MAINTENANCE INTERVALS - Safety
Contents
1. 119 Ripper Tip and Shank Protector Inspect Heplace cu c r E DEEP i 120 Window Washer Reservoir Fill 125 Window Wipers Inspect Replace 126 Every 10 Service Hours or Daily Seat Belt Inspect sssssssssss 120 Every 10 Service Hours Backup Alarm Test sessseeeeeeee 89 Bucket Lower Pivot Pin Lubricate 90 Cooling System Level Check 95 Engine Oil Level Check sussen 99 Final Drive Inspect sseeeeeeeee 103 Fuel Tank Water and Sediment Drain 107 Hydraulic System Oil Level Check 111 Hydrostatic Transmission Gear Box Oil Level EE SRM E UE 114 Indicators and Gauges Test 115 Pump Drive Oil Level Check 118 Track Adjustment Check sassen 122 Walk Around Inspection esssssss 123 Windows Clean seeseeeeenenr 125 85 Maintenance Section Maintenance Interval Schedule Every 50 Service Hours Idler Swing Link Lubricate 115 Every 50 Service Hours or Weekly Track Pins Inspect sseeseeeeeeeeeess 122 Every 100 Service Hours or 2 Weeks Loader Linkage Pins Lubricate 116 Multipurpose Bucket Lubricate2. AS 5 i Coa eo Illustration 303 g00295726 Always check the condition of the seat belt and the condition of the belt mounting hardware before you operate the machine Inspect the belt mounting hardware Replace any belt mounting hardware that is damaged or worn Regardless of the appearance replace the seat belt once during every three year interval 101031396 Steering Linkage Lubricate SMCS Code 4318 086 S N 9BL1 1398 Illustration 304 900517031 Lubricate two fittings S N 9BL1399 Up The steering control on these machines has been changed There is no longer a necessary lubrication of the steering control i01029644 Track Adjustment Adjust SMCS Code 4170 025 Grease is under high pressure Grease coming out of the relief valve under pres sure can penetrate the body causing injury or death Do not watch the relief valve to see if grease is es caping Watch the track or track adjustment cylin der to see if the track is being loosened Loosen the relief valve only one turn 1 Move the machine forward for a distance of two times the length of the machine Allow the machine to stop without the use of the service brakes Shut off the engine Adjust the tracks while you are in the machine s typical operating conditions If packing conditions prevail on the job the tracks should be adjusted with packing material Illustration 305 900514519 2 Loosen the bolts and
3. 116 Every 250 Service Hours or Monthly Air Conditioner Test cccccccecesseeeeesssteeeeeesaes 87 Air Conditioner Belt Inspect Adjust Replace 87 Alternator and Fan Belts Inspect Adjust Replace e EEA AR L A E nnn 88 Battery Inspect ssee 89 Cooling System Additive DEAC Add 92 Engine Oil and Filter Change 100 Engine Valve Lash Check sssse 101 Equalizer Bar End Pins Lubricate 101 Equalizer Bar Pins Lubricate 102 Final Drive Oil Level Check 104 Fuel System Secondary Filter Replace 106 Pivot Shaft Oil Level Check 117 Recoil Piston Lubricate sssss 119 Steering Linkage Lubricate 120 Track Adjustment Adjust sssse 121 Water Pump Belt Inspect Adjust Replace 124 Every 500 Service Hours or 3 Months Engine Crankcase Breather Clean 99 Fuel System Primary Filter Water Separator Element Replace sseeeeeee 105 Fuel Tank Cap and Strainer Clean 107 Every 1000 Service Hours or 6 Months Hydraulic System Oil Filter Replace 110 Hydrostatic Transmission Oil Filter Replace 112 Every 2000 Service
4. Battery Battery Cable or Battery Disconnect Switch Replace SMCS Code 1401 510 1402 510 1411 510 1 Turn the engine start switch key to the OFF position Turn all of the switches to the OFF position 2 Turn the battery disconnect switch to the OFF position Remove the key 3 Disconnect the battery cable at the battery disconnect switch The battery disconnect switch is connected to the machine frame 4 Disconnect the negative battery cable at the battery 5 Make necessary repairs or replace the battery 6 Connect the negative battery cable at the battery 7 Connect the battery cable at the battery disconnect switch 8 Install the key and turn the battery disconnect switch to the ON position i01033528 Bucket Lower Pivot Pin Lubricate SMCS Code 6108 086 PN Illustration 204 900289467 Lubricate two fittings There is one fitting on each side of the bucket i01027107 Bucket Teeth and Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 6822 040 6822 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket tips 1 Raise the bucket and block up the bucket Only block up the bucket to a sufficient height for removing the bucket tips 2 Shut off the engine Illustration 205 900928098 3 Drive the pin out of the bucket tip from the retainer side of the bucket tip Remove the bucket tip and the retainer 4 Clean the
5. Clean the oil filler cap and install the oil filler cap Close the access door i01028387 Pump Drive Oil Level Check SMCS Code 3108 535 FLV Illustration 297 g00518349 1 Open the front access door that is on the right side of the machine behind the operator s compartment Illustration 298 g00691238 2 Slowly remove the oil filler cap in order to relieve any pressure g00691239 Illustration 299 3 Maintain the oil level between the LOW and the FULL marks on the dipstick If necessary add oil 4 Clean the oil filler cap and install the oil filler cap 5 Close the access door 00768727 Radiator Core Clean SMCS Code 1353 070 1805 1810 Illustration 300 900351807 Compressed air high pressure water or steam can be used in order to clean the radiator Clean the dust tree leaves and debris from the radiator core Clean the radiator when you determine that the condition of the radiator necessitates cleaning The use of compressed air is preferred For the complete procedure and instructions refer to Special Publication SEBD0518 Know Your Cooling System 119 Maintenance Section Radiator Core Clean i01027309 Radiator Pressure Cap Clean Replace SMCS Code 1353 070 Z2 1353 510 Z2 S P d de 9 2 LE A 900528755 Illustration 301 1 Remove the radiator pressure cap slowly in order to relieve the pressure 2 Inspect the radiator pressu
6. er before using 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 Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts g00527561 Illustration 249 Note Replace the secondary filter at every 250 service hour interval eee N Illustration 250 g00527473 1 Shut off the fuel tank supply valve 2 Remove the secondary filter 3 Clean the filter mounting base Make sure that the old seal is removed 4 Coat the seal of the new filter with clean diesel fuel 5 Install a new secondary filter Hand tighten the filter When the seal contacts the base tighten the filter by an additional 3 4 turn Rotation index marks are positioned on the filter at 90 degree intervals Use these rotation index marks as a guide when you tighten the filter Note Install a new dry filter Never fill a new filter with fuel before you install the filter Dirty fuel can damage the fuel injectors This damage will cause premature problems in the fuel system 6 Open the fuel tank supply valve 7 Prime the fuel system Refer to Operation and Maintenance Manual Fuel System Pri
