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MAINTENANCE INTERVALS - Safety

1. 3 Remove cotter pins 8 Slide retaining pins 4 in order to remove the used brake pads 4 Insert the new brake pads The thinner part of the brake pad goes to the rear of the machine 5 Replace the pins and the cotter pins 6 Use a 1 4 inch allen wrench in order to turn the rod in the clockwise direction until the gap is 38 mm 0 015 inch 7 Replace the cap on the hole in the lever assembly 8 Make the final adjustment from the cab Repeatedly apply the parking brake and release the parking brake This should be done until the travel of the lever decreases and the travel becomes constant 01191328 Power Take Off Drive Shaft Lubricate SMCS Code 3253 086 Note Lubricate the PTO drive shaft with Caterpillar Molybdenum Grease MPGM See Operation and Maintenance Manual Lubricating Greases g00407284 Illustration 356 209 Maintenance Section Power Take Off Drive Shaft Lubricate Lubricate one fitting on the spline The fitting can be accessed when you are underneath the machine 101171817 Quick Hitch Lubricate SMCS Code 7120 086 S N 6GS1 Up S N 6HS1 Up Illustration 357 g00404278 Lubricate the quick hitch at location 1 and at location 2 When you are using the three point hitch lubricate both sides of the quick hitch 100840114 Radiator Core Clean SMCS Code 1353 070 1805 1810 g00377172 Illustration 358 1 Raise the hood Note See Operation a
2. and the battery negative to battery negative Jump start only with an energy source with the same voltage as the stalled machine Turn off all lights and accessories on the stalled machine Otherwise they will operate when the energy source is connected 160 Maintenance Section Battery Recycle Illustration 241 g00383593 Raise the hood Note See Operation and Maintenance Manual Engine Compartment Hood Raise Lower Tighten the battery retainers on all batteries Perform the following requirements e Clean the top of the batteries with a clean cloth e Keep the terminals clean and coated with petroleum jelly i00058390 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 100811471 Braking System Test SMCS Code 4100 081 4267 081 Turn off the engine The pedal should move with light pedal effort for approximately one quarter of the total travel At this point pedal effort should increase substantially If the engine is turned off the brakes may be spongy The brake system accumulator is depleted Start the engine in order to charge the brake system accumulator Note Consult any Caterpillar dealer or refer to the Service Manual for the procedure for purging air from the brakes and for trou
3. Check SMCS Code 4180 535 FLV Note Inspect the oil level frequently if you operate the machine in extremely wet conditions or extremely muddy conditions 1 Park the machine on a hard level surface Place chocks at the front of the belts and at the rear of the belts fe eS re aae ms Illustration 351 2 Deflate the air from spring 1 through valve assembly 2 3 Rotate the midroller so that oil level fill plug 3 is located at the 2 o clock position 4 Clean the area around oil level fill plug 3 Then remove oil level fill plug 3 5 Maintain the oil level to the bottom of the threads of the hole for oil level fill plug 8 If the oil level is low add oil See Operation and Maintenance Manual Refill Capacities for additional information 6 Install oil level fill plug 3 7 Repeat the procedure on the other midwheels Make sure that you check the midwheels on the inner side of the undercarriages and outer side of the undercarriages 8 Inflate the spring with air through valve assembly 2 See Operation and Maintenance Manual Air Spring Pressure for the correct inflation pressure ESSSSSSSSSSSSSA ROR J VAREUEEEETESEC 207 Maintenance Section Oil Filter Inspect g00633890 100649305 Oil Filter Inspect SMCS Code 1318 507 3067 507 5068 507 Inspect A Used Filter for Debris Illustration 352 g00100013 The element is sho
4. Consult any Caterpillar dealer for a 136 5646 Cassette Cleaning Kit 1 In order to clean the cleaner cassette saturate the pads with the cassette s cleaning fluid 2 Insert the cleaner cassette into the cassette player 3 Play the cleaner cassette for twenty seconds 4 Remove the cleaner cassette Store the cleaner cassette in a clean dry place 100813182 Cooling System Additive DEAC Add SMCS Code 1352 044 A WARNING Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools
5. Remove the filler cap b Add the correct type of oil Add oil until the oil level is between the ADD mark and the FULL mark on the sight glass Note See Operation and Maintenance Manual Lubricant Viscosities for the correct type of hydraulic oil c Clean the filler cap Install the filler cap d Maintain the oil level between the ADD mark and the FULL mark on the sight glass 100837820 Transmission Oil Level Check SMCS Code 3030 535 FLV 3080 535 FLV A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before Opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates g00409238 Illustration 390 The sight glass for the transmission is located on the left side of the transmission case The sight glass is visible between the front idler and the midwheels on the left side of the machine Illustration 391 g00409239 1 Check the oil level with
6. Replace Illustration 322 g00407261 3 Remove the element by hand Also you can use a strap wrench in order to remove the element 4 Drain the filter element and dispose of the fuel 5 Clean the water separator bowl Install the clean water separator bowl onto a new primary filter Note The water separator bowl is reusable If it is difficult to look in the water separator bowl replace the water separator bowl 6 Clean the mounting surface for the filter Apply clean diesel fuel to the new fuel filter gasket Tighten the filter by one turn after the filter contacts the filter base goo0406649 Illustration 323 7 Open the fuel valve in order to turn on the fuel Operate the hand priming pump in order to fill the primary filter water separator 8 Start the engine Run the engine at 1000 rom to 1200 rom until the air is pumped through the engine Some misfiring may occur However the engine will not be damaged 00836142 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE A WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Personal injury can result when using cleaner sol vents To help prevent personal injury follow the instruc tions a
