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MAINTENANCE INTERVALS - Safety

1. Illustration 217 g00753954 1 Open the engine hood The water separator is located on the bottom of the primary fuel filter on the right side of the machine 2 Attach a hose to the bottom of the drain valve 2 Open the drain valve 1 on the bottom of the water separator bowl Allow the water and the fuel to drain into a suitable container 3 Close the drain valve Note The water separator is under suction during normal engine operation Tighten the drain valve securely in order to prevent air leakage into the fuel system 4 Close the engine hood SEBU7889 16 167 Maintenance Section Fuel System Primary Filter Water Separator Element Replace 102223712 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 1263 510 FQ NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will
2. Illustration 261 g01350605 HMU in the articulation joint Use the following steps to lubricate the splines on the steering column SEBU7889 16 189 Maintenance Section Steering Cylinder Bearings Lubricate Illustration 262 g01350606 1 HMU 2 Bolts 3 Steering Column 1 Support the metering pump 1 Loosen the four bolts 2 that hold the pump Do not loosen the hose couplings 2 Lower the pump in order to expose the splines on the end of the steering column 3 3 Clean the male splines on the steering column Clean the female splines in the pump 4 Apply proper grease to the splines Refer to Operation and Maintenance Manual Lubricant Viscosities for selecting the proper grease 5 Push the pump into position 6 Tighten the four bolts that hold the pump 7 Test the steering system 102399608 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Illustration 263 g01136858 1 Location of the grease fittings for the rod ends 2 Remote location of the grease fittings for the head ends Illustration 264 g01105611 Location of the grease fittings for the rod ends both side
3. g00718876 Illustration 250 If there is play between the quick coupler and the hooks of the work tool inspect the quick coupler and the hooks for wear or for damage Make any necessary repairs before you operate the work tool Quick Coupler Lubricate If Equipped SMCS Code 6129 086 Illustration 251 Wipe off the coupler pins Coat the coupler pins with new grease 101442049 Radiator Core Clean SMCS Code 1353 070 KO 1 Open the engine hood The radiator assembly is located at the rear of the machine Illustration 252 g00765907 184 Maintenance Section Receiver Dryer Refrigerant Replace SEBU7889 16 2 Remove bolt 2 Swing the condenser away from the radiator Use the control knob 1 in order to release the hydraulic oil cooler Swing the hydraulic oil cooler 3 and the condenser 4 away from the radiator ANY NIN N a ANN Illustration 253 g00101939 3 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 4 Swing the hydraulic oil cooler back into the operating position and replace the two bolts 5 Swing the air conditioner condenser back into the operating
4. Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended to 3000 hours S O S services may extend the oil change even longer Consult your Caterpillar dealer for details When Required Automatic Lubrication Grease Tank Fill 132 Battery or Battery Cable Inspect Replace 134 Bucket Cutting Edges Inspect Replace 138 Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust Replace cceeceeeeeeereeeees 139 Bucket Tips Inspect Replace c ccceee 141 Camera Clear siiiu tenira nA 144 Circuit Breakers Reset e eeeeeeeeeneeeeeees 146 Engine Air Filter Primary Element Clean Replace ii iain Migs a R 155 Engine Air Filter Secondary Element Replace 157 Ether Starting Aid Cylinder Replace 165 Fuel System Prime ccccceeeeeeeeeeeeeeteeeeeeenaes 165 Fuses Replace cccccccceceeeeeeeeeeeeenceeeeeeeeeteees 170 High Intensity Discharge Lamp HID Replace 171 Oil Filter Inspect c ccccceceeeeeeeeeeeeeeenteeeeees 178 Pallet Fork Inspect eeceeeeeeeeeeeeteeeeeeeeeeeeees 179 Radiator Core Clean cc ccccceseeeeeeesneeeeeenaes 183 Ride Control Accumulator Check 05 185 Secondary Steering Test iier 186 Window Wa
5. 136 SEBU7889 16 Maintenance Section Belt Inspect Adjust Replace Illustration 150 g01120034 1 Idler Pulley 4 Tensioner 7 Serpentine Belt 2 Compressor If Equipped 5 Square Hole 8 Crankshaft Pulley 3 Alternator 6 Water Pump 9 Axle Oil Cooler Pump If Equipped SEBU7889 16 137 Maintenance Section Brake Accumulator Check A tensioner 4 keeps the correct tension on the belt 7 Insert a ratchet with a square drive into the hole 5 Rotate the tensioner counterclockwise in order to relieve tension on the belt Remove the belt Install the new belt Be sure that the new belt is routed correctly as shown View A represents machines that are not equipped with an air conditioner View B represents machines that are equipped with an air conditioner View C represents machines that are equipped with an air conditioner and an axle oil cooler pump Rotate the tensioner counterclockwise in order to install the new belt Release the tensioner when the new belt is installed The correct tension will automatically be applied i01714079 Brake Accumulator Check SMCS Code 4263 535 Q eee Oe Te OO Illustration 151 g00882020 1 Turn the engine start switch to the ON position The alert indicator for brake oil pressure should come on if the braking system is not at normal operating pressure
6. 144 Maintenance Section Bucket Upper Pivot Bearings Lubricate SEBU7889 16 101897750 Bucket Upper Pivot Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD Illustration 170 g00987399 Wipe off the fitting before any lubricant is applied Apply lubricant through the fitting 101449996 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Note Clean the cab air filters more often if the machine is being operated in dusty conditions Illustration 171 g00759048 1 Remove the filter cover behind the seat Two threaded knobs 1 are used in order to remove the cover Remove the filter element 2 2 Open the access door 3 on the left side of the cab Remove the filter element 3 Clean the filter elements with pressure air or wash the filter elements in warm water with a nonsudsing household detergent 4 If water and detergent are used to clean the filter elements rinse the filter elements in clean water and allow the filter elements to air dry thoroughly Note If either filter element is damaged install a new filter element 5 Install the filter elements Install the filter cover and close the access door 102816405 Camera Clean If Equipped SMCS Code 7348 070 In order to maintain sufficient vision keep the Work Area Vision System WAVS camera lens and the display clean SEBU7889 16 145 Maintenance Section Case Drain Screen Strainer
7. 2 Start the engine Run the engine at half speed for two minutes in order to increase the accumulator pressure The alert indicator for brake oil pressure should go off 3 Stop the engine Apply the service brake pedal and release the service brake pedal until the alert indicator for brake oil pressure comes on This will decrease the accumulator pressure A minimum of five applications of the service brake pedal are required 4 If the alert indicator comes on after less than five applications of the brake measure the accumulator precharge pressure An authorized Caterpillar dealer can measure the nitrogen gas pressure in the accumulator Use only dry nitrogen gas for recharging 101732078 Brake Discs Check SMCS Code 4255 535 Reference For the correct procedure refer to the Testing and Adjusting Service Manual of the braking system for your machine or consult your Caterpillar dealer 101739721 Braking System Test SMCS Code 4251 081 4267 081 e Fasten the seat belt before you test the brakes e Park the machine on a dry level surface e Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles e Make sure that the steering frame lock is in the unlocked position The following tests are used to determine whether the braking system is functional These tests are not intended to measure the maximum brake holding effort The required brake holding effort for
8. Replace 8 x cesictd a a a tea elena 172 Hydraulic System Oil Filter Replace 176 Hydraulic System Oil Sample Obtain 177 Transmission Oil Sample Obtain 0 0 193 Every 1000 Service Hours or 6 Months Articulation Bearings Lubricate ccceeee 132 Battery Hold Down Tighten aaaea 134 Case Drain Screen Strainer Steering Pump Hydraulic Fan Pump Motor Clean 145 Drive Shaft Universal Joints Lubricate 154 Roading Fender Hinges Lubricate 185 Rollover Protective Structure ROPS Inspect 185 Steering Pilot Oil Screen Command Control Steering Clean Replace cccceeeeeees 190 Transmission Oil Change seese 191 Every 2000 Service Hours or 1 Year Brake Discs Check ccecccseeeeeeeeseteeeeeenaes 137 Differential and Final Drive Oil Change 151 Engine Valve Lash Check seeen 164 Engine Valve Rotators Inspect eee 164 Hood Tilt Actuator Lubricate 172 Hydraulic System Oil Change n 173 Hydraulic Tank Breaker Relief Valve Clean 178 Service Brake Wear Indicator Check 187 Steering Column Spline Command Control Steering s LUD MCALe iira vats cccaseianecta a a a 188 Every Year Cooling System Coolant Sample Level 2 QDtAIN 5 E ENE O T TT 150 Receiver Dryer Refrigerant Replace 184 Every 3000 Service
9. Steering Pump Hydraulic Fan Pump Motor Clean Display J__________y FERS SO GCSOVG Illustration 172 g01223034 WAVS display Use a soft damp cloth in order to clean the display The display has a soft plastic surface that can be easily damaged by an abrasive material The display is not sealed Do not immerse the display with liquid Camera i02067499 Case Drain Screen Strainer Steering Pump Hydraulic Fan Pump Motor Clean SMCS Code 4304 070 Z3 5057 070 Z3 Illustration 173 g01223051 The WAVS camera is located on the rear of the machine in the center of the fan guard Use a damp cloth or water spray in order to clean the camera lens The camera is a sealed unit The camera is not affected by high pressure spray The camera is equipped with an internal heater to help counteract the effects of condensation snow or ice Note For more information on WAVS refer to Operation and Maintenance Manual SEBU8157 Work Area Vision System Illustration 174 g01059455 Case drain screen 3 and case drain screen 5 are located in hydraulic line 2 and hydraulic line 4 Hydraulic line 2 and hydraulic line 4 are located behind the hydraulic oil tank 1 Hydraulic line 2 is the case drain for the hydraulic fan pump Hydraulic line 4 is the case drain for the steering pump 1 Disconnect the hydraulic line 2 from the hydraulic tank 1 2 Remove the case drain s
10. 1 Turn the engine start switch key OFF Turn all of the switches OFF SEBU7889 16 135 Maintenance Section Belt Inspect Adjust Replace 2 Turn the battery disconnect switch OFF Remove the key 3 Disconnect the negative battery cable from the disconnect switch Note Do not allow the disconnected battery cable to contact the disconnect switch 4 Disconnect the negative battery cable at the battery 5 Disconnect the positive battery cable at the battery 6 Inspect the battery terminals for corrosion Inspect the battery cables for wear or damage 7 Make any necessary repairs If necessary replace the battery cables or the battery 8 Connect the positive battery cable at the battery 9 Connect the negative battery cable at the battery 10 Connect the battery cable at the battery disconnect switch 11 Install the key and turn the battery disconnect switch ON Recycle the Battery Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility i03690607 Belt Inspect Adjust Replace SMCS Code 1397 025 1397 040 1397 510 Your machine is equipped with a single serpentine belt Stop the engine Open the rear hood The belt is located at the front of the engine Inspect the condition of the serpentine belt Replace the belt if the belt is worn or frayed
11. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes before obtaining the oil sample This will thoroughly mix the transmission oil for a more accurate sample Illustration 273 g01108497 194 Maintenance Section Window Washer Reservoir Fill SEBU7889 16 2 The sampling valve for the transmission oil is located on the transmission oil filter base on the right side of the machine under the platform Use the in line sampling valve in order to obtain a sample of transmission oil Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis and Special Publication PEHP6001 How To Take A Good Oil Sample 102266578 Window Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solvent or equivalent System
