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MAINTENANCE INTERVALS - Safety

1. Illustration 133 g01093541 The sight gauge is located on the left side of the machine The sight gauge can be viewed through the vents on the left side of the machine 1 Maintain the coolant level within the sight gauge SEBU7 808 11 Illustration 134 g01093449 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 2 If the coolant level is low slowly remove the cooling system pressure cap on the top left side of the machine and add the required coolant in order to maintain the coolant level within the sight gauge Note If it is necessary to add coolant daily check for leaks 3 Inspect the cooling system pressure cap and the cap seal Clean the cap and install the cap If the cap is damaged install a new cooling system pressure cap 4 Inspect the radiator core for debris Clean the radiator core if necessary Reference Refer to Operation and Maintenance Manual Radiator Core Clean for more information 117 Maintenance Section Cooling System Coolant Sample Level 1
2. Illustration 252 g01095817 The sampling valve for the transmission oil is located on the transmission oil filter base on the left side of the machine SEBU7 808 11 Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining an oil sample from the transmission housing Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining an oil sample from the transmission housing 101394768 Turbocharger Inspect SMCS Code 1052 040 If the turbocharger fails during engine operation severe damage to the turbocharger compressor wheel and to the entire engine can result Turbocharger bearing failures can cause large quantities of oil to enter the intake system and the exhaust system Loss of engine oil can result in serious engine damage Do not continue to operate the engine when a turbocharger bearing failure is accompanied by a significant loss of engine performance Engine smoke and speeding up of the engine with no load are characteristics of a loss of engine performance Reference For more information about inspecting the turbocharger refer to the appropriate Service Manual for your machine s engine 02161333 Window Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window wash
3. Illustration 106 g01093110 Open the battery compartment on the right rear side of the machine Over time the vibration of an operating machine can cause the battery hold downs to loosen To help to prevent loose batteries and the possibility of loose cable connections tighten the eight nuts on the two hold downs to a torque of 2 50 0 25 N m 22 2 lb in 106 Maintenance Section Battery or Battery Cable Inspect Replace i 03657099 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 Ay WARNING Personal injury may occur from failure to properly service the batteries Batteries give off flammable fumes that can ex plode Electrolyte is an acid and can cause per sonal injury if it contacts the skin or eyes Prevent sparks near the batteries Sparks could cause vapors to explode Do not allow jumper ca ble ends to contact each other or the engine Im proper jumper cable connections can cause an ex plosion Always wear protective glasses when working with batteries 1 Turn the engine start switch key OFF Turn all of the switches OFF 2 Turn the battery disconnect switch OFF Remove the key 3 Disconnect the negative battery cable from the disconnect switch Note Do not allow the disconnected battery cable to contact the disconnect switch 4 Disconnect the negative battery cable at the battery 5 Disconnect the positive battery cable at t
4. PAOA WaT P Illustration 230 g01094991 On each side of the machine the radiator core can be accessed through the vents and through the narrow access doors rF io yt We a gia On ae ies CFT Pit Te ee EAMES rt UN N RAA ee EON lt ORBAZE OE POOR AZO Fig SOONG AEE INA WACA A pf Lt ae Toh tl al dd DAA AA T EATA awa 4 POE ANL g00100062 Illustration 231 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator core However the use of compressed air is preferred Refer to Special Publication SEBD0518 Know Your Cooling System for the complete procedure for cleaning the radiator core SEBU7808 11 i02728869 Refrigerant Receiver Dryer Replace SMCS Code 7322 510 n a awl z N Illustration 232 g01095018 The refrigerant dryer is located behind the cab Open the access panel on the operator platform in order to access the dryer Before any service work is performed on the air conditioning system refer to the Service Manual SENR5664 Machine Preparation for Troubleshooting section in Testing and Adjusting 1 Stop the engine for five minutes in order to equalize the pressure in the air conditioning system SEBU7 808 11 Illustration 233 g00654556 Typical In Line Dryer 1 Inlet hose with air conditioner quick disconnects 2 Outlet hose with air conditioner quick disconne
5. o Sf z 5 K z M E 15A E TA E TOA bros E td e af TA oe 20A e 20A Illustration 196 g01353212 Typical example Open 10 amp Open 15 amp Open 20 amp Voltage Converter 2 10 Amp Side Receiver Mast 10 Amp Input Output 10 Amp Horn 10 amp Stairway Access Light 10 amp OYO MOVDODO O MOODODADPDAOAO BHHWH Oe 143 Maintenance Section Fuses Replace Voltage Converter 15 Amp Product Link 10 amp Rotating Beacon 10 amp Headlights 15 amp Rear Work Lights 15 amp Front Work Lights 15 amp Front Work Lights 2 15 amp Headlights 2 15 amp Payload Control System 10 amp Electrical Monitoring System 10 amp Power train Electronic Control Module ECM 10 amp Implement Control 10 amp Electrical Power Accessories 10 amp Side Receiver Mast 10 amp 144 Maintenance Section High Intensity Discharge Lamp HID Replace Rear Monitor Vision 10 amp Voltage Converter 10 amp Autolube System 10 amp Window Wipers 10 amp Seat 15 amp Blower Fan 20 amp OOAOAE 102245859 High Intensity Discharge Lamp HID Replace If Equipped SMCS Code 1434 510 Ay WARNING HID lamps operate at very high voltages To avoid electrical shock and personal injury disconnect power before servicing HID lamps Ay WARNING HID bulb
6. SEBU7808 11 04164902 Automatic Lubrication System Components Check If Equipped SMCS Code 7540 535 Ay WARNING 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 Reference Before any service work is performed on the lubrication system refer to Special Instructions REHS1394 or consult your Cat dealer Autolube systems need to be adjusted before being put into use to ensure each joint gets the appropriate amount of grease Different applications require frequency volume and proportioning adjustments from the recommended or factory settings SEBU7 808 11 E J ja EE T Tam l 101 Maintenance Section Automatic Lubrication System Components Check wE H Illustration 95 99193203 A A Pin F F Pin K K Pin B B Pin G G Pin L Steering Cylinder Pins C C Pin H Pin for Upper Articulation Joint X Trunnions E E Pin J Pin for Lower Articulation Joint Y Y Pin 1 Remove any buildup of grease Check that each Table 13 pin joint is receiving a fresh supply of grease Pins Qty Injectors Settings Turns Reference If a fresh supply of grease is not A 0 present refer to Special Instructions REHS1394 B 2 8 for system troubleshooting pr
7. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpil All Rights alana CATERPI LLAR A OB nS EBU7808 11 A R February 2011 Operation and Maintenance Manual 988 H Wheel Loader BXY1 3999 988H SEBU7808 11 04147189 Maintenance Interval Schedule SMCS Code 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance All adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging are included Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals Note The aftertreatment system can be expected to function properly for the useful life of the engine emissions durability period as defined by regulation All prescribed maintenance requirements must be followed Note Before each consecutive interval is performed all maintenan
8. 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 133 Maintenance Section Engine Oil and Filter Change 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 PEDP 036 S O S Fluid Analysis Reference Special Publication PEDP 7076 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 b
9. 1 and wipe the dipstick with a clean cloth Then insert the dipstick and remove the dipstick again This will ensure a more accurate measurement of the engine oil level T Illustration 171 g00999790 3 When the engine is stopped maintain the oil level within crosshatched region A of the dipstick This region of the dipstick is marked Safe Starting Range 4 If necessary remove oil filler cap 2 and add oil Clean the oil filler cap and install the oil filler cap 5 Close the engine access door SEBU7 808 11 Engine Oil Sample Obtain SMCS Code 1348 008 7542 i i m U f i os 7 a Z et rt ep a a o_o E i Illustration 172 g01001331 The sampling valve for the engine oil is located on the engine oil filter base on the right side of the engine compartment 03711621 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 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 Mai
10. Install the cooling system pressure cap Stop the engine 102156106 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 116 Maintenance Section Cooling System Coolant Level Check NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life When a Caterpillar Extended Life Coolant ELC is used an Extender must be add
11. Obtain 02279462 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 Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Level 1 results may indicate a need for Level 2 Analysis Obtain the sample of the coolant as close as possible
12. ol lo g01002123 Illustration 185 Type 1 2 The water separator is located on the bottom of the primary fuel filter Open the drain valve on the water separator bowl Allow the water and the fuel to drain into a suitable container 3 Use a strap type wrench to remove the filter from the filter mounting base 4 Remove the water separator bowl from the filter element Clean the water separator bowl and the O ring groove Note The water separator bowl is reusable Do not discard the water separator bowl Cole Ae Aa O Illustration 186 g01482573 Type 2 a The steel fuel filter Type 2 is not reusable 5 Inspect the O ring seal in the water separator bowl for damage Replace the O ring seal if necessary 6 Lubricate the O ring seal with clean diesel fuel or with engine oil Place the O ring seal in the water separator bowl 7 Install the water separator bowl onto the new filter element by hand Do not use tools to tighten the water separator bowl SEBU7 808 11 Illustration 187 g00101318 8 Apply a thin coat of oil to the seal on the new filter Install the new 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 fuel filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the fuel filt
13. seal if necessary Install seal 5 and cover assembly 3 7 Replace the transmission oil filter Reference Refer to Operation and Maintenance Manual Transmission Oil Filter Replace for the correct procedure 8 Clean the transmission drain plug Install the transmission drain plug 9 Fill the transmission with oil Reference Refer to Operation and Maintenance Manual Capacities Refill for the proper amount of oil 10 Clean the filler cap and install the filler cap 162 Maintenance Section Transmission Oil Filter Replace Illustration 245 g00935383 Transmission Breather 11 Open the access door in the platform behind the cab Remove the transmission breather 12 Wash the breather in a clean nonflammable solvent Allow the breather to air dry or use air pressure to dry the breather Install the breather 13 Start the engine and run the engine at low idle 14 Slowly operate the transmission control in order to circulate the oil Return the transmission to neutral 15 Stop the engine Inspect the entire transmission for leaks Illustration 246 99093091 16 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure SEBU7808 11 i02595697 Transmission Oil Filter Replace SMCS Code 3067 510 NOTICE Care must be taken to ensure that fluids are contained during performance