7. suitable container 5 Close the drain valve Fill the system with a solution which consists of clean water and of cooling system cleaner The concentration of the cooling system cleaner should be 6 to 10 percent 6 Start the engine Run the engine for 90 minutes Stop the engine Drain the cleaning solution into a suitable container 7 While the engine is stopped flush the system with water Flush the system until the draining water is clear 8 Close the drain valve Replace the drain hose and the access plate 9 Add the coolant solution See the following topics e Operation and Maintenance Manual Cooling System Specifications e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Refill Capacities Note If you are using Caterpillar antifreeze do not add the supplemental coolant additive at this time Also do not change the supplemental coolant additive element at this time 10 Start the engine Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes 11 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe 12 If the gasket is damaged replace the radiator cap Install the radiator cap Close the engine compartment access cover 13 Stop the engine 100060003 Cooling System Extended Life Coolant Change SMCS Code 1350 044 1395 044 For information about adding an extender
8. 108 Maintenance Section Fuses Replace Illustration 254 900513901 3 Open the drain valve 4 Allow the water and the sediment to drain into a suitable container 5 Close the drain valve Place the drain line back into the opening 6 Close the access door i01026832 Fuses Replace SMCS Code 1417 510 900518349 Illustration 255 The fuses are located inside the access door of the engine compartment The access door is located on the right side of the machine Fuses Fuses protect the electrical system from damage that is caused by overloaded electrical circuits Replace a fuse if the element separates If the fuse of a particular electrical system requires frequent replacement check the electrical circuit Repair the electrical circuit if necessary NOTICE Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result NOTICE If it is necessary to replace fuses frequently an elec trical problem may exist Contact your Caterpillar dealer Illustration 256 g00691293 Horn 1 10 Amp d we CE Backup Alarm 2 10 Amp Flood Lights 3 20 Amp Electronic Monitoring System 4 10 Amp um Key Start Switch 5 10 Amp Cigar Lighter 6 10 Amp Cab Power fuse 7 10 Amp 9 A Illustration 257 900691294 Front Flood Lights 8 10 Amp Front Windshield Wip
9. 7 Always measure the oil level with dipstick 1 in order to ensure that the correct amount of oil was added 101 Maintenance Section Engine Valve Lash Check 8 On the dipstick maintain the oil level between the ADD mark and FULL mark 9 Close the access cover i01300278 Engine Valve Lash Check SMCS Code 1102 535 1105 535 Refer to Systems Operation Testing and Adjusting SENR3583 3114 3116 and 3126 Engines for the correct procedures when you check engine valve lash and or fuel injector timing Note Make sure that qualified service personnel check the injector fuel timing If an adjustment is necessary make sure that qualified service personnel adjust the injector fuel timing Special tools and training are required Note The correct fuel timing specification is shown on the Engine Information Plate Fuel timing specifications will be different with each engine application and with each power rating Consult your Caterpillar dealer for the complete adjustment procedure i01035233 Equalizer Bar End Pins Lubricate SMCS Code 7206 086 PN 7207 086 PN NOTICE Apply lubricant to the fittings with a hand operated grease gun only Use of pressure operated lubricating equipment damages the seals Illustration 235 900513609 102 Maintenance Section Equalizer Bar Pins Inspect Illustration 236 900513612 Lubricate the equalizer bar pins through the fittings There is one f
10. air cleaner only with the engine stopped Engine damage could result 900526726 Illustration 227 Run the engine at high idle If the yellow piston in the filter element indicator enters the red zone service the air cleaner Stop the engine i01031529 Engine Crankcase Breather Clean SMCS Code 1317 070 900530992 Illustration 228 1 The access door is located on the right side of the machine Open the access door 99 Maintenance Section Engine Crankcase Breather Clean Illustration 229 900530999 2 Loosen the breather outlet hose clamps Remove the hose from the breather cover 3 Loosen the breather inlet hose clamp Remove the engine crankcase breather 4 Check the condition of the cover seal Replace the cover seal if the cover seal is damaged 5 Wash the breather element and the breather element cover assembly in a clean nonflammable solvent 6 Shake the breather element until the breather element is dry You may also use pressure air to dry the breather element 7 Check the condition of the hose Replace the hose if the hose is damaged 8 Install the breather element cover assembly 9 Install the hose and the breather outlet hose clamps 10 Close the access door i01028265 Engine Oil Level Check SMCS Code 1302 535 FLV 1326 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Do not under
11. cause the engine to overheat 4 Install a new seal in the thermostat housing Install a new thermostat and a new gasket Install the thermostat housing on the engine cylinder head 5 Install the elbow and the hose Tighten the hose clamp i01024741 Engine Air Filter Primary Element Clean Replace SMCS Code 1051 070 PY 1051 510 PY 1054 070 PY 1054 510 PY Illustration 218 g00518349 1 Open the front access door on the right side of the machine g00526756 Illustration 219 2 Remove the air cleaner cover iF Illustration 220 g00526765 3 Remove the primary filter element from the air cleaner housing Illustration 221 900287513 4 Clean the inside of the air cleaner housing 5 Inspect the primary element If the pleats the gaskets or the seals are damaged discard the element Replace a damaged primary element with a clean primary element NOTICE Do not clean the filter elements by bumping or tapping them Do not use filter elements with damaged pleats gaskets or seals Engine damage can result Make sure the cleaned filter elements are completely dry before installing into the filter housing Water re maining in the elements can cause false indications of contamination in Scheduled Oil Sampling test results 6 If the primary element is not damaged clean the primary element The filter elements can be cleaned by using the following methods e Pressure air e Pressur
12. fill or overfill engine crankcase with oil Either condition can cause engine damage 100 Maintenance Section Engine Oil and Filter Change Illustration 230 900529383 1 Open the rear access door that is on the right side of the machine behind the operator s compartment E 900529386 Illustration 231 2 Check dipstick 1 while the engine is running Maintain the oil level between the marks on the engine running side of the dipstick Check dipstick 1 while the engine is stopped Maintain the oil level between the marks on the engine stopped side of the dipstick Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the FULL mark on the engine stopped side of the dipstick 3 Remove oil filler cap 2 If necessary add oil 4 Clean the oil filler cap and install the oil filler cap 5 Close the access door i01029148 Engine Oil and Filter Change SMCS Code 1308 510 1318 510 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 machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Pr