12. from the engine oil pan 4 Open the engine hood 160 Maintenance Section Engine Oil Level Check SEBU7889 16 Illustration 206 g01120399 5 Use a strap type wrench to remove the filter element Inspect the filter 6 Clean the filter mounting base with a clean cloth Make sure that the used filter gasket has been completely removed Illustration 207 g00101318 7 Apply a thin film of clean engine oil to the seal on the new filter element 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 or 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 9 Connect an oil pump to the male coupler for the high speed arrangeme
13. times Use filtered dry air at a maximum pressure of 207 kPa 30 psi Note Pressurized air will not remove deposits of carbon and oil 6 When you clean the primary element always begin in the inside of the element clean side This will force dirt particles toward the outside of the element dirty side Illustration 201 g00328470 7 Place a light bulb inside the filter element Use a 60 watt blue light in a dark room or in a similar facility Inspect the primary element for light that may show through the filter material 8 Inspect the primary element while you rotate the element Inspect the primary element for tears and or holes Do not use a primary element that has any tears and or holes in the filter material Do not use a primary element with damaged pleats gaskets or seals 9 If it is necessary compare the primary element to a new primary element Use a new primary element that has the same part number This may be necessary in order to confirm the results of the inspection 10 Discard a damaged primary element Use Steps 11 through 13 to install a clean primary element NOTICE Do not use a filter if the pleats the gaskets or the seals are damaged 11 Install a clean primary filter element over the engine air filter secondary element Apply firm pressure to the end of the primary element as you gently rock the filter element This seats the primary element SEBU7889 16 157 Maintenanc
14. HID lamp Note In order to avoid failure to the bulb that is premature avoid touching the bulb s surface with your bare hands Clean any fingerprints from the bulb with alcohol prior to operation 5 Reassemble the housing for the HID lamp Ensure that any printing on the lens is oriented correctly with respect to the HID lamp s mounting position on the machine 6 Reattach the electrical power to the HID lamp 7 Check the HID lamp for proper operation Note Consult your Caterpillar dealer for additional information on HID lamps 101615750 Hood Tilt Actuator Lubricate SMCS Code 7275 086 Illustration 227 g00765332 The hood tilt actuator is located on the right side of the machine 1 Raise the engine hood in order to extend the tilt hood actuator 2 Remove the wiper and lubricate the entire length of the inner post by hand 3 Wipe off the fittings before you apply any lubricant Apply lubricant through the two fittings on the cylinder Apply approximately 15 to 20 pumps of grease 4 Close the engine hood i03658090 Hydraulic System Biodegradable Oil Filter Element Replace If Equipped SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent co
15. Hours Steering Column Spline HMU Steering WUD IC ALC oea a a A 188 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccccceceeeeseeseseserteees 186 Every 5000 Service Hours Drive Shaft Support Bearing Lubricate 154 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 148 Every 6000 Service Hours or 6 Years Cooling System Water Temperature Regulator ReplaGe EEE EE A E A EN 150 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 146 132 Maintenance Section Articulation Bearings Lubricate SEBU7889 16 103022485 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Illustration 142 g00763990 Wipe off all fittings before any lubricant is applied Apply lubricant through one fitting on the upper hitch and through one fitting on the lower hitch 103661144 Automatic Lubrication Grease Tank Fill If Equipped SMCS Code 7540 544 TNK The Automatic TWIN Greasing System Reference Refer to System Operation RENR 6331 for mo
16. Illustration 145 g01105565 Wipe all fittings before lubricating Grease fitting 1 will lubricate the axle pivot bearing that is on the front of the rear axle Grease fitting 2 will lubricate the axle pivot bearing that is on the rear of the rear axle Note 5P 0960 Molybdenum Grease is preferred 1P 0808 Multipurpose Grease grease may be used 101897507 Backup Alarm Test If Equipped SMCS Code 7406 081 Turn the engine start switch to the ON position in order to perform the test Apply the service brake Place the transmission into REVERSE The backup alarm should sound immediately The backup alarm will continue to sound until the transmission is placed into NEUTRAL or into FORWARD 3 Illustration 146 g00881968 A three position switch on the backup alarm regulates the volume of the alarm The backup alarm is set for the highest sound level when the machine is shipped from the factory The setting should remain on HIGH unless the job site requires a lower sound level 134 Maintenance Section Battery Clean SEBU7889 16 102218821 Battery Clean SMCS Code 1401 070 Illustration 147 g01119949 g01119948 Illustration 148 Open the battery compartment on the left side of the machine under the platform Remove the battery hold down Cle
17. ROPS for bolts that are loose or damaged Use original equipment parts only to replace bolts that are damaged or missing Tighten the four cab mounting bolts to a torque of 850 100 N m 629 74 lb ft Note Apply oil to all bolt threads before installation Failure to apply oil can result in improper bolt torque 186 Maintenance Section Seat Belt Inspect SEBU7889 16 Do not repair the ROPS by welding reinforcement plates to the ROPS Consult your Caterpillar dealer for repair of cracks in any welds in any castings or in any metal section of the ROPS 102429589 Seat Belt Inspect SMCS Code 7327 040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 257 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 dat
18. System Primary Filter Water Separator Drain SEBU7889 16 1 o o Eg e a oxo 0 S o lm O J H O t lt i a 3 2 g01125195 Illustration 216 1 Open the engine hood in order to access the fuel priming pump The fuel priming pump is located on the right side of the machine 2 Place the drain hose 3 into a suitable container in order to catch the fuel Open the drain valve 2 Move the toggle switch 1 in order to activate the priming pump 3 Operate the priming pump until fuel comes out of the drain hose Operate the priming pump until the fuel that flows from the drain hose has no air bubbles Turn off the drain valve Turn off the priming pump 101439459 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates
19. a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Illustration 182 g01120318 The sampling valve for the cooling system is located on the upper coolant tube between the water pump and the radiator 150 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU7889 16 Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags e Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sam
20. cause accelerated wear to fuel system parts Fuel system should be primed prior to starting the engine Illustration 218 g00765025 1 Open the engine hood The primary fuel filter is located on the right side of the machine 2 Open drain valve 3 on the bottom of water separator bowl 2 Allow the water and the fuel to drain into a suitable container 3 Support the sediment bowl and rotate the retaining ring 2 counterclockwise Remove the sediment bowl Clean the water separator bowl and the O ring groove Note The water separator bowl is reusable Do not discard the water separator bowl 4 Remove the water separator element 1 from the mounting base by using a strap type wrench 5 Inspect the O ring seal on the water separator bowl Replace the O ring seal if necessary Illustration 219 g00101318 6 Lubricate the O ring seal with clean diesel fuel Place the O ring seal in the water separator bowl 7 Install the sediment bowl onto the new filter element 8 Apply a thin coat of clean diesel fuel to the seal on the new filter element Install the new filter element hand tight until the seal of the fuel filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the fuel filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tig
21. oil change interval is available pro vided that the operating conditions and recommend ed multigrade oil types are met When these require ments are not met shorten the oil change interval to 250 hours or use an S O S Services oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine The normal engine oil change interval is listed in this Operation and Maintenance Manual Maintenance Interval Schedule Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals Also refer to Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Poor maintenance of air filters or of fuel filters requires reduced oil change intervals Consult your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Cat oil filters are recommended Program A Verification for an Oil Change Interval of 500 Hours This program consists of three oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 h
22. position and replace the two bolts 6 Close the engine hood 102894326 Receiver Dryer Refrigerant Replace SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system Illustration 254 g01107270 1 Refrigerant accumulator 2 Refrigerant dryer SEBU7889 16 185 Maintenance Section Ride Control Accumulator Check Access refrigerant accumulator 1 from the left side of the machine Access in line refrigerant dryer 2 from the right side of
23. rotator will shorten valve life because of accelerated wear on the valves Note If a damaged valve rotator is not replaced some valve face guttering could result Metal particles from the valve could fall into the cylinder This could cause damage to the piston head and to the cylinder head SEBU7889 16 165 Maintenance Section Ether Starting Aid Cylinder Replace 102188275 Ether Starting Aid Cylinder Replace If Equipped SMCS Code 1456 510 CD Ether is poisonous and flammable Breathing ether vapors or repeated contact of ether with skin can cause personal injury Use ether only in well ventilated areas Do not smoke while changing ether cylinders Use ether with care to avoid fires Do not store replacement ether cylinders in living areas or in the operator s compartment Do not store ether cylinders in direct sunlight or at temperatures above 49 C 120 F Discard cylinders in a safe place Do not puncture or burn cylinders Keep ether cylinders out of the reach of unautho rized personnel To avoid possible injury be sure the brakes are ap plied and all controls are in Hold or Neutral when starting the engine eo y 7 Illustration 215 g01106393 1 Open the access door The ether starting aid cylinder is mounted on the left side of the machine next to the air cleaner 2 Loosen retaining clamp 1 and unscrew eth
24. that the oil level is at the FULL mark on the sight gauge 4 Install the filler cap Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 176 Maintenance Section Hydraulic System Oil Filter Replace SEBU7889 16 12 Start the engine and run the engine for at least ten seconds Then stop the engine and add hydraulic oil to the tank until the oil level is at the FULL mark on the sight gauge Install the filler cap 13 Start the engine and run the engine at low idle Cycle the implements so that all hydraulic systems are filled with oil Note If the alert indicator for a low oil level comes on stop the engine and immediately add oil to the hydraulic tank The oil level should not be below the suction ports in the hydraulic tank while the engine is running 14 Add hydraulic oil to the tank until the oil level is at the FULL mark on the sight gauge 15 Stop the engine Top off the hydraulic tank so that the oil level is at the FULL mark on the sight gauge Install the filler cap Note The oil must be free of air bubbles If air bubbles are present in the hydraulic oil air is entering the hydraulic system Inspect the hydraulic suction line and the hose clamps 16 If necessary tighten any loose clamps or any loose connections Replace any damaged hoses 103696956 Hydraulic