14. the supplemental steering system is not operating Stop the machine immediately Repair the supplemental steering system before returning the machine to service 159 Maintenance Section Secondary Steering Test 101061080 Starting Motor Inspect SMCS Code 1453 040 Caterpillar recommends a scheduled inspection of the starting system Check the starting motor and the battery charger for proper operation Check for loose electrical connections Reference For the complete procedure for inspecting the starting system refer to the Systems Operation Testing and Adjusting manual for your machine s engine 102168764 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD Wipe off the fittings before any lubricant is applied There is a total of four fittings gt JIVA Nod errs H DE lerik ay si ka g a a A Illustration 238 g01098863 Apply lubricant through the fitting on the head end of each steering cylinder 160 Maintenance Section Tire Inflation Check Illustration 239 g01098864 The bearing on the rod end of each steering cylinder is lubricated through two remote fittings on the inside of the right front loader frame Apply lubricant through fitting 1 for the right steering cylinder Apply lubricant through fitting 2 for the left steering cylinder 02305841 Tire Inflation Check SMCS Code 4203 535 Al N N Illustration 240 g
15. 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 118 Maintenance Section Cooling System Coolant Sample Level 2 Obtain 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 e Keep the lids on empty sampling 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 e Never collect samples from expansion bottles e Never collect samples from the drain for a system rS Illustration 135 g01093449 Slowly remove the cooling system pressure cap Open the left side engine access door Illustration 136 g01120387 Remove the cap over the coolant sample port SEBU7808 11 Attach a hose to a couple Install the threaded end of the coupling into the drain valve in order to unseat the internal drain valve Close the engine access door and return the
16. 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 131 Maintenance Section Engine Oil Level Check 8 Clean the end of the male coupler for the high speed arrangement Connect an oil pump to the male coupler for the high speed arrangement Fill the crankcase with oil Reference Refer to Operation and Maintenance Manual Capacities Refill for the proper amount of oil 9 Clean the end of the male coupler for the high speed arrangement Clean the cap that covers the male coupler and install the cap 10 Start the engine and allow the oil to circulate Check for leaks 11 Check the engine oil level Reference Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure 12 Close the engine access doors 01923584 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 Illustration 169 g00841382 1 Open the engine access door on the left side of the machine 132 Maintenance Section Engine Oil Sample Obtain f p Oa aia Fiy g01001056 Illustration 170 2 Remove engine oil dipstick
17. System Coolant Sample Level 2 DLAT Ceira wie ied tans den A A 118 Crankshaft Vibration Damper Inspect 120 Differential and Final Drive Oil Change 120 Electronic Unit Injector Inspect Adjust 124 Engine Mounts Inspect cccceeeeeeeeeeeeeeeees 129 Engine Valve Lash Check ccceccceeeeeeeeeees 135 Engine Valve Rotators Inspect eeeee 135 Hydraulic System Oil Change c 0eeeee 144 Hydraulic Tank Breaker Relief Valve Clean 149 Lift Cylinder Pin Oil Level Check 151 Loader Boom Pin Oil Change cccseeeees 152 Refrigerant Receiver Dryer Replace 156 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccceccceecsssesseeeeseeseeens 158 Every 4000 Service Hours or 2 Years Hydraulic System Oil Change cc0eeeee 144 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 115 Lift Cylinder Pin Oil Change ccccceeeeeee 149 SEBU7 808 11 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change Cooling System Water Temperature Regulator Replace SEBU7808 11 02154861 Alternator Inspect SMCS Code 1405 040 Illustration 92 g01092657 The alternator is located on the right side of the
18. drain valve in order to unseat the drain valve Allow the hydraulic oil to drain into a suitable container 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 8 Remove the pipe nipple in order to close the drain valve Install the hydraulic tank drain plug 9 Change the hydraulic oil filter Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Replace for the correct procedure 10 Fill the hydraulic tank with clean oil Make sure that the oil level is at the FULL mark on sight gauge 4 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 11 Install filler cap 2 Note The steering pump and the implement pump must be primed before the engine is started This is necessary in order to ensure proper operation of the pumps Filling the Cases of the Implement Pump and the Steering Pump The cases of the steering pump and the implement pump must be filled with oil before the engine is started This is necessary in order to ensure proper operation of the pumps 1 Open the access doors that are located behind the operator compartment SEBU7 808 11 147 Maintenance Section Hydraulic System Oil Filter Steering and Implement Pilo
19. machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation 108 Maintenance Section Bucket Cutting Edges Inspect Replace Parking Brake Holding Ability Test Ay WARNING Personal injury can result if the machine moves while testing If the machine begins to move reduce the engine speed immediately and apply the service brake pedal This test is performed when the parking brake is engaged If the machine begins to move compare the engine rpm to the engine rpm of a prior test This will indicate the amount of system deterioration 1 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 01548255 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Ay WARNING Personal injury or death can result if the bu
20. on the differential and final drives Note This procedure requires a sample for each final drive and each differential There will be a total of three samples per axle and six samples for this procedure in total Make sure that you properly record the location of each oil sample Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample 103947685 Drive Shaft Spline Center Lubricate SMCS Code 3253 086 3253 086 SN 3253 NOTICE To prevent damage to the seal fully articulate the ma chine to the right or to the left before lubricating the spline 124 Maintenance Section Drive Shaft Support Bearing Lubricate Illustration 149 g02157619 Wipe all fittings before applying lubricant Apply lubricant through one fitting on the drive shaft spline 03715441 Drive Shaft Support Bearing Lubricate SMCS Code 3267 086 BD Wipe off the fitting before any lubricant is applied L Illustration 150 g01093575 Center Drive Shaft The fitting for the drive shaft support bearing is located toward the front of the articulation joint Apply lubricant through one or two fittings SEBU7808 11 i02061807 Electronic Unit Injector Inspect Adjust SMCS Code 1251 025 1251 040 1290 025 1290 040 Ay WARNING The Electronic Control module pr
21. replace if worn or damaged 3 Install a new gasket on the regulator housing Install a new water temperature regulator 4 Install the bolts and the cover 5 Tighten the hose clamps 6 Refill the cooling system 101923122 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 g01000821 Illustration 140 The crankshaft vibration damper is located at the rear end of the engine compartment Damage to the vibration damper or failure of the vibration damper will increase torsional vibrations These vibrations will result in damage to the crankshaft and to other engine components A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range SEBU7 808 11 Caterpillar recommends replacing the vibration damper for any of the following reasons e The engine has had a failure because of a broken crankshaft e The S O S oil analysis detected a worn crankshaft front bearing e The S O S oil analysis detected a large amount of gear train wear that is not caused by a lack of oil The vibration damper can be used again if none of the above conditions are found and the damper is not damaged Inspect the vibration damper for dents in the outer case Dents in the outer case may cause failure of the damper Install a new vibration damper if the damper is damaged Reference Refer to the Disassembly and Assembly manual for your machine s engine for the necessary repla
22. 01 040 SQ 6001 510 SQ 6102 040 SQ 6102 510 SQ Illustration 110 g01000783 Note Do not use any lubricants on any part of this control The moving parts of this control are self lubricated Use the following procedure in order to clean the control levers 1 Disconnect the wiring from the controls 2 Disassemble the controls Wash the parts with warm soapy water Ja oo Rinse the parts thoroughly with water 5 Dry the parts thoroughly 6 Reassemble the controls 7 Reconnect the wiring to the controls g00554961 Illustration 111 Check for bucket stops that are damaged or missing Replace the bucket stops if necessary Note Recalibrate the tilt position sensor after you recalibrate the bucket stops Consult your Caterpillar dealer for more information on calibrating the tilt position sensor 03574841 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Personal injury or death can result from the bucket falling Block the bucket before changing bucket tips Note In order to maximize the life of the bucket tip and the penetration of the bucket tip the bucket tip can be rotated 110 SEBU7 808 11 Maintenance Section Bucket Tips Inspect Replace 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
23. 01160201 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 SEBU7 808 11 102229100 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 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 in order to warm the transmission oil 2 Park the machine on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake Stop the engine Illustration 241 g01095645 3 There is an access hole in the transmission guard for the transmission drain plug Note The drain valve is an ecology drain valve 4 Remove the transmission drain plug from the bottom of the transfer gear case Att
24. 03 g00935879 1 Maintain the hydraulic oil level within the designated range 3 2 If necessary press hydraulic tank breaker relief valve 1 in order to relieve any tank pressure Then remove hydraulic tank filler cap 2 and add hydraulic oil 3 If hydraulic oil was added clean the hydraulic tank filler cap and install the hydraulic tank filler cap 02156928 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 008 7542 N Illustration 204 g0 1093962 Obtain a sample of the hydraulic oil from the hydraulic oil sampling valve The sampling valve is located on the hydraulic oil filter base on the front of the hydraulic tank 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 149 Maintenance Section Hydraulic System Oil Sample Obtain 101923846 Hydraulic Tank Breaker Relief Valve Clean SMCS Code 5118 070 g01001206 Illustration 205 The hydraulic tank breaker relief valve is located on the side of the hydraulic tank 1 To relieve the pressure in the hydraulic tank press the button on the top of the hydraulic breaker Remove the hydraulic tank breaker relief valve 2 Clean the hydraulic tank breaker relief valve in a clean nonflammable solvent Shake the r
