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MAINTENANCE INTERVALS - Safety

1. Illustration 162 g01100124 1 Alternator 2 Idler 3 Tensioner 4 Compressor 5 Idler 6 Idler 7 Serpentine Belt 8 Crankshaft Pulley Tensioner 3 keeps the correct tension on belt 7 Insert a ratchet with a square drive into tensioner 3 Rotate the tensioner counterclockwise in order to relieve tension on the belt Remove the belt Install the new belt Be sure that the new belt is routed correctly as shown Rotate the tensioner counterclockwise in order to install the new belt Release the tensioner when the new belt is installed The correct tension will automatically be applied 146 Maintenance Section Brake Accumulator Check SEBU7887 19 105092713 Brake Accumulator Check SMCS Code 4263 535 OO ee Illustration 163 g00882020 1 Turn the engine start switch to the ON position The alert indicator for brake oil pressure should come on if the braking system is not at normal operating pressure 2 Start the engine Run the engine at half speed for 2 minutes in order to increase the accumulator pressure The alert indicator for brake oil pressure should go off 3 Stop the engine by turning the machine start switch to off Wait 5 seconds then turn machine start switch to on but do not start the engine Wait for the display monitor to go through startup key on level checks and operator selection A
2. sssssssss 189 Every 250 Service Hours or 3 Months Engine Oil and Filter Change 168 Pallet Fork Lubricate sssessss 188 Steering Column Play Check 193 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtalht ione eie 158 Every 500 Service Hours Transmission Oil Filter Replace 199 Every 500 Service Hours or 3 Months Differential and Final Drive Oil Sample Obtain 161 Engine Oil and Filter Change 168 Fuel System Primary Filter Water Separator Element Replace ssssssssssssss 173 Fuel System Secondary Filter Replace 174 Fuel Tank Cap and Strainer Clean 175 Hydraulic System Biodegradable Oil Filter Element Replace e nde dee ee dedii ducis 178 Hydraulic System Oil Filter Replace 182 Hydraulic System Oil Sample Obtain 183 Transmission Oil Sample Obtain 201 Every 1000 Service Hours Drive Shaft Universal Joints Lubricate 163 Every 1000 Service Hours or 6 Months Articulation Bearings Lubricate 142 Battery Hold Down Tighten 144 Roading Fender Hinges Lubricate 190 Rollov
3. 900590670 a Place the Pin Master on the bucket tooth b Align extractor 5 with the pin c Strike the Pin Master at the back of the tool 4 and remove the pin SEBU7887 19 151 Maintenance Section Bucket Tips Inspect Replace Illustration 173 g00590819 6 Retainer 7 Retaining washer 8 Adapter 2 Clean the adapter and the pin 3 Fit retainer 6 into retaining washer 7 Install this assembly into the groove that is in the side of adapter 8 Illustration 174 g00101359 4 Install the new bucket tip onto the adapter Note The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration 5 Drive the pin through the bucket tip The pin can be installed by using one of the following methods e From the other side of the retainer drive the pin through the bucket tip the adapter and the retainer e Use a Pin Master Follow Step 5 a through Step 5 e for the procedure Note To correctly install the pin into the retainer the pin must be driven in from the right side of the tooth Improper installation of the pin can result in the loss of the bucket tip g00590666 Illustration 175 4 Back of Pin Master 9 Pin setter 10 Pin holder a Insert the pin through the bucket tooth b Place the Pin Master over the bucket tooth and locate the pin in the hole of holder 10 c Strike the tool with a hammer at the b
4. Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 Illustration 257 900762107 Inspect the ROPS for bolts that are loose or damaged Use original equipment parts only to replace bolts that are damaged or missing Tighten the four cab mounting bolts to a torque of 850 100 N m 629 74 Ib ft Note Apply oil to all bolt threads before installation Failure to apply oil can result in improper bolt torque Do not repair the ROPS by welding reinforcement plates to the ROPS Consult your Caterpillar dealer for repair of cracks in any welds in any castings or in any metal section of the ROPS 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 258 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 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 ex
5. 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 Repair the supplemental steering system before returning the machine to Service SEBU7887 19 193 Maintenance Section Service Brake Wear Indicator Check 102197967 Service Brake Wear Indicator Check SMCS Code 4255 535 IND Reference For information about checking the service brake wear indicator refer to Testing and Adjusting Braking System for the machine that is being serviced or consult your Caterpillar dealer 102837395 Steering Column Play Check SMCS Code 4310 535 4338 535 Illustration 260 g01411297 1 Hold the steering wheel with both hands 2 Try to move the steering wheel from one side to the other side The maximum allowed movement in t
6. for the correct procedure 11 Fill the hydraulic tank with clean oil Make sure that the oil level is at the FULL mark on sight gauge 3 Install the filler cap Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 12 Start the engine and run the engine for at least ten seconds Then stop the engine and add hydraulic oil to the tank until the oil level is at the FULL mark on the sight gauge Install the filler cap 13 Start the engine and run the engine at low idle Cycle the implements so that all hydraulic systems are filled with oil Note If the alert indicator for a low oil level comes on stop the engine and immediately add oil to the hydraulic tank The oil level should not be below the suction ports in the hydraulic tank while the engine is running 14 Add hydraulic oil to the tank until the oil level is at the FULL mark on the sight gauge 15 Stop the engine Top off the hydraulic tank so that the oil level is at the FULL mark on the sight gauge Install the filler cap Note The oil must be free of air bubbles If air bubbles are present in the hydraulic oil air is entering the hydraulic system Inspect the hydraulic suction line and the hose clamps 16 If necessary tighten any loose clamps or any loose connections Replace any damaged hoses 182 Maintenance Section Hydraul
7. 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 NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts 6 Prime the fuel system Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure 7 Close the engine hood SEBU7887 19 175 Maintenance Section Fuel Tank Cap and Strainer Clean 102877580 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 Z2 1273 070 STR Illustration 223 901432093 1 Cap 2 Strainer 3 Fuel Tank Open the rear grill in order to access the fuel tank cap 1 Remove the fuel tank cap 2 Inspect the seal for damage If the seal is damaged replace the cap 3 Remove the strainer from the filler tube 4 Wash the fuel tank cap and the strainer in a clean nonflammable solvent 5 Install the strainer Illustration 224 901431287 6 Inspect the fuel cap boot if equipped If the fuel cap boot is damaged re
8. 1 0 L 1 06 qt of 1U 9891 Hydraulic Oil Additive Fill the axles with oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the type of lubricant and for the refill capacity 5 Clean the dipstick fill plugs and install the dipstick fill plugs 6 Run the machine on level ground for a few minutes in order to equalize the oil level in the axle Check the oil level in the axle Reference Refer to Operation and Maintenance Manual Differential and Final Drive Oil Level Check for the correct procedure 101102280 Differential and Final Drive Oil Level Check SMCS Code 3278 535 FLV 4011 535 FLV Note Before you measure the oil level operate the machine for a few minutes in order to equalize the oil level 1 Park the machine on level ground Lower the bucket and apply slight downward pressure Engage the parking brake Stop the engine Illustration 195 900285312 Front Axle Illustration 196 900287527 Rear Axle SEBU7887 19 161 Maintenance Section Differential and Final Drive Oil Sample Obtain 2 Remove dipstick fill plug 1 on the left side of the axle Wipe off the level gauge with a clean cloth and reinsert the plug This will ensure a more accurate measurement of the oil level Note Make sure that the plug is installed completely before you check the oil level If the plug is not installed completely an incorrect oil le
9. BD Wipe off all fittings before any lubricant is applied Illustration 242 901962679 Apply lubricant through three fittings on each side of the logging fork There is a total of six fittings 102106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 243 900100013 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 SEBU7887 19 185 Maintenance Section Pallet Fork Inspect Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of 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
10. cool Then loosen cap slowly to relieve the pressure Illustration 189 g01000175 Open the access door on the left side of the machine Coolant level sight gauge 1 is located on the top radiator Maintain the coolant level within the sight gauge Add coolant if necessary Note If it is necessary to add coolant daily inspect the cooling system for leaks 102375131 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 Note It is not necessary to obtain a Coolant Sample Level 1 if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC This includes the following types of coolants e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat Diesel Engine Antifreeze Coolant DEAC e Commercial heavy duty coolant antifreeze NOTICE Always use 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 interpretatio
11. dry air with a maximum pressure of 207 kPa 30 psi Illustration 204 g00281692 Note When the primary air filter elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side 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 primary air filter elements which require 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 SEBU7887 19 165 Maintenance Section Engine Air Filter Secondary Element Replace Inspecting the Primary Air Filter Elements Illustration 205 900281693 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 order to confirm the result compare the primary air filter element to a new primary air filter e
12. engine valve lash because special tools and training are required 102770364 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to prevent being burned by hot oil or spray Electrical shock hazard The electronic unit injec tor system uses 90 120 volts Illustration 216 g01372247 1 Start the engine Run the engine at low idle Illustration 217 900038585 2 Watch the top surface of each valve rotator Whenever an inlet valve closes or an exhaust valve closes each valve rotator should turn 3 If a valve rotator fails to rotate consult your Caterpillar dealer for service Note Caterpillar recommends replacing valve rotators that are operating improperly An improperly operating valve rotator will shorten valve life because of accelerated wear on the valves Note If a damaged valve rotator is not replaced some valve face guttering could result Metal particles from the valve could fall into the cylinder This could cause damage to the piston head and to the cylinder head SEBU7887 19 171 Maintenance Section Ether Starting Aid Cylinder Replace 104844134 Ether Starting Aid Cylinder Replace If Equipped SMCS Code 1456 510 CD Ether is poisonous and flammable Breathing ether vapors or repeated contact of ether with skin can cause personal injury Use ether on
13. harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals Also refer to Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Poor maintenance of air filters or of fuel filters requires reduced oil change intervals Consult your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Cat oil filters are recommended Program A Verification for an Oil Change Interval of 500 Hours This program consists of three oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type in the Lubricant Viscosities for Ambient Temperatures Table in this O
14. lock and secure it in the stored po sition before resuming operation Failure to do so could result in serious injury or death Illustration 169 g01259751 Refer to Operation and Maintenance Manual Steering Frame Lock before entering the articulation joint Wipe off the fittings before any lubricant is applied 150 Maintenance Section Bucket Lower Pivot Bearings Lubricate SEBU7887 19 101924084 Bucket Lower Pivot Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD Illustration 170 901001411 Wipe off all fittings before any lubricant is applied Apply lubricant through one fitting on each side of the machine 103657242 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 Bucket Tips g00101352 Illustration 171 1 Usable 2 Replace the tip 3 Replace the tip Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip Remove the pin from the bucket tip The pin can be removed by one of the following methods e Use a hammer and a punch from the retainer side of the bucket to drive out the pin e Use a Pin Master Follow Step 1 a through Step 1 c for the procedure pes 30 _ F Za Nee O N 7 C Illustration 172 4 Back of Pin Master 5 Extractor 0
15. lubricant and for the refill capacity iene Illustration 276 g01002778 12 Remove the breather from the top of the transfer case Wash the breather in a clean nonflammable solvent Install the breather 13 Start and run the engine at low idle Inspect the machine for leaks Slowly operate the transmission controls in order to circulate the transmission oil 14 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure 102194865 Transmission Oil Filter Replace SMCS Code 3004 510 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 Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 277 901108389 The transmission oil filter is l
16. 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 Start the engine and run the engine at low idle Inspect the hydraulic system for leaks Illustration 231 g01185406 6 Maintain the oil level above the ADD COLD mark on the sight gauge Add hydraulic oil if necessary 103563580 Hydraulic System Oil Change SMCS Code 5056 044 Selection of the Oil Change Interval Your machine may be able to use a 4000 hour interval for the hydraulic oil The hydraulic oil is in the system that is not integral to the service brakes the clutches the final drives or the differentials The standard change interval is 2000 hours The oil should be monitored during intervals of 500 hours The extended 4000 hour interval can be used if the following criteria are met 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 drai
17. not immerse the display with liquid Camera Illustration 182 901223051 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 103696954 Circuit Breakers Reset SMCS Code 1420 529 The circuit breaker panel is located on the left side of the machine under the front of the cab next to the battery box 154 Maintenance Section Cooling System Coolant ELC Change SEBU7887 19 N Illustration 183 g01988115 Depress the button in order to reset the circuit breakers If the circuit is functioning properly the button will remain depressed If the button will not remain depressed check the appropriate electrical circuit hk Illustration 184 901388117 1 50 Amp Circuit Breaker 2 90 Amp Circuit Breaker 80 Amp Circuit Breaker 4 20 Amp Circuit Breaker 5 30 Amp Circuit Breaker i01921776 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Pressurized system Hot co
18. slight downward pressure 2 Engage the parking brake Stop the engine Illustration 273 901002772 3 Remove drain plug 1 on the bottom of the transfer case 4 Change the transmission oil filter Reference Refer to Operation and Maintenance Manual Transmission Oil Filter Replace for the correct procedure Illustration 274 900884724 5 The magnetic strainer is on the right rear side of the transfer case Remove the four bolts the cover and the seal that holds the magnets and the screen in place 6 Remove the screen and the magnets from the transfer case housing 7T Wash the screen in a clean nonflammable solvent Use a bristle brush or pressure air to clean the screen Clean the magnets Replace any damaged magnets SEBU7887 19 199 Maintenance Section Transmission Oil Filter Replace 8 Clean the cover Inspect the cover seal Replace the cover seal if the seal is damaged 9 Insert the magnets and the screen into the transfer case housing Install the seal the cover and the four bolts 10 Clean the transmission oil drain plug and install the transmission oil drain plug Illustration 275 g01106816 11 Remove the oil filler cap on the left side of the machine and fill the transmission with oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the type of
19. tank filler cap 2 and the filler strainer The filler strainer is located right beneath the hydraulic tank filler cap Wash the filler cap and the strainer in a clean nonflammable solvent Install the strainer 5 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary wt a 8 8 0 Eu in o o y a B A a o fo 4 a F E B o o a ER E mH t Illustration 234 g01108775 6 The hydraulic tank has a remote drain plug which is located on the right side of the machine under the platform Remove drain plug 4 Wash the drain plug in a clean nonflammable solvent 7 The hydraulic tank is equipped with an ecology drain valve Attach a hose to a suitable drain adapter Install the adapter in the drain valve and allow the oil to drain into a suitable container 8 After you have drained the oil remove the adapter from the drain opening NOTICE Never start the engine while the hydraulic oil tank is being drained or while the hydraulic oil tank is empty Excessive wear and damage to the hydraulic compo nents can occur 9 Close the drain valve Install the drain plug 10 Change the hydraulic oil filter Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Replace
20. unfiltered oil The particles could enter the lubricating system and the particles could cause damage 104004068 Pallet Fork Inspect SMCS Code 6136 040 Descriptions of the Fork Tine Parts pre WM 4 ut 2 Illustration 244 1 Blade The horizontal part of the fork tine that supports the load 2 Heel The radius on the fork tine that connects the blade to the shank 3 Shank The vertical part of the fork tine that has the hooks that support the fork tines attached 4 Hook or Hanger Carriers that mount the fork tines to the carriage 5 Tip The free end of the blade 901598401 186 Maintenance Section Pallet Fork Inspect SEBU7887 19 Surfaces Qu P 9 8 N 11 C m d 6 10 C 7 11 7 g01598403 Illustration 245 6 Upper Face of the Blade The upper surface of the blade that carries the load 7 Bottom of Heel The lower surface of the blade that includes the tapers 8 Front Face of Shank The distance for the load center is measured from the front face of the shank and the face of the shank contacts the load 9 Flanks The side faces of the blade and the shank 10 Blade Bevel The upper and lower surfaces of the tip on the blade that are tapered for easy insertion of the fork tines 11 Tip Flanks The side surfaces of the tip on the blade t
21. 54 142 Maintenance Section Articulation Bearings Lubricate SEBU7887 19 102613559 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD Crushing Hazard Connect the steering frame lock between front and rear frames before servicing the machine in the articulation area Disconnect the steering frame lock and secure it in the stored po sition before resuming operation Failure to do so could result in serious injury or death Refer to Operation and Maintenance Manual Steering Frame Lock before entering the articulation joint Wipe all fittings before applying grease 1d Illustration 154 901236829 Apply grease to one fitting on the upper pivot bearing 1 and one fitting on the lower pivot bearing 2 i04155776 Automatic Lubrication Grease Tank Fill Autolube If Equipped SMCS Code 7540 544 TNK The Automatic TWIN Greasing System Reference Refer to System Operation RENR 6331 for more information on the Automatic TWIN Greasing System A pressure hazard is present Severe personal in jury or death can result from removing hoses or fittings that are under pressure Relieve the pres sure in the system before you remove hoses or fittings Illustration 155 901068678 1 Reservoir 2 Dust Cap 3 Fill Location Grease reservoir 1 is located near the rear fender on th
22. 887 19 163 Maintenance Section Drive Shaft Universal Joints Lubricate Apply lubricant through the fitting on the drive shaft support bearing Refer to Operation and Maintenance Manual Lubricant Viscosities for the proper grease 102571972 Drive Shaft Universal Joints Lubricate SMCS Code 3251 086 Note Do not grease the universal joints more than the recommended interval e Illustration 202 901069141 1 Wipe off the grease fittings before lubricating 2 Lubricate all five grease fittings on the universal joints Refer to Operation and Maintenance Manual Lubricant Viscosities for the proper grease 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
23. Display and RH Indicator Display 4t eene 10 Amperes 14 Tilt Position Sensor and Lift Position SENSOR iiia Ie ades ie sinit als 10 Amperes 15 Lever Sensors and LH Brake Pedal SENSON ui opi paaa eoi NS 10 Amperes 16 Air Seat and Heated Seat 10 Amperes 17 EMS Quad Gauge Tachometer and Backlights serana ia Eaa 10 Amperes 18 Wiper and Washer for the Front and the Rear Windows 2 0 cecceeeeeeeeeeeeeeeneteeees 10 Amperes 19 Payload Control System PCS 10 Amperes 20 Voltage Converter for Radio 10 Amperes 21 Voltage Converter Memory Attachment ssssssss 10 Amperes 22 Engine ECM sss 15 Amperes 23 Transmission ECM 15 Amperes 24 Implement ECM 15 Amperes 25 ECAP and Center Dash Indicator Display ne rhe 10 Amperes 26 LH Tail and Clearance Lights 10 Amperes 27 Hood Actuator ssss 10 Amperes 28 Stop Lamps ssss 10 Amperes 29 Horn iiie det 10 Amperes 30 Voltage Converter Memory Standard z oaa aera a 10 Amperes 31 Key Start Switch and Product Link 10 Amperes 32 Dome Lamps sess 10 Amperes 102245859 High Intensity Discharge Lamp HID Replace If Equipped SMCS Code 1434 510 HID lamps operate at very high voltages To avoid electrical shock and personal i
24. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR LLLI Operation and Maintenance Manual 966H and 972H Wheel Loaders GTA1 Up 972H LCC1 Up 972H A6D1 Up 966H A7D1 Up 972H RYF1 Up 966H A6G1 Up 966H A7G1 Up 972H A6J1 Up 966H A7J1 Up 972H TAL1 Up 966H SAFETY CAT COM 140 Maintenance Section Maintenance Interval Schedule SEBU7887 19 105121809 Maintenance Interval Schedule SMCS Code 7000 S N GTA1 Up S N LCC1 Up S N A6D1 Up SIN A7D1 Up S N A6G1 Up S N A7G1 Up S N A6J1 Up S N A7J1 Up S N TAL1 Up 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 ma