25. 6 Understanding the S O S Oil Analysis Tests Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours Caterpillar s standard SOS Fluids Analysis or an equivalent oil sampling program should be used The current guidelines for cleanliness of the oil should be observed Refer to Measured Data If an oil sampling program is not available the standard 2000 oil change interval should be used Measured Data The following information should be monitored through sampling of the oil e Significant changes in wear metals should be monitored These metals include iron copper chromium lead aluminum and tin e Significant changes in the following additives should be monitored zinc calcium magnesium and phosphorus e Contaminants should not be present These contaminants include fuel and antifreeze Water content should be 5 percent or less e The silicon level should not exceed 15 parts per million for new oil The particle counts should be monitored e The recommended level of cleanliness for Caterpillar machines that are operated in the field is ISO 18 15 or cleaner The cleanliness should be monitored by particle count analysis The levels of contamination should not exceed the normal by more than two ISO codes Action should be taken in order to determine the cause of the contamination The system should be returned to the original levels of contamination There shou
26. 987705 Apply lubricant through fittings 2 and 3 on both lift cylinders Apply lubricant through fittings 5 6 and 7 SEBU7889 16 141 Maintenance Section Bucket Lower Pivot Bearings Lubricate 101897748 Bucket Lower Pivot Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD Illustration 159 g00765618 For pin joint 1 apply lubricant through one remote fitting on each side of the machine Illustration 161 g00987389 fa g i Z 5 Ps Wipe off all fittings before any lubricant is applied Apply lubricant through one fitting on each side of the machine Illustration 160 g00765808 For pin joint 4 apply lubricant through a remote 103657242 fitting on the right side of the machine Use the fitting Bucket Tips p Inspect Replace that is toward the front of the machine SMCS Code 6805 040 6805 510 Personal injury or death can result from the bucket falling Block the bucket before changing bucket tips 142 Maintenance Section Bucket Tips Inspect Replace SEBU7889 16 Bucket Tips g00101352 Illustration 162 1 Usable 2 Replace the tip 3 Replace the tip Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip _ Remove the pin from the bucket tip The pin can be removed by one of the following methods e Use a hammer and a punch from the retainer side o
27. Cooling System Coolant Sample Level 1 Opti niee a aiaa a EE a 149 Engine Oil Sample Obtain a se 161 Every 250 Service Hours or Monthly Battery Clean ou ie ceeeeeeeeeeeeeeeeseeeneeeeeeeeneaeees 134 Belt Inspect Adjust Replace eeee 135 Brake Accumulator Check cceeeettteeeee 137 Braking System Test 0 renere 137 Differential and Final Drive Oil Level Check 153 Drive Shaft Spline Center Lubricate 154 Engine Oil High Speed and Oil Filter Change 158 Quick Coupler Lubricate cceceeeeeeerees 183 Every 250 Service Hours or 3 Months Engine Oil and Filter Change s es 161 Pallet Fork Lubricate 0 eccceeeeseeeeeeeenneeees 182 Steering Column Play Check n se 187 Every 500 Service Hours Transmission Oil Filter Replace 06 192 SEBU7889 16 131 Maintenance Section Maintenance Interval Schedule Every 500 Service Hours or 3 Months Differential and Final Drive Oil Sample Obtain 153 Engine Crankcase Breather Clean a an 158 Engine Oil High Speed and Oil Filter Change 158 Engine Oil and Filter Change n se 161 Fuel System Primary Filter Water Separator Element Replace 2 ccecceeeeeeeeeeeeeeseees 167 Fuel System Secondary Filter Replace 168 Fuel Tank Cap and Strainer Clean 169 Hydraulic System Biodegradable Oil Filter Element
28. EBU7889 16 177 Maintenance Section Hydraulic System Oil Level Check Note There are rotation index marks on each hydraulic oil filter that are spaced 90 degrees or 1 4 or a turn away from each other When you tighten the hydraulic oil filters use the rotation index marks as a guide 4 Tighten each filter according to the instructions that are printed on each filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filters Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filters to the amount that is required for final installation Make sure that the installation tool does not damage the filters 5 Start the engine and run the engine at low idle Inspect the hydraulic system for leaks 6 Maintain the oil level above the ADD COLD mark on the sight gauge Add hydraulic oil if necessary Refer to the Operation and Maintenance Manual Hydraulic System Oil Level Check for information about adding oil 103696955 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV Illustration 235 g01988179 The hydraulic tank is located behind the cab of the machine The sight gauge is on the left side The lift arms must be lowered with the bucket flat in order to check the hydraulic oil Check the hydraulic oil level while the engine is sto
29. Failure to follow these recommendations can result in shortened cooling system component life When a Caterpillar Extended Life Coolant ELC is used an Extender must be added to the cooling system Use a 8T 5296 Coolant Conditioner Test Kit to check the concentration of the coolant Reference For additional information about the addition of Extender refer to Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer b olo Illustration 180 g01120130 The cooling system pressure cap is located under the engine hood at the rear of the machine Tilt the hood in order to access the cooling system pressure cap The cap is located on the radiator tank on the left side of the machine 1 Slowly loosen the cooling system pressure cap in order to relieve any system pressure Remove the cooling system pressure cap 2 If necessary drain enough coolant from the radiator in order to allow the addition of the Extender to the cooling system The cooling system drain valve 2 is located on the lower left side of the radiator SEBU7889 16 149 Maintenance Section Cooling System Coolant Level Check 3 Add 1 5 L 1 6 qt of Extender to the cooling system Reference Refer to Operation and Maintenance Manual Capacities Refill for the correct amount 4 Check the coolant leve
30. If the opposite side of the cutting edge is not worn use the opposite side of the cutting edge The end bits are not reversible If both sides are worn install a new cutting edge 6 Install bolts 1 Tighten the bolts to the specified torque Reference Refer to Specifications SENR3130 Ground Engaging Tool G E T Fasteners SEBU7889 16 139 Maintenance Section Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust Replace 7 Start the engine Raise the bucket and remove the blocking Lower the bucket to the ground 8 After a few hours of operation check the bolts for proper torque Bucket Wear Plates Personal injury or death can result from the bucket falling Block the bucket before changing bucket wear plates Illustration 153 g00879740 Inspect the wear plates Replace the wear plates before damage to the bottom of the bucket occurs Consult your Caterpillar dealer for replacement of wear plates Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust Replace SMCS Code 6001 025 CLR 6001 040 CLR 6001 510 24 6119 025 CLR 6119 040 CLR 6119 510 24 Inspect the Linkage Illustration 154 g01345690 1 Lift Arm 2 Bucket 3 Inspection Points for the Bucket Hinge Periodically inspect the bucket linkage The gap between the bucket and the linkage should not exceed the thinnest shim that is available for the bucket assembly 1 Lower the lift arm assem
31. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR o BA Operation and Maintenance Manual 950H and 962H Wheel Loaders and IT62H Integrated Toolcarrier J5J 1 Up 950H Machine K5K 1 Up 950H Machine M1G 1 Up 950H Machine N1A 1 Up 950H Machine J6J 1 Up 962H Machine K6K 1 Up 962H Machine M3G 1 Up 962H Machine N4A 1 Up 962H Machine M5G 1 Up IT62H Machine SAFETY CAT COM 130 Maintenance Section Maintenance Interval Schedule SEBU7889 16 103842629 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 Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals
32. System Oil Filter Replace SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before 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 ial a FT 0l Illustration 233 g01121627 The hydraulic filters are located on the right side of the machine under the platform There are two hydraulic oil filters Each filter must be replaced during this procedure 1 Use a strap type wrench to remove each filter element Dispose of the used filter elements properly 2 Clean the filter mounting bases Make sure that all of the used seals are completely removed Illustration 234 g00101318 3 Apply a thin coat of clean hydraulic oil to the seals on the new filters Install each new hydraulic filter hand tight until the seals of the hydraulic oil filters contact each base Note the position of the index marks on each filter in relation to a fixed point on each filter base S
33. ULL mark Add oil if necessary Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the type of lubricant and for the refill capacity 4 Clean the plug and install the plug 5 Repeat Step 2 through Step 4 for the rear axle 102778954 Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4011 008 4070 008 7542 Illustration 193 g00667052 Front axle Illustration 194 g00667053 Rear axle The axles are not equipped with sampling valves Obtaining a sample of the differential and final drive oil will require a vacuum pump or an equivalent Withdraw the fluid through the filler opening on the right side of each axle 154 Maintenance Section Drive Shaft Spline Center Lubricate SEBU7889 16 Reference Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information about obtaining an fluid sample 103657243 Drive Shaft Spline Center Lubricate SMCS Code 3253 086 SN Wipe all of the fittings before you apply grease to the fittings NOTICE To prevent damage to the seal articulate the machine full right or left before lubricating the splines 1 Start the engine Raise the bucket Release the parking brake Articulate the machine to the right or to the left in order to properly lubricate the splined shaft 2 Lower the bucket to the ground Engage the parking
34. an the battery terminals and the surfaces of the batteries with a clean cloth Coat the battery terminals with petroleum jelly Make sure that the battery cables are installed securely Replace the battery hold down Refer to Operation and Maintenance Manual Battery Hold Down Tighten for the correct torque Close the battery compartment 102185798 Battery Hold Down Tighten SMCS Code 7257 527 Illustration 149 g00882014 Open the battery compartment on the left side of the machine under the platform Over time the vibration of an operating machine can cause the battery hold down to loosen To help to prevent loose batteries and the possibility of loose cable connections tighten the locknut in the center of the hold down to a torque of 14 3 N m 10 2 Ib ft i03657099 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 Personal injury may occur from failure to properly service the batteries Batteries give off flammable fumes that can ex plode Electrolyte is an acid and can cause per sonal injury if it contacts the skin or eyes Prevent sparks near the batteries Sparks could cause vapors to explode Do not allow jumper ca ble ends to contact each other or the engine Im proper jumper cable connections can cause an ex plosion Always wear protective glasses when working with batteries
