note The coolant tank is located on the right side of the engine compartment Illustration 110 g01357729 2 Slowly loosen the cap 1 in order to relieve system pressure Remove the cap 116 Maintenance Section Cooling System Coolant ELC Change ee TEE A Of A ey gee i en RES y A deei i g01357744 Illustration 111 3 Locate the drain for the engine coolant on the side of the engine Attach a drain hose to the drain valve that is shown in illustration 111 Open the drain and allow the coolant to drain into a suitable container Illustration 112 g01359660 4 Remove the access panel under the rear of the machine
40. ode 1308 507 3004 507 5068 507 Inspect a Used Filter for Debris Illustration 156 g00100013 The element is shown with debris SEBU8458 01 Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage i02708481 Quick Coupler Clean Inspect SMCS Code 6129 040 6129 070 Personal injury or death can result from improp erly checking for a leak Always use a board or cardboard when checking for a leak E
41. oil through the hole for the filler plug Install the plug after obtaining the sample 148 Maintenance Section Wheel Nut Torque Check i 03599802 Wheel Nut Torque Check SMCS Code 4210 535 Check the torque on new wheels or repaired wheels after every ten service hours until the specified torque is maintained The nut and the stud should be clean and dry for reassembly Apply one drop of lubricating oil to the stud before installing the nut onto the stud Torque the wheel nuts to a torque of 360 25 N m 266 18 lb ft Use a star pattern when you torque the nuts Check the nuts on all four wheels 102699172 Window Washer Reservoir Fill SMCS Code 306 544 NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solvent or equivalent System damage can result from freezing SEBU8458 01 g01359225 Illustration 178 1 Fill Pipe 2 Windshield Washer Reservoir The windshield washer reservoir is located in the engine compartment on the left side Pour the window cleaning solution into the fill pipe The reservoir is located under the counterweight Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 Inspect the condition of the wiper blades Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs 101409502 Windows Clean SMCS Code 7310 070 Use commercially available window cleaning solutions in order to
42. om electrical shock en sure that the negative battery cable is disconnect ed first 3 Disconnect the negative battery cable at the battery 109 Maintenance Section Battery or Battery Cable Inspect Replace 4 Perform the necessary repairs Replace the cable or the battery as needed 5 Disconnect the positive battery cable Remove the old battery from the machine 6 Place the new battery in the machine Connect the positive battery cable to the battery 7 Connect the negative battery cable at the battery 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 102699193 Brake Pads Check SMCS Code 4267 4273 imi 6 Illustration 103 g01355884 The brake pads are located behind the front axle on the drive shaft Measure the thickness of the brake pads If the thickness of either of the two brake pads is less than 4 00 mm 0 16 inch replace the brake pads Refer to Disassembly and Assembly Brake Caliper Remove and Disassembly and Assembly Brake Caliper Install 110 Maintenance Section Brake System Fluid Change 102699194 Brake System Fluid Change If Equipped SMCS Code 4258 044 7579 044 BRK Ay WARNING Hot oil and components can cause personal in jury Do not allow hot oil or compo
43. rential Lock 10 Amp D W En 4 Front Wiper and Washer 15 Amp k t 5 ECM 15 Amp 6 Electronic Display 10 Amp 0 6 OSPOOSBB AADEOOX AO SEBU8458 01 7 Work Tool Circuit 15 Amp 8 Rear Wiper and Washer 10 Amp 9 Air Suspension Seat 15 Amp 10 Fuel Shutoff 15 Amp 11 Rear Window Defroster 20 Amp 12 Rear Work Lights 10 Amp 13 Air Conditioner 15 Amp 14 Left Tail Light 10 Amp 15 Right Tail Light 10 Amp 16 Implement Detent 10 Amp 17 High Beam Lights 15 Amp 18 Directional Signal Lights 10 Amp 19 Front Work Lights 10 Amp 20 Radio 5 Amp SEBU8458 01 ODY eOOSdVO 21 HVAC Blower Fan 20 Amp 22 Heated Seat 5 Amp 23 Beacon 10 Amp 24 Ignition Switch 10 Amp 25 Electrical Power 10 Amp 26 Hazard Lights 10 Amp 27 Lights 10 Amp 28 Starting Aid 10 Amp 29 Brake Lights 10 Amp 30 Electrical Power 10 Amp 31 Horn 10 Amp 133 Maintenance Section Fuses Replace Relays 40 41 42 Illustration 146 g01356831 32 Implement Detent 33 Ride Control 34 Clutch for the Air Conditioner Compressor 35 Hydraulic 36 Hydraulic 37 Differential Lock 38 Rear Window Defroster e OOH S 134 Maintenance Section Hinges Lubricate 39 Reverse Light 40 Fuel Pump 41
44. rge valve 5 Fully depress the service brake that is being purged 6 Close the purge valve 7 Release the service brake 8 Repeat Steps 4 through 7 until no air is in the fluid that drains from the purge valve Ensure that the reservoir remains full of fluid 9 Start the engine Run the machine for a few minutes Check for any leaks Maintain the fluid level between the marks on the reservoir SEBU8458 01 i02699196 Brake System Fluid Level Check If Equipped SMCS Code 4258 535 FLV 7579 535 BRK 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Brake fluid reservoirs are available only on standard machines 1 Park the machine on a hard level surface 2 The fluid reservoir is located in the compartment in front of the cab 3 Check the fluid level when the engine is stopped 4 Maintain the fluid le
