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MAINTENANCE INTERVALS - Safety

1. 7 Observe sight gauge 2 in order to maintain the coolant levels 8 Install the cooling system pressure cap Close the access door Fast Fill If your machine is equipped with a service center you may drain the coolant through the fast fill port or you may add the coolant through a fast fill port Sy O G e es a Na Illustration 126 g01338918 1 Remove the dust cover 3 2 Attach the hose to the male coupling Use a 127 9087 Nozzle for this port 3 Drain the coolant or add the coolant as needed Reference For more information refer to Operation and Maintenance Manual Service Center 102540933 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL When a Caterpillar Extended Life Coolant ELC is used an Extender must be added to the cooling system 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 SOE ADSL SLL LSAT g01272269 Illustration 127 1 The cooling system pressure cap is located inside the access door 1 on top of the engine compartment Slowly remove the cooling system pressure cap 2 Use a coolant test kit in order to check the concentration of the coolant NOTICE Care must be taken to ensure that
2. 100993589 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 102 Maintenance Section Battery Hold Down Tighten SEBU8075 11 102533077 Battery Hold Down Tighten SMCS Code 7257 527 T LH LLL D i H U 7 kall Illustration 100 Open the battery compartment on the right rear corner of the cab platform 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 locknuts two per battery to a torque of 14 2 N m 10 1 5 Ib ft 101835250 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 1 Turn the engine start switch key to the OFF position Turn all of the switches to the OFF position 2 Turn the battery disconnect switch to the OFF position Remove the key 3 Disconnect the positive battery cable at the battery disconnect switch The battery disconnect switch is connected to the machine frame Note Do not allow the disconnected battery cable
3. 24 Spare 10 Amp 25 Spare 10 Amp 26 Spare 15 Amp 27 Spare 15 Amp 28 Spare 15 Amp 29 Spare 10 Amp 30 Spare 10 Amp 31 Spare 10 Amp 32 Precleaner for the Cab 10 Amp 33 Side Wipers 10 Amp 34 Blower Motor 20 Amp 35 Monitoring System 15 Amp 36 Power Train Control 15 Amp 37 Front Floodlights Fender 10 Amp 38 Front HID Lights ROPS 15 Amp 39 Rear HID Lights Fender 10 Amp 40 Spare 10 Amp 134 Maintenance Section High Intensity Discharge Lamp HID Replace SEBU8075 11 102245859 High Intensity Discharge Lamp HID Replace If Equipped SMCS Code 1434 510 HID lamps operate at very high voltages To avoid electrical shock and personal injury disconnect power before servicing HID lamps HID bulbs become very hot during operation Before servicing remove power from lamp for at least five minutes to ensure lamp is cool NOTICE Although HID bulb materials may change over time HID bulbs produced at the time of the printing of this manual contain mercury When disposing of this com ponent or any waste that contains mercury please use caution and comply with any applicable laws _ 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 N
4. or consult your Caterpillar dealer 5 Observe the sight gauge in order to maintain the coolant level within the sight gauge 6 Install the cooling system pressure cap and close the access door 102540722 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes N No N N N N AAS SL LLL ATT Illustration 129 g01272283 1 Observe the sight gauge in order to maintain the coolant level within the sight gauge 114 Maintenance Section Cooling System Coolant Sample Level 1 Obtain SEBU8075 11 PSOE x ii N N N N N N N N N N Ni Illustration 130 g01272269 2 If additional coolant is necessary remove the cooling system pressure cap that is located inside the access door 1
5. 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 SEBU8075 11 125 Maintenance Section Engine Oil Sample Obtain 4 o o uv Illustration 155 g01267792 1 The engine oil level gauge 2 is located inside the engine access door on the left side of the machine Open the access door A Illustration 156 g01239233 2 Check the engine oil level while the engine is stopped Maintain the engine oil level in the shaded area A of the engine oil level gauge 3 If necessary add oil through the filler tube 1 4 Close the access door Engine Oil Sample Obtain SMCS Code 1348 008 7542 g02606459 Illustration 157 The sampling valve for the engine oil is located on the engine oil filter base on the left side of the machine Reference Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information about obtaining a fluid sample 102534690 Engine Oil and Filter Change SMCS Code 1318 510 Hot oil and hot components can cause personal injury Do not allow hot oil or hot 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
6. Illustration 195 g01278534 2 The hydraulic filter is located on the left side of the pump compartment Open the access doors 146 Maintenance Section SEBU8075 11 Hydraulic System Oil Level Implement Hydraulic Fan Check 2 Lower the attachment to the ground and stop the engine Illustration 196 g01278787 Remove the filter and dispose of the filter properly Apply a thin coat of oil to the seal on the new filter Install the new filter hand tight until the seal of the filter contacts the base Note the position of the index marks on the filter in relation to a fixed point Illustration 197 g01270582 on the filter base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 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 Close the access doors 103247262 Hydraulic System Oil
7. repair damaged bucket wear plates or replace damaged bucket wear plates 1 Raise the bucket and block up the bucket 2 Loosen bolts and remove wear plates 3 Install new wear plates Tighten the bolts to the specified torque Reference For more information refer to Specifications SENR3130 Torque Specifications or consult your Caterpillar dealer 103247220 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Note The filters must be cleaned more often if the machine is being operated in dusty conditions Illustration 114 g01267423 1 Lift the cover on the outside rear of the cab Illustration 115 g01267424 2 Remove retainer 2 from the cover Remove fresh air filter 1 Illustration 116 g01267426 3 Remove the filter cover behind the seat Remove the recirculation filter 4 Clean the filter elements with pressure air or wash the filter elements in warm water with a nonsudsing household detergent SEBU8075 11 109 Maintenance Section Camera Clean 5 If water was used to wash the filter elements rinse the filter elements in clean water and allow the filter elements to air dry thoroughly 6 Install the recirculation filter and the filter cover behind the seat 7 Install fresh air filter 1 and retainer 2 Close the cover on the outside rear of the cab 102816405 Camera Clean
8. 4 Clean the breaker relief valve in a clean nonflammable solvent Dry the breaker relief valve thoroughly by shaking or by using compressed air 5 Install the breaker relief valve 6 Close the access door 7 Repeat steps 2 through 5 for the front axle breaker relief valve 104401714 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates The axle oil cooler filter should be replaced when a failure occurs in the axles Note The oil filters contain a 140 micron screen Illustration 95 g02586177 The axle oil cooler filters are located under the engine compartment There is an access area on the underside of the machine a Te J g01451765 Illustration 96 1 Stop the engine 2 Push the button on the top of each axle breaker relief valve in order to relieve any pressure Note Refer to Operation and
9. 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 o Remove the bulb from the HID lamp A 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 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 102599085 High Pressure Screens Clean Replace If Equipped SMCS Code 5068 070 Z3 5068 510 Z3 There are a total of 7 hydraulic screens on your machine If the system becomes contaminated or if a major failure occurs clean the screens If a screen is damaged replace the screen Illustration 177 g01260005 The screen for the steering pump is located inside the access door directly behind the cab Il
10. E Pin J Pin for Lower Articulation Joint Y Y Pin 1 Remove any buildup of grease Check that each Table 17 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 procedures C 2 2 Check the grease level at the top vent port of the E 3 5 reservoir F 2 2 Reference For filling procedures refer to G 1 8 Operation and Maintenance Manual Automatic Lubrication Grease Tank Fill H 1 2 J 1 Settings of the Injectors for the i 3 Autolube System i 5 The controller of the autolube system is preset from X 2 8 the factory The lubrication is dispensed at 15 minute Y 0 8 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 17 Note By using the above sett
11. Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the refill capacity of each axle 13 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 Remove the final drive filler plugs and add the remaining oil 14 Operate the machine for a few minutes and recheck the oil level The oil level should reach the bottom of the filler plug opening 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 15 Repeat this procedure for the other differential and final drives 102912377 Differential and Final Drive Oil Level Check SMCS Code 3278 535 FLV 4050 535 FLV Note Perform this procedure on one axle at a time Illustration 138 g01449379 1 Position the wheels so that the final drive drain plug 1 is in the lowest position This will ensure that the final drive filler plug 2 is in the correct position 2 Push the button on the top of each axle breaker relief valve in order to relieve any pressure Note Refer to Operation and Maintenance Manual Axle Breaker Relief Valve Clean for the axle breaker relief valve locations 3 Remove the final drive filler plug The oil level should be at the bottom of the filler plug opening If necessary add SAE 50
12. on top of the engine compartment 3 Add the appropriate amount of coolant and install the filler cap 102534322 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers 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 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 op
13. 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 i03247100 Axle Breaker Relief Valve Clean SMCS Code 5118 070 ZX There is a breaker relief valve on both axles The front axle breaker relief valve is located inside the front frame above the axle housing Illustration 92 g01450318 Front axle breaker relief valve The access door for the rear axle breaker relief valve is located behind the cab in the middle of the cab platform Illustration 93 Rear axle breaker relief valve location Illustration 94 g01450394 Rear axle breaker relief valve 1 Open the access door in order to access the rear axle breaker relief valve 2 Push the top of the breaker relief valve in order to relieve any pressure 100 Maintenance Section Axle Oil Cooler Filter Replace SEBU8075 11 3 Remove the breaker relief valve
14. A used thermostat can be installed if the thermostat conforms to test specifications and the thermostat is not damaged Do not install a used thermostat that has excessive buildup or deposits NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a thermostat Depending on load failure to operate with a thermo stat could result in either an overheating or an over cooling condition NOTICE If the thermostat is installed incorrectly it will cause the engine to overheat 4 Install a new seal in the thermostat housing Install a new thermostat and a new gasket 5 Install the hoses 6 Add extended life coolant until the coolant level is visible in the sight gauge 116 Maintenance Section Crankshaft Vibration Damper Inspect SEBU8075 11 102517124 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 g01259311 Illustration 134 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 the other engine components A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range Caterpillar recommends replacing the vibration damper for any