25. 0378 Axle Oil Cooler Filter Replace SMCS Code 3004 510 AOC 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 103 Maintenance Section Axle Oil Cooler Filter Replace Illustration 98 g01092743 Front Filter AA Illustration 99 g01092745 Rear Filter The filters are located under the access door on the left cab platform 1 Stop the engine 2 Use a strap type wrench to remove the filters Dispose of the used filters properly 3 Clean the filter mounting bases Make sure that all of the used seal is removed from each filter mounting base Illustration 100 g00101318 104 Maintenance Section Axle Oscillation Bearings Lubricate 4 Apply a thin coat of clean differential oil to the seal of each new oil filter Install each new oil filter hand tight until t
26. 1394313 Engine Water Pump Inspect SMCS Code 1361 040 Failure of the engine water pump may cause severe engine overheating problems such as cracks in the cylinder head or piston seizure Visually inspect the water pump for leaks If you find leaks all of the seals on the water pump must be replaced Note For more information refer to the appropriate Disassembly and Assembly manual for your machine s engine 136 Maintenance Section Ether Starting Aid Cylinder Replace 101548876 Ether Starting Aid Cylinder Replace If Equipped SMCS Code 1456 510 CD Ay WARNING 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 Illustration 179 g00805191 1 Open the engine access door on the right side of the machine 2 Loosen cylinder retaining clamp 1 Remove empty ethe
27. 6 Installation 1 Clean the adapter and the area around the latch if necessary Illustration 112 g00101352 1 Usable 2 Replace 3 Overworn 2 Install the new bucket tip onto the adapter with a slight clockwise rotation Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip Removal Illustration 115 g01124736 3 Install the retainer Make sure that the retainer s LES latch catches under the tip pocket ay G Za 4 Make sure that the latch is properly seated by illustration 113 g01389463 trying to remove the bucket tip Note Retainers are often damaged during the Side Cutters If Equipped removal process Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced Illustration 116 g01389740 Bucket with side cutters Illustration 114 g01175361 Side cutters SEBU7808 11 1 Remove the mounting bolts and the side cutters 2 Clean the mounting surface of the side plate on the bucket and of the side cutter Remove any burrs or protrusions on the mating surfaces Illustration 117 g01389456 7 Side cutter Note Some side cutters may be rotated for additional wear 3 Install the side cutter Note Certain bolts may require thread compound 4 Hand tighten the bolts 11 10 Illustration 118 g01389457 Section A A From Illustration 117 8 Side cutter 9 Shear ledge on a side cutt
28. 6118 535 FLV 153 Maintenance Section Loader Boom Pin Oil Level Check Illustration 220 g01094359 A Pin Joint 2 Clean the area around the filler plugs for both A pin joints Slowly loosen each filler plug 3 If the oil escapes from the filler opening the oil level is correct If the oil level is low add SAE 80W90 until oil escapes from the filler opening 4 Clean the filler plugs and install the filler plugs 101613549 Loader Boom Pin and Lift Cylinder Pin Inspect SMCS Code 5102 040 PN 6501 040 PN g00560643 Illustration 219 1 Park the machine on level ground and engage the parking brake Lower the bucket so that the bottom of the bucket is flat on the ground Illustration 221 g00818239 Inspect the Loader Boom Pin A for signs of leakage If signs of leakage are found check the oil level in the pin joint Refer to Operation and Maintenance Manual Loader Boom Pin Oil Level Check for the correct procedure Inspect Lift Cylinder Pins Y and K for signs of leakage If signs of leakage are found refer to Operation and Maintenance Manual Lift Cylinder Pin Oil Level Check for information on checking the oil level of the pins 154 Maintenance Section Loader Pins and Bearings Lubricate 102158811 Loader Pins and Bearings Lubricate SMCS Code 5104 086 BD 6117 086 BD 7070 086 Illustration 222 g00560806 Wipe off the fittings before any lubricant is applied
29. 8 11 Illustration 164 g00841360 Illustration 165 g01000950 1 Open the engine access door on the right side of the machine The high speed arrangement is located on the right side of the engine compartment 2 Remove the cap that protects the male coupler Connect an oil pump to the male coupler Turn on the oil pump and withdraw the engine oil Illustration 166 g00841382 3 Open the engine access door on the left side of the machine SEBU7808 11 L r H AY D H t Lon au AA Mi z iy 1 i ff i Holy i a g01001013 Illustration 167 4 Use a strap type wrench to remove the engine oil filter Dispose of the used filter properly 5 Clean the filter mounting base Make sure that the used seal is completely removed Illustration 168 g00101318 6 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 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non
30. 808 11 Open the access door on the left side of the machine To check the condition of the service indicator try resetting the service indicator This should require less than three pushes of the reset button Next check the movement of the yellow piston in the service indicator Start the engine and accelerate the engine to high idle for a few seconds After the governor control pedal is released the yellow piston should remain at the highest position that was achieved during acceleration If either of these conditions are not met replace the service indicator 01625411 Engine Air Precleaner Clean SMCS Code 1055 070 NOTICE Service the air cleaner only with the engine stopped Engine damage could result Illustration 162 g00841375 1 Remove the precleaner 2 Inspect the air inlet screen for dirt and for trash Remove the screen Clean the screen if the screen is dirty 3 Inspect the precleaner tube openings Remove dirt and debris 4 Clean the precleaner with compressed air or wash the precleaner in warm water Dry all the parts 5 Install the precleaner screen SEBU7808 11 01923427 Engine Mounts Inspect SMCS Code 1152 040 g01000916 Illustration 163 Caterpillar recommends checking the engine mounts for deterioration Checking the engine mounts will ensure that the bolts have the proper torque This will prevent excessive engine vibration that is caused from improper
31. ERT TT vere 118 Loader Boom Pin Oil Level Check 153 Seat Side Rails Adjust ccccceeeeeeeeeeee eens 158 Every 500 Service Hours or 3 Months Cooling System Coolant Sample Level 1 DLAI tdiatsacantutssannen a aneeauataniat 117 Differential and Final Drive Oil Sample Obtain 123 Engine Oil High Speed and Oil Filter Change 129 Engine Oil and Filter Change c cccceees 132 Fuel System Primary Filter Water Separator Element Replace cccccsecceeceeeseeeeeeeees 138 Fuel System Secondary Filter Replace 139 Fuel Tank Cap and Strainer Clean 140 Hydraulic System Oil Filter Steering and Implement Pilot Replace ci cloiiaicataucsicuetinatnoutonneiem inten 147 Hydraulic System Oil Sample Obtain 149 Transmission Oil Filter Replace 00 162 Transmission Oil Sample Obtain 164 Every 1000 Service Hours or 6 Months Articulation Bearings Lubricate c c0ee 99 Battery Hold Down Tighten cc seceeeeeee 105 Case Drain Oil Filters Replace 008 113 Drive Shaft Support Bearing Lubricate 124 Rollover Protective Structure ROPS Inspect 157 Transmission Oil Change ccccseceeeeeeeeeees 160 Every 2000 Service Hours or 1 Year Axle Oil Cooler Filter Replace ce 103 Cooling
32. K 2 Clean the area around the filler plug for pin joint K Slowly loosen the filler plug 3 If the oil escapes from the filler opening the oil level in the pin joint is correct If the oil level is low add SAE 80W90 until oil escapes from the filler opening 4 Clean the filler plug and install the filler plug 152 Maintenance Section Loader Boom Pin Oil Change g01094064 Illustration 216 g01094065 Pin Joint Y 5 Repeat the procedure for pin joint Y 02280356 Loader Boom Pin Oil Change SMCS Code 6118 044 OC 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 SEBU7 808 11 1 Park the machine on level ground and engage the parking brake Lower the bucket so that the bottom of the bucket is flat on the ground Stop the engine Illustration 217 g00811718 The A pin joints 1 do not have drain plugs a Illustration 218 g01094359 A Pin Joint 2 Remove the filler
33. Start the engine and run the engine at low idle 11 Slowly operate the transmission control in order to circulate the transmission oil Return the transmission to neutral 12 Stop the engine Check the transmission oil filter for leaks 163 Maintenance Section Transmission Oil Level Check Illustration 249 g00935572 13 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure 101833015 Transmission Oil Level Check SMCS Code 3030 535 FLV Illustration 250 g00936405 The sight gauge 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 oil Park the machine on level ground 164 Maintenance Section Transmission Oil Sample Obtain Illustration 251 g00936406 2 Check the oil level in the sight gauge Maintain the oil level within the operating range while the engine is running Note The oil level varies significantly when the engine is stopped The oil level will be considerably higher than the operating range The oil level should be above the middle of the gauge before the engine is started 3 If necessary remove the filler cap and add oil Clean the filler cap and install the filler cap 102161205 Transmission Oil Sample Obtain SMCS Code 3080 008 7542 mul Co gfeoad tad
34. There is a total of nine fittings ANA Illustration 223 g01094968 B Pin Joint For the B pin joint apply lubricant through the fitting on the top of the boom SEBU7808 11 Lo Illustration 224 g01094969 C Pin Joints For the C pin joints apply lubricant through the fittings at the bottom of each bucket link 1 Illustration 225 g01094970 E Pin Joints For the E pin joints apply lubricant through three remote fittings on the bucket links Illustration 226 g01094972 F Pin Joint Right Side SEBU7808 11 Illustration 227 g01094974 F Pin Joint Left Side For the F pin joints apply lubricant through the fittings at the bottom of each tilt lever Illustration 228 g01094975 G Pin Joint For the G pin joint apply lubricant through one remote fitting on the inside of the right front loader frame 155 Maintenance Section Oil Filter Inspect 02106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 9068 507 Inspect a Used Filter for Debris Illustration 229 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
35. ach a hose to a Oil Drain Coupling Install the threaded end of the coupling into the drain valve in order to unseat the internal drain valve Allow the oil to drain into a suitable container SEBU7808 11 oc Bo gt Illustration 242 5 g01095647 The transmission oil filler tube is located near the articulation joint on the left side of the machine Remove the transmission oil filler cap in order to ease drainage Illustration 243 g01095648 6 The transmission magnetic screen is located on the left side of the transfer gear case The screen may be accessed through the left side of the rear frame as shown Use the following procedure to clean the transmission magnetic screen NOTICE Do not drop or rap the magnets against any hard ob jects Replace any damaged magnets 161 Maintenance Section Transmission Oil Change Illustration 244 g00838905 a Remove bolts 1 and washers 2 Remove cover assembly 3 and seal 5 b Remove screen tube assembly 6 and suction screen 7 c Wash the screen tube assembly and the suction screen in a clean nonflammable solvent d Install screen tube assembly 6 and suction screen 7 e Inspect seal 5 for damage Replace the