7. See the appropriate topics in your machine s Operation and Maintenance Manual for all cooling system requirements Note For more information about Extended Life Coolant ELC see Operation and Maintenance Manual Extended Life Coolant ELC Some engines utilize Extended Life Coolant ELC See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval If an ELC was previously used flush the cooling system with clean water No other cleaning agents are required Change the engine coolant more frequently if you find any of the following conditions e The cooling system is heavily contaminated e The engine overheats e You observe foaming in the radiator e The oil cooler has failed and oil is in the coolant e Fuel has contaminated the cooling system e The cooling system contains non Caterpillar products It is important to replace the thermostat in order to avoid any unexpected failure of the thermostat This is a good preventive maintenance practice that reduces the chances of unscheduled downtime Failure to replace the thermostat on a regularly scheduled basis could cause severe engine damage Note If you are only replacing the thermostat drain the coolant from the cooling system so that the level of the coolant is below the thermostat housing Always operate Caterpillar engines with a thermostat because these engines have a shunt design cooling system
8. Swing Stops Replace 100824934 Drawbar Wearplates Swing Stops Replace SMCS Code 7119 510 WK Illustration 270 Se On machines that are equipped with a PTO the location of the sampling valve for the differential and for the final drive is on top of the PTO g00397577 Illustration 272 Replace the wearplates for the drawbar and for the drawbar support if the thinnest portion of the wearplate is worn to a minimum of 3 mm 0 12 inch 1 Remove the drawbar pins 2 Support the drawbar from the bottom Lift the drawbar 3 mm 0 12 inch is the required height aa aaa 3 Remove the four bolts on the top plate from the Illustration 271 g00399738 drawbar On machines without the PTO the location of the differential and ba the final drive is on top of the differential case cover 4 Remove the top plate from the drawbar by lifting straight up Use a rotating motion 2 Use a sampling gun in order to obtain the oil sample from the sampling valve Do not take 5 Replace the wearplates the oil sample from the drain stream because a stream of dirty oil from the bottom of the 6 Install the top plate and the four bolts Tighten the compartment will contaminate the sample bolts to a torque of 475 60 N m 350 44 lb ft Likewise never dip an oil sample from an oil container or pour a sample from a used filter 7 Install the drawbar pins Consult any Caterpillar Dealer for complete Replace swing stops when the rubber i
9. and damaged bolts Replace damaged bolts and missing bolts with original equipment parts only 2 Tighten all of the ROPS mounting bolts to a torque of 400 70 N m 800 50 lb ft 3 Do not attempt to straighten the ROPS structure Do not repair the ROPS by welding reinforcement plates to the structure Do not drill into the ROPS structure If there are any cracks in the welds in the castings or in any metal section of the ROPS consult your Caterpillar dealer for repairs 100718241 Seat Belt Inspect SMCS Code 7327 040 Illustration 369 g00037721 Always check the condition of the seat belt and the condition of the belt mounting hardware before you operate the machine Inspect the belt mounting hardware Replace any belt mounting hardware that is damaged or worn Regardless of the appearance replace the seat belt once during every three year interval 100731002 Seat Belt Replace SMCS Code 7327 510 Illustration 370 g00037721 Regardless of the appearance replace the seat belt once during every three year interval 101171857 Service Brake Disc Wear Check SMCS Code 4251 535 Use the following procedure in order to check for worn brake discs 1 Operate the machine until the oil reaches normal operating temperatures 2 Park the machine on a smooth level surface Illustration 371 g00398983 3 Move the transmission control lever to the NEUTRAL position Illustratio
10. 19 10 Amp Red Starting aid 20 10 Amp Red Turn signals 21 15 Amp Blue Turn signals for a trailer 22 10 Amp Red Left tail light 23 10 Amp Red Control for the three point hitch 24 15 Amp Blue Rear power port on the right side console 25 10 Amp Red Right tail light 26 10 Amp Red Horn 27 10 Amp Red Work lights for trailer 196 Maintenance Section Fuses Circuit Breakers and Relays Replace Reset Fuse Panel for the Right Side Console Illustration 332 g00403433 The fuse panel for the right side console is located on the front of the right side console near the floor RH CONSOLE _m_ Da3 20A oo 1 2 5 eee 34 39 aeo 58 43 42 O olO o o 0 o o 20A 10A 20A 10A ojo o a a o o o g00633668 Illustration 333 197 Maintenance Section Fuses Circuit Breakers and Relays Replace Reset Table 48 Fuses Number Rating Color Description 28 10 Amp Red Pair 4 of the auxiliary power terminals 29 20 Amp Yellow Pair 3 of the auxiliary power terminals 30 30 Amp Green Pin 1 from No 3 power plug 31 10 Amp Red Spare 32 10 Amp Red Pair 2 of the auxiliary power terminals 33 20 Amp Yellow Pair 1 of the auxiliary power terminals 34 30 Amp Green Pin 1 from No 2 power plug 35 15 Amp Blue Cigar Lighter 36 10 Amp Red Pin 2 from No 2 power plug 37 10 Amp Red Pin 2 from No 3 power plug 38 10 Am
11. 250 Service Hours Air Conditioner Test 0 ccccscceessseceeessteeeeeees 155 Air Conditioner Belt Inspect Adjust Replace 155 Alternator and Fan Belts Inspect Adjust RE PlaCG cee Has hideeies O TAA 159 Battery INSPOCt oo eeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeees 159 Cooling System Additive DEAC Add 163 Differential and Final Drive Oil Sample Obtain 173 Engine Crankcase Breather Clean 00 180 Engine Oil and Filter Change ccee 181 Engine Oil Sample Obtain eeeeeeeeeees 183 Fuel System Primary Filter Water Separator Clean Replace cccceeccecseeeeeeeeeeeeeeeeeeaeeeeeeeees 189 Fuel System Secondary Filter Replace 190 Fuel Vent Breather Clean sissies 193 Steering and Hydraulic System Oil Sample COD ta 281 aehevle Cocks E tere ints no Bot A tee 215 Transmission Oil Sample Obtain 0 221 Every 500 Service Hours Cooling System Coolant Sample Obtain 166 Front Axle Lubricate ececseeeeeeeeeeeeeeeeneees 185 Main Drive Shaft Slip Spline Lubricate 205 Power Take Off Drive Shaft Lubricate 209 Steering System Oil Filter Replace 216 Transmission Oil Filter Replace c0 219 Every 1000 Service Hours Differential and Final Drive Oil and Screens Change Clean cccceecceceeeeeeeseeeeeeeeeteeeeeeeeees 170 Front Idler