35. and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type in the Lubricant Viscosities for Ambient Temperatures Table in this Operation and Maintenance Manual Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each increment is an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above References Reference Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Reference Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Reference Special Publication PEDP7035 Optimizing Oil Change Intervals Reference Special Publication PEDP7036 S O S Fluid Analysis Reference Special Publication PEDP7076 U
36. bly 1 to suitable blocking Rest the bucket 2 on the ground 2 Use a gauge to measure the gap at the hinge 3 If the measurement exceeds the required amount new shims must be installed Installing Shims for the Hinge on the Bucket Note Refer to the Disassembly and Assembly Manual Bucket Remove for the correct procedure for removing the pins in the linkage 140 Maintenance Section Bucket Linkage and Loader Cylinder Bearings Lubricate SEBU7889 16 Illustration 155 g01345720 2 Bucket 4 Install washers on lift arm Illustration 156 g01345724 2 Bucket 4 Install washers on tilt arm Install washers and pin assembly to the bucket When possible use washers on both sides of the lift arm in order to reduce the gap between the lift arm and the hinges on the bucket Note Refer to the Disassembly and Assembly Manual Bucket Install for the correct procedure for installing the pins in the linkage 101897623 Bucket Linkage and Loader Cylinder Bearings Lubricate SMCS Code 5102 086 BD 5104 086 BD 6107 086 BD Integrated Toolcarrier Wipe off all of the fittings before you apply any lubricant Illustration 157 g00764050 Apply lubricant through twelve fittings on each side of the machine There are a total of 24 fittings Wheel Loader Wipe off all fittings before any lubricant is applied Illustration 158 g00
37. brake Stop the engine Note Since the steering frame lock cannot be connected in this case remove the engine start switch key and turn the battery disconnect switch to the OFF position Illustration 195 g01106848 3 Apply grease to the fitting 1 Apply grease until the relief 2 overruns Note 5P 0960 Molybdenum Grease is preferred 1P 0808 Multipurpose Grease may be used 4 Start the engine Raise the bucket Release the parking brake Reposition the machine in a straight direction without articulation 5 Lower the bucket to the ground Apply a slight down pressure Engage the parking brake Stop the engine 102445874 Drive Shaft Support Bearing Lubricate SMCS Code 3267 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Wipe off the fitting before any lubricant is applied Illustration 196 g00764668 Apply lubricant through the remote fitting on the right side of the machine Use the fitting that is toward the rear of the machine 102445879 Drive Shaft Universal Joints Lubricate SMCS Code 3251 086 Note Check for sealed universal joints that do not require lubrication Wipe off all fittings before any lubricant is applied SEBU7889 16 155 Maintenance Section Engine Ai
38. ces of the blade and the shank 10 Blade Bevel The upper and lower surfaces of the tip on the blade that are tapered for easy insertion of the fork tines 11 Tip Flanks The side surfaces of the tip on the blade that are tapered for easy insertion of the fork tines 12 Top of Shank The upper surface on the shank 13 Shaft The tubes that are mounted on the fork tines for mounting the fork tines to the carriage Dimensions o r BH A T aa 3 S A A Illustration 242 Section A A g01598405 SEBU7889 16 181 Maintenance Section Pallet Fork Inspect T Thickness The thickness of the blade at the closest point to the heel W Width The width of the blade at the closest point to the heel BH Back Height The distance from the bottom of the blade to the top of the shank BL Length The length of the blade is measured from the front face on the shank to the tip on the blade A Angle The angle from the upper surface of the blade to the front face of the shank Inspection of the Fork Tines Check the fork tines daily for any twisting or bending of the fork tines If any twisting or bending is observed the fork tines should be changed prior to any lifting operation If the fork tines are damaged consult your Caterpillar dealer Check the fork tines for wear or for damage Inspect the welds the loc
39. cosity grade of 10W Cat HYDO Advanced 10 has a 50 increase in the standard oil drain interval up to 3000 hours for machine hydraulic systems over second and third choice oils when you follow the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual 6000 hour oil drain intervals are possible when using S 0 S Services oil analysis When you switch to Cat HYDO Advanced 10 cross contamination with the previous oil should be kept to less than 10 Consult your Caterpillar dealer for details about the benefits from the improved performance designed into Cat HYDO Advanced 10 Oil Filters Caterpillar oil filters are recommended The filter change interval is listed in this Operation and Maintenance Manual Maintenance Interval Schedule Oil Refer to the Operation and Maintenance Manual Lubricant Viscosities Table for the proper oil to use in your machine Note Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems Other References Reference Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Reference Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Reference Special Publication PEDP7035 Optimizing Oil Change Intervals Reference Special Publication PEDP7036 S O S Fluid Analysis Reference Special Publication PEDP707
40. creen 3 from the hydraulic line 2 3 Wash the case drain screen 3 in a clean nonflammable solvent 4 Dry the case drain screen 3 by using pressurized air 5 Inspect the case drain screen 3 for damage Note If the case drain screen 3 is damaged replace the case drain screen 3 6 Install the case drain screen 3 7 Connect hydraulic line 2 8 Repeat Step 1 through Step 7 for hydraulic line 4 and case drain screen 5 146 Maintenance Section Circuit Breakers Reset SEBU7889 16 103696954 Circuit Breakers Reset SMCS Code 1420 529 The circuit breaker panel is located on the left side of the machine under the front of the cab next to the battery box g01988115 Illustration 175 Depress the button in order to reset the circuit breakers If the circuit is functioning properly the button will remain depressed If the button will not remain depressed check the appropriate electrical circuit Illustration 176 g01988117 1 50 Amp Circuit Breaker 2 90 Amp Circuit Breaker 3 80 Amp Circuit Breaker 4 20 Amp Circuit Breaker 5 5 30 Amp Circuit Breaker 102219194 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slow
41. damage can result from freezing Illustration 274 g01136879 a Window Washer Reservoir The window washer reservoir is located under an access door on the platform on the right side of the machine Fill the window washer reservoir through the filler opening i01469067 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 Illustration 275 g00766456 Inspect the wiper blades Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs 100037755 Windows Clean SMCS Code 7310 070 Illustration 276 g00038949 Use commercially available window cleaning solutions in order to clean the windows Clean the outside windows from the ground unless handholds are available
42. diment to drain into a suitable container 3 Tighten the bolt on the side of the drain 102200478 Fuses Replace SMCS Code 1417 510 NOTICE Replace fuses with the same type and size only Oth erwise electrical damage can result If it is necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer Fuses The fuses protect the electrical system from a circuit that has been overloaded Change a fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary Illustration 225 g01000750 SEBU7889 16 171 Maintenance Section High Intensity Discharge Lamp HID Replace Illustration 226 g01078009 The fuses are located in the cab on the right side of the operator seat 1 Axle Oil Cooler Clutch ee 20 Amperes 2 HMU Shift Handle 00 ee 10 Amperes 3 HVAC Blower cceeeeeeeeseeeeees 20 Amperes 4 Quick Coupler cccceccesseeeeeeenees 10 Amperes 5 Rear Cab Floodlights e 15 Amperes G SPAle aieiaa ist aa eaten 10 Amperes 7 Secondary Steering 10 Amperes 8 ECM Switched Power 005 10 Amperes 9 Front Cab Floodlight
43. during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts Illustration 220 1 g00754126 Open the engine hood The secondary fuel filter 1 is located on the right side of the engine The secondary fuel filter is inverted The filter must be properly drained before removal Open the drain valve 2 Drain the fuel into a suitable container The secondary fuel filter can now be removed Remove the filter by using a strap type wrench Inspect the fuel filter element for debris by cutting the filter open Discard the used fuel filter element properly Clean the filter mounting base Make sure that all of the used seal is removed from the filter mounting base Illustration 221 g00101318 SEBU7889 16 169 Maintenance Section Fuel Tank Cap and Strainer Clean 6 Apply a thin coat of clean diesel fuel t
44. e Section Engine Air Filter Secondary Element Replace 12 Clean the cover for the air cleaner housing Align the slot on the cover with the pin on the air cleaner housing Install the cover 13 Close the engine 102445996 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE Burn Hazard Engine components may be hot dur ing and after machine operation Hot components can cause serious personal in jury Do not contact hot components with bare skin NOTICE Service the air filter only with the engine stopped En gine damage could result NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Note Replace the secondary element when you service the primary element for the third time If a clean primary element has been installed and a warning for the air filter still occurs replace the secondary element Also if the exhaust smoke remains black and a clean primary element has been installed replace the secondary element 1 Remove the primary element Reference Refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace for the correct procedure Z Illustration 202 g00864077 2 Remove the secondary element g00864079 Illustration 203 3 Cover the air inlet opening Clean the inside of the air cleaner housing 4 Inspect the gasket between the air inlet
45. e of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 102429594 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 elie Riis 4 g01152685 Illustration 258 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 103694709 Secondary Steering Test SMCS Code 4300 081 SE 4300 081 SST 4324 081 4324 The service brake must be checked in order to en sure proper operation before you test the supple mental steering system Perso
46. ebris 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 103123002 Pallet Fork Inspect SMCS Code 6136 040 Descriptions of the Fork Tine Parts AQ daoo 4 po 2 Illustration 240 1 Blade The horizontal part of the fork tine that supports the load 2 Heel The radius on the fork tine that connects the blade to the shank 3 Shank The vertical part of the fork tine that has the hooks that support the fork tines attached 4 Hook or Hanger Carriers that mount the fork tines to the carriage 5 Tip The free end of the blade g01598401 180 Maintenance Section Pallet Fork Inspect SEBU7889 16 Surfaces Q ao 9 8 11 e Pa 6 10 C i 7 11 7 g01598403 Illustration 241 6 Upper Face of the Blade The upper surface of the blade that carries the load 7 Bottom of Heel The lower surface of the blade that includes the tapers 8 Front Face of Shank The distance for the load center is measured from the front face of the shank and the face of the shank contacts the load 9 Flanks The side fa
47. ection SEBU7889 16 Steering Column Spline Command Control Steering Lubricate Steering Column Spline Command Control Steering Lubricate SMCS Code 4310 086 SN 4338 086 SN regs g00812993 Illustration 260 1 Remove the steering shaft from the machine Reference Refer to Disassembly and Assembly Manual for the removal procedure and for the installation procedure 2 Wipe off all of the fittings before any lubricant is applied 3 Refer to Operation and Maintenance Manual Lubricant Viscosities for the proper grease to use Apply the grease through fittings 1 2 3 4 5 6 7 and 8 4 Install the steering shaft on the machine 102690920 Steering Column Spline HMU Steering Lubricate SMCS Code 4310 086 SN 4338 086 SN The metering pump is located under the cab Crushing 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