36. akes e Park the machine on a dry level surface 107 Maintenance Section Brake Accumulator Check 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 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 Ay WARNING 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 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
37. 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 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 F a e e T N Illustration 192 g01093885 The fuel tank drain valve is located on the left side of the machine at the bottom of the fuel tank Illustration 193 g01093886 Open the fuel tank drain valve Allow the water and sediment to drain into a suitable container Close the fuel tank drain valve 141 Maintenance Section Fuel Tank Water and Sediment Drain 02741651 Fuses Replace SMCS Code 1417 510 Note Your machine may not be equipped with all of the fuses that are discussed in this topic Fuses The fuses protect the electrical system from damage that is caused by overloaded circuits Replace a fuse if the element separates If the element of a new fuse separates inspect the circuit Repair the circuit if necessary aa amp Illustrati
38. are 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 g01001201 Illustration 199 The hydraulic oil filter is located behind the mud flap on the front of the hydraulic tank Note The mud flap may be removed for easier access to the filter 1 Stop the engine 148 Maintenance Section Hydraulic System Oil Level Check Illustration 200 g01001186 2 Use a strap type wrench to remove the hydraulic oil filter element Dispose of the used filter properly 3 Remove the filler cap and the strainer from the hydraulic oil filler tube Wash the filler cap and the strainer in a clean nonflammable solvent Allow the strainer to air dry 4 Inspect the strainer for damage Replace the strainer if necessary Install the strainer and the filler cap 5 Clean the filter mounting base Make sure that all of the used gasket is removed from the filter mounting base Illustration 201 g00101318 6 Apply a thin coat of hydraulic oil to the seal o
39. be contaminated Contaminated fuel will cause accelerated wear to fuel system parts The fuel system should be primed prior to starting the engine Illustration 188 g00841360 1 Open the engine access door on the right side of the machine 140 Maintenance Section Fuel Tank Cap and Strainer Clean ii SG i i a lt _ lt oe ta FES Ae g01002138 Illustration 189 2 Remove the used filter element Dispose of the used filter element properly 3 Clean the filter mounting base Make sure that all of the used seal is removed Illustration 190 g00101318 4 Apply a thin coat of clean diesel fuel to the seal on the new fuel filter Install the 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 t
40. bove 130 Maintenance Section Engine Oil High Speed and Oil Filter Change 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 Understanding the S O S Oil Analysis Tests Procedure for Changing the Engine Oil and Filter Ay WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Your machine may be equipped with a high speed arrangement for changing the engine oil The high speed arrangement allows the engine oil to be changed faster than the conventional method SEBU780
41. ce from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended to 3000 hours S O S services may extend the oil change even longer Consult your Cat dealer for details When Required Automatic Lubrication Grease Tank Fill 99 Automatic Lubrication System Components CHECK erun elie bic aul uti tated 100 Axle Oil Cooler Filter Replace cce 103 Battery or Battery Cable Inspect Replace 106 Bucket Lift and Bucket Tilt Control Inspect Clean inen aa 109 Bucket Tips Inspect Replace cccceeeeee 109 Camera Clean ccccccccceccceeceeeeeeeeeeceeeeeeeeeeeaeees 112 Circuit Breakers Reset cccecceeeeeeeseeeeeees 114 Engine Air Filter Primary Element Clean RODIACE sena E 124 Engine Air Filter Secondary Element Replace 126 Engine Air Precleaner Clean cceeceeeeeee 128 Ether Starting Aid Cylinder Replace 136 Fuel System Prime cccceccseecseeceeeeeeeeeeeeeeees 136 PUSES Replace iiei erann sures a Aan Ra 141 97 Maintenance Section Maintenance Interval Schedule High Intensity Discharge Lamp HID Replace 144 Loader Boom Pin Oil Level Check 153 Oil Filter INSP Ct eee cecceeeeeeeseeeeeeeeeeeenaees 155 Radiator Core Clean cccccscccsseceeeecseeseeesees 156 Seat Side Rail
42. cement procedure 03879434 Differential and Final Drive Oil Change SMCS Code 3278 044 4050 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 SEBU7 808 11 121 Maintenance Section Differential and Final Drive Oil Change Illustration 141 g00801038 Final Drive Illustration 142 g00840713 Front Differential 1 Position the wheels so that the front final drive drain plugs 2 are facing downward Remove the front final drive drain plugs 2 and the front differential drain plug 4 Allow the oil to drain into a suitable container 2 Remove the front final drive filler plugs 1 and the front differential filler plug 3 3 After the oil has drained clean the drain plugs and install the drain plugs 4 Fill the final drives to the bottom of the filler plug openings Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the co
43. cket is not blocked up Block the bucket before changing cutting edge SEBU7808 11 Illustration 109 g00804790 Check for bolts that are missing or loose Replace any missing bolts and tighten any loose bolts Reference Refer to Operation and Maintenance Manual Torques for Ground Engaging Tool Bolts for the correct torque Inspect the cutting edges and the end bits If wear or damage is evident use the following procedure to replace the components 1 Raise the bucket and place blocking under the bucket Lower the bucket onto the blocking Note Do not block up the bucket too high Block up the bucket enough for removing the cutting edges and the end bits 2 Remove bolts 1 Remove cutting edges 2 and the end bits 3 Clean the contact surfaces Inspect the cutting edges and install the cutting edges If the opposite side of the cutting edge is not worn use that side If both sides of the cutting edge are worn install a new cutting edge 4 Install bolts 1 Tighten the bolts to the specified torque 5 Raise the bucket and remove the blocking Lower the bucket to the ground 6 After a few hours of operation check the bolts for proper torque SEBU7808 11 101923042 Bucket Lift and Bucket Tilt Control Inspect Clean SMCS Code 5258 571 5702 571 109 Maintenance Section Bucket Lift and Bucket Tilt Control Inspect Clean 102612625 Bucket Stops Inspect Replace SMCS Code 60
44. cts 2 Disconnect the inlet hose 1 from the old in line dryer 3 Connect the inlet hose that was disconnected in Step 2 to the inlet on the new in line dryer 4 Start the engine and operate the air conditioning system 5 With the air conditioning system in operation disconnect the outlet hose 2 from the old in line dryer 6 Stop the engine for five minutes in order to equalize the pressure in the air conditioning system 7 Connect the outlet hose 2 that was disconnected in Step 5 to the outlet on the new in line dryer Note Do not add oil to the in line dryer Note If the in line dryer assembly does not have quick disconnects 30 mL 1 oz of refrigerant oil will need to be added to the air conditioner system Refer to the Service Manual SENR5664 Refrigerant Recovery section in Testing and Adjusting for the proper procedure 157 Maintenance Section Rollover Protective Structure ROPS Inspect 102159129 Rollover Protective Structure ROPS Inspect SMCS Code 7325 040 ae as THH E n yaa mar Illustration 234 g01095101 Inspect the 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 1500 200 N m 1106 147 5 lb ft Note Apply oil to all bolt threads before installation Failure to apply oil can result in improp
45. e engine does not start or the engine misfires further priming is necessary SEBU7808 11 Note Failure to tighten fittings could result in fuel leaks 9 Clean residual fuel from the engine components 10 Close the engine access door on the left side of the machine 102962202 Fuel System Primary Filter Water Separator Check Drain SMCS Code 1263 535 1263 543 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 181 g00841382 1 Open the engine access door on the left side of the machine 137 Maintenance Section Fuel System Primary Filter Water Separator Check Drain cogo of Ja T Eran A _ Da _ i TE MO Illustration 182 g01002112 Type 1 i gt i AB NLY l HEC ay Ti iin ajin na zN L Qa F TT Hib 1 K 1 g01482573 Illustration 183 Type 2 2 The water separator is located on the bottom of the primary fuel filter Open the drain valve on the bott
46. e you begin to take the samples e Keep the unused sampling bottles stored in plastic bags SEBU7808 11 e Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location e Keep the lids on empty sampling 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 e Never collect samples from expansion bottles e Never collect samples from the drain for a system ro Illustration 137 g01093449 Slowly remove the cooling system pressure cap Open the left side engine access door Illustration 138 g01120387 Remove the cap over the coolant sample port Attach a hose to a couple Install the threaded end of the coupling into the drain valve in order to unseat the internal drain valve Close the engine access door and return the pressure cap Submit the sample for level 2 analysis 119 Maintenance Section Cooling System Water Temperature Regulator Replace For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer i01925931 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Ay WARNING Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is co
47. ed to the cooling system Illustration 130 g01093449 The cooling system pressure cap is located on the left side of the machine on the top of the radiator 1 Slowly loosen the cooling system pressure cap in order to relieve system pressure Remove the cooling system pressure cap 2 Use a 8T 5296 Coolant Test Kit to check the concentration of the coolant If it is necessary adjust the concentration of the coolant Illustration 131 g01093450 SEBU7 808 11 3 If necessary drain enough coolant from the radiator in order to allow the addition of the Extender The coolant drain valve is located at the rear of the machine under the engine compartment 4 Add 3 L 100 fl oz of Extender to the cooling system 5 Check the coolant level Reference Refer to Operation and Maintenance Manual Cooling System Level Check for the correct procedure 6 Install the cooling system pressure cap 102156161 Cooling System Coolant Level Check SMCS Code 1350 535 FLV eat felelelele ele18 reli iatera arala Ol C k Si 4 E We T ee Illustration 132 g01093538 aa
48. efore 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 Be g01001064 Illustration 173 1 Lower the bottom guard Open the crankcase drain valve 1 and allow the oil to drain into a suitable container Reference Refer to Operation and Maintenance Manual Power Guard Control for the proper removal of bottom guard 134 Maintenance Section Engine Oil and Filter Change 2 Close the drain valve 1 Raise the bottom guard Illustration 174 g00841382 3 Open the engine access door on the left side of the machine ags E H alar A ne ae a a a ee A p L TI IL u A ee E e ss t f i Illustration 175 g01001013 4 Use a strap type wrench to remove the engine oil filter Dispose of the used filter properly 5 Clean the filter mounting base Make sure that the used gasket is completely removed Illustration 176 g00101318 SEBU7808 11 6 Apply a thin film of clean engine oil to the seal on the new filter element Install a new engine oil filter hand tight un