12. Drive Oil and Screens Change Clean Note Operate the machine in order to warm the differential final drive oil before you perform this procedure Note At operating temperature the differential final drive oil is hot See the Safety Section in this manual for information about hot oil and fluid penetration The magnetic drain plugs are located on the bottom of each final drive and on the PTO if equipped Illustration 262 g00396239 3 Remove bolts 2 and cover 3 4 Remove the screen and magnets 5 Remove the magnets from the screen 6 Wash the screen and the magnets in a clean a ee ee nonflammable solvent Allow the screen and Illustration 260 900396137 magnets to dry 1 Park the machine on a level surface 7 Install the magnets into the screen 8 Install the screen and the magnets into the screen housing g00396157 Illustration 261 2 Remove drain plugs 1 on both sides Clean drain plugs 1 on both sides If the machine is Illustration 263 900396239 equipped with a PTO remove the drain plug at the bottom of the PTO Allow the oil to drain into 9 Install cover 3 and bolts 2 a suitable container The container must have a minimum capacity of 209 L 55 US gal Inspect the drain plug seals Replace damaged seals Install the drain plugs Note The oil screen must be removed and cleaned if the differential or final drives are drained or disassembled for any reason The different
13. Hood Raise Lower b Remove oil filler cap 2 c Add the correct type of engine oil Add engine oil until the engine oil level is between the ADD mark and the FULL mark on the dipstick Note See Operation and Maintenance Manual Lubricant Viscosities for the correct type of engine oil d Clean oil filler cap 2 and install oil filler cap 2 e Close the hood f Start the engine Run the engine at low idle for five minutes Check for leaks Stop the engine After five minutes check the engine oil level on dipstick 1 Maintain the engine oil level between the ADD mark and the FULL mark Engine Oil Sample Obtain SMCS Code 1000 008 7542 008 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates 184 Maintenance Section Engine Valve Lash Check Obtain the sample of the engine oil as c
14. Level Check Illustration 296 g00409711 7 Apply a thin coat of clean engine oil to the new oil filter seals Install the new oil filter by hand When the filter seal contacts the filter base tighten the filter elements by an additional turn of 270 degrees Rotation index marks are spaced at 90 degree intervals Use these rotation index marks as a guide for proper tightening HL Illustration 297 g004097 12 8 Remove the oil filler cap Add the correct type of engine oil Add engine oil See Operation and Maintenance Manual Lubricant Viscosities Illustration 298 g00409706 9 Before you start the engine make sure that the oil level is between the ADD mark and the FULL mark on the ENGINE STOPPED side of the dipstick NOTICE In order to prevent crankshaft or bearing damage crank the engine to fill all of the filter element before you start the engine 10 Start the engine Run the engine at low idle speed for five minutes in order to check for leaks Stop the engine 11 After five minutes check the oil level Maintain the engine oil level between the ADD mark and the FULL mark on the ENGINE STOPPED side of the dipstick 101183623 Engine Oil Level Check SMCS Code 1302 1308 1826 535 FLV A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Do not under fill or overfill engine cr
15. and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates See the appropriate topics in your machine s Operation and Maintenance Manual for all cooling system requirements Use 8T 5296 Test Group to check the concentration of the coolant If necessary add supplemental coolant additive 163 Maintenance Section Cooling System Additive DEAC Add NOTICE Do not exceed the recommended six percent sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temperature components Excessive supplemental coolant additive concentration could also result in ra diator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supple mental coolant additive and the spin on element if equipped at the same time The use of those addi tives together could result in supplemental coolant additive concentration exceeding the recommended six percent maximum 1 Park the machine on a hard level surface Allow the engine to cool and allow the radiator to cool Illustration 248 g00387093 2 Raise the hood in order to access the radiator Note See Operation a
16. cold oil and a stopped engine The oil level should be between the ADD mark and the FULL mark on the sight glass 2 If the oil level is low add oil M g00409258 Illustration 392 a Remove the filler cap b Add the correct type of oil Add oil until the oil level is between the ADD mark and the FULL mark on the sight glass Note See Operation and Maintenance Manual Lubricant Viscosities for the correct type of hydraulic oil c Clean the filler cap Install the filler cap d Maintain the oil level between the ADD mark and the FULL mark on the sight glass 221 Maintenance Section Transmission Oil Sample Obtain i00836604 Transmission Oil Sample Obtain SMCS Code 3030 008 7542 008 A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Obtain the sample of the
17. crankcase breather is not maintained on a regular basis it can become plugged A plugged breather will cause excessive crankcase pressure that may cause crankshaft seal leakage g00407758 Illustration 290 The crankcase breather is located on the left side of the engine Use the following procedure in order to clean the crankcase breather 1 Raise the hood See Operation and Maintenance Manual Engine Compartment Hood Raise Lower Illustration 291 g00407759 2 Loosen breather outlet hose clamp 1 Remove the hose from the engine crankcase breather 3 Remove three bolts 2 g00407760 Illustration 292 4 Remove breather assembly 3 5 Wash the breather in a clean nonflammable solvent Allow the breather to dry 6 Install a clean dry breather assembly 3 7 Install bolts 2 8 Inspect the hoses for damage If necessary replace the hoses 9 Install the hoses and tighten clamp 1 See Operation and Maintenance Manual Standard Torque for Worm Drive Band Hose Clamps 01183617 Engine Oil and Filter Change SMCS Code 1308 1318 510 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjus
18. 167 Maintenance Section Cooling System Extended Life Coolant Change Note Thermostats can be reused if the thermostats meet certain test specifications The tested thermostats must not be damaged and the tested thermostats must not have an excessive buildup of deposits 1 Park the machine on a hard level surface Allow the engine to cool and allow the radiator to cool 2 Raise the hood in order to access the radiator Note See Operation and Maintenance Manual Engine Compartment Hood Raise Lower Illustration 254 900387093 3 Slowly loosen the filler cap in order to relieve the pressure Remove the filler cap 4 Inspect the filler cap gasket Replace the filler cap if the gasket is damaged 00387852 Illustration 255 5 Attach a hose to the nipple on the drain valve Open the drain valve that is under the radiator Allow the coolant to drain into a suitable container Note Always discard drained fluids according to local regulations 168 Maintenance Section Cooling System Extended Life Coolant Extender Add 6 Flush the cooling system with water until the draining water is transparent Fully drain the cooling system 7 Close the drain valve 8 Add the coolant solution Refer to Operation and Maintenance Manual Refill Capacities 9 Start the engine while the filler cap is removed Operate the engine until the coolant reaches the normal operating temperature and until the coola
19. 40 g00408139 2 Slowly remove the filler cap for the hydraulic oil tank in order to relieve the pressure The filler cap is located on top of the hydraulic tank Access the filler cap from the left walkway 3 Remove the filler screen Clean the filler screen Inspect the screen If necessary replace the screen Illustration 341 g00637436 4 Remove the drain plug Note In order to drain the hydraulic oil tank you need a straight pipe nipple The pipe nipple should be a one inch nipple Clamp a hose to the nipple 5 Install the hose fitting or the nipple in the drain valve As the nipple is inserted into the fitting a check valve opens The check valve allows the oil to drain into a suitable container 6 Remove the nipple and the hose assembly 7 Install the drain plug Use Steps 8 through 11 to replace the return oil screen NOTICE Make sure that you replace the return oil screen for every 1000 service hours A plugged return oil screen or a contaminated return oil screen can damage the components of the hydraulic system Illustration 342 g00408141 8 Remove the plug from the cover for the return screen Allow the oil to drain into a suitable container g00408142 Illustration 343 9 Loosen the four bolts on the rear of the housing for the screen The screen is located on top of the axle Access the screen from the bottom of the machine Allow the oil to drain into a suitable container 203 Mai
20. 9 1 Park the machine so that the drain is located at the bottom of the hub 2 Remove the magnetic drain plug 3 Inspect the magnetic plug for signs of excessive wear Some metal filings are usually present Any large pieces or excessive metal filings indicate imminent bearing failure If large pieces are found the hub should be disassembled and inspected Consult any Caterpillar dealer for more information 4 Clean the drain plug 5 Install the drain plug By Illustration 310 g00408683 6 Remove the hub s center plug Add the necessary amount of oil and replace the plug See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities for proper oil quantities Note There is a vent hole in the center of the plug A small amount of dust that collects around the vent is normal This is not a sign of abnormal leakage g00408684 Illustration 311 7 Maintain the oil level so that the oil touches line 1 in the sight glass in the center of the idler 8 Check the oil level after ten minutes If necessary add oil Repeat until the oil level is maintained 101191200 Front Idler Hubs Oil Level Check SMCS Code 4159 535 HU 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 container
21. Hubs Oil Change 0cceeeeeeee 185 Hydraulic System Oil Change ceccees 202 Hydraulic System Oil Return Filter Replace 205 Midwheel Hub Oil Level Check ceceees 206 Rollover Protective Structure ROPS Inspect 211 Service Brake Disc Wear Check snesen 212 Slotted Cast Drive Wheel Scrapers Adjust 213 Transmission Breather Clean 0 ccccscceee 217 Transmission Oil Change cceeeeeeseeeeees 218 Every 1000 Service Hours or 1 Year Air Conditioner Desiccant Receiver Dryer Replace cnra oaeen ei thea a 157 Engine Air Filter Primary Element Replace 177 Every 2000 Service Hours Electronic Unit Injectors Test eeee 175 Engine Valve Lash Check assesseer 184 Parking Brake Pads Inspect Replace 208 Every Year Cooling System Coolant Sample Obtain 166 Seat Belt Inspect 02 eceeeeeeeeeeeeeseteeeeteeeeeeees 212 154 Maintenance Section Maintenance Interval Schedule Every 3000 Service Hours Cooling System Extended Life Coolant Extender PNG vee E EE BE E A E E 168 Every 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 164 Every 3 Years Seat Belt Replace ss ssssssseeeeeeeeeesereeereesseseen 212 Every 6000 Service Hours or 6 Years Cooling System Extended Life Coolant CHANGE irschecdiicbedieecetireaneesPevradees ct eareeeslandvted Bete 166 Ra
22. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A SEBU7072 07 CATERPILLAR January 200 Operation ane Maintenance manual Challenger 65E Challenger 75E Challenger 85E and Challenger 95E Agricultural Tractors 6GS1 Up Machine 6HS1 Up Machine 6JS1 Up Machine 6KS1 Up Machine 101476347 Maintenance Interval Schedule SMCS Code 7000 Note All safety information warnings and instructions must be read and understood before you perform any operation or any maintenance procedure Before each consecutive interval is performed all of the maintenance requirements from the previous interval must also be performed When Required Air Conditioner Drain Line Clean s s s 157 Battery Recycle sassis orei i a 160 Cab Air Filter Clean Replace cceeee 161 Drawbar Wearplates Swing Stops Replace 174 Engine Air Filter Primary Element Clean 175 Engine Air Filter Secondary Element Replace 178 Engine Compartment Hood Raise Lower 179 Ether Starting Aid Cylinder Replace 184 Fuel System Fill eccccecceeeseeeeeeeeeeeteeeeeneeeeees 187 Fuel System Water Separator Drain 191 Fuel System Prime cccceeeeeeeeeesteeeeeeeeeeeees 192 Fuel Tank Water and Sediment Drain 192 Fuses Circuit Breakers and Relays R place ROS6U vis sc