15. Code 4251 081 4267 081 1 Fasten the seat belt 2 Make sure that the steering frame lock is in the unlocked position 3 Park the machine on a hard dry level surface 4 Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles The following tests are used to determine whether the braking system is functional These tests are not intended to measure the maximum brake holding effort The required brake holding effort for sustaining a machine at a specific engine rpm varies from one machine to another machine The variations include differences in the engine setting the power train efficiency the brake holding ability etc Service Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake This test is performed when the service brakes are engaged If the machine begins to move compare the engine rpm to the engine rpm of a prior test This will indicate the amount of system deterioration 1 Start the engine Raise the work tool slightly Apply the service brake Release the parking brake 2 Move the hydraulic lockout control to the UNLOCKED position 3 Place the transmission in THIRD SPEED FORWARD while the service brakes are applied 4 Gradually increase the engine speed to high idle The machine should not move 5
16. Illustration 162 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 g01239795 Illustration 163 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 128 Maintenance Section Ether Starting Aid Cylinder Replace SEBU8075 11 104411153 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD Breathing ether vapors or repeated contact of ether with skin can cause personal injury Person al injury may occur from failure to adhere to the following procedures Use ether only in well ventilated areas Do not smoke while changing ether cylinders Use ether with care to avoid fires Do not store replacement ether cylinders in living areas or in the operator s compartment Do not store ether cylinders in direct sunlight or at temperatures above 49 C 120 F Discard cylinders in a safe place Do not puncture or burn cylinders Keep ether cylinders out of the reach of unautho rize
17. Reduce the engine speed to low idle Place the transmission in neutral Engage the parking brake Lower the work tool to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation Parking Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move reduce the engine speed immediately and apply the service brake pedal This test is performed when the parking brake 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 work tool slightly Engage the parking brake 2 Move the hydraulic lockout control to the UNLOCKED position 3 Place the transmission in THIRD SPEED FORWARD while only the parking brake is engaged The parking brake indicator light should come on 4 Gradually increase the engine speed to high idle The machine should not move 5 Reduce the engine speed Place the transmission in neutral Lower the work tool 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 SEBU8075 11 105 Maintenance Section Bucket Cutting Edges Inspect Re
18. Repair the supplemental steering system before returning the machine to service 103688974 Service Brake Wear Indicator Check SMCS Code 4255 535 IND 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 This procedure requires two people One person must engage the service brakes and the other person must measure the disc wear Care must be taken when you perform this procedure Oil leakage from the brake system will occur Keep all other personnel away from the machine or in sight of the operator 1 Park the machine on a level surface away from other equipment and other personnel and lower the implement to the ground Place the transmission in NEUTRAL Engage the parking brake and turn off the engine 2 Install the steering lock and chock the wheels 3 Start the engine in order to build brake system pressure 4 Stop the engine Allow the axle oil to settle before proceeding to the next step Note Keep the engine off when the br
19. TNK 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 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 Pri
20. access door 132 Maintenance Section Fuel Tank Cap and Strainer Clean SEBU8075 11 102536034 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 Z2 1273 070 STR Illustration 172 g01269180 The fuel tank cap is located on the left side of the bumper 1 Remove the fuel tank cap 2 Remove the strainer from the filler opening 3 Wash the fuel tank cap and the strainer in a clean nonflammable solvent 4 Install the strainer into the filler opening 5 Install the fuel tank cap Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S N Illustration 173 g02609856 The three drain valves are under the fuel tank at the rear of the machine Illustration 174 g01111712 1 Open the drain valves Allow the water and the sediment to drain into a suitable container 2 Close the drain valves 102534113 Fuses Replace SMCS Code 1417 510 NOTICE Replace the fuses with the same type and size only Otherwise electrical damage can result If it is necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer Fuses Fuses protect the electrical system from damage that is caused by overloaded circuits Replace the fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary Illustration 175 g01267032 SEBU8
21. goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system NOTICE If the refrigerant system has been open to the outside air without being plugged for more than 30 minutes the receiver dryer must be replaced Moisture will en ter an open refrigerant system and cause corrosion which will lead to component failure SEBU8075 11 151 Maintenance Section Rollover Protective Structure ROPS Inspect Illustration 209 g01449602 The refrigerant dryer is located behind the cab Refer to Service Manual SENR5664 Air Conditioning and Heating System with R 134a Refrigerant for All Caterpillar Machines for the proper procedure to change the receiver dryer assembly and for the procedu
22. installed recheck the belt adjustment after 30 minutes of operation Note This machine is equipped with a belt tensioner 2 The belt tensioner automatically adjusts the belt to the correct position 5 Install the engine access covers 6 Close the grill assembly Replace 1 Replace the belt if any of the following conditions exist e Excessive cracking e Excessive wear e Excessive damage 2 Park the machine on level ground Lower the bucket to the ground Move the transmission control switch to the NEUTRAL position and engage the parking brake Shut off the engine 3 The battery disconnect switch is located on the control panel on the left side of the rear bumper Turn the battery disconnect switch to the OFF position 4 Open the grill assembly on the right side of the machine 5 Remove the engine access covers in order to gain access to the belt 6 Release the tension on the serpentine belt 1 Insert a ratchet into the square hole in the belt tensioner and rotate the belt tensioner in a clockwise direction 7 Remove the belt 8 Install a new belt 9 When you release the tension off the belt tensioner the belt will automatically adjust to the correct position Recheck the belt tension 10 Turn the battery disconnect switch to the ON position 11 Install the engine access covers 12 Close the grill assembly 104402685 Brake Accumulator Check SMCS Code 4263 535 Hydraulic accum
23. nitrogen if necessary Reference Refer to the Tire Inflation Information section of the Operation and Maintenance Manual for more information SEBU8075 11 155 Maintenance Section Transmission Magnetic Screen Clean 102512909 Transmission Magnetic Screen Clean SMCS Code 3030 070 MGS 3159 070 MGS Illustration 217 g01257508 The transmission magnetic screen is located on the left side of the transmission Illustration 218 g00110013 1 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 2 Remove covers 1 and seals 2 3 Remove screen tube assemblies 3 and suction screens 4 4 Wash the screen tube assemblies and the suction screens in clean nonflammable solvent Allow the components to dry 5 Install screen tube assemblies 3 and suction screens 4 6 Inspect seals 2 for damage Replace the seals if necessary 7 Install seals 2 and covers 1 102539319 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 NENG25
24. 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 0 S oil analysis detected a large amount of gear train wear that is not caused by a lack of oil e The alignment marks on the hub and on the outer ring are not in alignment because the rubber seal has separated The vibration damper can be used again if none of the above conditions are found and the damper is not damaged Note Some wobble on the outer ring of the vibration damper is normal Consult your Caterpillar dealer for more information 103595170 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 Note Perform this procedure on one axle at a time Illustration 135 g01449379 1 Position the wheels so that the final drive drain plug 1 is in the lowest position This will e
25. 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 c 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 want 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 7 Repeat steps 5 through 6 c for the other filter 8 The oil filler cap 2 is located above the engine oil filters Remove the filler cap 9 Fill the engine crankcase with 126 L 33 US gal of clean oil 10 Clean the filler cap and install the filler cap 11 Start the engine and allow the oil to warm Check the engine for leaks Illustration 160 001239233 12 The engine oil level gauge 3 is located to the left of the filler cap Maintain the engine oil level in the shaded area A of the oil level gauge 13 If necessary add oil through the filler tube 14 Close the access door and stop the engine Fast Fill If your machine is equipped with a service center you may drain the engine oil throu
26. oil until the oil level reaches the bottom of the filler plug opening 118 Maintenance Section Differential and Final Drive Oil Sample Obtain SEBU8075 11 Note If the oil level is higher than the filler plug opening drain the oil to the proper level Install the filler plug Illustration 139 g01449418 Front axle ie Illustration 140 g01449417 Rear axle 4 Remove the differential filler plug The oil level should be at the bottom of the filler plug opening If necessary add SAE 50 oil until the oil level reaches the bottom of the filler plug opening Note If the oil level is higher than the filler plug opening drain the oil to the proper level Install the filler plug 5 Repeat the procedure for the other differential and final drives 102912423 Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4050 008 4070 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of
27. 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 for a few minutes before obtaining the oil sample This will thoroughly mix the oil for a more accurate sample Illustration 141 g01449379 Final Drive Filler Plug SEBU8075 11 119 Maintenance Section Drive Shaft Spline Center Lubricate Illustration 142 g01449418 Front Differential Filler Plug ie Illustration 143 g01449417 Rear Differential 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 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 Sp
28. to contact the disconnect switch 4 Disconnect the negative battery cable at the battery that is connected to the battery disconnect switch If the machine has four 12 volt batteries disconnect the negative battery cables of two of the batteries 5 Make any necessary repairs or replace the battery 6 Reconnect the negative battery cable at the battery that is connected to the battery disconnect switch 7 Reconnect the positive battery cable at the battery disconnect switch 8 Install the key and turn the battery disconnect switch to the ON position 104170030 Belt Inspect Adjust Replace SMCS Code 1397 025 1397 040 1397 510 Inspect 1 Park the machine on level ground Lower the bucket to the ground Move the transmission control switch to the NEUTRAL position and engage the parking brake Shut off the engine Illustration 101 g01254405 2 Open the grill assembly on the right side of the machine Illustration 102 g01278197 3 Remove the engine access covers in order to gain access to the belt SEBU8075 11 103 Maintenance Section Brake Accumulator Check Illustration 103 g01233393 4 Inspect the condition of the serpentine belt 1 The belt deflection should not be more than 14 to 20 mm 0 55 to 81 inch under 110 N 25 Ib of force Use a 144 0235 Belt Tension Gauge in order to measure the tension Note If a new belt is