49. 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 103307817 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 in additional increments of 500 hours The extended 4000 hour interval can be used if the following criteria are met SEBU7808 11 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 viscosity grade of 10W Cat HYDO Advanced 10 has a 50 increase in the standard oil drain interval up to 3000 hours for machine hydraulic systems over second and third choice oils when you follow the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual 6000 hour oil drain intervals are possible when using S O S Services oil analysis When you switch to Cat HYDO Advanced 10 cross contamination with the previous oil should be kept to less than 10 Co
50. elief valve dry or use pressure air 3 Install the hydraulic tank breaker relief valve 02157156 Lift Cylinder Pin Oil Change SMCS Code 7070 044 OC 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 150 SEBU7 808 11 Maintenance Section Lift Cylinder Pin Oil Change Illustration 206 geno pene Illustration 208 Pin Joint K 1 Park the machine on level ground and engage daii the parking brake Lower the bucket so that the 5 Fill the pin joint with SAE 80W90 oil until oil rope of the bucket is flat on the ground Stop escapes from the filler opening ngine 6 Clean the filler plug and install the filler plug ey tH i a g01094058 y sk eh Se R r Illustration 207 g01094056 Pin Joint K Illustration 209 2 Remove the drain p
51. em Personal 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 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 returned to normal operation If there is no response to the steering input
52. er 10 Side plate on a bucket 11 0 0 mm 0 0 inch 5 Make sure that there is not a gap between the side plate on the bucket and the shear ledge on the side cutter 6 Torque the mounting bolts to the correct specification 111 Maintenance Section Bucket Tips Inspect Replace Side Protectors If Equipped Inspect the wear of the side protector When too much wear is present replace the protector Illustration 119 g01389458 Illustration 120 g01903698 Illustration 121 g01389459 12 Side protector 13 Pin 14 Retainer 15 Side plate 16 Shim 1 Hit pin 13 from the side of the bucket without the retainer in order to remove side protector 12 from side plate 15 112 Maintenance Section Bucket Wear Plates Inspect Replace 2 Clean side protector 12 pin 13 retainer 14 and side plate 15 before installation Note Lateral clearance between the side plate and the side protector should not exceed 1 mm 0 04 inch Shims 16 may be required in order to decrease the lateral clearance which will decrease movement Install the shims 16 between the side plate and the side protector on the opposite side of the retainer 3 Put retainer 14 in side plate 15 4 Align two pin holes of the new protector and the side plate Hit the pin from the retainer side of the bucket Note If the pin and or the retainer are worn replace the pin and or the retainer i01098709 Bucket Wear P
53. er 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 10 Tighten the drain valve on the water separator bowl Note The water separator element is under suction during normal engine operation The drain valve must be tightened in order to prevent air leakage into the fuel system 11 Prime the fuel system in order to fill the filter element with fuel Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure 139 Maintenance Section Fuel System Secondary Filter Replace 102301079 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them The fuel will not be filtered and could
54. er bolt torque 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 158 Maintenance Section Seat Belt Replace Illustration 235 g00932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure f
55. er element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components 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 151 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 125 Maintenance Section Engine Air Filter Primary Element Clean Replace Illustration 152 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 Illustration 153 g00328468 5 If the primary element is not damaged clean the primary element Press
56. er element by an additional 3 4 turn 6 Repeat the above steps for the other two case drain filters 7 Start the engine and run the engine at low idle Operate the steering the brakes and the implement 8 Stop the engine Inspect the filters for leaks Make any necessary repairs 114 Maintenance Section Circuit Breakers Reset 02155537 Circuit Breakers Reset SMCS Code 1420 529 in order to reset the circuit breaker If the circuit is functioning properly the button will remain depressed If the button will not remain depressed check the appropriate electrical circuit Circuit Breakers Depress the button F Illustration 127 g01093167 The circuit breakers are located under a small access door on the right cab platform 4 Main Circuit 1 105 amp Alternator 2 105 amp Engine Start Switch 3 10 amp Electronic Control Module ECM 4 15 amp SEBU7 808 11 102156049 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Ay WARNING Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure 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 di
57. er solvent or equivalent System damage can result from freezing SEBU7808 11 Illustration 253 g01095908 The window washer reservoir is located beneath an access panel on the left cab platform Fill the reservoir with window washer solvent 102168843 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 Illustration 254 g01098903 Inspect the front wiper blade and the rear wiper blade Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs 165 Maintenance Section Window Wiper Inspect Replace 100037755 Windows Clean SMCS Code 7310 070 Illustration 255 g00038949 Use commercially available window cleaning solutions in order to clean the windows Clean the outside windows from the ground unless handholds are available
58. gine 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 Refer to Operation and Maintenance Manual Monitoring System for the location of the alert indicators 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 The rate for this process is 1 second on and 1 second off Do this process 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 with new discs The number of applications could be as low as three when the lining material on the brake discs is at replacement thickness 4 lf the alert indicator comes on after less than 3 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 Reference Refer to Testing and Adjusting RENR6365 834H 836H Tier 3 Braking System Accumulator Charging Valve Brake Test and Adjust for the correct procedure 101739721 Braking System Test SMCS Code 4251 081 4267 081 e Fasten the seat belt before you test the br
59. h suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 144 g00801038 1 Position the wheels so that final drive drain plug 2 is facing downward Remove oil filler plug 1 The oil level should be at the bottom of the filler plug opening Add oil if necessary Reference Refer to Operation and Maintenance Manual Lubricant Viscosities for the correct type of oil If the oil level is higher than the filler plug opening do not allow the oil to drain to the proper level Install the filler plug SEBU7808 11 Illustration 145 g00801039 Front Differential Illustration 146 g00840708 Rear Differential 2 Remove differential filler plug 3 The oil level should be at the bottom of the filler plug opening Add oil if necessary Reference Refer to Operation and Maintenance Manual Lubricant Viscosities for the correct type of oil If the oil level is higher than filler plug opening do not allow the oil to drain to the proper level Install filler plug 3 SEBU7808 11 102339342 Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4050 008 4070 008 7542 NOTICE A
60. hat 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 1E Til WUNI E Illustration 197 g01152499 3 The hydraulic tank is located on the right side 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 Remove the filler strainer from the hydraulic tank filler neck 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 SEBU7 808 11 6 Remove the drain plug from the bottom of the hydraulic tank Wash the drain plug in a clean nonflammable solvent 7 Install a 6B 3156 Pipe Nipple into the
61. he 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 SEBU7 808 11 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 01832060 Belts Inspect Adjust Replace SMCS Code 1397 025 1397 040 1397 510 Note The alternator and the refrigerant compressor are driven by a single serpentine belt Illustration 107 g00935723 1 Stop the engine Access the belt from the right side of the machine Illustration 108 g00935724 Note The belt can be serviced via the engine access door or the vent and the firewall can be removed for easier access SEBU7808 11 2 Inspect the condition of belt 2 If the belt is cracked or frayed replace the belt 3 Use a ratchet with a square head to loosen belt tensioner 1 during replacement Make sure that the belt is installed in the correct pattern as shown 02215711 Brake Accumulator Check SMCS Code 4263 535 1 Turn the en
62. he rotation index marks as a guide 5 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 6 Prime the fuel system SEBU7 808 11 Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure 7 Close the engine access door i 02496986 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR 1273 070 Z2 The fuel tank cap is located on the left side of the machine 1 Remove the fuel tank cap 2 Inspect the seal for damage Replace the seal if necessary 3 Remove the filter assembly from the cap Illustration 191 g00930457 Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 4 Remove the strainer from the filler tube 5 Wash the fuel tank cap and the strainer in a clean nonflammable solvent 6 Install a new cap filter kit Install the other components in reverse order 7 Install the strainer and the fuel tank cap SEBU7808 11 102156799 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M
63. he seal of the oil filter contacts the base Note the position of each index mark on each filter in relation to a fixed point on each filter base Note There are rotation index marks on each oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten each oil filter use the rotation index marks as a guide 5 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 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 6 Start the engine and run the engine at low idle Check for leaks 7 Check the level of the differential oil Reference Refer to Operation and Maintenance Manual Differential and Final Drive Oil Level Check for the correct procedure 103506621 Axle Oscillation Bearings Lubricate SMCS Code 3268 086 BD 3278 086 BD Wipe off the fittings before any lubricant is applied th 61 NA oS E EUO ai Roe ee E 1 5 oes SS Illustration 101 g01841714 SEBU7808 11 Illustration 102 g01841715 Apply lubricant through the two remote fittings on the right side of the machine Fitting 1 applies grease to the rear axle osci