23. NG2500 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 314 g00637419 This machine is equipped with two filler tubes for the fuel tank One filler tube is located on each side of the machine See Operation and Maintenance Manual Refill Capacities 188 Maintenance Section Fuel System Fill Illustration 315 g00406645 1 In order to remove the filler cap lift tab 1 Illustration 316 g00406646 2 Rotate tab 1 in the clockwise direction to the stop The filler cap can now be removed Note Filling the fuel tank too fast may cause only one side of the fuel tank to fill Allow enough time for the fuel level to equalize before you add more fuel g00406647 Illustration 317 A 5P 8501 Padlock can be used in hole 2 in order to prevent unauthorized access to the fuel tank Note A 9P 7121 Fuel Tank Strainer is available for the filler tube Consult any Caterpillar dealer Filling the Fuel System After the Engine Runs Dry of Fuel 1 Fill the fuel tank with fuel Illustration 318 g00406648 2 Locate air purge plug 8 on the secondary fuel filter base Loosen the plug by two full turns g00406649 Illustration 319 3 Unlock the hand priming pump Operate the hand priming pump until fuel appears at the air bleed p
24. 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 See the appropriate topics in your machine s Operation and Maintenance Manual for all cooling system requirements Change the engine coolant more frequently if you find any of the following conditions e The cooling system is heavily contaminated e The engine overheats e You observe foaming in the radiator e The oil cooler has failed and oil is in the coolant e Fuel has contaminated the cooling system e The cooling system contains non Caterpillar products It is important to replace the thermostat in order to avoid any unexpected failure of the thermostat This is a good preventive maintenance practice that reduces the chances of unscheduled downtime Failure to replace the thermostat on a regularly scheduled basis could cause severe engine damage Note If you are only replacing the thermostat drain the coolant from the cooling system so that the level of the coolant is below the thermostat housing Always operate Caterpillar engines with a thermostat because these engines have a shunt design coolin
25. ankcase with oil Either condition can cause engine damage 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 Park the machine on a hard level surface Stop the engine before you check the engine oil level Allow the oil to cool for five minutes wi Illustration 299 g00409705 2 Check dipstick 1 while the engine is stopped Illustration 300 g00409706 3 Maintain the engine oil level between the ADD mark and the FULL mark on the ENGINE STOPPED side of the dipstick Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the FULL mark on the ENGINE STOPPED side of the dipstick 4 If the engine oil level is low add engine oil wil i f g00409707 Illustration 301 183 Maintenance Section Engine Oil Sample Obtain a Raise the hood in order to access oil filler cap 2 Note See Operation and Maintenance Manual Engine Compartment
26. are evenly spaced 1 Before you obtain an S O S oil sample operate the machine until the oil is warm and the oil is well circulated Then obtain the S O S oil sample NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead to customer and dealer concerns 216 Maintenance Section Steering System Oil Filter Replace g00408518 Illustration 376 The sampling valve for the hydraulic system is located on the base for the steering filter Access the sampling valve from the right side of the machine 2 Use a sampling gun in order to obtain the oil sample from the sampling valve Do not take the oil sample from the drain stream because a stream of dirty oil from the bottom of the compartment will contaminate the sample Likewise never dip an oil sample from an oil container or pour a sample from a used filter Consult any Caterpillar Dealer for complete information and assistance about the S O S oil analysis program 100837415 Steering System Oil Filter Replace SMCS Code 4304 5068 Hot oil and components can cause personal in jury Do not allow hot oil or compon
27. arks are spaced at 90 degree intervals Use these rotation marks as a guide for proper tightening 101191341 Three Point Hitch Lubricate SMCS Code 7120 086 S N 6GS1 Up S N 6HS1 Up Note Lubricate the three point hitch linkage with Caterpillar Multipurpose Molybdenum Grease MPGM See Operation and Maintenance Manual Lubricating Greases Illustration 379 g00404318 Lubricate one fitting 1 at the bottom of both lift cylinders Lubricate two fittings 2 on the pitch control link 217 Maintenance Section Three Point Hitch Lubricate Illustration 380 g00404338 Lubricate two fittings 3 on each lift link Lubricate one fitting 4 on each pin of the rockshaft assembly Lubricate one fitting 5 at the top of both lift cylinders Lubricate one fitting 6 at the location of the rockshaft that is attached to the machine 100837670 Transmission Breather Clean SMCS Code 3030 070 BRE The breather is located on the left front corner of the transmission g00409139 Illustration 381 1 Remove the breather 2 Wash the breather in a clean nonflammable solvent Allow the breather to dry 3 Install the breather 218 Maintenance Section Transmission Oil Change i00838006 Transmission Oil Change SMCS Code 3030 3080 044 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fl