13. oil add oil through the filler tube Install the filler cap Close the access door 115 Maintenance Section Idler Swing Link Lubricate 01028607 Idler Swing Link Lubricate SMCS Code 4159 086 Illustration 285 900514512 Apply lubricant through a total of four fittings There are two fittings on each idler There is one link on each side of the machine Lubricate the fitting on each end of the shaft that is in each link 101028558 Indicators and Gauges Test SMCS Code 4100 081 7000 081 7450 081 Illustration 286 900509099 1 Look for broken lenses or indicator lights in EMS panel 3 Start the engine 116 Maintenance Section Loader Linkage Pins Lubricate 900509098 Illustration 287 2 Check the operation of the Electronic Monitoring System Move EMS test switch 2 to the ON position Fault alarm 1 should sound The fault light and all of the EMS indicators should begin to flash The fault light and the EMS indicators will continue to flash until the EMS test switch is released Turn on all of the machine lights Check for proper operation Sound the forward horn Stop the engine Make any necessary repairs before you operate the machine 101028613 Loader Linkage Pins Lubricate SMCS Code 61 18 086 PN Illustration 289 7 4 E 74 n em T eoep 1 46 j wie Px 3 A o 9 77 A ae E Illustration 290 900529743 Lubricate eleven f
14. particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 117 Maintenance Section Oil Filter Inspect 01030884 Pivot Shaft Oil Level Check SMCS Code 4153 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 293 g00514516 The oil plugs are located on both sides of the machine Remove the plug on one side of the machine Check the oil level Maintain the oil level within 13 mm 0 5 inch of the bottom of the filler plug opening If necessary add oil Repeat the procedure on the other side of the machine Pump Drive Oil Change SMCS Code 3108 044 OC g00518349 Illustration 294 118 Maintenance Section Pump Drive Oil Level Check Illustration 295 2 Illustration 296 3 Open the front access door that is on the right side of the machine behind the operator s compartment 900691065 Slowly remove the oil filler cap in order to relieve any pressure 900513569 Remove the crankcase drain access cover which is in the crankcase guard Remove the pump drive drain plug Allow the oil to drain Clean the drain plug and install the drain plug Install the crankcase drain access cover Fill the pump drive housing with the correct amount of oil Refer to Operation and Maintenance Manual Refill Capacities for additional information
15. the threaded end of the tool into the drain opening in order to release the check valve Drain the oil into a suitable container 8 When the oil is completely drained from the hydrostatic transmission remove the tool Thoroughly clean the drain plug and install the drain plug Install the front access plate 9 Fill the hydrostatic transmission with oil Refer to Operation and Maintenance Manual Refill Capacities for additional information 900532113 Illustration 281 10 Check the oil level The oil level should be between the ADD and FULL marks on the dipstick while the engine is running 11 Check the sight gauge Maintain the oil level between the ADD mark and the FULL mark 12 If it is necessary to add oil add oil through the filler tube 13 Install the filler cap 14 Put the tool back into the tool box and close the access doors on both sides of the machine i01028334 Hydrostatic Transmission Gear Box Oil Level Check SMCS Code 3030 535 FLV 3081 535 FLV Illustration 282 g00518349 1 Open the front engine compartment access door on the right side of the machine Illustration 283 900691048 2 The hyarostatic transmission is a pressurized compartment Slowly remove the oil fill cap in order to relieve any pressure Illustration 284 900691049 3 Check the sight gauge Maintain the oil level between the ADD mark and the FULL mark If itis necessary to add
16. to your cooling system see Operation and Maintenance Manual Cooling System Extended Life Coolant Extender Add or consult your Caterpillar dealer Flushing the ELC from the Cooling System Some engines utilize Extended Life Coolant ELC See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval If an ELC was previously used flush the cooling system with clean water No other cleaning agents are required Flushing a Standard Coolant from the Cooling System If you change to an ELC from another type of coolant use a Caterpillar cleaning agent to flush the cooling system After you drain the cooling system thoroughly flush the cooling system with clean water All of the cleaning agent must be removed from the cooling system Note See the Operation and Maintenance Manual Cooling System Coolant Change for the draining procedure and for the flushing procedure 100743002 Cooling System Extended Life Coolant Extender Add SMCS Code 1350 1352 544 NL 1395 544 NL When a Caterpillar Extended Life Coolant ELC 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 11 RECOMMENDED AMOUNT OF EXTENDER BY COOLING SYSTEM CAPACITY Recommended Amount of Extender 0 57 L 60 qt
17. 0 71 L 75 qt 0 95 L 1 qt 1 18 L 1 25 qt Cooling System Capacity 22 to 30 L 6 to 8 US gal 30 to 38 L 8 to 10 US gal 38 to 49 L 10 to 13 US gal 49 to 64 L 13 to 17 US gal Refer to Operation and Maintenance Manual Refill Capacities for the cooling system capacity For additional information about adding an extender see Operation and Maintenance Manual Coolant Recommendations or consult your Caterpillar dealer 101028430 Cooling System Level Check SMCS Code 1353 535 FLV 1395 535 FLV ey Illustration 216 900529527 The cooling system pressure cap is in the hood at the right rear of the machine 95 Maintenance Section Cooling System Extended Life Coolant Extender Add 900528755 Illustration 217 1 Remove the cooling system pressure cap slowly in order to relieve the pressure 2 Maintain the coolant level at 13 mm 0 5 inch from the bottom of the filler pipe If it is necessary to add coolant daily check the system for leaks 3 Install the cooling system pressure cap 4 Inspect the radiator core for debris Clean the radiator core if necessary Use compressed air 30 psi maximum high pressure water or steam in order to remove dust and debris from the radiator core However the use of compressed air is preferred 101034885 Cooling System Water Temperature Regulator Clean Replace SMCS Code 1355 070 1355 510 1393 Replace the therm
18. 10 SE NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Note Replace the secondary filter element when you service the primary element for the third time If a clean primary element has been installed and the filter element indicator still enters the red zone replace the secondary filter element Also if the exhaust smoke remains black and a clean primary filter element has been installed replace the secondary filter element 900518349 Illustration 224 1 Open the front access cover on the right side of the machine 2 Remove the housing cover and the primary element 900526888 Illustration 225 3 Remove the secondary element 4 Cover the air inlet opening Clean the inside of the air cleaner housing 5 Inspect the gasket between the air inlet and the housing If the gasket is damaged replace the gasket 6 Uncover the air inlet opening Install a new secondary element 7 Install the primary element and the air cleaner housing cover 8 Close the access cover i01024629 Engine Air Precleaner Clean SMCS Code 1050 070 900526704 Illustration 226 1 Inspect the air inlet screen for dirt and for trash 2 Remove the screen Clean the screen if the screen is dirty 3 Inspect the precleaner tube for dirt and for dust 4 Clean the precleaner tube with pressure air if the precleaner tube is dirty NOTICE Service the