64. ie crs anceeaumiestancuncianssansaeenes aes 137 Fuel Tank Water and Sediment Drain 141 Tire Inflation Check ccccccceceseeeeeeeeeeneeeeeees 160 Every 100 Service Hours or 2 Weeks Axle Oscillation Bearings Lubricate 104 Steering Cylinder Bearings Lubricate 159 Initial 250 Service Hours Electronic Unit Injector Inspect Adjust 124 Engine Valve Lash Check ccccecceeeeeeeees 135 Engine Valve Rotators Inspect c 0e 135 Transmission Oil Filter Replace 00 162 Every 250 Service Hours or Monthly Battery Cleahece a chactesnct Bee sice tee tea censt ss 105 Belts Inspect Adjust Replace ccceeeeeee 106 Brake Accumulator Check cccccseeeeeeeeees 107 Braking System Test cccccccsseceeeeseeseeesees 107 Differential and Final Drive Oil Level Check 122 Drive Shaft Spline Center Lubricate 123 Engine Air Filter Service Indicator Inspect Replace cccceeccsececeeeceeceeeecseeseeeeees 128 Engine Oil High Speed and Oil Filter Change 129 Engine Oil Sample Obtain eee 132 Engine Oil and Filter Change cccccceeee 132 98 Maintenance Section Maintenance Interval Schedule Initial 500 Service Hours Cooling System Coolant Sample Level 2 DEE a Reet a Tee era nnn toe MeO emt Brera Len B
65. in the filter element can indicate a possible failure lf metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 156 Maintenance Section Radiator Core Clean 102158840 Radiator Core Clean SMCS Code 1353 070 KO lo H m m O COL Ooo
66. 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 SEBU7 808 11 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 101625408 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE 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 but a warning for the air filter still occurs replace the secondary element Also replace the secondary element if the exhaust smoke remains black after installation of a clean primary element Illustration 155 g00841360 1 Open the engine access door on the right side of the machine SEBU7 808 11 Illustration 156 g00804954 4 Illustration 157 g00804960 2 Remove cover 1 and primary element 2 Illu
67. l 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 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 lf 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 a
68. lates Inspect Replace SMCS Code 6120 040 6120 510 Illustration 122 g00577650 Before damage to the bottom of the bucket occurs repair damaged bucket wear plates or replace damaged bucket wear plates Consult your Caterpillar dealer for the procedures 101908538 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 SEBU7808 11 Illustration 123 g00994599 1 Remove the filter cover behind the seat Remove the filter element 2 Open the access door 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 SEBU7808 11 Display FEES SOTSOSG Illustration 124 g01223034 WAVS display Use a soft damp cloth in order to clean the display The display has a soft plastic surface tha
69. llation bearing Fitting 2 applies grease to the front axle oscillation bearing 102319912 Backup Alarm Test SMCS Code 7406 081 Turn the engine start switch key to the ON position in order to perform the test Apply the service brake Move the transmission direction control lever to the REVERSE position The alarm should start to sound immediately The alarm will continue to sound until the transmission direction control lever is moved to the NEUTRAL position or to the FORWARD position SEBU7808 11 105 Maintenance Section Battery Clean 102155427 Battery Clean SMCS Code 1401 070 Illustration 105 g01093084 01091949 Illustration 103 i Open the battery compartment on the right rear side The backup alarm is located behind the rear grill of the machine Clean the battery terminals and the surfaces of the batteries with a clean cloth Coat the battery terminals with petroleum jelly Make sure that the battery cables are installed securely i02155501 Battery Hold Down Tighten SMCS Code 7257 527 Illustration 104 g01117861 The volume for the backup alarm is nonadjustable
70. lug for pin joint K The drain plug is located on the right side of the machine Allow the oil to drain into a suitable container 3 Remove the filler plug for pin joint K The filler plug is located on the right side of the machine 4 After the oil has drained clean the drain plug and install the drain plug Illustration 210 Pin Joint Y 7 Remove the drain plug for pin joint Y The g01094061 drain plug is located on the inside of the left front loader frame Allow the oil to drain into a suitable container SEBU7808 11 g01094064 Illustration 212 g01094065 Pin Joint Y 8 Remove the filler plug for pin joint Y The filler plug is located on the inside of the left front loader frame 9 After the oil has drained clean the drain plug and install the drain plug 10 Fill the pin joint with SAE 80W90 oil until oil escapes from the filler opening Note It will be necessary to use a funnel and a hose to fill the pin joint through the filler opening 11 Clean the filler plug and install the filler plug 151 Maintenance Section Lift Cylinder Pin Oil Level Check 02157325 Lift Cylinder Pin Oil Level Check SMCS Code 070 535 FLV CSN Illustration 213 g00560502 1 Park the machine on level ground and engage the parking brake Lower the bucket so that the bottom of the bucket is flat on the ground Illustration 214 g01094058 Pin Joint
71. lways 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 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 oil for a more accurate sample Illustration 147 g01167372 Differential Filler Plug 123 Maintenance Section Differential and Final Drive Oil Sample Obtain N a Illustration 148 g00760182 Final Drive Filler Plug 2 The differential and final drives are not equipped with sampling valves Obtaining an oil sample will require the use of a vacuum pump or equivalent in order to extract the oil from the component Extract the oil through the filler openings
72. machine Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and for proper battery charging Keep the batteries fully charged Air temperature affects the cranking power of the batteries Keep the batteries warm The engine will not crank if the batteries are too cold A warm engine will not crank if the batteries are too cold When the engine is operated for short periods of time the batteries may not fully recharge Make sure that the alternator is properly functioning The alternator will charge the batteries Reference For additional information refer to the appropriate Service Manual for this machine 02147795 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD Wipe off the fittings before any lubricant is applied 99 Maintenance Section Alternator Inspect Illustration 93 g01092660 Apply grease through one fitting on the upper pivot bearing Illustration 94 g01092661 Apply grease through one fitting on the lower pivot bearing 02216552 Automatic Lubrication Grease Tank Fill If Equipped SMCS Code 540 544 TNK Ay WARNING 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 100 Maintenance Section Automatic Lubrication System Compone
73. mounting Reference For the proper bolt torques refer to the Specifications manual for your machine s engine Engine Oil High Speed and Oil Filter Change If Equipped 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 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 129 Maintenance Section Engine Mounts Inspect 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 Oi
74. n the new filter Install the new hydraulic oil filter hand tight until the seal of the hydraulic oil filter contacts the filter 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 hydraulic oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the hydraulic oil filter use the rotation index marks as a guide SEBU7 808 11 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 Start the engine and run the engine at low idle Inspect the hydraulic system for leaks 9 Check the level of the hydraulic oil Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check for the correct procedure 01923843 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV Note The work tool must be positioned on the ground in order to have an accurate reading g01001204 Illustration 202 The hydraulic tank is located on the right side of the machine SEBU7 808 11 Illustration 2
75. ng program is not available the standard 2000 oil change interval should be used Measured Data The following information should be monitored when you sample the oil e Significant changes in wear metals should be monitored These metals include iron copper chromium lead aluminum and tin e The following additives should be observed for significant changes 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 normal levels 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 e There should not be significant changes in sodium silicon copper and potassium e The allowable level of oxidation is 40 percent 0 12 Abs units e The kinematic viscosity at 100 C 212 F should not exceed a 2 cSt change 146 Maintenance Section Hydraulic System Oil Change Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure t
76. nsult your Cat dealer for details about the benefits from the improved performance designed into Cat HYDO Advanced 10 Oil Filters Caterpillar oil filters are recommended The interval for changing the oil filter should be 500 hours Oil The 4000 hour interval for changing the oil is for the following oil types e Caterpillar Hydraulic Oil HYDO e CaterpillarTransmission Drive Train Oil TDTO e Caterpillar TDTO TMS e Caterpillar Diesel Engine Oil e Caterpillar Biodegradable Hydraulic Oil HEES e Caterpillar Multipurpose Tractor Oil MTO e Heavy Duty Diesel Engine Oil with a minimum zinc content of 900 parts per million ppm Heavy duty oils are identified by the following classifications Cat ECF 1 API CF API CG 4 and TO 4 Cat ECF 1 API CF API CG 4 and TO 4 oils must have a minimum zinc additive of 900 parts per million ppm in order to be considered acceptable for use in a hydraulic system Note Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems These oils are more likely to cause corrosion and excessive wear 145 Maintenance Section Hydraulic System Oil Change Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours Caterpillar s standard S O S 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 sampli
77. ntenance Manual Maintenance Interval Schedule SEBU7808 11 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 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 lf 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
78. nts Check The Centro Matic Lubrication System Reference Before any service work is performed on the lubrication system refer to Special Instructions REHS1394 or consult your Caterpillar dealer Bulk Fill 1 In order to fill the reservoir remove the lower and upper plugs from the side of the reservoir 2 Attach the appropriate pump to the lower inlet 3 Fill the reservoir until visual indicator on the lid of the tank indicates FULL or until the grease appears at the top vent port Reference For the correct type of grease refer to Operation and Maintenance Manual Lubricant Viscosities 4 Remove the pump and replace both plugs The Quicklub Lubrication System Reference Before any service work is performed on the lubrication system refer to Special Instructions REHS1396 or consult your Caterpillar dealer Filling the Reservoir 1 Fill the reservoir through the grease fitting The grease fitting is located at the base of the reservoir Reference For the correct type of grease refer to Operation and Maintenance Manual Lubricant Viscosities 2 Refill the reservoir when the grease reaches the MIN mark on the reservoir 3 Fill the reservoir to the MAX mark on the reservoir Priming the System After the reservoir has been filled with the recommended lubricant loosen the fitting to the supply line Operate the pump until lubricant flows from the outlet Then tighten fitting