28. ated The rubber seal should face upward The metal grill should face downward 9 Lift tray 2 10 Secure the tray with latch 1 Cleaning Filter Elements Clean the filter element with pressure water or clean the filter element with pressure air Do not tap the filter element in order to clean the element Whenever you use pressure water use a maximum pressure of 280 kPa 40 psi Do not use a nozzle Whenever you use pressure air use a maximum pressure of 205 kPa 30 psi 1 Wash the element in a solution that consists of warm water and of nonsudsing household detergent Soak the element for at least 15 minutes Do not soak the element for more than 24 hours Agitate the element in order to loosen dirt particles 2 Rinse the filter element with clean water Rinse the filter from the clean side toward the dirty side 3 Air dry the element by circulating warm air The air should be less than 71 C 160 F Do not use a light bulb in order to dry the filter Inspect the element for visible debris After you clean the element inspect the element Do not use an element that has damaged pleats damaged gaskets or damaged seals 100834918 Cassette Player Head Clean SMCS Code 7338 070 Note Failure to clean the cassette player s head after 24 hours of playing time may result in damage to the head Note The 136 5646 Cassette Cleaning Kit contains all of the items that are needed for this procedure
29. be visible in the coolant recovery bottle If the engine coolant level is low check the system for leaks As needed repair the cooling system Use the following procedure in order to add coolant 1 Park the machine on a hard level surface Allow the engine to cool and allow the radiator to cool g00393145 Illustration 259 2 Slowly loosen the filler cap in order to relieve the pressure Remove the filler cap 3 Inspect the filler cap gasket Replace the filler cap if the gasket is damaged 4 As needed add coolant Maintain the coolant level to the bottom of the filler pipe 5 Install the filler cap i01176380 Differential and Final Drive Oil and Screens Change Clean SMCS Code 3258 044 4050 044 4070 A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar 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 171 Maintenance Section Differential and Final
30. bleshooting Do not operate the machine until the brakes are functioning properly The transmission control should be in the NEUTRAL position and the parking brake should be engaged before performing this test Illustration 242 900385335 1 Turn off the engine Depress the brake pedal several times until pedal effort becomes much lighter This action depletes the pressure in the brake system accumulator 2 Start the engine Allow the engine to run for 30 seconds g00385433 Illustration 243 3 The accumulator pressure indicator for the brakes should turn off If the accumulator pressure indicator does not turn off do not operate the machine Consult any Caterpillar dealer for more information Illustration 244 g00385335 4 Depress the brake pedal The pedal effort should now be firmer If the pedal effort is not firmer do not operate the machine Consult any Caterpillar dealer for more information 01158299 Brakes Indicators and Gauges Test SMCS Code 4100 081 7000 081 7450 081 g00386456 Illustration 245 Check for inoperative gauges Check for inoperative switches and or burned indicator lamps Start the engine Stop the engine Make any needed repairs before you operate the machine The indicator lamps can be checked Use the following procedure 1 Turn off the engine 2 Engage the parking brake 161 Maintenance Section Brakes Indicators and Gauges Test 3 Shift th
31. bly causing personal injury To prevent unexpected hood lowering always engage the hood support latch as soon as the hood is in the full raised po sition Raise the Hood g00405328 Illustration 286 1 Pull out on rubber latch 1 This will release the rubber latch Release the rubber latches on each side of the machine 2 Raise the hood by a short distance Then a gas strut raises the hood to the RAISED position 179 Maintenance Section Engine Compartment Hood Raise Lower Illustration 287 g00405419 Latch 2 for supporting the hood is located on the left side of the machine 3 Rotate latch 2 for supporting the hood counterclockwise in order to release latch 2 Lower the Hood go0405419 Illustration 288 Latch 2 for supporting the hood is located on the left side of the machine 1 Rotate latch 2 for supporting the hood clockwise in order to release latch 2 Note You may need to slightly move the hood in order to lower the hood 180 Maintenance Section Engine Crankcase Breather Clean g00405328 Illustration 289 2 Pull the hood downward Hook rubber latches 1 over the hooks on the side of the hood Press downward on the bottom portion of the rubber latch Engage rubber latches 1 on both sides of the machine Note You will hear a click when rubber latches 1 are engaged 100836354 Engine Crankcase Breather Clean SMCS Code 1317 070 NOTICE If the
32. ck SMCS Code 4199 535 Illustration 375 g00410355 The belt s life may be shortened by missing scrapers or scrapers that are not properly adjusted Make sure that the scrapers are in place and that the bolts are tight Severely worn scrapers should be replaced 100837121 Steering and Hydraulic System Oil Sample Obtain SMCS Code 4129 008 5050 008 7542 008 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin 215 Maintenance Section Slotted Cast Drive Wheel Scrapers Check NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Obtain the sample of the hydraulic oil as close as possible to the recommended sampling interval The recommended sampling interval is every 250 service hours In order to receive the full effect of S 0 S oil analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that
33. contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE It is important that the vent cap is free to breath If excessive vacuum or pressure is allowed to build up in the differential case leakage of oil through the final drive seals may result g00633525 Illustration 267 Illustration 268 g00396318 1 Park the machine on level ground Check the oil level at the sight gauge at the rear of the final drive housing The oil level should be above the center of the sight gauge Note An inaccurate reading can occur if the machine is not level Make sure that the machine is parked on level ground before you check the oil level or before you add oil g00629623 Illustration 269 2 To add oil remove the breather cap from the filler tube The filler tube is located on the left rear of the machine Add the oil so that the sight gauge registers the oil level above the center 3 Clean the filler cap Install the filler cap Inspect the vent cap 173 Maintenance Section Differential and Final Drive Oil Sample Obtain 101191090 Differential and Final Drive Oil Sample Obtain SMCS Code 3258 008 4050 008 7542 008 A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test