48. ed to normal operation If there is no response to the steering input the supplemental steering system is not operating Stop the machine immediately Repair the supplemental steering system before returning the machine to service 102197967 Service Brake Wear Indicator Check SMCS Code 4255 535 IND Reference For information about checking the service brake wear indicator refer to Testing and Adjusting Braking System for the machine that is being serviced or consult your Caterpillar dealer 103589859 Steering Column Play Check SMCS Code 4310 535 4338 535 Illustration 259 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 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 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 188 Maintenance S
49. er ELC Add SEBU7889 16 Illustration 179 g01120228 7 Maintain the coolant level in the sight gauge on the upper right side of the radiator 8 Install the cooling system pressure cap Stop the engine 102219407 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC
50. er starting aid cylinder 2 3 Remove the gasket Install the new gasket that is provided with each new ether starting aid cylinder 4 Install new ether starting aid cylinder 2 hand tight Tighten retaining clamp 1 securely 5 Close the engine hood 102230611 Fuel System Prime SMCS Code 1250 548 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The fuel system needs to be primed due to the following circumstances e The primary fuel filter has been changed e The secondary fuel filter has been changed e The fuel injectors have been removed e The engine has run out of fuel Note The volume of air in the water separator is small Usually it is not necessary to prime the fuel system if only the water separator element has been changed Your machine is equipped with an electric fuel priming pump The priming pump is located on the right side of the engine above the primary fuel filter 166 Maintenance Section Fuel
51. es in order to equalize the oil level in the axle Check the oil level in the axle Reference Refer to Operation and Maintenance Manual Differential and Final Drive Oil Level Check for the correct procedure SEBU7889 16 153 Maintenance Section Differential and Final Drive Oil Level Check 101902117 Differential and Final Drive Oil Level Check SMCS Code 3278 535 FLV 4011 535 FLV Note Before you measure the oil level operate the machine for a few minutes in order to equalize the oil level 1 Park the machine on level ground Lower the bucket and apply slight downward pressure Engage the parking brake Stop the engine Nia Illustration 191 g00989672 Dipstick fill plug for the front axle Illustration 192 g00989674 Dipstick fill plug for the rear axle 2 Remove the dipstick fill plug Wipe off the level gauge with a clean cloth and reinsert the plug This will ensure a more accurate measurement of the oil level Note Make sure that the plug is installed completely before you check the oil level If the plug is not installed completely an incorrect oil level reading can occur 3 Remove the dipstick fill plug again and check the oil level Maintain the oil level between the ADD mark and the F
52. ey Start Switch and Product Link 10 Amperes 32 Dome Lamps ssis 10 Amperes 102245859 High Intensity Discharge Lamp HID Replace If Equipped SMCS Code 1434 510 HID lamps operate at very high voltages To avoid electrical shock and personal injury disconnect power before servicing HID lamps HID bulbs become very hot during operation Before servicing remove power from lamp for at least five minutes to ensure lamp is cool NOTICE Although HID bulb materials may change over time HID bulbs produced at the time of the printing of this manual contain mercury When disposing of this com ponent or any waste that contains mercury please use caution and comply with any applicable laws 172 Maintenance Section Hood Tilt Actuator Lubricate SEBU7889 16 1 Remove the electrical power from the high intensity discharge lamp HID The electrical power must be removed from the HID lamp for at least five minutes in order to ensure that the bulb is cool 2 Disassemble the housing for the HID lamp in order to have access to the bulb Note On some HID lamps the bulb is an integral part of the lens assembly The bulb is not removed separately from the lens assembly Replace the entire lens assembly on these HID lamps 3 Remove the bulb from the HID lamp 4 Install the replacement bulb in the HID lamp If the bulb is an integral part of the lens assembly install the replacement lens assembly in the
53. f the bucket to drive out the pin e Use a Pin Master Follow Step 1 a through Step 1 c for the procedure Mr 7 perf lt lt _ O _ CE Sees SE b 7 MA g00590670 4 Back of Pin Master 5 Extractor Illustration 163 a Place the Pin Master on the bucket tooth b Align extractor 5 with the pin c Strike the Pin Master at the back of the tool 4 and remove the pin Illustration 164 g00590819 6 Retainer 7 Retaining washer 8 Adapter 2 Clean the adapter and the pin 3 Fit retainer 6 into retaining washer 7 Install this assembly into the groove that is in the side of adapter 8 Illustration 165 g00101359 4 Install the new bucket tip onto the adapter Note The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration 5 Drive the pin through the bucket tip The pin can be installed by using one of the following methods e From the other side of the retainer drive the pin through the bucket tip the adapter and the retainer e Use a Pin Master Follow Step 5 a through Step 5 e for the procedure Note To correctly install the pin into the retainer the pin must be driven in from the right side of the tooth Improper installation of the pin can result in the loss of the bucket tip SEBU7889 16 143 Maintenance Section Bucket Tips Inspect Replace g00590666 Illustratio
54. f the seal is damaged 9 Install a new filter element into the transmission filter housing Clean the filter housing drain plug and install the drain plug 10 Start the engine Slowly operate the transmission controls in order to circulate the transmission oil Check the machine for oil leaks 11 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure 101468938 Transmission Oil Level Check SMCS Code 3030 535 FLV Illustration 272 g00766406 The sight gauge for the transmission oil level is located on the left side of the machine near the articulation joint 1 Operate the machine for a few minutes in order to warm the transmission oil 2 Park the machine on a hard level surface Put the transmission control into the NEUTRAL position Lower the bucket to the ground with a slight downward pressure Engage the parking brake Note Before the machine is started the transmission oil level should be above MIN START mark 1 on the upper end of the sight gauge 3 Check the oil level while the engine is running at low idle While the engine is running at low idle the transmission oil level should be between the MIN mark 3 and the MAX mark 2 4 If necessary remove the filler cap and add oil 102195036 Transmission Oil Sample Obtain SMCS Code 3080 008 7542
55. ference Special Publication PEDP7035 Optimizing Oil Change Intervals Reference Special Publication PEDP7036 S O S Fluid Analysis Reference Special Publication PEDP7076 Understanding the S O S Oil Analysis Tests Procedure for Changing the Engine Oil and Filter NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Your machine may be equipped with a high speed arrangement for changing the engine oil The high speed arrangement allows service personnel to change the oil from the engine access door on the right side of the machine The high speed arrangement allows the oil to be changed faster than conventional methods Illustration 205 g01120397 1 Open the service door that is located on the right side of the machine 2 Remove the cap that protects the male coupler Connect an oil pump to the fitting The fitting on the machine is a male coupler 3 Turn on the oil pump and withdraw the engine oil
56. for a few minutes in order to warm the transmission oil 2 Park the machine on a hard level surface Lower the bucket to the ground with a slight downward pressure Engage the parking brake and stop the engine Illustration 268 g00766059 Typical example Note Remove the bolts 1 that hold the transmission guard 2 Remove the transmission guard on the underside of the machine in order to access the magnetic strainer Illustration 269 g00766094 Typical example 3 Remove transmission oil drain plug 7 Allow the oil to drain into a suitable container Clean the drain plug and install the drain plug 4 Remove four cover bolts and magnetic strainer cover 3 5 Remove suction screen 4 and tube 6 from the housing Remove three magnets 5 from the tube 6 Wash the tube and the screen in a clean nonflammable solvent 7 Use a cloth a stiff bristle brush or pressurized air to clean the magnets NOTICE Do not drop or rap the magnets against any hard sur face Replace any damaged magnets 8 Clean the cover and inspect the cover seal Replace the seal if necessary 9 Install three magnets 5 on the tube Insert suction screen 4 and tube 6 in the housing 10 Install the cover and the cover bolts 11 Replace the transmission oil filter Reference Refer to Operation and Maintenance Manual Transmission Oil Filter Replace for the cor
57. he oil filler cap 9 Start the engine and allow the oil to warm Check for any oil leaks 10 Check the oil level on dipstick 2 Reference Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure 11 Close the engine hood and stop the engine 164 Maintenance Section Engine Valve Lash Check SEBU7889 16 101181536 Engine Valve Lash Check SMCS Code 1105 535 For the correct procedure refer to the appropriate Service Manual module for your machine s engine or consult your Caterpillar dealer Note A qualified mechanic should adjust the engine valve lash because special tools and training are required 102770364 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to prevent being burned by hot oil or spray Electrical shock hazard The electronic unit injec tor system uses 90 120 volts Illustration 213 g01372247 1 Start the engine Run the engine at low idle Illustration 214 g00038585 2 Watch the top surface of each valve rotator Whenever an inlet valve closes or an exhaust valve closes each valve rotator should turn 3 If a valve rotator fails to rotate consult your Caterpillar dealer for service Note Caterpillar recommends replacing valve rotators that are operating improperly An improperly operating valve
58. hten the fuel filter use the rotation index marks as a guide 9 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 10 Close drain valve 3 168 Maintenance Section Fuel System Secondary Filter Replace SEBU7889 16 Note The water separator element is under suction during normal engine operation Tighten the drain valve securely in order to prevent air leakage into the fuel system 11 Prime the fuel system in order to fill the water separator element with fuel Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure 12 Close the engine hood 102223730 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Care must be taken to ensure that fluids are contained
59. ief valve dry or use pressure air to dry the breaker relief valve 3 Install the hydraulic tank breaker relief valve 103657276 Logging Fork Clamp Lubricate If Equipped SMCS Code 6113 086 BD 6410 086 BD Wipe off all fittings before any lubricant is applied Illustration 238 g01962679 Apply lubricant through three fittings on each side of the logging fork There is a total of six fittings 102106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 239 g00100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts SEBU7889 16 179 Maintenance Section Pallet Fork Inspect 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 d