19. 5 Remove the filter element cover that is located in the operator s compartment 6 Remove the filter element Clean the filter element with pressure air or wash the filter element in warm water and a nonsudsing household detergent 7 Rinse in clean water and air dry thoroughly 8 Install the filter element Install the filter cover i01026720 Circuit Breakers Reset SMCS Code 1417 529 1420 529 900512386 Illustration 210 in order to reset the circuit breaker If the electrical system is working properly the button will remain depressed If the button does not remain depressed check the appropriate electrical circuit Repair the electrical circuit if necessary A Circuit Breaker Reset Push in the button Alternator Reset 2 50 Amp e Air Conditioning Reset 1 40 Amp 900512537 Illustration 211 Additional circuit breakers for the air conditioning and the fan are in the operators compartment a Air Conditioning 3 15 Amp C Fan 4 15 Amp Cooling System Additive DEAC Add SMCS Code 1352 044 i01029247 See the appropriate topics in your machine s Operation and Maintenance Manual for all cooling System requirements Use 8T 5296 Test Group to check the concentration of the coolant If necessary add supplemental coolant additive Reference Refer to Operation and Maintenance Manual Refill Capacities for additional information NOTICE Do not exceed the
20. EUTRAL position or to the FORWARD position Illustration 201 900037563 A three position switch is at the rear of the alarm The three positions on the switch are high low and medium The three position switch regulates the volume of the alarm The alarm is set from the factory at the highest sound level The setting should remain on high unless the job site requires a lower sound level 89 Maintenance Section Backup Alarm Test i01026617 Battery Inspect SMCS Code 1401 040 Tighten the battery retainers on all batteries at every 1000 hour interval Perform the following procedure at every 1000 hour interval Illustration 202 900528139 1 Open the rear engine access cover on one side of the machine Lower the battery access cover at the rear of the machine lS 1 g00528145 Illustration 203 2 Clean the top of the battery with a clean cloth Keep the terminals clean and coated with petroleum jelly Install the terminal covers after you coat the terminals 3 Close the battery access cover 4 Repeat Steps 1 through 3 for the battery that is on the opposite side of the machine 90 Maintenance Section Battery Recycle 00637582 Battery Recycle SMCS Code 1401 561 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 00637583
21. Hours or 1 Year Hydraulic System Oil Change 109 Every 2000 Service Hours or 1 Year Final Drive Oil Change uses 103 Hydrostatic Transmission Gear Box Oil Change speren seieren enira 113 Pump Drive Oil Change s e 117 Track Roller Frame Inspect 123 Every 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 93 Cooling System Extended Life Coolant Extender Addc nts tue ete e erit eid 95 86 Maintenance Section Maintenance Interval Schedule Cooling System Water Temperature Regulator Clean Replace sese 95 Every 6000 Service Hours or 4 Years Cooling System Extended Life Coolant Change 94 i01029831 Air Conditioner Test SMCS Code 7320 081 Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air condition ers or wherever refrigerant gas may be present Illustration 192 900508963 1 Start the engine Operate the engine at HIGH IDLE 900511723 Illustration 193 2 Set the air conditioner control for maximum cooling Set the fan control knob to the HIGH position 3 To stabilize the air conditioning system run the air conditioning system for two minutes 87 Maint
22. Hydrostatic Transmission Oil Filter Replace SMCS Code 3067 Use caution when changing oil or changing filters Hot oil or components can cause burns if they contact skin 900529445 The machine should be parked on a level surface All attachments should be lowered to the ground The transmission lock lever should be in the LOCKED position The engine should be OFF Illustration 269 The sight gauge for the hydraulic tank is located on the right front side of the machine 900529974 Illustration 270 900514508 Illustration 272 1 Maintain the oil level to the FULL mark in the 1 Remove the crankcase drain access cover sight gauge which is in the crankcase guard 2 Pull the drain line out of the opening 3 Remove the drain plug from the end of the hose Illustration 271 900529447 2 If the hydraulic system requires additional hydraulic oil remove the filler cap and add oil 900529104 through the filler tube Illustration 273 4 Open both access doors on the left side of the 3 Clean the filler cap and install the filler cap machine Illustration 274 900531266 5 Open the drain valve that is located below the transmission oil filter Drain the oil into a suitable container 6 Close the drain valve Replace the drain plug in the drain line 7 Put the drain hose back into the opening Install the access cover 900691057 Illustration 275 8 Remove the transmissio
23. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A lu SEBU6744 04 ATERPILLAR o Operation ane Maintenance manual 963B Track Type Loader 9BL1 Up Machine i01649245 Maintenance Interval Schedule SMCS Code 7000 Note All safety information warnings and instructions must be read and understood before you perform any operation or any maintenance procedure Before each consecutive interval is performed all of the maintenance requirements from the previous interval must also be performed When Required Battery Recycle eseeeeeee 90 Battery Battery Cable or Battery Disconnect Switch Beplace eterne eee eee 90 Bucket Teeth and Cutting Edges Inspect az 90 Cab Air Filter Clean Replace 91 Circuit Breakers Reset l e 92 Engine Air Filter Primary Element Clean Replace sse 96 Engine Air Filter Secondary Element Replace 98 Engine Air Precleaner Clean 98 Equalizer Bar Pins Inspect 102 Ether Starting Aid Cylinder Replace 102 Fuel System Prime seesesssss 104 Fuses Replace sseeee 108 Oil Filter Inspect ssseeeee 117 Radiator Core Clean sieer 119 Radiator Pressure Cap Clean Replace
24. adapter the pin and the retainer Install the retainer in the groove 5 Install a new bucket tip over the retainer in the runner position or in the digger position 6 Drive the pin through the retainer through the adapter and through the bucket tip from the opposite side of the retainer 7 To change the cutting edges remove the two bolts and two nuts Then remove the cutting edge 8 Install the new cutting edge the two bolts and two nuts 9 Start the engine 10 Raise the bucket and remove the supporting block Lower the bucket to the ground i01027465 Cab Air Filter Clean Replace SMCS Code 7342 070 Fl 7342 510 FI Note Clean filters more often in dusty conditions Illustration 206 Illustration 207 Illustration 208 91 Maintenance Section Cab Air Filter Clean Replace Li Fod t aA F ML EUR breite rr 1 Open the engine access door on the left side of the machine 900512358 2 Open the filter cover in order to remove the filter elements 900512359 3 Remove the filter elements Install new filter elements or clean the filter elements Clean the filer elements with pressure air or wash the filter elements in warm water and a nonsudsing household detergent Rinse in clean water and air dry thoroughly Replace the filter cover 92 Maintenance Section Circuit Breakers Reset 4 Close the access door for the engine compartment Illustration 209 900512360