34. cts reduces the effective ness of the ELC and shortens the ELC service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for premixed or concentrate coolants Use only Caterpillar ELC Extender with Caterpillar ELC Failure to follow these recommendations can result in shortened cool ing system component life See the appropriate topics in your machine s Operation and Maintenance Manual for all cooling system requirements Note For more information about Extended Life Coolant ELC see Operation and Maintenance Manual Extended Life Coolant ELC When a Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval Refer to Table 46 for the recommended amount of Extender With the exception of adding the Extender and maintaining your coolant level no other maintenance is required Table 46 Recommended Amount of Extender By Cooling System Capacity Model System Cooling Recommended System Amount of Capacity Extender Challenger Folded 50 to 64 L 1 18 L 40 fl oz 65E and Core 13 to 17 Challenger Radiator US gal 75E Challenger Multiple 65 to 83 L 1 60 L 54 fl oz 65E and Row 17 to 22 Challenger Module US gal 75E Radiator Challenger Standard 65 to 83 L 1 60 L 54 fl oz 85E a
35. d Bolting On Guide Blocks for more information Portions of grouser 4 that separate from the belt will not significantly reduce traction Replace a belt when the grouser height is less than 13 mm 0 5 inch and when track slippage routinely exceeds 10 percent g00410519 Illustration 399 Pieces of rubber may separate from the following components on the undercarriage e Idlers 5 e Midwheels 6 225 Maintenance Section Windows Clean e Drive wheels 7 The rubber may come off the components because of rocks and debris that enter the undercarriage Replace any idler or any midwheel that has 50 percent of the rubber missing Replace the drive wheel when missing rubber from the drive wheel causes track slippage between the belt and drive wheel 100828448 Windows Clean SMCS Code 7310 070 7340 070 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Illustration 400 go0400521 Park the machine on a hard level su
36. d supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead to customer and dealer concerns Testing the coolant can be done at your Caterpillar dealer Caterpillar S O S Coolant Analysis is the best way to monitor the condition of your coolant and your cooling system S O S Coolant Analysis is a program that is based on periodic samples Level is a basic analysis which should be performed for DEAC and Extended Life Coolant ELC The sample should be obtained after every 500 hours of use See Operation and Maintenance Manual S O S Coolant Analysis for more information Level Il is a comprehensive analysis which should be performed annually See Operation and Maintenance Manual S O S Coolant Analysis for more information 101158344 Cooling System Extended Life Coolant Change SMCS Code 1350 1395 044 NL A WARNING Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant
37. denser core 4 6 Direct pressurized air or direct pressurized water at the condenser Clean the condenser core of foreign material The use of compressed air is preferred Blow out the debris from the fan side first Then clean debris from the front compartment Note Use pressurized air with a maximum pressure of 205 kPa 30 psi Use pressurized water with a maximum pressure of 280 kPa 40 psi 7 After cleaning push condenser core 4 against the mounting plates Engage latches Illustration 235 g00378017 8 In order to disengage support 3 lift the support Lower air cooler 2 Secure air cooler 2 with the rubber latches g00377172 Illustration 236 9 Lower the hood Note See Operation and Maintenance Manual Engine Compartment Hood Raise Lower 157 Maintenance Section Air Conditioner Desiccant Receiver Dryer Replace i00803697 Air Conditioner Desiccant Receiver Dryer Replace SMCS Code 7320 510 DSS Replace the receiver dryer in the system Consult any Caterpillar dealer for the correct procedure and instructions Note Use the pressure in the Service Manual to check the charge The charge is the pressure for the R 134A refrigerant i01183049 Air Conditioner Drain Line Clean SMCS Code 7320 070 QN 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 col
38. diator Pressure Cap Clean Replace 211 Between 250 Service Hours and 1000 Service Hours or between first and fourth oil change Engine Valve Lash Check ccceceeeeseeeees 184 100805495 Air Conditioner Test SMCS Code 7320 081 Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air condition ers or wherever refrigerant gas may be present Check Suction Line Perform this procedure when the ambient air temperature is at least 21 C 70 F 1 Start the engine Operate the engine at 2000 rom 2 Set the air conditioner control for maximum cooling Set the fan speed switch to HIGH SPEED 3 Allow the air conditioning system to run for ten minutes in order to stabilize the air conditioning system 4 Raise the hood in order to access the air conditioner condenser Note See Operation and Maintenance Manual Engine Compartment Hood Raise Lower 5 Feel the suction line and the discharge line in order to check the system for refrigerant If the system contains refrigerant the discharge line will be warmer than the suction line If the system contains no refrigerant or the system contains only a small amount of refrigerant poor cooling will result 155 Maintenance Section Air Conditioner Tes
39. e transmission out of the NEUTRAL position Apply the inching clutch pedal 4 Turn the engine start switch key to the START position The starter should not engage 5 Check all lights for operation All lights should be on except for the turn signals the hazard lights and the high beam indicator Check the high beam for operation See Operation and Maintenance Manual Light Switches 6 Check the warning alarm for operation The alarm should beep continuously 7 Return the transmission control to the NEUTRAL position The alarm should stop 8 Turn the engine start switch key to the OFF position 100984017 Cab Air Filter Clean Replace SMCS Code 7342 070 Fl 7342 510 FI Clean the cab air filter when there is a significant reduction in cab air circulation 1 Turn the engine start switch key to the OFF position g00409758 Illustration 246 2 Release latch 1 in order to access the cover 162 Maintenance Section Cassette Player Head Clean Illustration 247 g00409798 3 Lower tray 2 4 Remove element 3 5 Inspect the filter element for damage Do not use a damaged filter element 6 Clean the filter element See Cleaning Filter Elements 7 Clean the filter housing with a damp cloth Note Do not use pressure air in order to clean the tray Pressure air could move dust into the cab 8 Install the new filter or the clean filter Make sure that the filter is properly se