29. 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 125 g01273210 2 The coolant drain valve is located under the rear of the machine Open the drain valves Allow the coolant to drain into a suitable container 3 Flush the cooling system with clean water until the draining water is clean Close the drain valves 4 Replace the water temperature regulator Reference Refer to Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the correct procedure 112 Maintenance Section Cooling System Coolant Extender ELC Add SEBU8075 11 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 5 Add 268 L 71 US gal of Extended Life Coolant ELC 6 Start the engine Run the engine without the cooling system pressure cap until the thermostat opens and the coolant level stabilizes
30. to this Operation and Maintenance Manual Lubricant Viscosities for more information on the types of grease to use 102061807 Electronic Unit Injector Inspect Adjust SMCS Code 1251 025 1251 040 1290 025 1290 040 The Electronic Control module produces 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 102473339 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY Burn Hazard Engine components may be hot dur ing and after machine operation Hot components can cause serious personal in jury Do not contact hot components with bare skin To avoid personal injury always wear eye and face protection when u
31. 0 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 144 Maintenance Section Hydraulic System Oil Filter Implement Pilot Replace SEBU8075 11 Note The pressure must be removed from the system before service can be performed Refer to this Operation and Maintenance Manual System Pressure Release 1 Park the machine on a level surface and engage the parking brake Stop the engine g01451704 Illustration 192 2 The hydraulic filter is located in the rear of the machine under the engine compartment Clean the area in order to keep dirt out of the filter base Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage 3 Remove the used filter from the filter base Note Used filters should always be disposed of according to local regulations 4 Clean the filter base 5 Apply a thin coat of clean hydraulic oil to the seal on the new filter 6 Install the new filter by hand Instructions for the installation of the filter are printed on the side of each Cat spin on filter For filters that are not Cat branded refer to the installation instructions that are provided by the supplier of the filter 7 Start the engine and operate the m
32. 0 hours for machine hydraulic systems over second and third choice oils when you follow the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual 6000 hour oil drain intervals are possible when using S 0 S Services oil analysis When you switch to Cat HYDO Advanced 10 cross contamination with the previous oil should be kept to less than 10 Consult your 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 6000 hour interval for changing the oil is specific to HYDO Advance 10 The 4000 hour interval for changing the oil is for the following oil types e Cat Hydraulic Oil HYDO e CatTransmission Drive Train Oil TDTO e Cat TDTO TMS e Cat Diesel Engine Oil e Cat Biodegradable Hydraulic Oil HEES e Cat 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 ECF 1 CG 4 CF and TO 4 Note Industrial hydraulic oils are not recommended for use in Caterpillar hydraulic systems These oils are more likely to cause corrosion and excessive wear Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours C
33. 00 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 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 a o Toor of Illustration 219 g01271356 156 Maintenance Section Transmission Oil Change SEBU8075 11 3 The transmission drain plug is located on the bottom of the transmission case and the plug is accessible from the underside of the machine Remove the transmission drain plug and allow the oil to drain into a suitable container 4 Clean the drain plug and install the drain plug Illustration 220 g01271357 5 The access door for the transmission filters is located behind the cab in the middle of the cab platform Open the access door 000 00O Illustration 221 g01271358 There are two transmission filters 6 Remove the five bolts 1 and remove the cover 2 7 Remove the used filter element Be sure to dispose of the used filter properly 8 Install a new filter element and replace the cover 9 Install the cover and the five bolts 10 Repeat steps 6 through 9 for the other filter 11 Close
34. 075 11 133 Maintenance Section Fuses Replace The fuse panel is located under the access door on the right side of the cab platform 1 2 3 4 5 6 7 8 ae ee EB ae ae L i 2 ss pol e oP gl 14 ae a I 5 s ml 35 Oe ee 17 Os a l 37 i TE o s 9 I IL x 20 HA ae 40 g01267591 Illustration 176 1 Monitoring System 10 Amp 2 Voltage Converter 15 Amp 3 Stairway Access Light 15 Amp 4 Horn 15 Amp 5 Automatic Lubrication System 15 Amp 6 Engine Electronic Control Module 10 Amp 7 Transmission Electronic Control Module 10 Amp 8 Product Link 10 Amp 9 Implement Electronic Control Module 15 Amp 10 Spare 10 Amp 11 Beacon and Heated Mirror 15 Amp 12 Front Wipers and Rear Wipers 15 Amp 13 Seat and Air Compressor 15 Amp 14 Implement Electronic Control Module 10 Amp 15 Front Floodlights ROPS 15 Amp 16 Rear Floodlights Radiator 10 Amp 17 Rear Floodlights ROPS 10 Amp 18 WAVS Monitor 10 Amp 19 Spare 10 Amp 20 Spare 10 Amp 21 Spare 10 Amp 22 Spare 10 Amp 23 Spare 10 Amp
35. 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 begins 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 SEBU8075 11 99 Maintenance Section Axle Breaker Relief Valve Clean Table 18 Mee TIME Interval ON TIME Cycle Time otary Between Rotary of the Switch Cycles se Pump 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
36. 132 Hoses and Clamps Inspect Replace 135 Hydraulic System Oil Filter Hydraulic Fan Return Replaces E EEA EE E ES 143 Hydraulic System Oil Filter Implement Pilot ETO E E EE AEE E 144 Hydraulic System Oil Filter Steering Pilot Replace a e A a E a 145 Hydraulic System Oil Sample Implement Hydraulic Fany eara A a iaa lai 147 Hydraulic System Oil Sample Steering Brake ODAN re eea EEA 147 Transmission Oil Filter Replace 205 157 Transmission Oil Sample Obtain 0 158 Every 1000 Service Hours or 6 Months Articulation Bearings Lubricate 0 cceeee 95 Battery Hold Down Tighten cece 102 Drive Shaft Support Bearing Lubricate 120 Rollover Protective Structure ROPS Inspect 151 Transmission Oil Change ssec 155 Every 2000 Service Hours or 1 Year Axle Breaker Relief Valve Clean 0008 99 Brake Accumulator Check cceeeeeeeeeees 103 Differential and Final Drive Oil Change 116 Hydraulic System Oil Implement Hydraulic Fan CHANGE ch cies each eee dee Gane 138 Hydraulic System Oil Steering Brake CHAN GC E ETE E E T TTT 140 Hydraulic Tank Breaker Relief Valve Clean 148 Refrigerant Dryer Replace cceeeeeceeee 150 Service Brake Wear Indicator Check 153 Every Year Cooling System Coolant Sample Level 2 Ob
37. 33 Engine Crankcase Breather Clean SMCS Code 1317 070 The engine crankcase breathers are located on each side of the engine Perform this procedure for each breather 1 Park the machine on level ground Lower the bucket to the ground Move the transmission control switch to the NEUTRAL position and engage the parking brake Shut off the engine 2 Open the engine access door on the side of the machine Illustration 154 g01451213 3 Loosen breather outlet hose clamp 1 Remove the hose from the breather cover 4 Loosen breather inlet hose clamp 2 and remove breather 3 5 Remove the cover from the breather 6 Check the condition of the cover seal If the seal is damaged replace the seal 7 Wash the breather element and the cover in clean nonflammable solvent Shake the element dry or use air pressure 8 Inspect the hose for damage If necessary replace the hose 9 Install the breather element in the cover 10 Install breather 3 Tighten breather inlet hose clamp 2 11 Install the outlet hose and tighten breather outlet hose clamp 1 12 Close the engine access door 13 Repeat steps 2 through 12 for the other breather 102164781 Engine Mounts Inspect SMCS Code 1152 040 Caterpillar recommends checking the engine mounts for deterioration and for proper bolt torque This will help to prevent excessive engine vibration that is caused by improper mounting 102534375
38. 450909 1 Park the machine on level ground Lower the work tool to the ground Engage the parking brake and stop the engine 2 The oil level gauge for the ORS is located inside the small access door on the front of the engine compartment Open the access door 3 The oil level should be visible in the sight gauge 4 Ifthe oil level is low SAE 10W30 oil should be added For more information refer to Operation and Maintenance Manual Oil Renewal System Oil Add Note Keeping a daily maintenance log of all the additions of oil is necessary for determining whether the ORS is working properly 104411824 Radiator Core Clean SMCS Code 1353 070 KO Access the radiator cores through the side grill assemblies located at the rear of the machine 150 Maintenance Section Refrigerant Dryer Replace SEBU8075 11 NNN N y Illustration 208 g00100062 Compressed air high pressure water or steam can be used to remove dust and other debris from the radiator core However the use of compressed air is preferred Reference Refer to Special Publication SEBD0518 Know Your Cooling System for the complete procedure for cleaning the radiator core 102913523 Refrigerant Dryer Replace SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective
39. 8075 11 149 Maintenance Section Oil Renewal System Oil Add Oil Renewal System Oil Add If Equipped SMCS Code 1348 538 Note Keeping a daily maintenance log of all the additions of oil is necessary for determining whether the ORS is working properly Park the machine on level ground Lower the attachment to the ground Engage the parking brake and turn off the engine Note There may be two methods for adding oil to the ORS on your machine Manual SEER SCGSSGN SUSSRESR ES R Illustration 205 g01450909 In order to fill the ORS manually add oil through the filler tube until the sight gauge indicates that the ORS is FULL Fast Fill If Equipped o E a Fag i So Pi Illustration 206 g01446867 In order to fill the ORS attach a 126 7539 Nozzle to the male coupling 2 Fill the ORS until the sight gauge indicates that the ORS is FULL Note If equipped you may also use the FULL indicator light 1 in the service center in order to determine when the ORS is full Reference For more information refer to Operation and Maintenance Manual Service Center 102539506 Oil Renewal System Oil Level Check If Equipped SMCS Code 1348 535 FLV FSSSIGGGGSGSS NURSES ES Illustration 207 g01
40. 9 Install the filler strainer 140 Maintenance Section Hydraulic System Oil Steering Brake Change SEBU8075 11 Illustration 185 g01237715 10 Fill the hydraulic oil tank with clean oil Make sure that the oil level is within the green range A on the sight gauge 11 Start the engine and run the engine for at least ten seconds Then stop the engine and add hydraulic oil to the tank until the oil level is in the green range A on the sight gauge 12 Start the engine and run the engine at low idle Cycle the implements so that all hydraulic systems are filled with oil 13 Stop the engine and top off the hydraulic tank so that the oil level is within the green range A on the sight gauge Note The oil must be free of air bubbles If air bubbles are present in the hydraulic oil air is entering the hydraulic system Inspect the hydraulic suction line and the hose clamps 14 If necessary tighten any loose clamps or any loose connections Replace any damaged hoses 15 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary Install the filler cap 16 Stop the engine Close the access door Fast Fill Port If your machine is equipped with a service center you may drain the hydraulic oil through the fast fill port or you may add the hydraulic oil through a fast fill port Illustration 186 g01338923 1 Remove the dust