25. Steering Frame Lock before entering the articulation joint Illustration 156 901103093 Open the access panel on the right side of the machine in front of the steps Illustration 157 901105565 Wipe all fittings before lubricating Grease fitting 1 will lubricate the axle pivot bearing that is on the front of the rear axle Grease fitting 2 will lubricate the axle pivot bearing that is on the rear of the rear axle Note 5P 0960 Molybdenum Grease is preferred 1P 0808 Multipurpose Grease grease may be used 104404608 Backup Alarm Test If Equipped SMCS Code 7406 081 The backup alarm is on the rear of the machine Illustration 158 901043892 Turn the engine start switch to the ON position in order to perform the test Apply the service brake Place the transmission into REVERSE 144 Maintenance Section Battery Clean SEBU7887 19 The backup alarm should sound immediately The backup alarm will continue to sound until the transmission is placed into NEUTRAL or into FORWARD 102170472 Battery Clean SMCS Code 1401 070 ie i X Illustration 159 901100143 901100147 Illustration 160 Open the battery compartmen
26. ack of the tool 4 in order to start the pin d Slide pin holder 10 away from the pin and rotate the tool slightly in order to align pin setter 9 with the pin e Strike the end of the tool until the pin is fully inserted 6 After you drive the pin make sure that the retainer fits snugly into the pin groove K Series Tip Removal Illustration 176 g01389463 Note Retainers are often damaged during the removal process Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced 152 Maintenance Section Bucket Upper Pivot Bearings Lubricate SEBU7887 19 Illustration 177 g01175361 1 Use a pry bar in order to disengage retainer 5 2 Use the pry bar in order to remove retainer 5 from bucket tip 4 3 Remove bucket tip 4 from adapter 6 with a slight counterclockwise rotation 4 Clean adapter 6 Installation 1 Clean the adapter and the area around the latch if necessary 2 Install the new bucket tip onto the adapter with a slight clockwise rotation Illustration 178 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 101924086 Bucket Upper Pivot Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD Illustration 179 g01001416 Wipe off the fitting b
27. ansion bottles e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102375133 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Illustration 191 g01185306 Left side of the machine The sampling valve 1 for the cooling system is located on top of the engine toward the front of the engine on the left side of the machine Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis Reference For additional information about coolant analysis refer to Special Publicatio
28. ant Test Kit to check the concentration of the coolant Reference For additional information about the addition of Extender refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer Illustration 187 900807153 Cooling system pressure cap 1 is located under the hood at the rear of the machine Tilt the hood in order to access the cooling system pressure cap 1 Slowly loosen the cooling system pressure cap in order to relieve any system pressure Remove the cooling system pressure cap 2 If necessary drain enough coolant from the radiator in order to allow the addition of the Extender to the cooling system The cooling system drain valve 2 is located on the lower left side of the radiator 3 Add 1 18 L 40 fl oz of Extender to the cooling system QO Illustration 188 g01000160 4 Check the coolant level at sight gauge 3 Reference Refer to Operation and Maintenance Manual Cooling System Coolant Level Check for the correct procedure SEBU7887 19 157 Maintenance Section Cooling System Coolant Level Check 5 Install the cooling system pressure cap Close the engine hood 101921821 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is
29. ap at the hinge 3 If the measurement exceeds the required amount new shims must be installed Installing Shims for the Hinge on the Bucket Note Refer to the Disassembly and Assembly Manual Bucket Remove for the correct procedure for removing the pins in the linkage SEBU7887 19 149 Maintenance Section Bucket Linkage and Loader Cylinder Bearings Lubricate Illustration 168 g01001072 Illustration 167 g01345720 2 Bucket 4 Install washers on lift arm Install washers and pin assembly to the bucket When possible use washers on both sides of the lift arm to reduce the gap between the lift arm and the hinges on the bucket Note Refer to the Disassembly and Assembly Manual Bucket Install for the correct procedure for installing the pins in the linkage 103657090 Bucket Linkage and Loader Cylinder Bearings Lubricate Tem To lubricate pins 1 and 3 apply grease through SMCS Code 5102 086 BD 5104 086 BD the remote fittings that are located on the right side of 6107 086 BD the machine near the articulation joint The pins 2 4 5 6 and 7 do not have remote A WARNING grease fittings These pins have standard grease Crushing Hazard Connect the steering frame lock Tings between front and rear frames before servicing the machine in the articulation area Disconnect the steering frame
30. art the engine Raise the bucket Release the parking brake Reposition the machine in a straight direction without articulation 5 Lower the bucket to the ground Apply a slight down pressure Engage the parking brake Stop the engine 104040803 Drive Shaft Support Bearing Lubricate SMCS Code 3267 086 BD This procedure is to lubricate the drive shaft support bearings that have a grease fitting Some previous drive shaft support bearings are lubricated for life Drive shaft support bearings that are lubricated for life do not have grease fittings Note For better access articulate the machine to the right or to the left Because the steering frame lock cannot be connected remove the engine start switch key Turn the battery disconnect switch to the OFF position in order to keep the machine from being articulated In order to lubricate the drive shaft support bearing remove the plug if a grease zerk is not installed Install a grease zerk Do not grease the drive shaft support bearing more than the recommended interval NOTICE Do not over grease the drive shaft support bearing The excess grease may get into the brake area Dam age to the brakes or the loss of the brakes may occur Take precautions in order to avoid getting grease in the adjacent brake area Illustration 200 g01962154 o Illustration 201 902247513 Wipe off the fitting before any lubricant is applied SEBU7
31. bowl and the O ring groove Note The water separator bowl is reusable Do not discard the water separator bowl 5 Inspect the O ring seal on the water separator bowl Replace the O ring seal if necessary 6 Lubricate the O ring seal with clean diesel fuel or with engine oil Place the O ring seal in the water separator bowl 7 Install the water separator bowl onto the new filter element until the filter element is snug 8 Apply a thin coat of clean diesel fuel to the seal on the new filter Install the new fuel filter hand tight until the seal of the fuel filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the fuel filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the fuel filter use the rotation index marks as a guide 174 Maintenance Section Fuel System Secondary Filter Replace SEBU7887 19 9 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 10 Close drain valve 1 Note The water se
32. cal problem may exist Contact your Caterpillar dealer Fuses The fuses protect the electrical system from a circuit that has been overloaded Change a fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary Illustration 226 901000750 Illustration 227 901078009 The fuses are located in the cab on the right side of the operator seat 1 Axle Oil Cooler Clutch 20 Amperes 2 HMU Shift Handle 10 Amperes 3 HVAC Blower eese 20 Amperes 4 Quick Coupler sssusss 10 Amperes 5 Rear Cab Floodlights 15 Amperes 6 Spare nte Lat 10 Amperes 7 Secondary Steering 10 Amperes 8 ECM Switched Power 10 Amperes 9 Front Cab Floodlights 15 Amperes 10 Beacon and Heated Mirrors 10 Amperes SEBU7887 19 177 Maintenance Section High Intensity Discharge Lamp HID Replace 11 Turn Signal Flasher Front Flood Relays and Rear Flood Relays 10 Amperes 12 Machine Security System and Product Bn ges E 10 Amperes 13 LH Indicator
33. can cause an ex plosion Always wear protective glasses when working with batteries 1 Turn the engine start switch key OFF Turn all of the switches OFF SEBU7887 19 145 Maintenance Section Belt Inspect Adjust Replace 2 Turn the battery disconnect switch OFF Remove the key 3 Disconnect the negative battery cable from the disconnect switch Note Do not allow the disconnected battery cable to contact the disconnect switch 4 Disconnect the negative battery cable at the battery 5 Disconnect the positive battery cable at the battery 6 Inspect the battery terminals for corrosion Inspect the battery cables for wear or damage 7 Make any necessary repairs If necessary replace the battery cables or the battery 8 Connect the positive battery cable at the battery 9 Connect the negative battery cable at the battery 10 Connect the battery cable at the battery disconnect switch 11 Install the key and turn the battery disconnect Switch ON Recycle the Battery Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 103657235 Belt Inspect Adjust Replace SMCS Code 1397 025 1397 040 1397 510 Your machine is equipped with a single serpentine belt Stop the engine Open the rear hood The belt is located on the front of the engine
34. ck between front and rear frames before servicing the machine in the articulation area Disconnect the steering frame lock and secure it in the stored po sition before resuming operation Failure to do so could result in serious injury or death Refer to Operation and Maintenance Manual Steering Frame Lock before entering the articulation joint Personal injury can result from working with cleaning solvent Because of the volatile nature of many cleaning solvents extreme caution must be exercised when using them If unsure about a particular cleaning fluid refer to the manufacturer s instruc tions and directions Always wear protective clothing and eye protec tion when working with cleaning solvents Illustration 270 g03282677 The screen group for the steering oil is located in the articulation joint near the steering neutralizer valve on the right side 1 Disconnect hoses that are connected to the screen group 2 Remove the two connectors that are attached to the block 3 Use an allen wrench in order to remove the two screens from screen group 4 Wash the screens in a clean nonflammable solvent 5 Dry each screen with pressure air Inspect each screen for damage Replace the screen if the screen is damaged 6 Install the screens Install the connectors and connect the hoses SEBU7887 19 197 Maintenance Section Steering Pilot Oil Screen Command Control Steering Clean Rep
35. collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates SEBU7887 19 169 Maintenance Section Engine Oil and Filter Change 1 Open the engine hood 2 The drain plug is located on the left side of the engine oil pan toward the rear of the machine Open the oil drain valve and allow the oil to drain into a suitable container Close the drain valve FWD mg WIES AE KO yt dili Illustration 213 901109909 3 Use a strap type wrench to remove the engine oil filter from the right side of the engine Inspect the oil filter 4 Clean the filter mounting base Make sure that all of the used gasket has been completely removed Illustration 214 900101318 5 Apply a thin coat of oil to the seal on the new engine oil filter Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 or a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 6 Tighten the filter according to the instructions that are print