25. e water e Detergent washing When you use pressure air the maximum air pressure is 205 kPa 30 psi When you use pressure water the maximum water pressure is 280 kPa 40 psi 97 Maintenance Section Engine Air Filter Primary Element Clean Replace Illustration 222 900287514 7 When you clean the inside pleats and the outside pleats direct the air along the pleats or direct the water along the pleats The element can be washed in a solution that consists of warm water and of nonsudsing household detergent Fully rinse the pleats Allow the filter to air dry completely 8 Inspect the filter elements after you clean the filer elements Do not use a filter if the pleats the gaskets or the seals are damaged 9 Install a clean primary filter element I m 900526756 Illustration 223 10 Clean the cover and install the cover 11 Reset the filter element indicator 12 Start the engine If the yellow piston in the filter element indicator moves into the red zone install a new primary filter element Also if the exhaust smoke is black install a new primary filter element 13 Close the access door 98 Maintenance Section Engine Air Filter Secondary Element Replace Note A primary element may be cleaned for a maximum of six times Replace the primary element if the primary element has been used for one year i01024939 Engine Air Filter Secondary Element Replace SMCS Code 1051 510 SE 1054 5
26. ection Cooling System Coolant DEAC Change i01033591 Cooling System Coolant DEAC Change SMCS Code 1352 044 1395 044 NOTICE Make sure you read and understand the information in the topics Safety and Cooling System Specifica tions for all information pertaining to water antifreeze and supplemental coolant additive requirements be fore you proceed with maintenance of the cooling sys tem Drain the coolant whenever the coolant is dirty or whenever foaming is observed The radiator cap is located in the top of the hood ar 7T Ny a s lt 900528755 Illustration 213 Open the engine compartment access cover on the right side of the machine Use the cover as a step in order to attain access to the radiator filler cap Maintain a three point contact with the machine A three point contact consists of two feet and one hand or of one foot and two hands 1 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap 900532386 Illustration 214 94 Maintenance Section Cooling System Extended Life Coolant Change 2 The access plate for the drain hose is located at the rear of the machine under the bottom radiator guard Remove the bolts and the access plate 900512572 Illustration 215 3 Pull the drain hose for the radiator from the opening 4 The drain valve is under the radiator Open the drain valve Allow the coolant to drain into a
27. enance Section Air Conditioner Test 900530401 Illustration 194 4 Check for refrigerant in the system Feel suction line 1 and discharge line 2 If the system contains refrigerant the discharge line is warmer than the suction line If the system does not contain refrigerant or the system contains only a small amount of refrigerant poor cooling will result 5 Stop the engine Inspect the air conditioner belt Refer to Operation and Maintenance Manual Air Conditioner Belt Inspect Adjust Replace for additional information i01029934 Air Conditioner Belt Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 900530457 Illustration 195 1 Inspect the condition of the compressor drive belt The belt should deflect 14 to 20 mm 56 to 81 inch under 110 N 25 Ib of force 88 Maintenance Section Alternator and Fan Belts Inspect Adjust Replace a g00530459 Illustration 196 2 Loosen the compressor mounting bolt and the adjusting bracket bolt 3 To achieve the correct belt tension move the compressor inward or move the compressor outward Tighten the compressor mounting bolt and the adjusting bracket bolt Recheck the belt adjustment 4 If necessary repeat Steps 2 and 3 Check the cab air filters If necessary clean the filter elements 5 f poor cooling persists turn off the air conditioner Stop the engine Consult your Caterpillar dealer for air conditioner syste
28. ers 9 10 Amp Rear Windshield Wipers 10 10 Amp i01032276 Hydraulic System Oil Change SMCS Code 5050 044 Use caution when changing oil or changing filters Hot oil or components can cause burns if they contact skin Operate the machine in order to warm the oil Park the machine on level ground Lower all attachments to the ground with a slight downward pressure Move the transmission lock lever downward into the LOCKED position Stop the engine Note Use 6V 3155 Brace Assembly in order to support the bucket whenever the lift cylinders are in the RAISE position 109 Maintenance Section Hydraulic System Oil Change Illustration 258 900514381 1 Remove the top cover in order to gain access to the hydraulic oil filters that are located in the hydraulic tank Remove the hydraulic tank filler cap slowly in order to relieve any pressure Check the cap seal If the cap seal is cut or damaged replace the cap seal Illustration 259 900528224 2 Remove the filler strainer Wash the filler strainer in a clean nonflammable solvent 9 Illustration 260 g00520708 3 Remove the front access cover Remove the bottom access cover 110 Maintenance Section Hydraulic System Oil Filter Replace 900520709 Illustration 261 4 Remove the oil drain hose If the machine is equipped with an oil drain plug remove the plug Open the drain valve Drain all the oil into a suitable container Close
29. itting on each side of the machine i01030643 Equalizer Bar Pins Inspect SMCS Code 7206 040 PN 7207 040 PN cr Sen le So Illustration 237 g00530655 Check the equalizer bar pins for looseness and for unusual wear If unusual wear is evident see the Service Manual or consult your Caterpillar dealer for an inspection and for repair instructions 101041855 Equalizer Bar Pins Lubricate SMCS Code 7206 086 PN 7207 086 PN NOTICE Apply lubricant to the fittings with a hand operated grease gun only Use of pressure operated lubricating equipment damages the seals Illustration 238 900530655 900691029 Illustration 239 Lubricate the equalizer bar pins through the fittings There is one fitting on each side of the machine i01025219 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD Illustration 240 900518349 1 Open the engine access door 900691041 Illustration 241 2 The ether starting aid cylinder is mounted on the left side wall of the engine compartment 3 Loosen the cylinder retaining clamp Unscrew the empty ether starting aid cylinder and remove the empty ether starting aid cylinder 4 Remove the used gasket Install the new gasket that is provided with each new ether starting aid cylinder 5 Install the new ether starting aid cylinder Tighten the ether starting aid cylinder by hand Tighten the cylinder retaining clamp securely 6 Close the engine acces
30. ittings 100649279 Multipurpose Bucket Lubricate SMCS Code 6104 086 Illustration 288 Illustration 291 900289095 Apply lubricant through one fitting on each side of the bucket There is a total of two fittings i00649305 Oil Filter Inspect SMCS Code 1318 507 3067 507 5068 507 Inspect A Used Filter for Debris Illustration 292 900100013 The element is shown with debris Use a 4C 5084 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 damage to the engine and or the hydraulic system Engine bearings the crankshaft pumps valves cylinders and other parts may be damaged This can result in larger