60. ion 246 g01600076 2 Move the upper arm of the measuring device toward the face of the shank Ensure that the measuring device is held flat against the face of the shank in order to acquire an accurate measurement 3 Check the angle that was measured with the device for the angle of the heel 4 If the angle is between 87 degrees and 93 degrees the fork tine can remain in service Illustration 247 g01563105 typical example 5 If the angle is less than 87 degrees or greater than 93 degrees the fork tine must be taken out of service The fork tines must be inspected for the following conditions 1 Coat the shafts with grease e permanent deformation e stress cracks e other defects Consult your Caterpillar dealer for additional information Illustration 248 g01563115 typical example 2 Coat the mounting holes for the quick coupler with grease Reference Refer to Operation and Maintenance Manual SEBU6250 Caterpillar Machine Lubricant Recommendations for information on lubricants SEBU7889 16 183 Maintenance Section Quick Coupler Check 102778956 Quick Coupler Check If Equipped SMCS Code 6129 535 Installation Illustration 249 g00718871 When you install a work tool on the quick coupler inspect the engagement of the coupler pins If there is play between the coupler pins and the corresponding bores inspect the coupler pins and the bores for damage or wear
61. ions that are printed on each filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filters Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filters to the amount that is required for final installation Make sure that the installation tool does not damage the filters 5 Start the engine and run the engine at low idle Inspect the hydraulic system for leaks Illustration 230 g01121628 6 Maintain the oil level above the ADD COLD mark on the sight gauge Add hydraulic oil if necessary 103696957 Hydraulic System Oil Change SMCS Code 5056 044 Selection of the Oil Change Interval Your machine may be able to use a 4000 hour interval for the hydraulic oil The hydraulic oil is in the system that is not integral to the service brakes the clutches the final drives or the differentials The standard change interval is 2000 hours The oil should be monitored during intervals of 500 hours The extended 4000 hour interval can be used if the following criteria are met 174 Maintenance Section Hydraulic System Oil Change SEBU7889 16 HYDO Advanced 10 Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic and hydrostatic transmission systems when ambient temperature is between 20 C 4 F and 40 C 104 F Cat HYDO Advanced 10 has an SAE vis
62. ired Use the following procedure to change the Extended Life Coolant The cooling system pressure cap is located under the hood at the rear of the machine gt olo Illustration 177 g01120130 1 Slowly loosen the cooling system pressure cap in order to relieve system pressure The pressure cap is located on top of the radiator tank on the left side of the machine Illustration 178 g00753215 2 Open the drain valve on the bottom of the radiator The drain valve can be accessed from the left side of the machine Allow the coolant to drain into a suitable container 3 Flush the cooling system with clean water until the draining water is clean Close the drain valve 4 Replace the water temperature regulator Reference Refer to Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the correct procedure 5 Add the Extended Life Coolant Reference Refer to Operation and Maintenance Manual Capacities Refill for the refill capacity of the cooling system 6 Start the engine Run the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes 148 Maintenance Section Cooling System Coolant Extend
63. ks the shafts and the fork tines for damage If the components are damaged consult your Caterpillar dealer Refer to Daily Inspection for additional information Blade Thickness Illustration 243 g01600073 1 Measure the thickness of the shank Ensure that the measuring device is held square across the shank in order to acquire an accurate measurement Q Illustration 244 g01600074 2 Measure the blade of the fork tine near the heel Ensure that the measuring device is held square across the blade in order to acquire an accurate measurement 3 Compare the measurement of the blade and the measurement of the shank 4 If the difference in measurements is less than 10 the fork tine can remain in service 5 If the difference in measurements is greater than 10 the fork tine must be taken out of service Fork tine wear that is greater than 10 represents a 20 reduction in the capacity of the fork tine Consult your Caterpillar dealer for additional information Angle of the Heel Q ei Ne N 3 g01600075 Illustration 245 1 Place a measuring device in the top inside area of the heel on top of the blade Ensure that the measuring device is held flat against the blade in order to acquire an accurate measurement 182 SEBU7889 16 Maintenance Section Pallet Fork Lubricate 103082842 Pallet Fork Lubricate SMCS Code 6136 086 Illustrat
64. l Reference Refer to Operation and Maintenance Manual Cooling System Level Check for the correct procedure 5 Install the cooling system pressure cap Close the engine hood 102219429 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Illustration 181 g01120228 Open the service door on the left side of the machine The coolant level sight gauge is located on the left side of the radiator Maintain the coolant level within the sight gauge Add coolant if necessary Note If it is necessary to add coolant daily inspect the cooling system for leaks 102219431 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 Note It is not necessary to obtain a Coolant Sample Level 1 if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC This includes the following types of coolants e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat Diesel Engine Antifreeze Coolant DEAC e Commercial heavy duty coolant antifreeze NOTICE Always use
65. ld not be significant changes in sodium silicon copper and potassium The allowable level of oxidation is 40 percent 0 12 Abs units The kinematic viscosity of 100 C 212 F oil should not exceed a change of more than 2 cSt from new oil SEBU7889 16 175 Maintenance Section Hydraulic System Oil Change Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine in order to warm the hydraulic oil 2 Park the machine on level ground Lower the attachment to the ground and apply slight downward pressure Engage the parking brake and stop the engine FWD Illustration 231 g01988234 3 The hydraulic tank is behind the cab of the machine Press the button on the breaker relief valve 1 in order to relieve any tank pressure 4 Remove the hydraulic tank filler cap 2 and the filler strainer The filler strainer is located righ
66. ly to relieve the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates SEBU7889 16 147 Maintenance Section Cooling System Coolant ELC Change NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life Reference For information about the addition of Extender to your cooling system see Operation and Maintenance Manual Cooling System Coolant Extender ELC Add or consult your Caterpillar dealer If an Extended Life Coolant was previously used flush the cooling system with clean water No other cleaning agents are requ
67. mmable solvent 5 Dry each screen with pressure air Inspect each screen for damage Replace any damaged screens 6 Install the screens and tighten the allen head screws until the screens are snug 7 Install two connectors 2 and two hoses 1 102305841 Tire Inflation Check SMCS Code 4203 535 Al N N Illustration 267 g01160201 Always obtain proper tire inflation pressures and maintenance recommendations for the tires on your machine from your tire supplier Measure the tire pressure on each tire Inflate the tires with nitrogen if necessary Reference Refer to the Tire Inflation Information section of the Operation and Maintenance Manual for more information SEBU7889 16 191 Maintenance Section Transmission Oil Change 103347900 Transmission Oil Change SMCS Code 3030 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the engine
68. move the drain adapters from the drain valves 3 Clean the drain plugs and install the drain plugs Note If your machine is equipped with the axle oil cooler there are 2 magnetic filters that need to be cleaned If your machine is not equipped with the axle oil cooler skip the next step Illustration 187 Front Magnetic Oil Filter g01384244 Illustration 188 Rear Magnetic Oil Filter g01384247 4 Remove the magnetic plug on the front filter Clean the magnetic plug with a clean nonflammable solvent Install the magnetic plug Repeat the process for the rear magnetic filter 2 X Illustration 189 g00989672 Dipstick fill plug for the front axle Illustration 190 g00989674 Dipstick fill plug for the rear axle 5 Wipe off the dipstick fill plugs and the surfaces around the dipstick fill plugs 6 Remove the dipstick fill plugs Add 0 5 L 0 5 qt of 1U 9891 Hydraulic Oil Additive to each axle Fill the axles with oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the type of lubricant and for the refill capacity 7 Clean the dipstick fill plugs and install the dipstick fill plugs 8 Run the machine on level ground for a few minut
69. n 166 4 Back of Pin Master 9 Pin setter 10 Pin holder a Insert the pin through the bucket tooth b Place the Pin Master over the bucket tooth and locate the pin in the hole of holder 10 c Strike the tool with a hammer at the back of the tool 4 in order to start the pin d Slide pin holder 10 away from the pin and rotate the tool slightly in order to align pin setter 9 with the pin e Strike the end of the tool until the pin is fully inserted 6 After you drive the pin make sure that the retainer fits snugly into the pin groove K Series Tip Removal Illustration 167 g01389463 Note Retainers are often damaged during the removal process Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced Illustration 168 g01175361 1 Use a pry bar in order to disengage retainer 5 2 Use the pry bar in order to remove retainer 5 from bucket tip 4 3 Remove bucket tip 4 from adapter 6 with a slight counterclockwise rotation 4 Clean adapter 6 Installation 1 Clean the adapter and the area around the latch if necessary 2 Install the new bucket tip onto the adapter with a slight clockwise rotation Illustration 169 g01124736 3 Install the retainer Make sure that the retainer s latch catches under the tip pocket 4 Make sure that the latch is properly seated by trying to remove the bucket tip
70. nal injury death or property damage could occur if the supplemental steering system is test ed and the service brake is not operational Test the service brake before you test the supple mental steering system SEBU7889 16 187 Maintenance Section Service Brake Wear Indicator Check Perform the following procedure if your machine is equipped with a ground driven supplemental steering and if the procedure is required by local regulations Ensure that there are no hazards in the test area The test area must be unobstructed and level Operate the machine in second gear Ensure that all air tanks and accumulators are properly charged Ensure that there is no load in the work tool Position the machine with the bucket or the work tool in the carry position with the machine in neutral Release the parking brake Apply the service brakes and put the engine at low idle Ensure that The area around the machine is clear of personnel Shift the transmission to second gear forward and slowly release the service brakes Moderately increase the engine speed to high idle Shift the transmission to neutral Turn the ignition to the OFF position Allow the machine to coast While the machine is in motion turn the machine to the left and to the right If the machine responds to the steering input the supplemental steering system is operating Stop the machine with the service brakes Apply the parking brake The machine can then be return
71. nderstanding the S O S Oil Analysis Tests Procedure for Changing the Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Open the engine hood 2 The drain plug is located on the left side of the engine oil pan toward the rear of the machine Open the oil drain valve and allow the oil to drain into a suitable container Close the drain valve SEBU7889 16 163 Maintenance Section Engine Oil and Filter Change Illustration 210 g01125581 3 Use a strap type wrench to remove the engine oil filter from the right side of the engine Inspect the oil filter 4 Clean the filter mounting base Make sure that all of the used gasket has been completely removed Illustration 211 g00101318 5 Apply a thin coat of oil to the seal on the new engine oil filter Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position of