79. ocedures C 2 2 Check the grease level at the top vent port of the E 3 reservoir F 2 2 Reference For filling procedures refer to G 4 Operation and Maintenance Manual Automatic Lubrication Grease Tank Fill H 1 7 J 1 Settings of the Injectors for the 7 F 7 Autolube System P 5 The controller of the autolube system is preset from X 2 8 the factory The lubrication is dispensed at 15 minute y 0 g intervals and all of the injectors are preset at the full flow setting There may be an excessive buildup of grease around some of the joints As a result the grease reservoir may need filling more frequently The injectors for selected joints can be adjusted in order to reduce the flow of grease without adversely affecting the life of the pin The injectors are set by the factory at the full flow setting This setting is equivalent to 8 turns open When the injectors are adjusted the injectors should first be closed Then the injectors should be opened by the number of specified turns The recommended settings for the injectors at each pin location are listed in Table 13 Note By using the above settings the buildup of grease will be reduced The interval between refills of the reservoir will be extended to approximately 250 hours Grease levels in the reservoir must be checked in order to ensure an uninterrupted flow 102 Maintenance Section Automatic Lubrication System Components Check Timer Operation Aut
80. oduces high voltage To prevent personal injury make sure the Electronic Control Module is not powered and the unit injector solenoids are disconnected NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the unit injector lash is made The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result The operation of Caterpillar engines with improper adjustments of the electronic unit injector can reduce engine efficiency This reduced efficiency could result in excessive fuel usage and or shortened engine component life Adjust the electronic unit injector at the same interval as the valve lash adjustment Refer to your machine s Service Manual or your Caterpillar dealer for the complete adjustment procedure i01902270 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY Ay WARNING To avoid personal injury always wear eye and face protection when using pressurized air SEBU7808 11 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 filt
81. 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 247 g00935569 The transmission oil filter is located on the left side of the machine near the articulation joint Note The hose for the steering cylinder may obstruct the bottom of the filter 1 Stop the engine and remove the key 2 Turn the battery disconnect switch to the OFF position SEBU7 808 11 Illustration 248 g01299247 3 Remove drain plug 5 and allow any oil to drain into a suitable container 4 Install the drain plug once the oil has drained completely 5 Remove bolts 2 and cover plate 1 from the bottom of filter housing 4 6 Remove filter element 3 from filter housing 4 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 cover seal for the filter housing Replace the seal if the seal is damaged 9 Install a new filter element the cover plate and bolts on the bottom of the transmission oil filter housing 10
82. ol Then loosen cap slowly to relieve the pressure Replace the water temperature regulator on a regular basis in order to reduce the chance of unscheduled downtime and the chance of problems with the cooling system The water temperature regulator should be replaced after the cooling system has been cleaned Replace the water temperature regulator and replace the seals while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the water temperature regulator housing Note If you are only replacing the water temperature regulator drain the cooling system coolant to a level that is below the water temperature regulator housing NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age N LERN Illustration 139 g01002350 120 Maintenance Section Crankshaft Vibration Damper Inspect The water temperature regulator is located on the left side of the engine near the primary fuel filter 1 Remove the bolts that secure the regulator housing 1 Loosen the hose clamps 2 2 Remove the regulator housing Remove all of the used gasket from the housing 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
83. olube systems must be adjusted before being put into use to ensure each joint gets the appropriate amount of grease Different applications require frequency volume and proportioning adjustments from the recommended or factory settings Autolube settings must be monitored and adjusted as needed to account for changes in application temperature grease type and NLGI grade oO lt i s Ri E E5 oi Illustration 96 g01239276 6 Access plug Remove access plug 6 on the front of the pump in order to access the timer control The timer control group consists of the following e Manual lubrication switch e OFF timer rotary switch e ON timer rotary switch e Power ON LED e Pump ON LED SEBU7808 11 Illustration 97 g01238978 Timer control 7 OFF timer switch 8 ON timer switch 9 Power ON LED 10 Pump motor ON LED 11 Push button for manual lubrication OFF timer switch 7 can be adjusted to 15 values See Table 1 for the time interval for each value ON timer switch 8 can be adjusted to 15 values see Table 1 for the time interval for each value LED 9 is marked battery This LED will illuminate when power is sent to the pump control LED 10 is marked motor This LED will illuminate when the pump is pumping lubricant Press push button 11 for 2 seconds This process will initiate a manual lubrication cycle The OFF position of the timer begin
84. om of the water separator bowl Allow the water and the fuel to drain into a suitable container 3 Tighten the drain valve Note The water separator is under suction during normal engine operation The drain valve must be tightened in order to prevent air leakage into the fuel system 4 Close the engine access door 138 Maintenance Section SEBU7808 11 Fuel System Primary Filter Water Separator Element Replace 03355824 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 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 NOTICE Do not fill fuel filters with fuel before installing them The fuel will not be filtered and could be contaminated Contaminated fuel will cause accelerated wear to fuel system parts The fuel system should be primed prior to starting the engine Illustration 184 g00841382 1 Open the engine access door on the left side of the machine O F oor
85. on 194 g01093757 The fuses are located under a small access door on the right cab platform Note Your machine may be equipped with glass fuses or your machine may be equipped with blade fuses NOTICE Replace the fuses with the same type and size only Otherwise electrical damage can result If itis necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer 142 Maintenance Section Fuses Replace Glass Fuses If equipped Illustration 195 DY OOBODOO g01119139 Transmission Electronic Control 1 10 amp Implement Electronic Control 2 10 amp Blower Fan 3 20 amp Automatic Lubrication 4 10 amp Front Work Lights 5 15 amp Front Work Lights 6 10 amp Rotating Beacon 7 10 amp Voltage Converter 8 10 amp Seat 9 15 amp Front Work Lights 10 15 amp YO OS O O98 SEBU7 808 11 Rear Work Lights 11 15 amp Front Work Lights 12 15 amp Electronic Gauges 13 10 amp Lighter and Voltage Converter 14 10 amp Window Wipers 15 10 amp Horn 16 10 amp Stairway Access Light 17 10 amp Payload Control System 18 10 amp SEBU7808 11 Blade Fuses If equipped T _ sij U B E yle ze eee 5 het all al a s a _ amp zO pe E Met ho a E one SINE a a Q amp 5 aN ie t
86. or 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 SEBU7808 11 Illustration 236 g01152685 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 101547608 Seat Side Rails Adjust SMCS Code 7312 025 Illustration 237 g00804394 Caterpillar recommends adjusting the side rails after the initial 500 hours of machine operation After the initial 500 service hours perform this procedure when it is necessary Reference Refer to Service Manual SENR6615 Contour Series Seat for the adjustment procedure SEBU7808 11 103694709 Secondary Steering Test SMCS Code 4300 081 SST 4300 081 SE 4324 081 4324 Ay WARNING The service brake must be checked in order to en sure proper operation before you test the supple mental steering syst
87. plugs for both A pin joints 3 Attach a piece of tubing that is at least 610 mm 2 ft toa 1U 5718 vacuum pump Mark the tubing 305 mm 12 inch from the open end Cut the open end of the tube at a 45 degree angle in order to allow the tube to be inserted into the joint properly 4 Install a sampling bottle onto the vacuum pump and insert 305 mm 12 inch of the tubing through the filler plug opening Insert the correct amount of tubing through the filler plug opening in order to make sure that the end of the tubing is at the bottom of the oil cavity Use the mark on the tubing from step 3 as a guide SEBU7808 11 5 Fill the sampling bottle and withdraw the tube from the filler plug opening 6 Drain the sampling bottle into a suitable container 7 Until no oil remains in the A pin joints repeat the following steps 4 5 and 6 8 Fill each pin joint with 0 25 L 8 oz of SAE 80w90 oil 9 Install the filler plugs for both A pin joints 10 Start the engine Move the boom through a minimum of four complete cycles This will force any trapped air to the top of the joint Inspect the joint for leaks Check the oil level of the joint Reference Refer to Operation and Maintenance Manual Loader Boom Pin Oil Level Check for more information Reference Refer to Special Publication NEHP6013 S O S Fluid Analysis Products for more information 02157449 Loader Boom Pin Oil Level Check SMCS Code
88. pressure cap 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 02156175 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Level 1 results may indicate a need for Level 2 Analysis 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 befor
89. r starting aid cylinder 2 and discard the empty ether starting aid cylinder SEBU7 808 11 3 Remove the used gasket Install the new gasket that is provided with every new ether starting aid cylinder 4 Install new ether starting aid cylinder Tighten the ether starting aid cylinder hand tight Tighten the cylinder retaining clamp securely 5 Close the engine access door 102236759 Fuel System Prime SMCS Code 1250 548 1 Open the engine access door on the left side of the machine _ amp i I i o p p 1 of z ig NS ie H AA LE 3 hey Pit 1A E Aa y ya jH anea E Hes deol ti ine Ai 4 a oo mA lp RL C7 C Illustration 180 g01002079 2 Attach a piece of bulk hose to a sampling probe Install the sampling probe with the piece of bulk hose onto the valve assembly Note Consult your Caterpillar dealer for the proper tooling or refer to the parts manual for your machine 3 Position a suitable container under the hose 4 Turn the toggle switch 1 to the ON position Toggle switch 1 is for the fuel priming pump 5 Allow the air fuel mixture to flow into the suitable container until the fuel flows in a steady stream 6 Turn the toggle switch 1 to the OFF position 7 Remove the sampling probe with the piece of bulk hose from the valve assembly 8 Start the engine The engine should start The engine should run smoothly If th