41. BD 6107 086 BD Note This procedure is for machines that are not equipped with the automatic lubrication system 1 Illustration 105 g01451266 Typical example 1 Wipe off the fittings before any lubricant is applied 2 Apply lubricant to pins 1 2 3 and 4 through the grease fittings Illustration 106 g01451493 106 Maintenance Section Bucket Stops Inspect SEBU8075 11 In order to lubricate pin 1 apply grease through the remote fitting that is located on the right side of the machine near the articulation joint Illustration 107 g01451494 In order to lubricate pins 3 and 4 apply grease through the fittings that are located on the underside of the bucket links Note Pins 5 6 7 and 8 do not require grease Consult your Caterpillar dealer if these pins experience excessive leaking noise or excessive temperatures for further information 103247197 Bucket Stops Inspect SMCS Code 6107 040 SQ Illustration 108 g01449696 Note Do not use additional hydraulic force in order to make contact with the bucket stops Take all measurements at the time of initial contact in order to prevent twisting 1 Tilt back the bucket completely Check for uneven contact between the
42. Hours or Daily Backup Alarm Test 2 ceceeeeeeeeeeeeeeteeeees 101 Bucket Cutting Edges Inspect Replace 105 Bucket Linkage and Loader Cylinder Bearings LUDEA 2 2 oii a a ceca fetes peis feeds paacteeeea candi 105 Bucket Stops Inspect ecceceeeeeeeeeteeteees 106 Bucket Tips Inspect Replace ee 106 Bucket Wear Plates Inspect Replace 108 Cooling System Coolant Level Check 113 Engine Oil Level Check 124 Fuel System Primary Filter Water Separator Check Drain 0 00 eee eeeececeeeeeeeeeeeeneeeeeeennaeeeeeeeaaes 129 Hydraulic System Oil Level Implement Hydraulic Fan CHECK ccccccceesceeeecteeecteeeeneeeeeseeeseneeenes 146 Hydraulic System Oil Level Steering Brake CHECK wastes tas rn ltteers sath adie te ee 146 Oil Renewal System Oil Level Check 149 Seat Belt Inspect oo eee ee eeeeeeteeeeeeeeeeeeees 151 Transmission Oil Level Check 157 Every 50 Service Hours or Weekly Cab Air Filter Clean Replace cee 108 Fuel Tank Water and Sediment Drain 132 Tire Inflation Check cccceccccceeeeeeeeeeseeeeeees 154 Initial 250 Service Hours Hydraulic System Oil Filter Hydraulic Fan Return Replaces aaan iere tane aa er aoe abet 143 Hydraulic System Oil Filter Implement Pilot Replacement a Reed aaae enanar EE GRA 144 Hydraulic System Oil Fi
43. 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 Display ELES TOGSOTG Camera Illustration 117 g01223034 WAVS display Use a soft damp cloth in order to clean the display The display has a soft plastic surface that can be easily damaged by an abrasive material The display is not sealed Do not immerse the display with liquid Illustration 118 g01223051 The WAVS camera is located on the rear of the machine in the center of the fan guard Use a damp cloth or water spray in order to clean the camera lens The camera is a sealed unit The camera is not affected by high pressure spray The camera is equipped with an internal heater to help counteract the effects of condensation snow or ice Note For more information on WAVS refer to Operation and Maintenance Manual SEBU8157 Work Area Vision System 104290956 Case Drain Oil Filters Replace SMCS Code 5091 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and
44. Level Implement Hydraulic Fan Check SMCS Code 5056 535 FLV 1 Park the machine on a level surface and engage the parking brake Illustration 198 g01237715 3 The oil level gauge 1 is located on the right side of the machine Maintain the oil level within the green range A on the gauge 4 The filler tube for this hydraulic tank is located inside the access door to the right of the cab If necessary add oil through the filler tube 103247263 Hydraulic System Oil Level Steering Brake Check SMCS Code 5056 535 FLV 1 Park the machine on a level surface and engage the parking brake 2 Lower the attachment to the ground and stop the engine SEBU8075 11 147 Maintenance Section Hydraulic System Oil Sample Implement Hydraulic Fan Obtain Illustration 199 g01270623 Illustration 200 g01237715 3 The oil level gauge 1 is located on the left side of the machine Maintain the oil level within the green range A on the gauge 4 The filler tube for this hydraulic tank is located inside the access door to the left of the cab If necessary add oil through the filler tube Hydraulic System Oil Sample Implement Hydraulic Fan Obtain SMCS Code 5050 008 5056 008 7542 Illustration 201 g01279293 The sampling valve is located on the implement pilot filter The implement pilot filter is located on the r
45. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A OBS EBUBO75 11 CATERPILLAR ata Operation and Maintenance Manual 992K Wheel Loader H4C1 Up Machine SEBU8075 11 93 Maintenance Section Maintenance Interval Schedule 104749293 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 Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended to 3000 hours S O S
46. Maintenance Manual Axle Breaker Relief Valve Clean for the axle breaker relief valve locations 3 Remove the oil filter and discard the filter properly Make sure that the old seal is removed from the filter base 4 Clean the filter mounting base and apply a thin coat of oil to the seal on the new filter 5 Install the new filter hand tight until the seal of the 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 filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 6 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 7 Repeat the above steps for the remaining oil filter 8 Start the engine and operate the machine for a few minutes 9 Stop the engine Inspect the filters for leaks Make any necessary repairs SEBU8075 11 101 Maintenance Section Axle Oscillation Bearings Lubricate 102598561 Axle Oscillation Bearings Lubric
47. The kinematic viscosity at 100 C 212 F should not exceed a 2 cSt change Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that all fluids are contained during performance of inspection main tenance testing adjusting and the repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or dis assembling any component containing fluids Dispose of all fluids according to local regulations and mandates Note Be sure that you obtain an S O S hydraulic oil sample before you drain the hydraulic oil 1 Operate the machine in order to warm the oil 2 Park the machine on level ground Lower the work tool to the ground with a slight downward pressure Engage the parking brake and stop the engine Illustration 182 g01267032 3 Open the access door to the right of the cab Illustration 183 g01269818 4 Push the button on the top of breaker relief valve 1 in order to relieve any tank pressure 5 Remove hydraulic tank filler cap 2 Remove the strainer from the tube 6 Wash the strainer and the filler cap in a clean nonflammable solvent Illustration 184 g01269820 7 There is an access area for the drain plug on the bottom of the hydraulic tank Remove the oil drain plug and drain the oil into a suitable container 8 Clean the drain plug and install the drain plug
48. achine slowly for 10 to 15 minutes 8 Stop the engine 9 Check the hydraulic oil level Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Level Check 10 Check the machine for oil leaks Make any necessary repairs Hydraulic System Oil Filter Implement Pilot Replace SMCS Code 5068 510 II NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Stop the engine Illustration 193 g01278534 2 The hydraulic filter is located on the right side of the pump compartment Open the access doors SEBU8075 11 145 Maintenance Section Hydraulic System Oil Filter Steering Pilot Replace Illustration 194 g01278532 3 Remove the filter and dispose of the filter properly 4 Apply a thin coat of oil to the seal on the new filter Install the new filter hand tight until th
49. ake wear is measured 5 Push the button on the top of each axle breaker relief valve in order to relieve any pressure Note Refer to Operation and Maintenance Manual Axle Breaker Relief Valve Clean for the axle breaker relief valve locations 6 Place a suitable container below the plug in order to collect oil leakage from the brake system 7 Press and hold the service brake pedal Illustration 213 g01446483 8 Remove the plug NOTICE Do not allow the brake piston to retract while the pin is installed in the plug hole This could cause the pin to break off when the brake piston retracts It is possi ble for broken pieces of the tool to fall into the brake housing and cause damage 9 Insert a FT3105 brake wear gauge into the inspection hole If the brake wear gauge does not drop all the way into the inspection hole the brake wear is less than 50 Proceed to step 12 154 Maintenance Section Steering Cylinder Bearings Lubricate SEBU8075 11 If the brake wear gauge drops all the way into the inspection hole the brake wear is greater than 50 Proceed to step 10 10 Insert a FT3104 brake wear gauge into the inspection hole If the brake wear gauge does not drop all the way into the inspection hole the brake wear is between 50 and 75 Proceed to step 12 If the brake wear gauge drops all the way into the inspection hole the brake wear is greater than 75 Proceed to
50. ally pushing down ward on the governor shutdown rod A WARNING Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Do not fill fuel filter with fuel before installing the fuel filter Contaminated fuel causes accelerated wear to fuel system parts Note In order to reduce contamination in the system do not remove the primary fuel filter and the secondary fuel filter simultaneously Perform these operations separately Note After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines Illustration 168 1 g01268813 Open the engine access door on the left side of the machine Place a suitable container under the water separator in order to catch any fuel that might spill Clean up any spilled fuel Clean the outside of the water separator Illustration 169 3 g01237351 Install a suitable hose onto the drain 3 Place the end of the hose into a suitable container Open the drain Allow the fluid to drain into the container Tighten the d
51. ash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components 122 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU8075 11 The primary air filter element can be used up to six times after the element is properly cleaned When the primary air filter element is cleaned check for rips or tears in the filter material The primary air filter element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings NOTICE Do not clean the air filter elements by bumping or tap ping This could damage the seals Do not use ele ments with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air filter element before cleaning Inspect the air filter element for damage to the seal the gaskets and the outer cover Discard any damaged air filter elements There are two common methods that are used to clean the primary air filter element e Pressurized air e Vacuum cleaning Pressur
52. ate SMCS Code 3268 086 BD 3278 086 BD The two grease fittings for the axle oscillation bearings are located near the articulation joint on the left side of the machine cava A 66 Illustration 97 g01300491 1 Wipe off the fittings before any lubricant is applied 2 Apply lubricant through the two fittings until grease is visible around the bearings 3 Check that grease is visible around the bearings in order to ensure the proper fill 104488529 Backup Alarm Test SMCS Code 7406 081 Illustration 98 g02586397 The backup alarms are located behind the fan guard on the rear of the machine 1 Turn the engine start switch key to the ON position in order to perform the test 2 Apply the service brake 3 Move the transmission direction control switch to the REVERSE position The backup alarms should immediately sound The backup alarms will continue to sound until the transmission direction control switch is moved to the NEUTRAL position or to the FORWARD position 102533066 Battery Clean SMCS Code 1401 070 Illustration 99 g01267281 Open the battery compartment on the right rear corner of the cab platform 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