72. nge interval to 250 hours or use an S O S Services oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine 162 Maintenance Section Engine Oil and Filter Change SEBU7889 16 The normal engine oil change interval is listed in this Operation and Maintenance Manual Maintenance Interval Schedule Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals Also refer to Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Poor maintenance of air filters or of fuel filters requires reduced oil change intervals Consult your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Cat oil filters are recommended Program A Verification for an Oil Change Interval of 500 Hours This program consists of three oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity
73. nt Fill the crankcase with new oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 10 Clean the end of the male coupler Clean the cap that covers the male coupler and install the cap 11 Start the engine and allow the oil to warm Check the machine for oil leaks 12 Check the engine oil level Reference Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure 13 Stop the engine Close the engine access door and the engine hood 102097831 Engine Oil Level Check SMCS Code 1000 535 FLV NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage SEBU7889 16 161 Maintenance Section Engine Oil Sample Obtain Illustration 208 g00753678 1 Stop the engine Open the access door on the right side of the machine 2 Remove dipstick 2 and wipe off the dipstick with a clean cloth Then reinsert the dipstick and remove the dipstick again This will give a more accurate measurement of the oil level 3 Maintain the engine oil between the FULL mark and the ADD mark on dipstick 2 If necessary remove filler cap 1 and add oil 4 Close the engine access door Engine Oil Sample Obtain SMCS Code 1348 008 7542 NOTICE Care mus
74. ntaining 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 SEBU7889 16 173 Maintenance Section Hydraulic System Oil Change OFT 0l Illustration 228 g01121627 The hydraulic filters are located on the right side of the machine under the platform There are two hydraulic oil filters Each filter must be replaced during this procedure 1 Use a strap type wrench to remove each filter element Dispose of the used filter elements properly 2 Clean the filter mounting bases Make sure that all of the used seals are completely removed Illustration 229 g00101318 3 Apply a thin coat of clean hydraulic oil to the seals on the new filters Install each new hydraulic filter hand tight until the seals of the hydraulic oil filters contact each base Note the position of the index marks on each filter in relation to a fixed point on each filter base Note There are rotation index marks on each hydraulic oil filter that are spaced 90 degrees or 1 4 or a turn away from each other When you tighten the hydraulic oil filters use the rotation index marks as a guide 4 Tighten each filter according to the instruct
75. o ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates od FWD OFT 0l 7 Illustration 271 g01123392 The transmission oil filter is located on the right side of the machine under the platform 1 Operate the machine in order to warm the oil Park the machine on level ground Lower the bucket to the ground and apply slight downward pressure 2 Engage the parking brake and stop the engine 3 Open the access panel 4 Remove the filter housing drain plug and allow the oil to drain into a suitable container SEBU7889 16 193 Maintenance Section Transmission Oil Level Check 5 Use a strap type wrench to remove the filter housing 6 Remove the used filter element Dispose of the used filter element properly 7 Clean the filter housing and the filter housing base with a clean nonflammable solvent 8 Inspect the filter housing seal Replace the seal i
76. o the seal on the new filter Install a new fuel filter hand tight until the seal of the fuel filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the fuel filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the fuel filter use the rotation index marks as a guide 7 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 8 Prime the fuel system Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure 9 Close the engine hood 102875824 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 Z2 1273 070 STR Stop the engine Open the access door on the left side of the machine SS NR Illustration 222 g01431279 1 Cap 2 Strainer 3 Fuel Tank 1 Remove the fuel tank cap and the strainer from the fuel tank 2 Wash the strainer and the fuel tank cap in a clean nonflammable solvent 3 Install the strainer into the filler
77. opening 4 Inspect the seal for damage Replace the cap if the seal is damaged Install the fuel tank cap Illustration 223 g01431287 Fuel Cap Boot 170 Maintenance Section Fuel Tank Water and Sediment Drain SEBU7889 16 5 Inspect the fuel cap boot if equipped If the fuel cap boot is damaged replace the fuel cap boot If your machine does not have a fuel cap boot contact your Caterpillar dealer for information about the fuel cap boot 6 Wash the fuel cap boot in a clean nonflammable solvent 7 Install the fuel cap boot and the fuel tank cap 103657251 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar 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 eee as 7 ae sA m T __ ay Illustration 224 g01962163 The drain valve is under the fuel tank at the rear of the machine 1 Loosen the bolt 2 on the side of the drain 2 Allow the water and the se
78. ours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine SEBU7889 16 159 Maintenance Section Engine Oil High Speed and Oil Filter Change If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type in the Lubricant Viscosities for Ambient Temperatures Table in this Operation and Maintenance Manual Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each increment is an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above References Reference Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Reference Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Re
79. ousing Note If you are only replacing the water temperature regulator drain the coolant to a level that is below the water temperature regulator housing Reference Refer to Disassembly and Assembly C7 Engines for Caterpillar Built Machines for the correct procedure for replacing the water temperature regulator 102765211 Differential and Final Drive Oil Change SMCS Code 3278 044 4011 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar 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 Illustration 185 g00989676 Machine without axle oil cooler g00630605 Illustration 186 Machine with axle oil cooler Note The axle housings are equipped with ecology drain valves 152 Maintenance Section Differential and Final Drive Oil Change SEBU7889 16 1 Remove the drain plugs Attach a hose to a suitable drain adapter Install a drain adapter into each drain valve Allow the oil to drain into a suitable container 2 Re
80. pipe and the air cleaner housing Replace the gasket if the gasket is damaged 5 Uncover the air inlet opening Install a new secondary element 6 Install a clean primary element and the cover for the air cleaner housing 7 Close the access door 8 Repeat the procedure for the other air cleaner 158 Maintenance Section Engine Crankcase Breather Clean SEBU7889 16 102219769 Engine Crankcase Breather Clean SMCS Code 1317 070 1 Open the engine hood The engine crankcase breather is located on the right side of the machine Illustration 204 g01120363 2 The engine crankcase breather is located on the right side of the engine Loosen the outlet hose clamp and remove the outlet hose from the breather 3 Remove the bolt that fastens the breather to the engine 4 Check the condition of the seal on the breather cover Replace the seal if the seal is damaged 5 Wash the breather cover and the element in a clean nonflammable solvent 6 Shake the element dry or use pressure air to dry the element 7 Inspect the outlet hose for damage Replace the hose if necessary 8 Install the breather 9 Install the outlet hose and the hose clamp 10 Close the engine hood Engine Oil High Speed and Oil Filter Change If Equipped SMCS Code 1318 510 HZ Selection of the Oil Change Interval NOTICE A 500 hour engine
81. pling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102219546 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Illustration 183 g01120318 The sampling valve for the cooling system is located on the upper coolant tube between the water pump and the radiator Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper
82. pped Maintain the oil level above the ADD COLD mark on sight gauge 2 If necessary remove filler cap 1 slowly and add oil 102223893 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 008 7542 V s a D im 1 P H Illustration 236 g01122430 Obtain a sample of the hydraulic oil from the hydraulic oil sampling valve The sampling valve is located on the hydraulic oil filter base beneath the cab on the right side of the machine Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of hydraulic oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of hydraulic oil 178 Maintenance Section Hydraulic Tank Breaker Relief Valve Clean SEBU7889 16 102223896 Hydraulic Tank Breaker Relief Valve Clean SMCS Code 5118 070 Illustration 237 g01125171 The hydraulic tank breaker relief valve is located on the top of the hydraulic tank behind the cab of the machine 1 Press the button on the top of the hydraulic breaker in order to relieve the pressure in the hydraulic tank Remove the hydraulic tank breaker relief valve 2 Clean the hydraulic tank breaker relief valve in a clean nonflammable solvent Shake the breaker rel
83. r Filter Primary Element Clean Replace Illustration 197 g00291135 Apply lubricant through one fitting on each universal joint There are a total of five fittings 102491186 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY Burn Hazard Engine components may be hot dur ing and after machine operation Hot components can cause serious personal in jury Do not contact hot components with bare skin To avoid personal injury always wear eye and face protection when using pressurized air 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 must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine component
84. re information on the Automatic TWIN Greasing System A pressure hazard is present Severe personal in jury or death can result from removing hoses or fittings that are under pressure Relieve the pres sure in the system before you remove hoses or fittings Illustration 143 g01068678 Grease reservoir 1 is located near the rear fender on the right side of the machine Filling the Reservoir 1 Remove the dust cap 2 from the grease reservoir 1 2 Clean the filler tube assembly 3 and the coupling on the filler assembly 3 Install the filler assembly onto the filler tube assembly 3 4 Fill the grease reservoir 1 with grease to the maximum level which is indicated on the grease reservoir 1 Reference For the correct type of grease refer to Operation and Maintenance Manual Lubricant Viscosities 5 Remove the filler assembly and install the dust cap 2 SEBU7889 16 133 Maintenance Section Axle Oscillation Bearings Lubricate 102399602 Axle Oscillation Bearings Lubricate SMCS Code 3268 086 BD 3278 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Illustration 144 g01119922 Open the access panel on the right side of the machine in front of the steps