36. cording to local regulations and mandates 1 Operate the machine for a few minutes before obtaining the oil sample This will thoroughly mix the engine oil for a more accurate sample 2 Open the engine hood a ra O 47i 4 s Illustration 212 901106355 3 Use the sampling valve in order to obtain a sample of engine oil 4 Close the engine hood Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis and Special Publication PEHP6001 How To Take A Good Oil Sample 168 Maintenance Section Engine Oil and Filter Change SEBU7887 19 103649999 Engine Oil and Filter Change SMCS Code 1318 510 Selection of the Oil Change Interval NOTICE A 500 hour engine oil change interval is available pro vided that the operating conditions and recommend ed multigrade oil types are met When these require ments are not met shorten the oil change interval to 250 hours or use an S O S Services oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine The normal engine oil change interval is listed in this Operation and Maintenance Manual Maintenance Interval Schedule Abnormally harsh operating cycles or
37. dge The end bits are not reversible If both sides are worn install a new cutting edge 6 Install bolts 1 Tighten the bolts to the specified torque Reference Refer to Specifications SENR3130 Ground Engaging Tool G E T Fasteners 148 Maintenance Section SEBU7887 19 Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust Replace 7 Start the engine Raise the bucket and remove the blocking Lower the bucket to the ground 8 After a few hours of operation check the bolts for proper torque Bucket Wear Plates Personal injury or death can result from the bucket falling Block the bucket before changing bucket wear plates Illustration 165 g00879740 Inspect the wear plates Replace the wear plates before damage to the bottom of the bucket occurs Consult your Caterpillar dealer for replacement of wear plates Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust Replace SMCS Code 6001 025 CLR 6001 040 CLR 6001 510 Z4 6119 025 CLR 6119 040 CLR 6119 510 Z4 Inspect the Linkage Illustration 166 903003577 1 Lift Arm 2 Bucket 3 Inspection Points for the Bucket Hinge Periodically inspect the bucket linkage The gap between the bucket and the linkage should not exceed the thinnest shim that is available for the bucket assembly 1 Lower the lift arm assembly 1 to suitable blocking Rest the bucket 2 on the ground 2 Use a gauge to measure the g
38. e device for the angle of the heel 4 If the angle is between 87 degrees and 93 degrees the fork tine can remain in service Illustration 251 901563105 typical example 5 If the angle is less than 87 degrees or greater than 93 degrees the fork tine must be taken out of service The fork tines must be inspected for the following conditions 1 Coat the shafts with grease e permanent deformation e stress cracks e other defects Consult your Cat dealer for additional information Illustration 252 g01563115 typical example 2 Coat the mounting holes for the quick coupler with grease Reference Refer to Operation and Maintenance Manual SEBU6250 Caterpillar Machine Lubricant Recommendations for information on lubricants SEBU7887 19 189 Maintenance Section Quick Coupler Check 103657277 Quick Coupler Check If Equipped SMCS Code 6129 535 When you install a work tool on the quick coupler inspect the engagement of the coupler pins If there is play between the coupler pins and the corresponding bores inspect the coupler pins and the bores for damage or wear If there is play between the quick coupler and the hooks of the work tool inspect the quick coupler and the hooks for wear or for damage Make any necessary repairs before you operate the work tool 103657285 Quick Coupler Lubricate If Equipped SMCS Code 6129 086 Note Refer to Operation and Maintenanc
39. e Manual Lubricant Viscosities for more information on the types of grease to use Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on grease Wipe off all lubricant fittings before you apply lubricant through the lubricant fittings Do not lubricate the wedge and the wear plates Friction is needed in order to hold the wedge in place during backfilling 104039311 Radiator Core Clean SMCS Code 1353 070 KO Ensure that the engine is off before you perform this procedure 1 Open the radiator grill at the rear of the machine Illustration 253 901107157 2 Use the control knob 1 in order to release the hydraulic oil cooler Swing hydraulic oil cooler 2 and condenser 3 away from the radiator Illustration 254 900101939 3 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator fins The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi However the use of compressed air is preferred Refer to Operation and Maintenance Manual General Hazard Information for Safety information about using pressurized air and water 4 Swing the hydraulic oil cooler and the air conditioner condenser if equipped back into the ope
40. e oil from the component Extract the oil through the filler openings on the differential and final drives 3 Complete any additional required work Fill the differential and final drives with oil as required Install the dipstick fill plugs Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis and Special Publication PEHP6001 How To Take A Good Oil Sample 103657243 Drive Shaft Spline Center Lubricate SMCS Code 3253 086 SN Wipe all of the fittings before you apply grease to the fittings 162 Maintenance Section Drive Shaft Support Bearing Lubricate SEBU7887 19 NOTICE To prevent damage to the seal articulate the machine full right or left before lubricating the splines 1 Start the engine Raise the bucket Release the parking brake Articulate the machine to the right or to the left in order to properly lubricate the splined shaft 2 Lower the bucket to the ground Engage the parking brake Stop the engine Note Since the steering frame lock cannot be connected in this case remove the engine start switch key and turn the battery disconnect switch to the OFF position Illustration 199 g01106848 3 Apply grease to the fitting 1 Apply grease until the relief 2 overruns Note 5P 0960 Molybdenum Grease is preferred 1P 0808 Multipurpose Grease may be used 4 St
41. e right side of the machine Filling the Reservoir 1 Remove the dust cap 2 from the grease reservoir 1 2 Clean the filler tube assembly 3 and the coupling on the filler assembly Clean the filter located behind the coupling Refer to Operation and Maintenance Manual Automatic Lubrication Filler Filter Clean 3 Install the filler assembly onto the filler tube assembly 3 SEBU7887 19 143 Maintenance Section Axle Oscillation Bearings Lubricate 4 Fill the grease reservoir 1 with grease to the maximum level which is indicated on the grease reservoir 1 Reference For the correct type of grease refer to Operation and Maintenance Manual Lubricant Viscosities Note If a different brand of grease is used check for combatability If the new grease is not combatable with the grease in the reservoir the system must be purged Refer to System Operation RENR 6331 for more information about purging the system 5 Remove the filler assembly and install the dust cap 2 103657089 Axle Oscillation Bearings Lubricate SMCS Code 3268 086 BD 3278 086 BD Crushing Hazard Connect the steering frame lock between front and rear frames before servicing the machine in the articulation area Disconnect the steering frame lock and secure it in the stored po sition before resuming operation Failure to do so could result in serious injury or death Refer to Operation and Maintenance Manual
42. ed 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 B Illustration 215 900806758 7 Remove oil filler cap 1 on the right side of the engine Fill the crankcase with new oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 8 Clean the oil filler cap and install the oil filler cap 9 Start the engine and allow the oil to warm Check for any oil leaks 10 Check the oil level on dipstick 2 Reference Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure 11 Close the engine hood and stop the engine 170 Maintenance Section Engine Valve Lash Check SEBU7887 19 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
43. efer to Service Manual SENR5664 Refrigerant Accumulator Remove and Install for the replacement procedure of accumulator 1 Refer to Service Manual SENR5664 In Line Refrigerant Dryer Remove and Install for the replacement procedure of refrigerant dryer 2 Note When you operate the machine in a climate with high humidity replace the in line refrigerant dryer after every 1000 service hours or 6 months 102747279 Ride Control Accumulator Check SMCS Code 5077 535 R6 Note When the ride control accumulator is properly charged the bouncing motion of the machine is reduced by the ride control accumulator 1 Put a typical load in the bucket 2 Press the bottom of the ride control switch in order to activate the ride control function 3 Drive the machine over a rough road surface If the machine bounces too much or the accumulator piston striking the stop can be heard consult your Caterpillar dealer or refer to Service Manual Testing and Adjusting Ride Control Accumulator Test and Charge 103657286 Roading Fender Hinges Lubricate If Equipped SMCS Code 7252 086 RNG Wipe off the fitting before any lubricant is applied SEBU7887 19 191 Maintenance Section Rollover Protective Structure ROPS Inspect Illustration 256 g01963400 Open the roading fender Apply lubricant through one fitting on the hinge There is one hinge on each side of the machine 101457460
44. efore any lubricant is applied Apply lubricant through the fitting 101449996 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Note Clean the cab air filters more often if the machine is being operated in dusty conditions Illustration 180 900759048 SEBU7887 19 153 Maintenance Section Camera Clean 1 Remove the filter cover behind the seat Two threaded knobs 1 are used in order to remove the cover Remove the filter element 2 2 Open the access door 3 on the left side of the cab Remove the filter element 3 Clean the filter elements with pressure air or wash the filter elements in warm water with a nonsudsing household detergent 4 If water and detergent are used to clean the filter elements rinse the filter elements in clean water and allow the filter elements to air dry thoroughly Note If either filter element is damaged install a new filter element 5 Install the filter elements Install the filter cover and close the access door 102816405 Camera Clean If Equipped SMCS Code 7348 070 In order to maintain sufficient vision keep the Work Area Vision System WAVS camera lens and the display clean Display Eiseouegeosw Illustration 181 901223034 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