53. aterpillar s standard S O S Fluids Analysis or an equivalent oil sampling program should be used If an oil sampling program is not available the standard 2000 oil change interval should be used Measured Data The following information should be monitored 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 SEBU8075 11 139 Maintenance Section Hydraulic System Oil Implement Hydraulic Fan Change e The allowable level of oxidation is 40 percent 0 12 Abs units e
54. born Dirt and Grease Wash the windows with a good grade of naphtha of isopropyl alcohol or of Butyl Cellosolve Then wash the windows with soap and with water Polycarbonate Windows If equipped Wash polycarbonate windows with a mild soap or detergent Never use a cleaning solvent on polycarbonate windows Wash polycarbonate windows with warm water and a soft sponge or damp cloth Never use a dry cloth or paper towels on polycarbonate windows 160 SEBU8075 11 Maintenance Section Windows Clean Rinse the windows with a sufficient amount of clean water
55. bucket and rack stops 1 Note Cracking can occur on the boom or on the bucket if dump stop 2 on the bottom of the boom does not fully contact the dump stop on the bottom of the bucket Use the following steps to identify this problem 2 Clean dump stop 2 and the dump stop on the bucket 3 Apply a light coat of grease to the dump stop 2 The grease will help to determine the amount of contact that is being made when the dump stop 2 contacts the dump stop on the bucket 4 Tilt the bucket so that dump stop 2 and the dump stop on the bucket contact each other Partially tilt back the bucket in order to inspect the alignment 5 Inspect the dump stops and determine the amount of contact If even contact is being made across the dump stops no further action is required Reference If uneven contact exists refer to Special Instruction REHS0250 Boom Repair and Bucket Stop Alignment for instructions about repairing the bucket stops 102594942 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 SEBU8075 11 107 Maintenance Section Bucket Tips Inspect Replace Illustration 109 g00101352 1 Usable 2 Removal Procedure 3 Removal Procedu
56. ce 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 SEBU8075 11 153 Maintenance Section Service Brake Wear Indicator Check 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 the supplemental steering system is not operating Stop the machine immediately
57. ckle Consult your Cat dealer for the replacement of the seat belt and the mounting hardware Determine age of new seat belt before installing on seat A manufacture label is on belt webbing and imprinted on belt buckle Do not exceed install by date on label Complete seat belt system should be installed with new mounting hardware Date of installation labels should be marked and affixed to the seat belt retractor and buckle Note Date of installation labels should be permanently marked by punch retractable belt or stamp non retractable belt If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 101547608 Seat Side Rails Adjust SMCS Code 7312 025 Illustration 212 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 103694709 Secondary Steering Test SMCS Code 4300 081 SST 4300 081 SE 4324 081 4324 The service brake must be checked in order to en sure proper operation before you test the supple mental steering system 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 servi
58. contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Replace the case drain filters when a failure occurs within the hydraulic system 110 Maintenance Section Circuit Breakers Reset SEBU8075 11 Illustration 119 g01449523 Three case drain filters are located under the access doors in the cab platform Illustration 120 g01449520 Left Side of Compartment 1 Case Drain Filter Steering Illustration 121 g01449521 Right Side of Compartment 2 Case Drain Filter Implement 3 Case Drain Filter Fan 1 Stop the engine 2 Use a strap type wrench to remove the filter Dispose of the used filter 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 the new filter with clean hydraulic oil 5 Install the new filter by hand When the gasket contacts the filter base tighten the filter by an additional 3 4 turn 6 Repeat the above steps for the remaining case drain filters There are a total of three case drain filters 7 Start the engine and run the engine at low idle Operate the steering the brakes and the implements 8 Stop the engine Inspect the filters for leaks Make any necessary repairs Close all access doors 102534101 Circuit Breakers Reset SMCS Code 1420 529
59. cover 3 2 Attach the hose to the male coupling Use a 127 9088 Nozzle for this port 3 Drain the oil or add the oil as needed Reference For more information refer to Operation and Maintenance Manual Service Center 103245636 Hydraulic System Oil Steering Brake Change SMCS Code 5056 044 Personal injury can result from hydraulic oil pres sure and hot oil Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped Seri ous injury can be caused if this pressure is not re leased before any service is done on the hydraulic system Make sure all of the attachments have been low ered oil is cool before removing any components or lines Remove the oil filler cap only when the en gine is stopped and the filler cap is cool enough to touch with your bare hand SEBU8075 11 141 Maintenance Section Hydraulic System Oil Steering Brake Change 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 HYDO Advanced 10 Cat HYDO Advanced 10 is the preferred oil for use in most Caterpil
60. d personnel g02608016 Illustration 164 1 Open the access door on the right side of the machine The ether starting aid cylinder 1 is located next to the hinge of the access door 2 Loosen the cylinder retaining clamp Unscrew the empty ether starting aid cylinder and remove the ether starting aid cylinder 1 Open engine access cover 1 on the right side of the machine 2 Loosen clamp 2 and unscrew ether starting aid cylinder 3 3 Remove the used gasket Install the new gasket that is provided with the ether starting aid cylinder Install the new ether starting aid cylinder Tighten the clamp Note Install protective cap 4 if an ether starting aid cylinder will not be in place 104411257 Fuel System Prime SMCS Code 1250 548 Personal injury or death may result from failure to adhere to the following procedures Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters Prime the fuel system in order to purge trapped air and in order to fill the fuel filter g02608596 Illustration 165 Priming pump switch The switch for the priming pump is located near the hinge of the engine access door on the left side of the machine Note The engine start switc
61. der to circulate the oil Check the high pressure screens for leaks 10 Stop the engine 103898378 Hoses and Clamps Inspect Replace SMCS Code 1000 7554 040 7554 510 Inspect the Hoses and the Clamps The nonmetallic hoses and the clamps must be inspected periodically in order to ensure safe operation and continuous operation of the engine fuel system Take proper safety precautions before inspecting or replacing hoses and clamps Note Always use a board or cardboard when the engine components are checked for leaks Leaking fluid that is under pressure can cause serious injury or possible death including leaks that are the size of a pin hole Refer to Operation and Maintenance Manual General Hazard Information for more information 136 SEBU8075 11 Maintenance Section Hoses and Clamps Inspect Replace Nonmetallic Fuel Lines TOP VIEW OF ENGINE Illustration 181 902141367 1 Rear low pressure fuel lines 2 Front low pressure fuel lines Inspect hoses 1 and 2 of the engine fuel system e Outer covering that is chafed or cut for leaks that are caused by the following conditions e Outer covering that is ballooning locally Replace any non metallic fuel line hose which exhibits any of the following conditions e Flexible part of the hose that is kinked or crushed e Hoses which are cracked e Hoses which exhibit signs of leakage which are not
62. door 102535851 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Illustration 170 g01268813 1 Open the engine access door on the left side of the machine Illustration 171 g01269132 2 Remove the secondary fuel filter 1 Dispose of the used filter properly 3 Clean the filter mounting base Ensure that all of the used gasket is completely removed from the filter mounting base 4 Install the new filter a Apply a thin coat of oil to the seal on the new filter b Install the new filter hand tight until the seal of the 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 filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide c 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 5 Prime the fuel system 6 Start the engine and check the fuel filter for leaks 7 Close the
63. e seal of the 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 filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 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 Close the access doors 102554912 Hydraulic System Oil Filter Steering Pilot Replace SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Stop the engine
64. ecial Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample 104407788 Drive Shaft Spline Center Lubricate SMCS Code 3253 086 SN NOTICE To prevent damage to the seal articulate the machine full right or left before lubricating the splines 1 Start the engine Raise the work tool Release the parking brake 2 Articulate the machine to the left in order to access the drive shaft spline 3 Lower the work tool to the ground Stop the engine and engage the parking brake g02604197 Illustration 144 Note Wipe the fitting before you apply any lubricant 4 Apply lubricant through the fitting on the center drive shaft spline Note Refer to this Operation and Maintenance Manual Lubricant Viscosities for more information on the types of grease to use 120 Maintenance Section Drive Shaft Support Bearing Lubricate SEBU8075 11 104407849 Drive Shaft Support Bearing Lubricate SMCS Code 3267 086 BD The grease fitting can be accessed from the left side of the machine Note If necessary articulate the machine to the right for easier access to the drive shaft support bearing Illustration 145 g02604397 Note Wipe the fitting before you apply any lubricant 1 Apply lubricant through the fitting on the drive shaft support bearing Note Refer
65. en ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Level 1 results may indicate a need for Level 2 Analysis Illustration 131 Illustration 132 g01267735 The sampling port 1 is located on the thermostat housing Use the engine access door on the right side of the machine in order to gain access to the port For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer SEBU8075 11 115 Maintenance Section Cooling System Coolant Sample Level 2 Obtain 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 Submit the sample for Level 1 Analysis 102049802 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 Reference Refer to Operation and Maintenance Ma
66. 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 SEBU8075 11 113 Maintenance Section Cooling System Coolant Level Check Illustration 128 g01272333 3 If necessary drain enough coolant from the radiator in order to allow the addition of the Extender to the cooling system The coolant drain valve is located under the rear of the machine 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 4 Add the Extender to the cooling system Reference For the correct amount refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations
67. gh the fast fill port or you may add the engine oil through a fast fill port oS st Nal 5 Q hs ee Illustration 161 g01338920 1 Remove the dust cover 5 2 Attach the hose to the male coupling Use a 126 7539 Nozzle for this port 3 Drain the oil or add the oil as needed Reference For more information refer to Operation and Maintenance Manual Service Center SEBU8075 11 127 Maintenance Section Engine Valve Lash Check 104538255 Engine Valve Lash Check SMCS Code 1105 535 In order to perform the valve lash adjustment refer to Systems Operation Testing and Adjusting Engine Valve Lash Inspect Adjust Note A qualified mechanic should adjust the engine valve lash because special tools and training are required 103952000 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to prevent being burned by hot oil or spray 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 102482098 Engine Water Pump Inspect SMCS Code 1361 040