31. lugs and install the drain plugs 5 Slowly fill the final drive with oil The oil level is at the bottom of opening 2 Refer to Operation and Maintenance Manual Refill Capacities for the refill capacities for the final drives 6 Clean the filler plug and the oil level plug Install the plugs 7 Repeat this procedure for the opposite side of the machine 00640732 Final Drive Oil Level Check SMCS Code 4050 535 FLV g00287510 Illustration 245 1 Remove center oil level plug 1 2 Maintain the oil level to the bottom of the opening for plug 1 3 If oil is required remove oil filler plug 2 and add oil 4 Clean the plugs and reinstall the plugs 5 Check for leakage or excessive sprocket wear 6 Repeat the procedure on the other side of the machine 101025910 Fuel System Prime SMCS Code 1258 If the engine does not start air is trapped in the fuel lines to the engine Use the following procedure in order to purge air from the fuel lines Fuel Priming Pump g00527648 Illustration 246 1 Unlock the priming pump plunger Operate the plunger until you feel resistance 2 Push in the plunger Hand tighten the plunger 3 Start the engine If the engine does not start or if the engine continues to misfire or smoke continue to prime the fuel system 4 Run the engine at the LOW IDLE position until the engine runs smoothly 105 Maintenance Section Fuel System Primary Filte
32. m service if necessary 101029320 Alternator and Fan Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Illustration 197 g00529104 1 Open the rear engine compartment access door that is located on the left side of the machine Note Even if only one belt is worn or damaged replace the belts in sets Illustration 198 g00530143 2 Inspect the condition of the fan drive belt and the alternator belt Measure the belt deflection The belts should deflect 14 to 20 mm 56 to 81 inch under 110 N 25 Ib of force X Illustration 199 900530146 3 Loosen adjusting locknut 1 4 To achieve the correct belt adjustment move the alternator 2 inward or move the alternator outward as required 5 Tighten adjusting locknut 1 to a torque of 50 N m 37 Ib ft when the correct tension is achieved 6 If new belts are installed check the belt adjustment after 30 minutes of engine operation 7 Close the access door i01028564 Backup Alarm Test SMCS Code 7406 081 ia Illustration 200 900529664 The backup alarm is located at the rear of the machine behind the radiator grill Turn the engine start switch to the ON position in order to perform the test Move the speed direction control lever to the REVERSE position The backup alarm should sound immediately The backup alarm should continue to sound until the speed direction control lever is moved to the N
33. me for additional information 8 Start the engine Check for leaks i01035072 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR 1273 070 Z2 900689270 Illustration 251 1 Remove the fuel tank cap and the strainer 2 Disassemble the fuel cap Wash the cap and the strainer Wash these components in a clean nonflammable solvent 3 Inspect the seal of the fuel cap Replace the seal if the seal is damaged 4 Put a light coat of oil on the cap components 5 Install the strainer 6 Assemble the fuel cap and install the fuel cap 107 Maintenance Section Fuel Tank Cap and Strainer Clean i01028499 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Illustration 252 900514377 The drain valve is located on the right side of the machine 1 Open the access door 900514372 Illustration 253 2 Remove the drain line from the opening
34. move any trash buildup around the engine Remove any trash buildup that is under the floorplate Also remove any dirt buildup that is on the top of the crankcase guard e Inspect the cooling system for leaks and repair any cooling system leaks Check the hoses the radiator fins the radiator cap and the drain area e Inspect the precleaner screen for any dirt buildup and for debris buildup Remove any dirt or debris e Inspect the engine compartment for leaks and repair any engine compartment leaks Check around all seals and around all covers 124 Maintenance Section Water Pump Belt Inspect Adjust Replace e Inspect the condition of the steps and of the handholds Inspect the steps and the handholds for cleanliness If necessary repair the steps or clean the steps Inspect the Rollover Protective Structure ROPS for damage Inspect the Falling Object Protective Structure FOPS for damage Consult your Caterpillar dealer for any necessary repairs Illustration 314 900529108 e Inspect the hydraulic system for leaks Repair any hydraulic system leaks Inspect the hoses the seals and the flanges Inspect the final drive for leaks Repair any final drive leaks 900529109 Illustration 315 e Make sure that the covers and the guards are secured Inspect the covers and the guards for damage for loose bolts and for missing bolts e Inspect the transmission for leaks Repair any transmission leaks Check around
35. n oil filter 9 Remove the used filter element and the housing from the filter base Inspect the seal on the top of the housing Replace the seal if the seal is cut or damaged 10 Clean the filter housing with a clean dry cloth 11 Install a new filter element into the filter housing Install the cover assembly into the housing 12 Fill the transmission with oil Refer to Operation and Maintenance Manual Refill Capacities for the oil capacity of the transmission 13 Close the access doors 113 Maintenance Section Hydrostatic Transmission Gear Box Oil Change i01028321 Hydrostatic Transmission Gear Box Oil Change SMCS Code 3080 044 a a te mmo et tt EL te ery did arr er j bag ee Vo eot yh T Illustration 276 1 Open the engine access door on the left side of the machine Illustration 277 900532064 2 Open the tool box and remove the 25 4 mm 1 00 inch pipe nipple Illustration 278 114 Maintenance Section Hydrostatic Transmission Gear Box Oil Level Check 3 Open the engine access door on the right side of the machine Illustration 279 900514510 4 Remove the filler cap for the hydrostatic transmission 900517067 Illustration 280 5 Remove the filler cap for the pump drive 6 There are two access plates on the bottom of the machine Remove the front access plate that is located closest to the front of the machine 7 Remove the drain plug Insert
36. oducts Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates 900529974 Illustration 232 1 Remove the crankcase drain access cover which is in the crankcase guard 2 Remove the section of hose from the tool box Remove the crankcase drain plug Install the hose Open the valve Allow the oil to drain into a suitable container Illustration 233 900529975 3 Open the right engine access cover Remove the crankcase oil filter element and discard the crankcase oil filter element properly Make sure that all of the old filter seal is removed from the filter base 4 Apply a thin coat of oil to the new filter seals Install the new crankcase oil filter elements by hand When the gaskets contact the filter base tighten the filter elements by an additional turn of 270 degrees Rotation index marks are on the new filter elements These rotation index marks are spaced at 90 degree intervals Use these rotation index marks as a guide for proper tightening 5 Remove the hose Close the valve Return the hose to the tool box Install the crankcase drain plug Install the crankcase drain access cover 900530017 Illustration 234 6 Remove the oil filler cap 2 Fill the crankcase with new oil See Operation and Maintenance Manual Refill Capacities Clean the oil filler cap and install the oil filler cap