45. en with pressure air Inspect each screen for damage Replace the screen if the screen is damaged 6 Install the screens Install the connectors and connect the hoses 198 Maintenance Section Tire Inflation Check SEBU7887 19 102305841 Tire Inflation Check SMCS Code 4203 535 Al N Z Illustration 272 901160201 Always obtain proper tire inflation pressures and maintenance recommendations for the tires on your machine from your tire supplier Measure the tire pressure on each tire Inflate the tires with nitrogen if necessary Reference Refer to the Tire Inflation Information section of the Operation and Maintenance Manual for more information 102189470 Transmission Oil Change SMCS Code 3030 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the engine in order to warm the transmission oil Park the machine on level ground Lower the bucket and apply
46. er Protective Structure ROPS Inspect 191 Steering Pilot Oil Screen Command Control Steering Clean Replace sssse 196 Transmission Oil Change susss 198 Every 2000 Service Hours or 1 Year Brake Discs Check sseeseessee 146 Differential and Final Drive Oil Change 159 Electronic Unit Injector Inspect Adjust 163 Engine Valve Lash Check ssssse 170 Engine Valve Rotators Inspect 170 Hood Tilt Actuator Lubricate 178 Hydraulic System Oil Change 179 Hydraulic Tank Breaker Relief Valve Clean 184 Service Brake Wear Indicator Check 193 Steering Column Spline Command Control Steering L bricate interner rn tne 193 Every Year Cooling System Coolant Sample Level 2 ODA oes oet er ERR eren 158 Receiver Dryer Refrigerant Replace 190 Every 3000 Service Hours Steering Column Spline HMU Steering Lubricate secdesini iaire dti 194 Every 3 Years Seat Belt Replace sssssssssss 192 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 155 Cooling System Water Temperature Regulator Replace iid reote ie eere demit 158 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 1
47. erence Refer to Disassembly and Assembly RENR9214 C11 and C13 Engines for Caterpillar Built Machines for the correct procedure for replacing the water temperature regulator 102164355 Differential and Final Drive Oil Change SMCS Code 3278 044 4011 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 193 900287529 Front axle 160 Maintenance Section Differential and Final Drive Oil Level Check SEBU7887 19 Illustration 194 g00287531 Rear axle Note The axle housings are equipped with ecology drain valves 1 Remove drain plugs 2 Attach a hose to a suitable drain adapter Install the adapter in the drain valve and allow the oil to drain into a suitable container 2 Clean the drain plugs and install the drain plugs 3 Wipe off dipstick fill plugs 1 and the surfaces around dipstick fill plugs 1 4 Remove the dipstick fill plugs Fill each axle with
48. espect to the HID lamp s mounting position on the machine 178 Maintenance Section Hood Tilt Actuator Lubricate SEBU7887 19 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 104546258 Hood Tilt Actuator Lubricate SMCS Code 7275 086 Wipe all fittings before lubricating 2 SF e CS Illustration 228 g02148446 Hood tilt actuator the hood is removed for clarity 1 Fully raise the engine hood The hood tilt actuator is located on the right side at the rear of the machine 2 Fully extend the cylinder and wipe off the inner post with a clean cloth Then lubricate the entire length of the inner post 3 Wipe off both fittings on the cylinder Then apply the lubricant through the two fittings until the lubricant escapes back through each fitting 4 Fully close the engine hood 103657272 Hydraulic System Biodegradable Oil Filter Element Replace If Equipped SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Pub
49. 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 103694709 Secondary Steering Test SMCS Code 4300 081 SE 4300 081 SST 4324 081 4324 The service brake must be checked in order to en sure proper operation before you test the supple mental steering system Personal injury death or property damage could occur if the supplemental steering system is test ed and the service brake is not operational Test the service brake before you test the supple mental steering system Perform the following procedure if your machine is equipped with a ground driven supplemental steering and if the procedure is required by local regulations Ensure that there are no hazards in the test area The test area must be unobstructed and level Operate the machine in second gear Ensure that all air tanks and accumulators are properly charged Ensure that there is no load in the work tool Position the machine with the bucket or the work tool in the carry position with the machine in neutral Release the parking brake Apply the service
50. hat are tapered for easy insertion of the fork tines 12 Top of Shank The upper surface on the shank 13 Shaft The tubes that are mounted on the fork tines for mounting the fork tines to the carriage Dimensions Qr BH A T 3l He c A i Illustration 246 Section A A 01598405 SEBU7887 19 187 Maintenance Section Pallet Fork Inspect T Thickness The thickness of the blade at the closest point to the heel W Width The width of the blade at the closest point to the heel BH Back Height The distance from the bottom of the blade to the top of the shank BL Length The length of the blade is measured from the front face on the shank to the tip on the blade A Angle The angle from the upper surface of the blade to the front face of the shank Inspection of the Fork Tines Check the fork tines daily for any twisting or bending of the fork tines If any twisting or bending is observed the fork tines should be changed prior to any lifting operation If the fork tines are damaged consult your Cat dealer Check the fork tines for wear or for damage Inspect the welds the locks the shafts and the fork tines for damage If the components are damaged consult your Cat dealer Refer to Daily Inspection for additional information Blade Thickness Illustration 247 901600073 1 Measure the thickness of t
51. he shank Ensure that the measuring device is held square across the shank in order to acquire an accurate measurement el Illustration 248 g01600074 2 Measure the blade of the fork tine near the heel Ensure that the measuring device is held square across the blade in order to acquire an accurate measurement 3 Compare the measurement of the blade and the measurement of the shank 4 If the difference in measurements is less than 10 the fork tine can remain in service 5 f the difference in measurements is greater than 1096 the fork tine must be taken out of service Fork tine wear that is greater than 1096 represents a 20 reduction in the capacity of the fork tine Consult your Cat dealer for additional information Angle of the Heel Q ei iE X 7 901600075 Illustration 249 1 Place a measuring device in the top inside area of the heel on top of the blade Ensure that the measuring device is held flat against the blade in order to acquire an accurate measurement 188 SEBUT7887 19 Maintenance Section Pallet Fork Lubricate 103082842 Pallet Fork Lubricate SMCS Code 6136 086 Illustration 250 901600076 2 Move the upper arm of the measuring device toward the face of the shank Ensure that the measuring device is held flat against the face of the shank in order to acquire an accurate measurement 3 Check the angle that was measured with th
52. he steering column should not exceed 25 mm 1 0 inch If this movement exceeds this value please contact your Caterpillar dealer for the required service 102585698 Steering Column Spline Command Control Steering Lubricate SMCS Code 4310 086 SN 4338 086 SN PAN 900812993 Illustration 261 1 Remove the steering shaft from the machine Reference Refer to Disassembly and Assembly Manual for the removal procedure and for the installation procedure 2 Wipe off all of the fittings before any lubricant is applied 3 Refer to Operation and Maintenance Manual Lubricant Viscosities for the proper grease to use Apply the grease through fittings 1 2 3 4 5 6 7 and 8 4 Install the steering shaft on the machine 194 Maintenance Section Steering Column Spline HMU Steering Lubricate SEBU7887 19 103657300 Steering Column Spline HMU Steering Lubricate SMCS Code 4310 086 SN 4338 086 SN Illustration 262 901962195 The metering pump is located under the cab Crushing Hazard Connect the steering frame lock between front and rear frames before servicing the machine in the articulation area Disconnect the steering frame lock and secure it in the stored po sition before resuming operation Failure to do so could result in serious inj
53. he variations include differences in the engine setting the power train efficiency the brake holding ability etc Service Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake 1 Start the engine Raise the implement slightly Apply the service brake Release the parking brake 2 Move the transmission control to THIRD SPEED FORWARD while the service brakes are applied Make sure that the autoshift control is in the OFF position 3 Gradually increase the engine speed to high idle The machine should not move SEBU7887 19 147 Maintenance Section Bucket Cutting Edges Inspect Replace 4 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Engage the parking brake Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation Parking Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move reduce the engine speed immediately and apply the service brake pedal This test is performed when the parking brake is engaged If the machine begins to move compare the engine rpm to the engine rpm of a pri
54. ic System Oil Filter Replace SEBU7887 19 102375329 Hydraulic System Oil Filter Replace SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates lc o Illustration 235 901108153 The hydraulic filters are located on the right side of the machine under the platform There are two hydraulic oil filters Each filter must be replaced during this procedure 1 Use a strap type wrench to remove each filter element Dispose of the used filter elements properly 2 Clean the filter mounting bases Make sure that all of the used seals are completely removed Illustration 236 900101318 3 Apply a thin coat of hydraulic oil to the seals on the new filters Install each new hydraulic oil filter hand tight until the seals of the hydraulic oil filters contact each filter base Note the position of the index marks on each filter in relati
55. ining fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note The volume of the air in the water separator is small Usually it is not necessary to prime the fuel system if only the water separator element was changed 172 Maintenance Section Fuel System Primary Filter Water Separator Drain SEBU7887 19 Illustration 219 g00882774 1 Stop the engine and open the engine hood The fuel priming pump is located above the primary fuel filter on the right side of the machine This machine is equipped with an electric fuel priming pump The toggle switch for the pump is located on the filter base Operate the fuel pump for approximately 60 seconds 2 Start the engine Note Additional priming may be needed if you are priming because of the following circumstances e The engine will not start e The engine starts but the engine continues to misfire e The engine starts but the engine continues to emit smoke e The engine has run out of fuel e The fuel injectors have been removed from the engine Operate an electric fuel pump for approximately 30 seconds for this additio