68. h must be in the OFF position in order to prime the fuel system 1 Hold the priming pump switch upward in order to activate the electric fuel priming pump The priming pump will fill the engine fuel lines and the fuel filters with fuel SEBU8075 11 129 Maintenance Section Fuel System Primary Filter Water Separator Check Drain 2 As the air is purged from the fuel system fuel pressure will increase Listen for the electric fuel priming pump to come under load Do not continue priming the fuel system after the priming pump is under load Do not operate the priming pump for more than 2 minutes 3 If the engine starts but the engine runs rough continue to run the engine at low idle until the engine runs smoothly 4 If the engine does not start after several attempts consult your Cat dealer 104749591 Fuel System Primary Filter Water Separator Check Drain SMCS Code 1263 535 1263 543 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent contai
69. h the button on the top of the breaker relief valve 1 in order to relieve any tank pressure Illustration 188 g01269881 5 Remove hydraulic tank filler cap 2 Remove the strainer from the tube 6 Wash the strainer and the filler cap in a clean nonflammable solvent Q Illustration 189 g01269883 7 Remove the oil drain plug from the bottom of the hydraulic tank 8 Attach a hose to an oil drain coupling Install the oil drain coupling into the drain plug opening in order to open the internal drain valve Allow the oil to drain into a suitable container 9 Clean the drain plug and install the drain plug 10 Install the filler strainer SEBU8075 11 143 Maintenance Section Hydraulic System Oil Filter Hydraulic Fan Return Replace Illustration 190 g01237715 11 Fill the hydraulic oil tank with clean oil Maintain the oil level within the green range A on the sight gauge 12 Start the engine and run the engine for at least ten seconds Then stop the engine and add hydraulic oil to the tank until the oil level is within the green range A on the sight gauge 13 Start the engine and run the engine at low idle Operate the steering and the brakes in order to circulate the oil 14 Stop the engine and top off the hydraulic tank so that the oil level is within the green range A on the sight gauge Note The oil must be free of air bubb
70. haking or by using compressed air 5 Install the breaker relief valve 6 Close the access door 7 Repeat steps 1 through 6 for the other hydraulic tank 102106227 Oil Filter Inspect SMCS Code 1308 507 3067 507 4295 507 431F 507 5068 507 Inspect a Used Filter for Debris Illustration 204 g00100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts 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 SEBU
71. ight side of the pump compartment Reference For information on obtaining a sample refer to Special Publication SEBU6250 S O S Oil Analysis and Special Publication PEHP6001 How To Take A Good Oil Sample 102961623 Hydraulic System Oil Sample Steering Brake Obtain SMCS Code 4250 008 4300 008 5050 008 5056 008 7542 So fae aa w Illustration 202 g01279328 The sampling valve is located on the steering pilot filter The steering pilot filter is located on the left side of the pump compartment 148 Maintenance Section Hydraulic Tank Breaker Relief Valve Clean SEBU8075 11 Reference For information on obtaining a sample refer to Special Publication SEBU6250 S O S Oil Analysis and Special Publication PEHP6001 How To Take A Good Oil Sample 103247236 Hydraulic Tank Breaker Relief Valve Clean SMCS Code 5118 070 Illustration 203 g01270772 There is a breaker relief valve on both hydraulic tanks The implement hydraulic tank is located inside the access door to the right of the cab The steering hydraulic tank is located inside the access door to the left of the cab 1 Open the access door 2 Push the button on the top of the breaker relief valve in order to relieve any tank pressure 3 Remove the breaker relief valve 4 Clean the breaker relief valve in a clean nonflammable solvent Dry the breaker relief valve thoroughly by s
72. ings 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 98 Maintenance Section Automatic Lubrication System Components Check SEBU8075 11 Timer Operation Autolube 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 in O Erm Illustration 90 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 Illustration 91 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
73. ized Air Pressurized air can be used to clean a primary air filter element that has not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 149 g00281692 Note When the primary air filter element is cleaned always begin with the inside of the filter in order to force dirt particles toward the outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air filter element Dirt could be forced further into the pleats Vacuum Cleaning Vacuum cleaning is another method for cleaning a primary air filter element which requires daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Inspecting the Primary Air Filter Elements Illustration 150 g00281693 Inspect the clean dry primary air filter element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air filter element Rotate the primary air filter element Inspect the primary air filter element for tears and or holes Inspect the primary air filter element for light that may show through the filter material If it is necessary in
74. lar 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 0 S Services oil analysis When you switch to Cat HYDO Advanced 10 cross contamination with the previous oil should be kept to less than 10 Consult your 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 6000 hour interval for changing the oil is specific to HYDO Advance 10 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 b
75. lement and replace the cover 7 Install the cover and the five bolts 8 Repeat steps 4 through 7 for the other filter 9 Close the access door 102540584 Transmission Oil Level Check SMCS Code 3030 535 FLV 1 Operate the machine until the transmission oil is warm 158 Maintenance Section Transmission Oil Sample Obtain SEBU8075 11 2 Park the machine on level ground and lower all attachments to the ground with a slight downward pressure 3 Place the transmission in the NEUTRAL position Engage the parking brake and leave the engine on at low idle Illustration 226 g01271359 The transmission oil level gauge is near the articulation joint on the left side of the machine 4 Check the oil level The oil level must be within the sight gauge before you operate the machine 5 If the system requires additional oil slowly remove the filler cap and add oil through the filler tube until the oil level reaches the proper range The filler tube for the transmission is located above the sight gauge on the left side of the machine 6 Clean the cap and install the cap 7 Maintain the oil level within the proper range on the sight glass which is at the centerline of the drive shaft 102540655 Transmission Oil Sample Obtain SMCS Code 3080 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of in
76. les If air bubbles are present in the hydraulic oil air is entering the hydraulic system Inspect the hydraulic suction line and the hose clamps 15 If necessary tighten any loose clamps or any loose connections Replace any damaged hoses 16 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary Install the filler cap Fast Fill Port If your machine is equipped with a service center you may drain the hydraulic oil through the fast fill port or you may add the hydraulic oil through a fast fill port Pii d O pess Illustration 191 g01338925 1 Remove the dust cover 3 2 Attach the hose to the male coupling Use a 127 9088 Nozzle for this port 3 Drain the oil or add the oil as needed Reference For more information refer to Operation and Maintenance Manual Service Center Hydraulic System Oil Filter Hydraulic Fan Return Replace SMCS Code 5068 510 HFN Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG250
77. ling Use a 126 7538 Nozzle for this port 3 Drain the oil or add the oil as needed Reference For more information refer to Operation and Maintenance Manual Service Center 102540558 Transmission Oil Filter Replace SMCS Code 3067 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar 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 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 Illustration 224 g01271357 3 The access door for the transmission filter is located behind the cab in the middle of the cab platform Open the access door ee eQ Q9 2 20 1 rr eo gt g01271358 Illustration 225 4 Remove the five bolts 1 and remove the cover 2 5 Remove the used filter element Be sure to dispose of the used filter properly 6 Install a new filter e
78. lter Steering Pilot Replace iate ne er ae ai 145 Transmission Oil Filter Replace 005 157 Every 250 Service Hours or Monthly Axle Oscillation Bearings Lubricate 101 Battery Gloann E E 101 Belt Inspect Adjust Replace eeeee 102 Braking System Test 0 104 Drive Shaft Spline Center Lubricate 119 Engine Oil Sample Obtain ceeeeeeeees 125 Steering Cylinder Bearings Lubricate 154 Initial 500 Service Hours Electronic Unit Injector Inspect Adjust 120 Engine Valve Lash Check sesers 127 Engine Valve Rotators Inspect eee 127 Seat Side Rails Adjust ee eeeeteeeeeeees 152 94 Maintenance Section Maintenance Interval Schedule SEBU8075 11 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtain iscsi settee al ied idee Seve 115 Every 500 Service Hours or 3 Months Cooling System Coolant Sample Level 1 ODIA senan a faded tatidest daeagden aes 114 Differential and Final Drive Oil Level Check 117 Differential and Final Drive Oil Sample Obtain 118 Engine Crankcase Breather Clean a an 124 Engine Oil and Filter Change n e 125 Fuel System Primary Filter Clean Replace 130 Fuel System Secondary Filter Replace 131 Fuel Tank Cap and Strainer Clean 0
79. lustration 178 g01301067 SEBU8075 11 135 Maintenance Section Hoses and Clamps Inspect Replace There are two screens for the implement pump that are located inside the rear frame near the articulation joint If equipped a screen for the secondary steering pump is located inside the rear frame near the articulation joint These screens are accessible from the right side of the machine a Illustration 179 g01301066 The screen for the brake pump is located behind the hydraulic tank on the left side of the machine Illustration 180 g01301064 The screens for the fan pump and the fan motor are located behind the fan guard on the rear of the machine 1 Stop the engine 2 Remove the drain plug at the bottom of the filter housing Allow the oil to drain into a suitable container 3 Use a strap type wrench to remove the filter housing 4 Remove the high pressure screens from the filter housing 5 Clean the screen the drain plug the filter housing and the filter housing base with a clean nonflammable solvent Allow the components to dry 6 Install the screen and the drain plug in the filter housing 7 Install the filter housing on the filter housing base 8 Start the engine Make sure that the parking brake is engaged 9 Operate the steering the brakes and the attachment in or
80. ming 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 104164902 Automatic Lubrication System Components Check If Equipped SMCS Code 7540 535 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 SEBU8075 11 97 Maintenance Section Automatic Lubrication System Components Check Illustration 89 g01032039 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
81. nformation about inspecting the turbocharger refer to the appropriate Service Manual for your machine s engine 101892835 Window Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solvent or equivalent System damage can result from freezing Illustration 228 g00952003 The window washer reservoir is located behind the cab Fill the reservoir with window washer solvent as needed 101906590 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 Inspect the condition of the wiper blades Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs 104412316 Windows Clean SMCS Code 7310 070 Clean the outside of the windows from the ground unless handholds are available Illustration 229 g00566124 Typical example Cleaning Methods Commercial Window Cleaner Apply the cleaner with a soft cloth Rub the window with moderate pressure until all the dirt is removed Allow the cleaner to dry Wipe off the cleaner with a clean soft cloth Soap and Water Use a clean sponge or a soft cloth Wash the windows with a mild soap or with a mild detergent Also use plenty of lukewarm water Rinse the windows thoroughly Dry the windows with a moist chamois or with a moist cellulose sponge Stub