90. rrect amount of oil 5 Add three 1 L 1 1 qt bottles of 1U 9891 Hydraulic Oil Additive to the differential 6 Clean the filler plugs and install the filler plugs Illustration 143 g00840708 Rear Differential Filler Plug 3 7 Repeat steps 2 through 6 for the rear final drives and the rear differential Note Some machines require no 1U 9891 Hydraulic Oil Additive to the rear differential since those machines are without a rear brake system Reference Refer to Operation and Maintenance Manual Capacities Refill for the correct requirements of the additive to the differential 8 If the specified amount of oil will not fit in the final drives install the final drive filler plugs Operate the machine on level ground for a few minutes in order to equalize the oil level in the axles 9 Remove the final drive filler plugs and add the remaining oil The oil level should reach the bottom of the filler plug opening Note If the oil level is higher than the filler plug opening do not allow the oil to drain to the proper level Install the filler plug 122 Maintenance Section Differential and Final Drive Oil Level Check 101624405 Differential and Final Drive Oil Level Check SMCS Code 3278 535 FLV 4050 535 FLV 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 wit
91. s Adjust cc ceecceeeeeeeeeeees 158 secondary Steering Test cccccccseeeeeeeeeees 159 Window Washer Reservoir Fill 00008 164 Window Wiper Inspect Replace 00008 165 Every 10 Service Hours or Daily Alternator Inspect cccccccceccseecseeseeeeeeseesaes 99 Backup Alarm Test ccccceccseeceeeceeseeeeeeeees 104 Bucket Cutting Edges Inspect Replace 108 Bucket Stops Inspect Replace ccccee 109 Bucket Wear Plates Inspect Replace 112 Cooling System Coolant Level Check 116 Engine Air Filter Service Indicator Inspect 127 Engine Oil Level Check cccccccseeceeeeeeeeeees 131 Engine Water Pump Inspect ceeeeeees 135 Hydraulic System Oil Level Check 148 Loader Boom Pin and Lift Cylinder Pin Inspect 153 Loader Pins and Bearings Lubricate 154 Seat Belt Inspect ce cceccseeeseeeeeeneeseesaees 157 Starting Motor Inspect 20 eee ceeeceeeeeeeeee ees 159 Transmission Oil Level Check 00c 00008 163 Turbocharger Inspect cccceeesseeeeeeeeseeees 164 Windows Clean osiswileteesiaseceet ced crngeenerGenehncw 165 Every 50 Service Hours or Weekly Cab Air Filter Clean Replace cceeee 112 Fuel System Primary Filter Water Separator Check Dra o
92. s accumulating time when the ignition switch closes When the OFF position of the timer reaches the preset value the pump will turn ON The pump remains activated for the time period that is preset on the ON timer When the ignition is turned OFF the used time is saved for an unlimited duration Turn the ignition to the ON position The automatic lubrication operation will finish the cycle time Note Do not use the zero setting that is located on the timer switches Note The factory setting for the OFF position is 4 16 minutes The factory setting for the ON position is 2 4 minutes SEBU7808 11 Table 14 eee Interval ve aes Cycle Time Switch cee Switch A Setting Setting 0 0 minutes 0 0 minutes 1 4 minutes 1 2 minutes 2 8 minutes 2 4 minutes 3 12 minutes 3 6 minutes 4 16 minutes 4 8 minutes 5 20 minutes 5 10 minutes 6 24 minutes 6 12 minutes 7 28 minutes 7 14 minutes 8 32 minutes 8 16 minutes 9 36 minutes 9 18 minutes A 40 minutes A 20 minutes B 44 minutes B 22 minutes C 48 minutes C 24 minutes D 52 minutes D 26 minutes E 56 minutes E 28 minutes F 60 minutes F 30 minutes Note If the Lincoln 94824 Pump or the printed circuit board are replaced in the field contact Lincoln Technical Service Department at 314 679 4200 ext 4782 for instructions on special jumper pin setting for timer operation prior to installation and start up i0261
93. s 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 SEBU7 808 11 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 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
94. s engine or consult your Caterpillar dealer Note A qualified mechanic should adjust the engine valve lash because special tools and training are required Note The engine crankcase breather is located inside the valve cover This breather does not require a maintenance interval Caterpillar recommends replacing the crankcase breather during an engine overhaul In order to replace the breather element the valve cover will need to be replaced NOTICE Attempts to clean the engine crankcase breather may cause damage to the element 103952000 Engine Valve Rotators Inspect SMCS Code 1109 040 Ay WARNING 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 Caterpillar recommends replacing valve rotators that are operating improperly An improperly operating valve rotator will shorten valve life because of accelerated wear on the valves Also metal particles from a damaged valve rotator could fall into the cylinder and damage to the piston head and to the cylinder head may result 135 Maintenance Section Engine Valve Lash Check Illustration 178 g00882731 Start the engine and run the engine at low idle Watch the top surface of each valve rotator Whenever an inlet valve closes or an exhaust valve closes each valve rotator should turn If a valve rotator fails to turn consult your Cat dealer for service 10
95. sassembling 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 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 refer to Operation and Maintenance Manual Cooling System Coolant Extender ELC Add or consult your Caterpillar dealer If you change the coolant of a machine to Extended Life Coolant from another type of coolant use a Caterpillar cleaning agent to flush the cooling system After you drain the cooling system thoroughly flush the cooling system with clean water All of the cleaning agent must be removed from the cooling system SEBU7808 11 If an Extended Life Coolant was previously used flush the cooling system with clean water No other cleaning agents are required Use the following procedure to change
96. stration 159 127 Maintenance Section Engine Air Filter Service Indicator Inspect g00841372 Cover the air inlet opening Clean the inside of the air filter housing Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged Uncover the air inlet opening Install a new secondary filter element Install a clean primary element and install the cover on the air filter housing Fasten the clips in order to secure the cover Close the engine access door 01549255 Reference Refer to Operation and Maintenance Engine Air Filter Service Manual Engine Air Filter Primary Element Clean Replace for the correct procedure for Indicator Inspect servicing the primary element SMCS Code 7452 040 Illustration 158 g00805000 3 Remove the secondary filter element NOTICE service the air cleaner only with the engine stopped Engine damage could result 128 Maintenance Section Engine Air Filter Service Indicator Inspect Replace Illustration 160 g00804672 Open the engine access door on the left side of the machine The air filter service indicator is located on the air inlet line If the yellow piston in the filter service indicator is in the red zone service the air cleaner Engine Air Filter Service i01548088 Indicator Inspect Replace SMCS Code 7452 040 7452 510 Illustration 161 g00804672 SEBU7
97. t Replace Illustration 198 g00935858 2 Remove the cap from port 6 Attach a drain hose that is equipped with a quick connect fitting to tee 8 Place the end of the drain hose into a suitable container in order to collect excess hydraulic oil Pour clean hydraulic oil into port 6 Continue to pour hydraulic oil until the hydraulic oil comes out of the drain hose that is attached to tee 8 3 Remove the drain hose and install the cap onto port 6 The steering pump case is now filled 4 Remove the cap from port 9 Attach a drain hose that is equipped with a quick connect fitting to tee 7 Place the end of the drain hose into a suitable container in order to collect excess hydraulic oil Pour clean hydraulic oil into port 9 Continue to pour hydraulic oil until the hydraulic oil comes out of the drain hose that is attached to tee 7 5 Remove the drain hose and install the cap onto port 9 The case for the implement pump is now filled 6 Replace any hydraulic oil that was lost during the installation of the hoses Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check for more information Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction hoses and the hose clamps 102281910 Hydraulic System Oil Filter Steering and Implement Pilot Replace SMCS Code 5068 510 PS NOTICE C
98. t can be easily damaged by an abrasive material The display is not sealed Do not immerse the display with liquid Camera Illustration 125 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 SEBU815 7 Work Area Vision System 113 Maintenance Section Case Drain Oil Filters Replace 01543124 Case Drain Oil Filters Replace If Equipped SMCS Code 5091 510 Illustration 126 g00801622 1 Case drain filter for the steering pump 2 Case drain filter for the implement pump 3 Case drain filter for the fan motor The case drain filters are located under the access door in the platform behind the cab 1 Stop the engine 2 Use a strap type wrench to remove the filter element Dispose of the used filter element properly 3 Clean the filter mounting base Make sure that all of the used gasket is removed from the filter mounting base 4 Lubricate the gasket of a new filter element with clean hydraulic oil 5 Install the new filter element by hand When the gasket contacts the filter mounting base tighten the filt
99. the cooling system coolant ELC Illustration 128 g01093449 The cooling system pressure cap is located on the left side of the machine on the top of the radiator 1 Slowly loosen the cooling system pressure cap in order to relieve system pressure Remove the cooling system pressure cap ba Illustration 129 g01093450 The drain valve is located at the rear of the machine under the engine compartment 2 If equipped remove the bottom guard in order to access the coolant drain valve 3 Open the drain valve Allow the coolant to drain into a suitable container 4 Flush the cooling system with clean water until the draining water is transparent 5 Close the drain valve Replace the bottom guard if equipped 6 Replace the water temperature regulator 115 Maintenance Section Cooling System Coolant Extender ELC Add Reference Refer to Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the correct procedure 7 Add the coolant solution Reference Refer to Operation and Maintenance Manual Capacities Refill for the capacity of the cooling system 8 Start the engine Run the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes 9 Check the coolant level Reference Refer to Operation and Maintenance Manual Cooling System Level Check for the correct procedure 10
100. til the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 7 Tighten the filter according to the 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 Cat 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 177 g01001078 8 Remove the engine oil filler cap and fill the engine crankcase with oil Reference Refer to Operation and Maintenance Manual Capacities Refill for the proper amount of oil 9 Clean the oil filler cap and install the oil filler cap 10 Start the engine and allow the oil to circulate Check for leaks 11 Check the engine oil level Reference Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure SEBU7808 11 101923706 Engine Valve Lash Check SMCS Code 1105 535 For the correct procedure refer to the appropriate service Manual module for your machine
101. urized air can be used to clean a primary element that has not been cleaned more than two 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 126 Maintenance Section Engine Air Filter Secondary Element Replace 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 154 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

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