56. l thoroughly mix the transmission oil for a more accurate sample Illustration 279 g01108497 2 The sampling valve for the transmission oil is located on the transmission oil filter base on the right side of the machine under the platform Use the in line sampling valve in order to obtain a sample of transmission oil Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis and Special Publication PEHP6001 How To Take A Good Oil Sample 102189520 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 280 901106828 gm Window Washer Reservoir The window washer reservoir is located under an access door on the platform on the right side of the machine Fill the window washer reservoir through the filler opening 103657573 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 ees MEE g01962467 Illustration 281 202 Maintenance Section Windows Clean SEBU7887 19 Inspect the condition of the wiper blades on the front window and on the rear window Replace the wiper blades if the wiper blades are worn or damaged or if streaking occu
57. lace 103657340 Steering Pilot Oil Screen Command Control Steering Clean Replace If Equipped SMCS Code 4304 070 Z3 4304 510 Z3 S N GTA1 Up S N LCC1 Up S N A7D1 Up SIN RYF1 Up S N A6G1 Up S N A7G1 Up S N A6J1 Up S N A7J1 Up S N TAL1 Up Crushing Hazard Connect the steering frame lock between front and rear frames before servicing the machine in the articulation area Disconnect the steering frame lock and secure it in the stored po sition before resuming operation Failure to do so could result in serious injury or death Refer to Operation and Maintenance Manual Steering Frame Lock before entering the articulation joint Personal injury can result from working with cleaning solvent Because of the volatile nature of many cleaning solvents extreme caution must be exercised when using them If unsure about a particular cleaning fluid refer to the manufacturer s instruc tions and directions Always wear protective clothing and eye protec tion when working with cleaning solvents Illustration 271 g01962461 The screen group 3 is located behind the cab 1 Disconnect hoses 1 and 2 that are connected to the screen group 3 2 Remove the two connectors that are attached to the block 3 Use an allen wrench in order to remove the two screens from screen group 3 4 Wash the screens in a clean nonflammable solvent 5 Dry each scre
58. lement 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 Illustration 206 900281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow 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 result Note Replace the secondary element when you service the primary element for the third time If a clean primary element has been installed and a warning for the air filter
59. lication 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 ab Wa lc o Illustration 229 901108153 The hydraulic filters are located on the right side of the machine under the platform There are two hydraulic oil filters Each filter must be replaced during this procedure 1 Use a strap type wrench to remove each filter element Dispose of the used filter elements properly 2 Clean the filter mounting bases Make sure that all of the used seals are completely removed SEBU7887 19 179 Maintenance Section Hydraulic System Oil Change Illustration 230 g00101318 3 Apply a thin coat of hydraulic oil to the seals on the new filters Install each new hydraulic oil filter hand tight until the seals of the hydraulic oil filters contact each filter base Note the position of the index marks on each filter in relation to a fixed point on each filter base Note There are rotation index marks on each hydraulic oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the hydraulic oil filters use the rotation index marks as a guide 4 Tighten each filter according to the instructions that are printed on each filter Use the index
60. 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 102187095 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY 1 The rear hood should be opened in order to access the air filter The air filter is located on the right side of the machine Illustration 203 901105972 2 Remove the cover on air filter housings 3 3 Remove primary element 2 from the air filter housing 4 Clean the inside of air filter housing 1 5 Inspect the primary element If the pleats the gaskets or the seals are damaged discard the element Replace a damaged primary element with a clean primary element 164 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU7887 19 Cleaning Primary Air Filter Elements 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 wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must
61. ly in well ventilated areas Do not smoke while changing ether cylinders Use ether with care to avoid fires Do not store replacement ether cylinders in living areas or in the operator s compartment Do not store ether cylinders in direct sunlight or at temperatures above 49 C 120 F Discard cylinders in a safe place Do not puncture or burn cylinders Keep ether cylinders out of the reach of unautho rized personnel To avoid possible injury be sure the brakes are ap plied and all controls are in Hold or Neutral when starting the engine 1 eo y i Illustration 218 902976804 1 Open the access door The ether starting aid cylinder is mounted on the left side of the machine next to the air cleaner 2 Loosen retaining clamp 1 and unscrew ether starting aid cylinder 2 3 Remove the gasket Install the new gasket that is provided with each new ether starting aid cylinder 4 Install new ether starting aid cylinder 2 hand tight Tighten retaining clamp 1 securely 5 Close the engine hood i01715517 Fuel System Prime SMCS Code 1250 548 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent conta
62. mination e There should not be significant changes in sodium silicon copper and potassium e The allowable level of oxidation is 40 percent 0 12 Abs units e The kinematic viscosity of 100 C 212 F oil should not exceed a change of more than 2 cSt from new oil Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine in order to warm the hydraulic oil 2 Park the machine on level ground Lower the attachment to the ground and apply slight downward pressure Engage the parking brake and stop the engine Illustration 232 901185530 SEBU7887 19 181 Maintenance Section Hydraulic System Oil Change Illustration 233 g01185539 3 The hydraulic tank is behind the cab of the machine Press the button on breaker relief valve 1 in order to relieve any tank pressure 4 Remove hydraulic
63. n SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102186511 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age NOTICE Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a ther mostat installed If the thermostat is installed wrong it will cause the engine to overheat Inspect gaskets before assembly and replace if worn or damaged SEBU7887 19 159 Maintenance Section Differential and Final Drive Oil Change P g01105775 Illustration 192 Replace the water temperature regulator in order to reduce the chance of problems with the cooling system Replace the water temperature regulator and the seals while the cooling system is completely drained or while the coolant is drained to a level that is below the water temperature regulator housing Note If you are only replacing the water temperature regulator drain the coolant to a level that is below the water temperature regulator housing Ref
64. n 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 1096 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 Cil The 6000 hour interval for changing the oil is specific to HYDO Advanced 10 The 4000 hour interval for changing the oil is for the following oil types e Caterpillar Hydraulic Oil HYDO e Caterpillar Transmission and Drive Train Oil TDTO e Caterpillar TDTO TMS e Caterpillar Diesel Engine Oil 180 Maintenance Section Hydraulic System Oil Change SEBU7887 19 e Caterpillar Biodegradable Hydraulic Oils HEES e Caterpillar Multipurpose Tractor Oil MTO e Heavy duty diesel engine oils with a minimum zinc content of 900 ppm If Caterpillar oils cannot be used use heavy duty oils with the following classification Caterpillar ECF 1 API CG 4 API CF and TO 4 These oils must have a minimum zinc additive of 0 09 percent 900 ppm Note I
65. n that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Illustration 190 901185306 Left side of machine The sampling valve 1 for the cooling system is located on top of the engine toward the front of the engine on the left side of the machine Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples 158 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU7887 19 e Keep the unused sampling bottles stored in plastic bags e Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from exp
66. nal priming i01715535 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 220 900882783 1 Open the engine hood The water separator is located on the bottom of the primary fuel filter on the right side of the machine 2 Open the drain valve on the bottom of the water separator bowl Allow the water and the fuel to drain into a suitable container 3 Close the drain valve SEBU7887 19 173 Maintenance Section Fuel System Primary Filter Water Separator Element Replace Note The water separator is under suction during normal engine operation Tighten the drain valve securely in order to prevent air leakage into the fuel system 4 Close the engine h
67. ndustrial hydraulic oils are not recommended in Caterpillar hydraulic systems Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours Caterpillar s standard SOS Fluids Analysis or an equivalent oil sampling program should be used The current guidelines for cleanliness of the oil should be observed Refer to Measured Data If an oil sampling program is not available the standard 2000 oil change interval should be used Measured Data The following information should be monitored through sampling of the oil e Significant changes in wear metals should be monitored These metals include iron copper chromium lead aluminum and tin Significant changes in the following additives should be monitored zinc calcium magnesium and phosphorus e Contaminants should not be present These contaminants include fuel and antifreeze Water content should be 5 percent or less e The silicon level should not exceed 15 parts per million for new oil The particle counts should be monitored e The recommended level of cleanliness for Caterpillar machines that are operated in the field is ISO 18 15 or cleaner The cleanliness should be monitored by particle count analysis The levels of contamination should not exceed the normal by more than two ISO codes Action should be taken in order to determine the cause of the contamination The system should be returned to the original levels of conta
68. ng System Coolant Extender ELC Add SMCS Code 1352 544 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure 156 Maintenance Section Cooling System Coolant Extender ELC Add SEBU7887 19 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life When a Caterpillar Extended Life Coolant ELC is used an Extender must be added to the cooling system Use a 8T 5296 Cool
69. njury 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 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 C Remove the bulb from the HID lamp AR 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 r