45. scaping air or fluid under pressure even a pin hole size leak can penetrate body tis sue causing serious injury and possible death If fluid is injected into your skin it must be treated immediately by a doctor familiar with this type of injury Note Do not weld on the quick coupler without consulting your Caterpillar dealer 1 Clean the quick coupler prior to inspection in order to properly inspect the quick coupler Remove the work tool 139 Maintenance Section Quick Coupler Clean Inspect cH ip i IR k i l Illustration 157 g01359685 This is the back side of the quick coupler The lift arm and the tilt cylinder are removed for clarity 1 Coupler Pins 2 Hydraulic Cylinder 3 Top Edge 2 Tilt the quick coupler all the way forward in order to clean the debris away from the pins 3 Move the coupler pins 1 Ensure that the pins are not bent or broken 4 Make sure that the coupler pins extend through the bottom of the quick coupler assembly Check the pins for wear and check the pins for damage 5 Check the top edges 3 of the quick coupler assembly for wear or for damage Check the face of the quick coupler assembly for wear or for damage 6 Inspect the components inside the quick coupler for the following problems loose bolts oil leaks broken parts missing parts and cracked components 7 Inspect the hydraulic lines and the hydraulic fittings for damage or for wear Repair any wor
46. skin 1 Operate the machine for a few minutes before you obtain the fluid sample This will thoroughly mix the fluid for a more accurate sample 2 Obtaining a sample will require a vacuum pump or an equivalent 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 102699204 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Service the air cleaner only with the engine stopped Engine damage could result if the air cleaner is ser viced while the engine is running Service the air cleaner filter element when the yellow piston on the engine air filter service indicator enters the red zone Refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect SEBU8458 01 NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at 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 mu
47. st not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components Se A Ws Illustration 125 g01357913 Location of the engine air filter 1 Engine Air Filter Service Indicator 2 Engine Air Filter 1 Open the engine hood SEBU8458 01 Illustration 126 g01379338 2 Release the 3 clips on the air cleaner housing cover Remove the air cleaner housing cover Illustration 127 g01379340 3 Remove the primary filter element 4 Install a clean air filter element Install the air cleaner housing cover and fasten the clips 5 Reset the engine air filter service indicator If the yellow piston in the indicator remains in the red zone replace the secondary element 123 Maintenance Section Engine Air Filter Secondary Element Replace 102699205 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary filter element Never attempt to reuse it by cleaning The secondary filter element should be replaced at the time the primary element is serviced for the third time The secondary filter element should also be replaced if the yellow piston in the filter element indicator en ters the red zone after inst
48. t the steering system 02724032 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD Wipe all grease fittings before you apply any lubricant to the grease fittings Illustration 168 g01378086 Access both grease fittings on the right side of the machine Apply lubricant to the grease fitting for the rod end of the steering cylinder and for the head end of the steering cylinder 102699164 Tilt Cylinder Bearings and Bucket Linkage Bearings Lubricate SMCS Code 5104 086 BD 6107 086 BD NIN g01358743 Illustration 169 Wipe all grease fittings before you apply lubricant SEBU8458 01 Lubricate the grease fitting 1 for the head end of the tilt cylinder Lubricate the grease fitting 2 for the rod end of the tilt cylinder There is one grease fitting in the center of the machine Lubricate the grease fitting 3 for the upper pivot pin of the tilt linkage There is one grease fitting in the center of the machine Lubricate the grease fittings 4 for the lower pivot pin of the tilt linkage There is one grease fitting in the center of the machine Illustration 170 g01358746 Illustration 171 g01358749 145 Maintenance Section Tire Inflation Check Lubricate the grease fitting 5 for the upper pivot pin of the quick coupler assembly There is one grease fitting in the center of the machine Lubricate the grease fittings 6 for the lower pivot pin of the quick coupler assembly