37. olts is 170 x 40 N m 120 30 Ib ft Tighten the bolts for an additional 120 degrees If you are using bolts with a master link tighten the bolts to a torque of 170 x 40 N m 120 30 Ib ft Tighten the bolts for an additional 180 degrees i01034072 Track Adjustment Check SMCS Code 4170 535 Illustration 310 900529110 Check the track adjustment Check the track for wear and for excessive dirt buildup If the track appears to be too tight or too loose see Operation and Maintenance Manual Track Adjustment Adjust i01123943 Track Pins Inspect SMCS Code 4175 040 PN Fingers can be burned from hot pins and bush ings The pins and bushings in a dry joint can become very hot It is possible to burn the fingers if there is more than brief contact with these components Use the recommendations in order to extend the life of the undercarriage Use the recommendations in order to avoid excessive downtime 1 During the machine operation listen for unusual squeaking and for unusual squealing This can indicate a dry joint 2 Check the machine for dry joints weekly Check for dry joints immediately after machine operation After machine operation lightly touch the end of each track pin or bushing Touch the track pin or the track bushing with the back of your hand Make a mark on any dry track pin joint that is very hot to the touch 3 Do not hit the ends of the track pins with a sledge hammer in
38. order to loosen the track joints NOTICE Striking the end of a track pin introduces a significant amount of end play into the track joint and can result in early failures Consult your Caterpillar dealer s Custom Track Service expert if you detect dry joints or leaks Your Caterpillar dealers Custom Track Service expert can perform track inspection i01034291 Track Roller Frame Inspect SMCS Code 4151 040 900532999 Illustration 311 Inspect the track roller frame for leaks i01027709 Walk Around Inspection SMCS Code 7000 040 NOTICE Accumulated grease and oil on a machine is a fire hazard Remove debris with steam cleaning or high pressure water at the specified interval in the Maintenance In terval Schedule or each time any significant quantity of oil is spilled on the machine Note Watch closely for leaks If you observe leakage of any kind find the source of the leak and correct the leak Check the fluid levels more frequently 123 Maintenance Section Track Roller Frame Inspect Illustration 312 e Inspect all of the attachments for damage or for excessive wear Repair the attachments if the attachments are damaged e Inspect the attachment cylinders and the attachment control linkage for damage or for excessive wear Repair any damage e Inspect the lights for broken bulbs and for broken lenses Replace any broken bulbs and any broken lenses Illustration 313 g00529104 e Re
39. ostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system The thermostat should be replaced after the cooling system has been cleaned Replace the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age 96 Maintenance Section Engine Air Filter Primary Element Clean Replace Note If you are only replacing the thermostat drain the cooling system coolant to a level that is below the thermostat housing 1 Loosen the hose clamp and remove the hose from the elbow Disconnect the hose assembly from the thermostat housing assembly 2 Remove the bolts from the elbow Remove the elbow and the thermostat housing assembly 3 Remove the gasket the thermostat and the seal from the thermostat housing NOTICE Former thermostats may be used if they meet test specifications and are not damaged or have excessive buildup or deposits 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
40. pen both access doors for the engine compartment on the left side of the machine Loosen the retaining nut on the filter housing 4 Remove the case and the filter element Remove the filter element from the case 5 Wash the filter element and wash the case in a clean nonflammable solvent Dry the filter element by using pressure air When you use pressure air the maximum air pressure is 205 kPa 30 0 psi 6 Clean the filter housing base Inspect the filter seal Replace the seal if the seal is damaged or worn 7 Install the clean element into the case Install the case and the element into the housing base 8 Install the retaining nut and tighten the nut to a torque of 24 N m 18 0 Ib ft 9 Prime the fuel system Refer to Operation and Maintenance Manual Fuel System Prime for additional information Close the access door 106 Maintenance Section Fuel System Secondary Filter Replace i01025723 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Personal injury can result when using cleaner sol vents To help prevent personal injury follow the instruc tions and warnings on the cleaner solvent contain
41. r Water Separator Element Replace i01025530 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 070 1260 510 1261 A WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes A WARNING Personal injury or death can result from engine overspeed If the engine overspeeds it can cause injury or parts damage Be prepared to stop the engine by closing the air off to the air inlets or by manually pushing down ward on the governor shutdown rod A WARNING 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 Do not fill fuel filter with fuel before installing the fuel filter Contaminated fuel causes accelerated wear to fuel system parts 1 Open the access door for the engine compartment The access door is located on the right side of the machine Illustration 247 g00527473 2 Turn the fuel shutoff valve in order to shut off the fuel supply g00527475 Illustration 248 3 O
42. re cap for damage for foreign material and for deposits 3 Clean the radiator pressure cap with a clean cloth or replace the radiator pressure cap if necessary 4 Install the radiator pressure cap i01029751 Recoil Piston Lubricate SMCS Code 4157 086 Illustration 302 900514517 1 Remove the plug in the track roller frame 2 Connect a grease gun to the fitting Lubricate the recoil piston through the fitting 120 Maintenance Section Ripper Tip and Shank Protector Inspect Replace 3 Install the plug in the track roller frame 4 Repeat the procedure for the other recoil compartment i01220472 Ripper Tip and Shank Protector Inspect Replace SMCS Code 6808 040 6808 510 6810 6812 040 6812 510 When the ripper tip is worn close to the shank replace the ripper tip If the tip is too blunt the tip will not penetrate properly 1 Raise the ripper Place blocking under the ripper Lower the ripper onto the blocking The ripper should be high enough so that the ripper tip can be removed Do not place the ripper too high 2 f the ripper tip is worn drive out the pin Remove the tip and the shank pin retainer 3 Clean the shank pin retainer and the pin 4 Install the new tip and the retainer 5 Install the pin from the opposite side of the retainer 6 Raise the ripper and remove the blocking 7 Lower the ripper to the ground 100682230 Seat Belt Inspect SMCS Code 7327 040
43. recommended six percent sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temperature components Excessive supplemental coolant additive concentration could also result in ra diator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supple mental coolant additive and the spin on element if equipped at the same time The use of those addi tives together could result in supplemental coolant additive concentration exceeding the recommended six percent maximum e dfe 900528755 Illustration 212 1 Slowly loosen the filler cap in order to relieve the pressure Remove the cap 2 Add supplemental coolant additive Drain some coolant from the radiator into a suitable container in order to allow space for the extra coolant additive Note Always discard drained fluids according to local regulations 3 Add 0 24 L 50 pint of supplemental coolant additive for every 38 L 10 US gal of engine cooling capacity Note The engine cooling capacity of the 973 is 51 L 13 4 US gal 4 Inspect the filler cap gasket Replace the filler cap if the gasket is damaged 5 Install the filler cap 93 Maintenance S