70. nonflammable solvent The filter element is located inside the breather 4 Shake the breather or use pressure air in order to dry the breather 5 Inspect the breather hose for damage Replace the breather hose if it is necessary 6 Install the breather assembly Install the hose and install the hose clamp 7 Close the access door SEBU7887 19 167 Maintenance Section Engine Oil Level Check 102188149 Engine Oil Level Check SMCS Code 1000 535 FLV Illustration 210 g01106343 Open the service door that is located on the right side of the machine The oil level dipstick is located in the service door L ADD FULL Illustration 211 900746755 Maintain the oil level between the FULL mark and ADD mark on the dipstick Check the level of the engine oil while the engine is shut off Add oil if necessary Engine Oil Sample Obtain SMCS Code 1348 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids ac
71. 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 The primary air filter element can be used up to six times if the element is properly cleaned and the element is inspected 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 elements before cleaning Inspect the air filter elements 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 primary air filter elements e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air filter elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered
72. ocated on the right side of the machine under the platform 200 Maintenance Section Transmission Oil Level Check SEBU7887 19 1 Operate the machine in order to warm the oil Park the machine on level ground Lower the bucket to the ground and apply slight downward pressure 2 Engage the parking brake and stop the engine 3 Open the access panel 4 Remove the filter housing drain plug and allow the oil in the filter to drain into a suitable container 5 Use a strap type wrench to remove the filter housing 6 Remove the used filter element Dispose of the used filter element properly 7 Clean the filter housing and the filter housing base with a clean nonflammable solvent 8 Inspect the filter housing seal Replace the seal if the seal is damaged 9 Install the new filter element into the transmission filter housing Clean the filter housing drain plug and install the drain plug 10 Start the engine Slowly operate the transmission controls in order to circulate the transmission oil Check the machine for oil leaks 11 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure 101468938 Transmission Oil Level Check SMCS Code 3030 535 FLV Illustration 278 900766406 The sight gauge for the transmission oil level is located on the left side of the machine near the articulati
73. ode sehe latis Md 163 Engine Air Filter Secondary Element Replace 165 Ether Starting Aid Cylinder Replace 171 Fuel System Prime sssssssss 171 Fuses Replace ssssssssseee 176 High Intensity Discharge Lamp HID Replace 177 Oil Filter Inspect sssssssee 184 Pallet Fork Inspect ssssessss 185 Radiator Core Clean sess 189 Ride Control Accumulator Check 190 Secondary Steering Test ssssusss 192 Window Washer Reservoir Fill 201 Window Wiper Inspect Replace 201 Every 10 Service Hours or Daily Backup Alarm Test ssssssssssssss 143 Cooling System Coolant Level Check 157 Engine Oil Level Check 167 Fuel System Primary Filter Water Separator Drain eT 172 Hydraulic System Oil Level Check 183 Quick Coupler Check ssssssssse 189 Seat Belt Inspect sss 191 Transmission Oil Level Check 200 Windows Clean sssssseseeeeree 202 Every 50 Service Hours or Weekly Bucket Lower Pivot Bearings Lubricate 150 Cab Air Filter Clean Replace 152 Fuel Tank Water and Sediment Drain 175 Tire Inflation Check sssss
74. olant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Reference For information about adding Extender to your cooling system refer to Operation and Maintenance Manual Cooling System Coolant Extender ELC Add or consult your Caterpillar dealer If an Extended Life Coolant was previously used flush the cooling system with clean water No other cleaning agents are required Use the following procedure to change the Extended Life Coolant SEBU7887 19 155 Maintenance Section Cooling System Coolant Extender ELC Add Illustration 185 g00807153 The cooling system pressure cap 1 is located under the engine hood at the rear of the machine 1 Slowly loosen the cooling system pressure cap in order to relieve any system pressure 2 Open the acce
75. on joint 1 Operate the machine for a few minutes in order to warm the transmission oil 2 Park the machine on a hard level surface Put the transmission control into the NEUTRAL position Lower the bucket to the ground with a slight downward pressure Engage the parking brake Note Before the machine is started the transmission oil level should be above MIN START mark 1 on the upper end of the sight gauge 3 Check the oil level while the engine is running at low idle While the engine is running at low idle the transmission oil level should be between the MIN mark 3 and the MAX mark 2 4 If necessary remove the filler cap and add oil SEBU7887 19 201 Maintenance Section Transmission Oil Sample Obtain 102195036 Transmission Oil Sample Obtain SMCS Code 3080 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes before obtaining the oil sample This wil
76. on to a fixed point on each filter base Note There are rotation index marks on each hydraulic oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the hydraulic oil filters use the rotation index marks as a guide 4 Tighten each filter according to the instructions that are printed on each filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filters Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 5 Start the engine and run the engine at low idle Inspect the hydraulic system for leaks Illustration 237 g01185406 SEBU7887 19 183 Maintenance Section Hydraulic System Oil Level Check 6 The oil gauge and the hydraulic oil filler are on the left side of the machine above the platform Maintain the oil level above the ADD COLD mark on the sight gauge Add hydraulic oil if necessary 102375341 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV Illustration 238 g01185406 V a S Ur M om 7 I Illustration 239 g01185435 The hydraulic tank i
77. ood Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 1263 510 FQ NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them The fuel will not be filtered and could be contaminated Contaminated fuel will cause accelerated wear to fuel system parts The fuel system should be primed prior to starting the engine 1 Open the engine hood The primary fuel filter is located on the right side of the machine rere Illustration 221 g00806773 2 Open drain valve 3 on the bottom of water separator bowl 2 Allow the water and the fuel to drain into a suitable container 3 Use a strap type wrench in order to remove the primary fuel filter 1 Unscrew the sediment bowl from the fuel filter 4 Clean the water separator
78. or test This will indicate the amount of system deterioration 1 Start the engine Raise the implement slightly Engage the parking brake 2 Move the transmission control to THIRD SPEED FORWARD Make sure that the autoshift control is in the OFF position The parking brake indicator light should come on 3 Gradually increase the engine speed to high idle The machine should not move 4 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation 103657238 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges Illustration 164 900764365 1 Bolts for Cutting Edge 2 Cutting Edge Check the cutting edges and the end bits for wear and for damage Use the following procedure to service the cutting edges and the end bits 1 Raise the bucket and place blocking under the bucket 2 Lower the bucket onto the blocking Stop the engine 3 Remove bolts 1 cutting edge 2 and the end bits 4 Clean all contact surfaces 5 f the opposite side of the cutting edge is not worn use the opposite side of the cutting e
79. parator element is under suction during normal engine operation Tighten the drain valve securely in order to prevent air leakage into the fuel system 11 Prime the fuel system in order to fill the water separator element with fuel Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure 12 Close the engine hood 102187930 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Illustration 222 901106196 1 Open the hood Secondary fuel filter 1 is located on the right side of the machine 2 Open drain valve 2 in order to allow fuel to flow from the filter The fuel will flow out of hose 3 Catch the fuel in a suitable container and dispose of the fuel properly Close the drain valve Remove the fuel filter Dispose of the used filter properly 3 Clean the filter mounting base Make sure that all of the used gasket is removed 4 Lubricate the seal of a new fuel filter with clean diesel fuel Install the new fuel filter hand tight until the seal of the fuel filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the fuel filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the fuel filter
80. peration and Maintenance Manual Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each increment is an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above References Reference Special Publication SEBUG250 Caterpillar Machine Fluids Recommendations Reference Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Reference Special Publication PEDP7035 Optimizing Oil Change Intervals Reference Special Publication PEDP7036 S O S Fluid Analysis Reference Special Publication PEDP7076 Understanding the S O S Oil Analysis Tests Procedure for Changing the 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
81. place the fuel cap boot If your machine does not have a fuel cap boot contact your Caterpillar dealer for information about the fuel cap boot 7 Wash the fuel cap boot in a clean nonflammable solvent 8 Install the fuel cap boot and the fuel tank cap 103657251 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 176 Maintenance Section Fuses Replace SEBU7887 19 OMNES Illustration 225 901962163 The drain valve is under the fuel tank at the rear of the machine 1 Loosen the bolt 2 on the side of the drain 2 Allow the water and the sediment to drain into a suitable container 3 Tighten the bolt on the side of the drain 102200478 Fuses Replace SMCS Code 1417 510 NOTICE Replace fuses with the same type and size only Oth erwise electrical damage can result If itis necessary to replace fuses frequently an electri
82. pply the service brakes fully depress the pedal for a duration of one second Release the pedal for a duration of one second Repeat the application and release process until the alert indicator for brake oil presure comes on This will decrease the accumulator pressure A minimum of five applications of the service brake pedal are required 4 If the alert indicator comes on after less than five applications of the brake measure the accumulator precharge pressure An authorized Caterpillar dealer can measure the nitrogen gas pressure in the accumulator Use only dry nitrogen gas for recharging 101732078 Brake Discs Check SMCS Code 4255 535 Reference For the correct procedure refer to the Testing and Adjusting Service Manual of the braking system for your machine or consult your Caterpillar dealer i01739721 Braking System Test SMCS Code 4251 081 4267 081 Fasten the seat belt before you test the brakes e Park the machine on a dry level surface e Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles e Make sure that the steering frame lock is in the unlocked position The following tests are used to determine whether the braking system is functional These tests are not intended to measure the maximum brake holding effort The required brake holding effort for sustaining a machine at a specific engine rpm varies from one machine to another machine T