82. ning fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations Illustration 166 g01268813 1 The fuel filter is located inside the access doors on the left side of the machine Illustration 167 g02846476 2 Install a suitable drain hose onto the drain Place the other end of the hose into a suitable container 3 Open the drain Allow the fluid to drain into the container 4 After the separator is drained close the drain by hand pressure only Dispose of the drained fluid in a safe place 5 Close the access doors 130 Maintenance Section Fuel System Primary Filter Clean Replace SEBU8075 11 102535268 Fuel System Primary Filter Clean Replace SMCS Code 1260 070 1260 510 A WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes A WARNING Personal injury or death can result from engine overspeed If the engine overspeeds it can cause injury or parts damage Be prepared to stop the engine by closing the air off to the air inlets or by manu
83. nsure that the final drive filler plug 2 is in the correct position 2 Push the button on the top of each axle breaker relief valve in order to relieve any pressure Note Refer to Operation and Maintenance Manual Axle Breaker Relief Valve Clean for the axle breaker relief valve locations 3 Remove the final drive plug 1 and allow the oil to drain into a suitable container 4 Clean the drain plug and install the drain plug 5 Repeat steps 2 through 4 for the other final drive SEBU8075 11 117 Maintenance Section Differential and Final Drive Oil Level Check Illustration 136 g01449382 Front axle Illustration 137 g01449380 Rear axle 6 Remove the differential drain plug 3 and allow the oil to drain into a suitable container 7 Clean the drain plug and install the drain plug 8 Remove differential filler plug 4 Fill the differential with SAE 50 oil until the oil level reaches the bottom of the filler plug opening 9 Clean the filler plug and install the filler plug 10 Remove the final drive filler plug 2 Fill the final drive with SAE 50 oil until the oil level reaches the bottom of the filler plug opening 11 Clean the filler plug and install the filler plug 12 Repeat steps 10 through 11 for the other final drive Note Fill each axle with 4 7 L 5 qt of 1U 9891 Additive Note
84. nual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Submit the sample for Level 2 analysis Reference For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 103247291 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system A new thermostat should be installed after the cooling system has been cleaned Install the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age Note If you are only installing a new thermostat drain the cooling system coolant to a level that is below the thermostat housing Illustration 133 g01459869 1 Remove all hoses from the thermostat 2 Remove the bolts from the thermostat housing 3 Remove the gasket the thermostat and the seal NOTICE
85. or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension Contact your Cat dealer for the replacement of the seat belt and the mounting hardware Note The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts 152 Maintenance Section Seat Belt Replace SEBU8075 11 104421974 Seat Belt Replace SMCS Code 7327 510 The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts ef 0 4 Illustration 211 g01152685 Typical Example 1 Date of installation retractor 2 Date of installation buckle 3 Year of manufacture tag fully extended Web 4 Year of manufacture underside bu
86. order to confirm the result compare the primary air filter element to a new primary air filter element that has the same part number Do not use a primary air filter element that has any tears and or holes in the filter material Do not use a primary air filter element with damaged pleats gaskets or seals Discard damaged primary air filter elements Storing Primary Air Filter Elements If a primary air filter element that passes inspection will not be used the primary air filter element can be stored for future use SEBU8075 11 123 Maintenance Section Engine Air Filter Secondary Element Replace Illustration 151 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An air flow restriction may result To protect against dirt and damage wrap the primary air filter elements in Volatile Corrosion Inhibited VCI paper Place the primary air filter element into a box for storage For identification mark the outside of the box and mark the primary air filter element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 101693619 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 re
87. order to reset the circuit breaker If the system is functioning properly the button will remain depressed If the button does not stay depressed check the appropriate electrical circuit A Circuit Breaker Depress the button in Illustration 122 g01267032 The circuit breakers are located under the access door on the right side of the cab platform SEBU8075 11 111 Maintenance Section Cooling System Coolant ELC Change Illustration 123 g01267584 Engine Start Switch 1 10 amp Alternator 2 105 amp 4 Main Circuit 3 105 amp 102544211 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure oe N N PAS SL LLL P Illustration 124 g01273221 1 Open the small access door 1 on the top of the engine compartment Slowly remove cooling system pressure cap in order to relieve system 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
88. ormation about selecting and installing the proper hose clamps 8 Carefully inspect the engine for any spilled fuel Make sure that no fuel remains on or close to the engine Note Fuel must be added to the fuel system ahead of the fuel filter 9 Refill the fuel system Refer to this Operation and Maintenance Manual Fuel System Prime for information about priming the engine with fuel 10 Start the engine Inspect the fuel system for leaks 138 Maintenance Section Hydraulic System Oil Implement Hydraulic Fan Change SEBU8075 11 103245638 Hydraulic System Oil Implement Hydraulic Fan 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 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 300
89. place 102453840 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result if the bucket is not blocked up Block the bucket before changing cutting edge Illustration 104 g00804790 Check for bolts that are missing or loose Replace any missing bolts and tighten any loose bolts Reference For more information refer to Specifications SENR3130 Torque Specifications or consult your Caterpillar dealer 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 102919686 Bucket Linkage and Loader Cylinder Bearings Lubricate SMCS Code 5102 086 BD 5104 086
90. rain by hand pressure only Unscrew the bowl 2 from the primary filter 1 Use a Caterpillar strap wrench in order to remove the filter Discard the old seals and the canister in a safe place Clean the bowl Install a new filter a Apply a thin coat of oil to the seal on the new filter SEBU8075 11 131 Maintenance Section Fuel System Secondary Filter Replace b Install a new filter hand tight until the seal of the 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 filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide c Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 10 Screw the bowl onto the primary filter 11 Close the access doors 12 Be sure to dispose of the fuel in a safe place 13 Prime the fuel system Refer to Operation and Maintenance Manual Fuel System Prime for more information Close the access
91. re Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip Removal Illustration 110 g01124847 1 Bucket tip 2 Retainer 3 Adapter Note Retainers are often damaged during the removal process Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced Illustration 111 g01175361 1 Use a pry bar in order to disengage retainer 2 2 Use the pry bar in order to remove retainer 2 from bucket tip 1 3 Remove bucket tip 1 from adapter 3 with a slight counterclockwise rotation 4 Clean adapter 3 Installation 1 Clean the adapter and the area around the latch if necessary 2 Install the new bucket tip onto the adapter with a slight clockwise rotation Illustration 112 g01124736 3 Install the retainer Make sure that the retainer s latch catches under the tip pocket 4 Make sure that the latch is properly seated by trying to remove the bucket tip 108 Maintenance Section Bucket Wear Plates Inspect Replace SEBU8075 11 102453827 Bucket Wear Plates Inspect Replace SMCS Code 6120 040 6120 510 Personal injury or death can result from falling bucket When working under or around the bucket or link age with the bucket raised proper support must be provided for the bucket and or the linkage Illustration 113 g01289574 Before damage to the bottom of the bucket occurs
92. re to reclaim the refrigerant gas 102510283 Rollover Protective Structure ROPS Inspect SMCS Code 7325 040 NOTICE Do not attempt to straighten the ROPS structure Do not repair the ROPS by welding reinforcement plates to the structure If there are any cracks in the welds in the castings or in any metal section of the ROPS consult your Cater pillar dealer for repairs There are access covers near the base of the ROPS Remove the access covers from both sides of the rollover protective structure ROPS Inspect the ROPS for damage and for bolts that are loose or damaged Use original equipment parts only to replace bolts that are damaged or missing Tighten the mounting bolts to a torque of 1600 200 N m 1200 150 Ib ft Note Apply oil to all bolt threads before installation Failure to apply oil can result in improper bolt torque 104423622 Seat Belt Inspect SMCS Code 7327 040 Always inspect the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 210 g02620101 Typical example Inspect buckle 1 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect seat belt 2 for webbing that is worn or frayed Replace the seat belt if the webbing is worn or frayed Inspect all seat belt mounting hardware for wear
93. rs before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJO003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Nonmetallic Fuel Lines Personal injury can result from removing hoses or fittings in a pressure system Failure to relieve pressure can cause personal in jury Do not disconnect or remove hoses or fittings un til all pressure in the system has been relieved NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components Replace the non metallic fuel lines in a set 1 Stop the engine and turn off the fuel supply 2 Turn the battery disconnect switch to the OFF position 3 Drain the fuel from the fuel system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose Refer to Illustration 181 6 Replace the old hose with a new hose 7 Install hose clamps which have been inspected or install new hose clamps Refer to Specifications SENR3130 Torque Specifications Hose Clamps for inf
94. services may extend the oil change even longer Consult your Cat dealer for details When Required Automatic Lubrication Grease Tank Fill 96 Automatic Lubrication System Components GO CK apie scctics nati ct e EENE 96 Axle Oil Cooler Filter Replace 000 100 Battery Recycle ooo eeceeeeeeeeneneeeeeeenteeeeeeaaes 101 Battery or Battery Cable Inspect Replace 102 Camera Gleam esclarir iesean EAEE 109 Case Drain Oil Filters Replace 00 109 Circuit Breakers Reset l enn 110 Engine Air Filter Primary Element Clean Replace E E EE E E T 120 Engine Air Filter Secondary Element Replace 123 Ether Starting Aid Cylinder Replace 128 Fuel System Prime ccc ccceceeeeeeeeeeenteeeeeeeneaes 128 Fuses Replace 0 ceeeccccceceeeeeeeeeeeecneeeeeeeeeeeeees 132 High Intensity Discharge Lamp HID Replace 134 High Pressure Screens Clean Replace 134 Oil Filter Inspect imensei anie aaae 148 Oil Renewal System Oil Add eee 149 Radiator Core Clean ou ccccecesseeeeeesteeeeeeenaes 149 Seat Side Rails Adjust 0 0 0 ceeeeeeeteeeeentaes 152 Secondary Steering Test iien 152 Transmission Magnetic Screen Clean 155 Window Washer Reservoir Fill 0 00 0 159 Window Wiper Inspect Replace 006 159 Windows Clean ou cece cee cceccsceeeesseeeeeeeaeeeeene esas 159 Every 10 Service