85. rect procedure 192 Maintenance Section Transmission Oil Filter Replace SEBU7889 16 anes 9 N Pa 10 jja n U ha 12 4 a a no Illustration 270 Typical example Q g00766254 12 The filler tube for the transmission is located near the center hitch Remove the filler cap 8 and fill the transmission with oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 13 Remove the transmission breather from the top of the transfer case Wash the breather in a clean nonflammable solvent Install the breather 14 Start the engine Slowly operate the transmission controls in order to circulate the oil 15 Move the transmission control to the NEUTRAL position Stop the engine Inspect the transmission for leaks 16 Check the transmission oil level The sight gauge 9 is located near the filler tube The transmission oil should be at the mark 10 if the engine is off The oil should be between marks 11 and 12 when the engine is idling Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure i02225200 Transmission Oil Filter Replace SMCS Code 3004 510 3067 510 NOTICE Care must be taken t
86. s 0 15 Amperes 10 Beacon and Heated Mirrors 10 Amperes 11 Turn Signal Flasher Front Flood Relays and Rear Flood Relays n se 10 Amperes 12 Machine Security System and Product LAA K E cect Shatyieeet teas secudtiedsteue ends 10 Amperes 13 LH Indicator Display and RH Indicator Display erraia a e 10 Amperes 14 Tilt Position Sensor and Lift Position DENSON Maa adorador ne aa anainn 10 Amperes 15 Lever Sensors and LH Brake Pedal SONSOF i aie ai aa a 10 Amperes 16 Air Seat and Heated Seat 10 Amperes 17 EMS Quad Gauge Tachometer and Backlights ccceeeseeeeeeesteeeeeeenees 10 Amperes 18 Wiper and Washer for the Front and the Rear WINCOWS 22 cecceceeeeeeeeeeeeesetaeees 10 Amperes 19 Payload Control System PCS 10 Amperes 20 Voltage Converter for Radio 10 Amperes 21 Voltage Converter Memory Attachment iseis 10 Amperes 22 Engine ECM siinsesse 15 Amperes 23 Transmission ECM n se 15 Amperes 24 Implement ECM e 15 Amperes 25 ECAP and Center Dash Indicator Display peie tchhencaderttsadticesecancieesh al 10 Amperes 26 LH Tail and Clearance Lights 10 Amperes 27 Hood Actuator cceeeeeeeeeeee 10 Amperes 28 Stop Lamps eceeeeeeeeteeeees 10 Amperes 29 TOMI 2 rsrs ered eed ts et eee 10 Amperes 30 Voltage Converter Memory Standard anra 10 Amperes 31 K
87. s XX Illustration 265 g01105595 Remote location of the grease fittings for the rod ends Wipe off the fittings before any lubricant is applied The rod end of the steering cylinders are lubricated by using standard grease fittings 3 The head ends of the steering cylinders are lubricated by using remote grease fittings 4 that are located on the right side of the machine in front of the steps 190 Maintenance Section SEBU7889 16 Steering Pilot Oil Screen Command Control Steering Clean Replace 101467209 Steering Pilot Oil Screen Command Control Steering Clean Replace SMCS Code 4304 070 Z3 4304 510 Z3 Personal injury can result from working with cleaning solvent Because of the volatile nature of many cleaning solvents extreme caution must be exercised when using them If unsure about a particular cleaning fluid refer to the manufacturer s instruc tions and directions Always wear protective clothing and eye protec tion when working with cleaning solvents Illustration 266 g00765737 The screen group for the steering oil is located in the articulation joint near the steering neutralizer valve on the right side 1 Disconnect two hoses 2 Remove two connectors 2 from screen group 3 3 Use an allen wrench to remove one screen from each opening of the screen group 4 Wash the screens in a clean nonfla
88. s NOTICE Service the air filter only with the engine stopped En gine damage could result 1 Open the engine compartment The air filter is located on the right side of the machine Illustration 198 g00845360 2 Loosen the cover latches and remove the air cleaner cover Note The latches for the air cleaner housing may snap open when you release the latches 156 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU7889 16 Illustration 199 g00101415 3 Remove the primary filter element from the air cleaner housing In order to remove the engine air filter primary element pull the element outward While you pull the element outward rock the element Use Steps 4 through 6 in order to clean the primary element 4 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 Direct the air along the length inside of the filter This will help prevent damage to the paper pleats Note Do not aim the stream of air directly at the primary element Dirt could be forced further into the pleats Use Steps 7 through 10 in order to inspect the primary element Illustration 200 g00328468 5 If the primary element is not damaged clean the primary element Pressurized air can be used to clean a primary element that has not been cleaned more than two
89. s engaged If the machine begins to move compare the engine rpm to the engine rpm of a prior test This will indicate the amount of system deterioration 1 Start the engine Raise the implement slightly Engage the parking brake 2 Move the transmission control to THIRD SPEED FORWARD Make sure that the autoshift control is in the OFF position The parking brake indicator light should come on 3 Gradually increase the engine speed to high idle The machine should not move 4 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation 103657238 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges Illustration 152 g00764365 1 Bolts for Cutting Edge 2 Cutting Edge Check the cutting edges and the end bits for wear and for damage Use the following procedure to service the cutting edges and the end bits 1 Raise the bucket and place blocking under the bucket 2 Lower the bucket onto the blocking Stop the engine 3 Remove bolts 1 cutting edge 2 and the end bits 4 Clean all contact surfaces 5
90. sampling of the coolant Submit the sample for Level 2 analysis Reference For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102219561 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age SEBU7889 16 151 Maintenance Section Differential and Final Drive Oil Change NOTICE Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a ther mostat installed If the thermostat is installed wrong it will cause the engine to overheat Inspect gaskets before assembly and replace if worn or damaged Illustration 184 g00890574 Replace the water temperature regulator in order to reduce the chance of problems with the cooling system The water temperature regulator is located on the left side of the machine near the alternator Replace the water temperature regulator and replace the seals while the cooling system is completely drained or while the coolant is drained to a level that is below the water temperature regulator h
91. sher Reservoir Fill l a 194 Window Wiper Inspect Replace 000 194 Every 10 Service Hours or Daily Backup Alarm Test 2 ccceeeeeeeeeeeeteeeeenees 133 Cooling System Coolant Level Check 149 Engine Oil Level Check 160 Fuel System Primary Filter Water Separator Drain 22c eile saci nite ies a G ee tice 166 Hydraulic System Oil Level Check sassen 177 Quick Coupler Check 2 eseeeeeeeeeeeeeeeeeeees 183 Seat Belt Inspect 20 0 cece eeeeeeeeeeceeeeeeeeeees 186 Transmission Oil Level Check 193 Windows Clean 2 ccceececeeeeeeeeeteeesenneeaeees 194 Every 50 Service Hours or Weekly Bucket Lower Pivot Bearings Lubricate 141 Cab Air Filter Clean Replace ccceeee 144 Fuel Tank Water and Sediment Drain 170 Tire Inflation CHECK cccccceeeeeeeeeeeeeeneeeaeees 190 Every 100 Service Hours or 2 Weeks Axle Oscillation Bearings Lubricate 133 Bucket Linkage and Loader Cylinder Bearings Lubricate 3 2 2 2 abe aiid ities biz 140 Bucket Upper Pivot Bearings Lubricate 144 Logging Fork Clamp Lubricate 0 0 0 178 Steering Cylinder Bearings Lubricate 189 Initial 250 Service Hours Engine Valve Lash Check ceeeeeeeeeeeeeees 164 Transmission Oil Filter Replace 06 192 Every 250 Service Hours
92. sustaining a machine at a specific engine rpm varies from one machine to another machine The variations include differences in the engine setting the power train efficiency the brake holding ability etc Service Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake 1 Start the engine Raise the implement slightly Apply the service brake Release the parking brake 2 Move the transmission control to THIRD SPEED FORWARD while the service brakes are applied Make sure that the autoshift control is in the OFF position 3 Gradually increase the engine speed to high idle The machine should not move 138 Maintenance Section Bucket Cutting Edges Inspect Replace SEBU7889 16 4 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Engage the parking brake Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation Parking Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move reduce the engine speed immediately and apply the service brake pedal This test is performed when the parking brake i
93. t beneath the hydraulic tank filler cap Wash the filler cap and the strainer in a clean nonflammable solvent Install the strainer 5 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary Pom a eB o J y 8 cD i a oJ BI 4 a on Be o 8 mH C g Illustration 232 g01108775 6 The hydraulic tank has a remote drain plug which is located on the right side of the machine under the platform Remove drain plug 4 Wash the drain plug in a clean nonflammable solvent 7 The hydraulic tank is equipped with an ecology drain valve Attach a hose to a suitable drain adapter Install the adapter in the drain valve and allow the oil to drain into a suitable container 8 After you have drained the oil remove the adapter from the drain opening NOTICE Never start the engine while the hydraulic oil tank is being drained or while the hydraulic oil tank is empty Excessive wear and damage to the hydraulic compo nents can occur 9 Close the drain valve Install the drain plug 10 Change the hydraulic oil filter Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Replace for the correct procedure 11 Fill the hydraulic tank with clean oil Make sure
94. t be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes before obtaining the oil sample This will thoroughly mix the engine oil for a more accurate sample 2 Open the engine hood Illustration 209 g01121355 3 Use the sampling valve in order to obtain a sample of engine oil 4 Close the engine hood Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis and Special Publication PEHP6001 How To Take A Good Oil Sample i03652260 Engine Oil and Filter Change SMCS Code 1318 510 Selection of the Oil Change Interval NOTICE A 500 hour engine oil change interval is available pro vided that the operating conditions and recommend ed multigrade oil types are met When these require ments are not met shorten the oil cha
95. 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 or a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 6 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 Illustration 212 g01125595 7 Remove oil filler cap 1 on the right side of the engine Fill the crankcase with new oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 8 Clean the oil filler cap and install t
96. the machine Refer to Service Manual SENR5664 Refrigerant Accumulator Remove and Install for the replacement procedure of accumulator 1 Refer to Service Manual SENR5664 In Line Refrigerant Dryer Remove and Install for the replacement procedure of refrigerant dryer 2 Note When you operate the machine in a climate with high humidity replace the in line refrigerant dryer after every 1000 service hours or 6 months 102223929 Ride Control Accumulator Check SMCS Code 5077 535 R6 The ride control accumulator reduces the pitching of the machine If the machine seems to be bouncing excessively check the charge in the ride control accumulator Note Special tools and equipment are required to test the accumulator Reference For more information refer to Testing and Adjusting RENR8878 950H Wheel Loader 962H Wheel Loader and IT62H Integrated Toolcarrier Electrohydraulic System Ride Control Accumulator Test and Charge or consult your Caterpillar dealer Roading Fender Hinges Lubricate If Equipped SMCS Code 7252 086 RNG Wipe off the fitting before any lubricant is applied Illustration 255 g01963400 Open the roading fender Apply lubricant through one fitting on the hinge There is one hinge on each side of the machine 101457460 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 Illustration 256 g00762107 Inspect the

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