44. remove the cover for the track adjusting mechanism 121 Maintenance Section Track Adjustment Adjust 900514521 Illustration 306 3 Add grease with a grease gun in order to move the idler forward until the track is fully tight Illustration 307 9909289 130 4 Use a straight edge against the face Mark the rod with a pencil or with a marking pen Make a mark that is in line with the face 5 Mark the rod 10 mm 40 inch toward the idler from the first mark 6 Open the relief valve Allow the idler to move back until the second mark is behind the face Close the relief valve 7 Use the grease gun to move the idler forward until the second mark is in line with the face 122 Maintenance Section Track Adjustment Check Illustration 308 900484870 8 Measure dimension X as shown above Dimension X is the distance from the face of the bulkhead to the center of the pin in the yoke If dimension X is less than 138 mm 5 4 inch proceed to Step 9 If dimension X is greater than 138 mm 5 4 inch the front idler must be moved forward to a secondary position Refer to Power train Disassembly and Assembly SENR5367 Track Adjust for this procedure 9 Install the cover and tighten the bolts to a torque of 75 x 15 N m 55 50 11 Ib ft 10 Repeat Step 2 through Step 9 for the other track Bolt Torque for Track Shoes 900530297 Illustration 309 The torque requirement for track shoe b
45. s door 01028602 Final Drive Inspect SMCS Code 4050 040 900513619 Illustration 242 Inspect the final drives for leaks Check for damage to the sprocket 103 Maintenance Section Final Drive Inspect i01033513 Final Drive Oil Change SMCS Code 4050 044 FL V NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Wipe the covers and the surfaces around openings before checking or adding oil 900287508 Illustration 243 Note Perform the following procedure to the final drive on each side of the machine 1 Move the machine so that drain plug 3 is located on the bottom of the final drive 2 Remove filler plug 1 Remove drain plug 3 in the outer compartment Drain the oil into a suitable container 104 Maintenance Section Final Drive Oil Level Check 900287509 Illustration 244 3 Remove drain plug 4 from the inner compartment Allow the oil to drain into a suitable container 4 Clean the drain p
46. the drain valve 5 If the machine is equipped with a drain plug install the drain plug Replace the drain hose Install the bottom access cover and the front access cover 6 Change the hydraulic system filters Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Replace 7 Install the filler strainer 8 Fill the hydraulic oil tank Refer to Operation and Maintenance Manual Refill Capacities in order to determine the amount of hydraulic oil that is needed to fill the hydraulic oil tank 9 Install the filler cap 10 Start the engine Run the engine for a few minutes g00514508 Illustration 262 11 Maintain the oil level to the FULL mark in the sight gauge Add oil if necessary 12 Stop the engine Note The above procedure is for draining the tank Consult your Caterpillar dealer or refer to the Service Manual for instructions on completely draining the hydraulic system 101032044 Hydraulic System Oil Filter Replace SMCS Code 5068 510 Use caution when changing oil or changing filters Hot oil or components can cause burns if they contact skin Note Use a 6V 3155 Brace Assembly in order to support the bucket whenever the lift cylinders are in the RAISE position 1 Remove the tank cover 2 Slowly remove the hydraulic tank filler cap in order to relieve the system pressure A g00518266 Illustration 263 3 Remove the bolts from the filter co
47. the seals and around the covers Also check the hoses around the transmission 900529110 Illustration 316 e Inspect the tracks Repair the tracks if the tracks are damaged or excessively worn Tighten any loose bolts Replace missing bolts Check the tracks for excessive dirt buildup Check the tightness of the track Refer to Operation and Maintenance Manual Tracks e Check for loose bolts or for missing bolts Check the track components for damage and for wear e Inspect the operator compartment for cleanliness Remove any trash buildup and any dirt buildup e Inspect the instrument panel Repair any broken gauges and any broken lights e Make sure that the horn the backup alarm the lights the guards and the shield are working properly i01029383 Water Pump Belt Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Illustration 317 g00529104 1 Open the rear engine compartment access door that is located on the left side of the machine Illustration 318 NU EIE Leer 0 2 Inspect the condition of the water pump belt Measure the belt deflection The belt should deflect 13 0 to 19 0 mm 0 50 to 0 75 inch under 110 N 25 0 Ib of force 900530207 Illustration 319 3 Loosen the two bolts Slide the adjusting pulley until the correct belt tension is reached 4 Tighten the two bolts to a torque of 50 Nm 37 0 Ib ft 5 If a new belt is installed check the belt adjus
48. tment after 30 minutes of engine operation 6 Close the access door 125 Maintenance Section Windows Clean i01028126 Windows Clean SMCS Code 7310 070 7340 070 Illustration 320 900529298 Use a commercially available window cleaning solution in order to clean the windows Clean the outside windows from the ground unless handholds are available i01305551 Window Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar or any commercially available nonfreezing window washer solvent 900514526 Illustration 321 gm Windshield Washer The washer fluid lt 7 bottle is on the left side of the machine near the operator s compartment Remove the fluid bottle cap in order to fill the washer fluid bottle 126 Maintenance Section Window Wipers Inspect Replace Window Wipers Inspect Replace SMCS Code 7305 040 7305 510 900529040 Illustration 322 Inspect the condition of the windshield wiper blades Replace the windshield wiper blades if the windshield wiper blades are worn or damaged If the windshield wiper blades streak the windshield replace the windshield wiper blades
49. ver Use the handle to pull up the filter assembly Remove the filter assembly Illustration 264 900518269 4 Remove the filter element Properly discard the filter element Apply a thin coat of oil to the seal on the new filter Illustration 265 900518271 5 Inspect the new filter Install the new filter element by hand Install the retainer and the nut Tighten the nut to a torque of 10 1 5 Nem 7 4 1 1 Ib ft Illustration 266 900518274 111 Maintenance Section Hydraulic System Oil Level Check 6 Check the condition of the seal for the filter cover If the seal is damaged or if the seal is cut replace the seal Lubricate the seal with clean hydraulic oil Illustration 267 900518266 7 Install the filter assembly in the filter housing Use caution to align the filter assembly properly Install the cover and tighten the cover bolts 900528224 Illustration 268 8 Remove the filler strainer and clean the filler strainer Install the filler strainer and the filler cap i01032717 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV 7479 Use caution when changing oil or changing filters Hot oil or components can cause burns if they contact skin Note Use a 6V 3155 Brace Assembly in order to support the bucket whenever the lift cylinders are in the RAISE position 112 Maintenance Section Hydrostatic Transmission Oil Filter Replace i01031830
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