95. sing pressurized air NOTICE Service the air filter only with the engine stopped En gine damage could result SEBU8075 11 121 Maintenance Section Engine Air Filter Primary Element Clean Replace Illustration 146 g01266330 1 Open the rear access door on either side of the machine An air filter element is located on both sides of the engine compartment Illustration 147 g00281967 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 3 Remove air filter element 2 4 Clean the inside of the air filter housing 5 Install a clean primary air filter element Illustration 148 g01430841 6 Install the air cleaner cover 1 and tighten the latches Note Keep the latches for the air cleaner housing away from the muffler 7 Close the access door 8 Repeat this procedure for the air cleaner on the other side of the machine Cleaning the Primary Air Filter Element NOTICE Caterpillar recommends certified air filter cleaning ser vices available at participating Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not w
96. spection 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 227 g01272039 The sampling valve for the transmission is located at the base of the filters Reference Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information about obtaining a fluid sample 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 SEBU8075 11 159 Maintenance Section Window Washer Reservoir Fill 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 i
97. step 11 11 Insert a FT3103 brake wear gauge into the inspection hole If the brake wear gauge does not drop all the way into the inspection hole the brake wear is between 75 and 100 Brake service should be scheduled soon If the brake wear gauge drops all the way into the inspection hole the brake wear is greater than 100 Brake service should be scheduled immediately 12 Remove the brake wear gauge 13 Release the service brake pedal 14 Install the plug 15 Clean up spilled oil 16 Repeat steps 1 through 15 for each service brake 102916944 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD _ ie 7 Illustration 214 g01278462 1 Wipe off the grease fittings for the rod end of the steering cylinders There is one fitting on the rod end of both steering cylinders 2 Apply lubricant through the grease fittings Illustration 215 g01450458 3 Wipe off the remote grease fittings on the right side of the machine 4 Apply lubricant through the fittings 102305841 Tire Inflation Check SMCS Code 4203 535 Al IN IN g01160201 Illustration 216 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
98. sult Note Replace the secondary element when you service the primary element for the third time If a clean primary element has been installed and a warning for the air filter still occurs replace the secondary element Also if the exhaust smoke remains black and a clean primary element has been installed replace the secondary element 1 Remove the primary element Reference Refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace for the correct procedure R Illustration 152 g00864077 2 Remove the secondary element g00864079 Illustration 153 3 Cover the air inlet opening Clean the inside of the air cleaner housing 4 Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged 5 Uncover the air inlet opening Install a new secondary element 6 Install a clean primary element and the cover for the air cleaner housing 7 Close the access door 8 Repeat the procedure for the other air cleaner 124 Maintenance Section Engine Components Rebuild Install Reman SEBU8075 11 102550809 Engine Components Rebuild Install Reman SMCS Code 1000 022 MC Caterpillar recommends this additional maintenance for the following components on C32 Engines Consult your Caterpillar dealer for further information e Alternator e Fuel Transfer Pump e Injectors e Turbochargers 1044088
99. tain e E E E 115 Every 3000 Service Hours Electronic Unit Injector Inspect Adjust 120 Engine Valve Lash Check isecen 127 Engine Valve Rotators Inspect eee 127 Every 3000 Service Hours or 2 Years Crankshaft Vibration Damper Inspect 116 Engine Mounts Inspect iien 124 Every 3 Years Seat Belt Replace 20 0 cccccccecsststessseeeeeees 152 Every 5000 Service Hours or 3 Years Alternator Inspect ccceceeceeeeeeeeeeeeeeeeeteenaeees 95 Turbocharger Inspect eeseeeeeeeeeeereeeeeessee 158 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 112 Engine Water Pump Inspect eee 127 Every 6000 Service Hours or 4 Years Cooling System Water Temperature Regulator Replacestc4c c2 eet Ne 115 Every 7500 Service Hours or 757 000 L 200 000 US gal of Fuel Engine Components Rebuild Install Reman 124 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 111 SEBU8075 11 95 Maintenance Section Alternator Inspect 102904968 Alternator Inspect SMCS Code 1405 040 Illustration 86 g01445914 Access to the alternator is on the right side of the machine The alternator is located on the front of the engine Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and for proper ba
100. the access door ce Illustration 222 g01271359 12 The transmission oil filler cap is located near the articulation joint on the left side of the machine Remove the filler cap and add 170 L 45 US gal of transmission oil 13 Clean the filler cap and install the filler cap 14 Start and run the engine at low idle Inspect the transmission for leaks 15 Operate the transmission direction controls in order to circulate the transmission oil 16 Move the transmission direction control to NEUTRAL Engage the parking brake Inspect the entire power train for leaks 17 The sight gauge is located below the transmission oil filler cap on the left side of the machine The oil level must be within the sight gauge before you operate the machine 18 If the system requires additional oil slowly remove the filler cap and add oil through the filler tube until the oil level reaches the proper range 19 Clean the filler cap and install the filler cap Fast Fill Port If your machine is equipped with a service center you may drain the transmission oil through the fast fill port or you may add the transmission oil through a fast fill port SEBU8075 11 157 Maintenance Section Transmission Oil Filter Replace pmm V Illustration 223 g01450910 1 Remove the dust cover 3 2 Attach the hose to the male coup
101. the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Be sure that you obtain a S O S engine oil sample before you drain the engine oil 1 Park the machine on a level surface and engage the parking brake Stop the engine Illustration 158 g01267990 126 Maintenance Section Engine Oil and Filter Change SEBU8075 11 2 The drain valve 1 for the engine oil is located underneath the engine compartment toward the rear of the machine Open the drain valve and allow the oil to drain into a suitable container 3 Close the drain valve and clean the area around the drain valve Illustration 159 g01267994 4 The engine oil filters 4 are located inside the access door on the left side of the engine compartment 5 Remove the oil filter element and discard the filter properly Make sure that the old seal is removed from the filter base 6 Install a new filter a Apply a thin coat of oil to the seal on the new filter b Install the new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position
102. the result of loose couplings or clamps e Hoses which are soft SEBU8075 11 137 Maintenance Section Hoses and Clamps Inspect Replace Failure to replace a non metallic fuel line hose which exhibits any of the above conditions may result in a hazardous situation Inspect all clamps for the following conditions Replace any clamp which exhibits signs of any of the following conditions e Cracking e Looseness e Damage Inspect all couplings for leaks Replace any coupling which exhibits signs of leaks Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen The loose clamp can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Replace hoses that are cracked or soft Replace hoses that show signs of leakage Replace hoses that show signs of damage Replace hose clamps that are cracked or damaged Tighten or replace hose clamps which are loose Replace the Hoses and the Clamps 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 containe
103. ttery 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 only for short periods of time the batteries may not fully recharge Make sure that the alternator is properly functioning The alternator will charge the battery Consult your Caterpillar dealer for more information about testing the alternator 102597645 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD t g01300320 Illustration 87 1 The fitting for the lower hitch pin is located at the lower bearing The fitting can be accessed from the right side of the machine Wipe off the fitting before any lubricant is applied 2 Apply lubricant through the fitting a Illustration 88 g01450896 3 The remote fitting for the upper hitch pin is located near the articulation joint on the right side of the machine Wipe off the fitting before any lubricant is applied 4 Apply lubricant through the remote fitting 96 Maintenance Section Automatic Lubrication Grease Tank Fill SEBU8075 11 102216552 Automatic Lubrication Grease Tank Fill If Equipped SMCS Code 7540 544
104. ulator contains gas and oil under high pressure Improper removal or repair proce dures could cause severe injury To remove or re pair instructions in the service manual must be followed Special equipment is required for test ing and charging 1 Park the machine on level ground and lower the bucket Ensure that the area is clear of obstacles and personnel Block the wheels in order to prevent machine motion 2 Move the engine start switch to the ON position 3 Start the engine and run the engine for 1 minute in order to increase the accumulator pressure The alert indicator for the brake oil pressure should come on if the brake system is not at the normal operating pressure Release the parking brake Stop the engine 4 Move the engine start switch to the ON position Allow the monitoring system to completely cycle through the self test Depress the service brake pedal until the parking brake indicator comes on This will decrease the accumulator pressure A minimum of five applications should be required 5 If the parking brake indicator comes on with less than five applications of the service brake pedal measure the nitrogen precharge pressure of the accumulator 104 Maintenance Section Braking System Test SEBU8075 11 Your Cat dealer has the appropriate tools for measuring the precharge pressure of the brake accumulator Only use dry nitrogen gas for recharging i02060586 Braking System Test SMCS
105. urned to the original levels of contamination There should not be significant changes in sodium silicon copper and potassium The allowable level of oxidation is 40 percent 0 12 Abs units The kinematic viscosity at 100 C 212 F should not exceed a 2 cSt change 142 Maintenance Section Hydraulic System Oil Steering Brake Change SEBU8075 11 Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Be sure that you obtain an S O S hydraulic oil sample before you drain the hydraulic oil 1 Operate the machine in order to warm the oil 2 Park the machine on level ground Lower the work tool to the ground and apply slight downward pressure Engage the parking brake and stop the engine Illustration 187 g01269878 3 The hydraulic tank is located to the left of the cab Open the access door O S gt u C 4 Pus
106. y the following classifications CF CF 4 CG 4 and CH 4 Note Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems These oils are more likely to cause corrosion and excessive wear 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 If an oil sampling program is not available the standard 2000 oil change interval should be used Measured Data The following information should be monitored 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 ret

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