83. rating position 5 Close the radiator grill 190 Maintenance Section Receiver Dryer Refrigerant Replace SEBU7887 19 102894326 Receiver Dryer Refrigerant Replace SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system Illustration 255 901107270 1 Refrigerant accumulator 2 Refrigerant dryer Access refrigerant accumulator 1 from the left side of the machine Access in line refrigerant dryer 2 from the right side of the machine R
84. rs 104412316 Windows Clean SMCS Code 7310 070 Clean the outside of the windows from the ground unless handholds are available Illustration 282 900566124 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 Stubborn 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 Rinse the windows with a sufficient amount of clean water
85. s located on the left side of the machine behind the cab The lift arms must be lowered with the bucket flat in order to check the hydraulic oil Check the hydraulic oil level while the engine is stopped Maintain the oil level above the ADD COLD mark on sight gauge 2 If necessary remove filler cap 1 slowly and add oil 102375351 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar 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 Operate the hydraulic controls This will thoroughly mix the hydraulic oil for a more accurate sample Illustration 240 g01185445 2 If the machine is equipped with conventional oil open the access door to the service center on the right side of the machine The hydraulic oil filter is above the shelf The sampling valve for the hydraulic oil is located on the hydraulic oil filter ba
86. se 3 If the machine is equipped with biodegradable hydraulic oil open the access door to the service center on the right side of the machine The hydraulic oil filter is above the shelf The sampling valve for the hydraulic oil is located on the hydraulic oil filter base 4 Use the in line sampling valve in order to obtain a sample of hydraulic oil 184 Maintenance Section Hydraulic Tank Breaker Relief Valve Clean SEBU7887 19 5 Close the access door to the service center on the right side of the machine Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis and Special Publication PEHP6001 How To Take A Good Oil Sample 102375419 Hydraulic Tank Breaker Relief Valve Clean SMCS Code 5118 070 901185542 Illustration 241 The hydraulic tank breaker relief valve is located on the top of the hydraulic tank behind the cab of the machine 1 Press the button on the top of the hydraulic breaker in order to relieve the pressure in the hydraulic tank Remove the hydraulic tank breaker relief valve 2 Clean the hydraulic tank breaker relief valve in a clean nonflammable solvent Shake the breaker relief valve dry or use pressure air to dry the breaker relief valve 3 Install the hydraulic tank breaker relief valve Logging Fork Clamp Lubricate If Equipped SMCS Code 6113 086 BD 6410 086
87. ss door on the left side of the machine in order to access coolant drain valve 2 Open the drain valve at the bottom of the radiator Allow the coolant to drain into a suitable container 3 Flush the cooling system with clean water until the draining water is clean Close drain valve 2 4 Replace the water temperature regulator Reference Refer to Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the correct procedure 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 the Extended Life Coolant Reference Refer to Operation and Maintenance Manual Capacities Refill for the capacity of the cooling system 6 Start the engine Run the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes Illustration 186 g01000160 7 Maintain the coolant level in sight gauge 3 on the upper radiator 8 Install the cooling system pressure cap Stop the engine 101921794 Cooli
88. ssssssss 198 Every 100 Service Hours or 2 Weeks Axle Oscillation Bearings Lubricate 143 Bucket Linkage and Loader Cylinder Bearings Lubricate sirpi herein iieii ieai i 149 Bucket Upper Pivot Bearings Lubricate 152 Logging Fork Clamp Lubricate 184 SEBU7887 19 141 Maintenance Section Maintenance Interval Schedule Steering Cylinder Bearings Lubricate 195 Initial 250 Service Hours Electronic Unit Injector Inspect Adjust 163 Engine Oil Sample Obtain 167 Engine Valve Lash Check ssssss 170 Engine Valve Rotators Inspect 170 Transmission Oil Filter Replace 199 Every 250 Service Hours Drive Shaft Support Bearing Lubricate 162 Every 250 Service Hours or Monthly Battery Clean eroriren 144 Belt Inspect Adjust Replace 145 Brake Accumulator Check 146 Braking System Test sss 146 Cooling System Coolant Sample Level 1 Obtalli z 2 tnter be eli hebetes 157 Differential and Final Drive Oil Level Check 160 Drive Shaft Spline Center Lubricate 161 Engine Crankcase Breather Clean 166 Engine Oil Sample Obtain 167 Quick Coupler Lubricate
89. 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 166 Maintenance Section Engine Crankcase Breather Clean SEBU7887 19 R Illustration 207 g00864077 2 Remove the secondary element g00864079 Illustration 208 3 Cover the air inlet opening Clean the inside of the air cleaner housing Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged Uncover the air inlet opening Install a new secondary element Install a clean primary element and the cover for the air cleaner housing Close the access door Repeat the procedure for the other air cleaner 102197033 Engine Crankcase Breather Clean SMCS Code 1317 070 Illustration 209 901109682 Open the hood on the rear of machine in order to access the engine compartment The crankcase breather is located on the right side of the engine 1 Remove the four bolts 1 that hold the breather 2 onto the cover Remove the breather 2 Check the condition of the cover seal 3 Replace the seal if the seal is damaged 3 Wash the breather 2 and the filter element in a clean
90. t on the left side of the machine under the platform Remove the battery hold down 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 Replace the battery hold down Refer to Operation and Maintenance Manual Battery Hold Down Tighten for the correct torque Close the battery compartment 102185798 Battery Hold Down Tighten SMCS Code 7257 527 Illustration 161 900882014 Open the battery compartment on the left side of the machine under the platform Over time the vibration of an operating machine can cause the battery hold down to loosen To help to prevent loose batteries and the possibility of loose cable connections tighten the locknut in the center of the hold down to a torque of 14 3 N m 10 2 Ib ft 103657099 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 Personal injury may occur from failure to properly service the batteries Batteries give off flammable fumes that can ex plode Electrolyte is an acid and can cause per sonal injury if it contacts the skin or eyes Prevent sparks near the batteries Sparks could cause vapors to explode Do not allow jumper ca ble ends to contact each other or the engine Im proper jumper cable connections
91. tension 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 192 Maintenance Section Seat Belt Replace SEBU7887 19 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 eL 0 4 Illustration 259 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 buckle 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
92. ure to do so could result in serious injury or death Refer to Operation and Maintenance Manual Steering Frame Lock before entering the articulation joint Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Illustration 267 901105600 1 Location of the grease fittings for the rod ends 2 Remote location of the grease fittings for the head ends Illustration 268 g01105611 Location of the grease fittings for the rod ends both sides M Illustration 269 901105595 Remote location of the grease fittings for the rod ends Wipe off the fittings before any lubricant is applied The rod end of the steering cylinders are lubricated by using standard grease fittings 3 The head ends of the steering cylinders are lubricated by using remote grease fittings 4 that are located on the right side of the machine in front of the steps 196 Maintenance Section SEBU7887 19 Steering Pilot Oil Screen Command Control Steering Clean Replace 105121573 Steering Pilot Oil Screen Command Control Steering Clean Replace If Equipped SMCS Code 4304 070 Z3 4304 510 Z3 Crushing Hazard Connect the steering frame lo
93. ury or death Refer to Operation and Maintenance Manual Steering Frame Lock before entering the articulation joint Note Do not disconnect any hydraulic lines from the metering pump Use the following steps to lubricate the splines on the steering column 901294342 Illustration 263 1 Panel 2 Bolts 1 Remove five bolts 2 and panel 1 from each side of the machine Illustration 264 g01294346 g01294352 Illustration 265 2 Support the metering pump 3 Do not loosen the hose couplings 5 3 Loosen the four bolts 4 that hold the pump SEBU7887 19 195 Maintenance Section Steering Cylinder Bearings Lubricate Illustration 266 g01294357 4 Lower the pump in order to expose the splines 6 a Clean the male splines on the steering column Clean the female splines in the pump o Apply proper grease to the splines Refer to Operation and Maintenance Manual Lubricant Viscosities for selecting the proper grease N Push the pump into position co Tighten the four bolts that hold the pump Test the steering system 103657091 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD Crushing Hazard Connect the steering frame lock between front and rear frames before servicing the machine in the articulation area Disconnect the steering frame lock and secure it in the stored po sition before resuming operation Fail
94. vel reading can occur 3 Remove dipstick fill plug 1 again and check the oil level Maintain the oil level between the ADD mark and the FULL mark Add oil if necessary Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the type of lubricant and for the refill capacity 4 Clean the plug and install the plug 101921974 Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4011 008 4070 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes before obtaining the oil sample This will thoroughly mix the differential oil fora more accurate sample Illustration 197 g00884056 Rear axle Illustration 198 g00884059 Front axle 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 th
95. y change the maintenance intervals Note The aftertreatment system can be expected to function properly for the useful life of the engine emissions durability period as defined by regulation All prescribed maintenance requirements must be followed Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended substantially S O S services may extend the oil change even longer Consult your Cat dealer for details The following guidlines shoud be followed if the service hours are not met Items listed between 10 and 100 service hours should be performed at least every 3 months Items listed between 250 and 500 service hours should be performed at least every 6 months Items listed between 1000 service hours and 2500 service hours should be performed at least every year When Required Automatic Lubrication Grease Tank Fill 142 Battery or Battery Cable Inspect Replace 144 Bucket Cutting Edges Inspect Replace 147 Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust Replace ssussssss 148 Bucket Tips Inspect Replace 150 Camera Clean sse 153 Circuit Breakers Reset ssssssss 153 Engine Air Filter Primary Element Clean Replace iperen e i

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