49. tain the oil level at the bottom of the threads for the plug 6 Clean the differential level fill plugs and install the plugs for each differential Operate the machine for a few minutes in order to allow the oil to flow completely through the axles Remove the differential level fill plugs and recheck the oil level Add oil if necessary Install the differential level fill plugs for each differential Oil for the Wheel Illustration 120 g01357829 Wheel in the position for draining Illustration 121 SEBU8458 01 g01357831 Wheel in the position for filling Note Work on one wheel at a time l Move the machine so that the plug on the wheel is on the bottom of the wheel Remove the drain plug from the wheel Allow the oil to drain into a suitable container Move the machine so that the plug on the wheel is in the horizontal position Fill the wheel with oil See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities for information about the oil Maintain the oil level at the bottom of the threads for the plug Clean the plug and install the plug Operate the machine for a few minutes in order to allow the oil to flow completely through the axles Remove the plug and recheck the oil level Add oil if necessary Install the plug Repeat steps 1 through 6 for each wheel SEBU8458 01 102699138 Differential and
50. vel between the marks on the reservoir 5 If the fluid level is low add fluid a Remove the lid on the brake fluid reservoir b Add the correct type of brake fluid to the reservoir Refer to Operation and Maintenance Manual Lubricant Viscosities Chart for the correct fluid c Install the lid on the reservoir 6 Check for any leaks Maintain the fluid level between the marks on the reservoir 111 Maintenance Section Brake System Fluid Level Check 03751342 Braking System Test SMCS Code 4011 081 4267 081 Service Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles Make sure that the steering frame lock link is in the STORED position Test the brakes on a dry 25 slope Fasten the seat belt before you test the brakes The following tests are used to determine if the service brake is functional These tests are not intended to measure the maximum brake holding effort 1 Start the engine Raise the work tool slightly 2 Apply the service brake Release the parking brake The machine should not move under the following conditions e The engine is at low idle The bucket is empty e The machine is warmed up and the machine is full
51. y stopped e The service brake is firmly depressed If the machine moves consult your Caterpillar dealer 3 Engage the parking brake Lower the work tool to the ground Stop the engine 112 Maintenance Section Bucket Cutting Edges Inspect Replace NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the service brake before returning the machine to operation Parking Brake Holding Ability Test Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles Make sure that the steering frame lock link is in the STORED position Test the brakes on a dry 20 slope Note The test condition is different from the Service Brake test Fasten the seat belt before you test the brakes The following tests are used to determine if the parking brake is functional These tests are not intended to measure the maximum brake holding effort 1 Start the engine Raise the work tool slightly 2 Engage the parking brake Release the service brake gradually Note The parking brake indicator light should come on The parking brake light should flash if the machine is in gear The machine should not move under the following conditions e The engine is at low idle e The bucket is empty e The machine is warmed up and the machine is fully stopped e The parking brake is pulled up firmly If t
52. your Cat dealer for details about the benefits from the improved performance designed into Cat HYDO Advanced 10 Operate the machine for a few minutes in order to warm the hydraulic system oil The machine should be on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine Illustration 148 g01358251 1 Filler Cap 2 Hydraulic Tank 3 Upper Sight Gauge 4 Lower Sight Gauge 1 Open the engine hood SEBU8458 01 2 Remove the hydraulic tank filler cap 3 The hydraulic tank drain plug is located on the bottom of the hydraulic tank on the underside of the machine Remove the drain plug and allow the hydraulic oil to drain into a suitable container 4 Install the drain plug Illustration 149 g01358262 Hydraulic Oil Filter 5 Change the hydraulic system filter Refer to Operation and Maintenance Manual Hydraulic system Oil Filter Return Change 6 Fill the hydraulic system oil tank with hydraulic oil Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Note Observe the sight gauges for the hydraulic oil level as you fill the hydraulic system oil tank Do not overfill the tank 7 The sight gauges for the hydraulic oil level are located on the side of the tank below the filler cap Maintain the hydraulic oil level in the center of the top sig
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