40. econdary fuel filter is a highly efficient filter It is important to use a highly efficient filter due to the high injection pressures that are used in the fuel system Pressure may remain in the secondary fuel filter after the engine is shutdown Wait at least five minutes for residual pressure to subside before you remove the secondary fuel fil ter Failure to wait for the pressure to subside can re sult in personal injury Illustration 324 g00407538 1 Remove the secondary fuel filter element 2 Drain the filter element and dispose of the fuel 3 Clean the sealing surface of the filter base Make sure that all of the former O ring seal is removed 4 Apply clean diesel fuel to the new fuel filter gasket Tighten the filter by one turn after the filter contacts the filter base 191 Maintenance Section Fuel System Water Separator Drain Iil i Illustration 325 g00406649 5 Operate the hand priming pump in order to fill the secondary fuel filter 6 Start the engine Run the engine at 1000 rom to 1200 rpm until the air is pumped through the engine Some misfiring may occur However the engine will not be damaged NOTICE Do not crank the engine for more than 30 seconds Al low the starter to cool for two minutes before cranking again Turbocharger damage can result if the engine rpm is not kept low until the oil gauge display verifies that the oil pressure is sufficient 7 If the engine di
41. ee Operation and Maintenance Manual Engine Compartment Hood Raise Lower 2 Inspect the condition of the belt Replace any belt that is excessively worn 3 In order to check the belt tension apply 110 N 25 Ib force midway between the pulleys Correctly adjusted belts will deflect 14 mm 0 55 inch to 20 mm 0 79 inch 4 If the belt deflection is not correct adjust the belt Adjust Belt Tension r Cs g00633504 Illustration 240 159 Maintenance Section Alternator and Fan Belts Inspect Adjust Replace 1 Loosen pivot bolt 1 and adjustment nuts 2 and 3 2 Adjust nuts 2 and 3 in order to loosen or tighten belts 3 Tighten pivot bolt 1 4 Measure the belt tension If the belt deflection is not correct repeat this procedure 100808497 Battery Inspect SMCS Code 1401 040 A WARNING Batteries give off flammable fumes that can ex plode resulting in personal injury Prevent sparks near the batteries They could cause vapors to explode Do not allow the jump start cable ends to contact each other or the machine Do not smoke when checking battery electrolyte levels Electrolyte is an acid and can cause personal in jury if it contacts skin or eyes Always wear eye protection when starting a ma chine with jump start cables Improper jump start procedures can cause an ex plosion resulting in personal injury Always connect the battery positive to battery positive
42. ent actuate the control twenty times to the top of the control s stroke The effort should increase as each stroke is applied If the automatic adjustment has not been done for an extended period excessive amounts of using the control is required in order to properly adjust the caliper If excessive use of the control is required or if the control feels loose after actuating twenty times use the following procedure g00406500 Illustration 354 1 Remove the cap over the hole in the center of the input lever assembly This is on the parking brake caliper which is located in front of the differential and below the cab 2 Insert a 6 35 mm 0 25 inch Allen wrench through the hole into the end of the rod Turn counterclockwise until the rod is backed out fully 3 Use the Allen wrench in order to turn the rod clockwise until the gap from the pad to the rotor is 0 38 mm 0 015 inch on each side of the rotor 4 Replace the cap on the hole in the lever assembly 100837547 Parking Brake Pads Inspect Replace SMCS Code 4267 040 4267 510 g00409019 Illustration 355 The brake pads should be replaced when the thickness of the lining on front brake pad 1 is less than 10 mm 38 inch 1 Remove cap 2 from the hole in the center of the lever assembly 2 Insert a 1 4 inch allen wrench through the hole into the rod Turn the allen wrench in the clockwise direction until the rod is all the way backed out
43. ents to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Illustration 377 g00408918 An indicator on the dash panel will illuminate when the steering filter is blocked 1 Place an oil pan below the filter that will be replaced You may lose a small amount of oil when you replace each filter go0408858 Illustration 378 2 The steering filter is located on the left side of the machine The filter is located below the cab in front of the midbeam Access the steering filter below the machine Remove the filter element Inspect the filter for debris See Operation and Maintenance Manual Oil Filter Inspect 3 Wipe the sealing surface of the filter base Make sure that you remove all of the former filter seal 4 Apply a thin coat of oil to the seal on the new filter Install the filter by hand When the filter seal contacts the filter base tighten the filter element by an additional turn of 270 degrees Rotation m
44. er primary element pull the element outward While you pull the element outward rock the element 178 Maintenance Section Engine Air Filter Secondary Element Replace 3 Install a clean primary filter element over the engine air filter secondary element Apply firm pressure to the end of the primary element as you gently rock the filter element This seats the primary element 4 Clean the cover for the air cleaner housing Align the slot on the cover with the pin on the air cleaner housing Install the cover 100831582 Engine Air Filter Secondary Element Replace SMCS Code 1051 1054 510 SE NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Note Replace the engine air filter secondary element when you service the engine air filter primary element for the third time Replace the secondary filter element if the exhaust smoke remains black and a clean primary filter element has been installed Also replace the secondary filter element whenever the secondary filter element appears dirty or the secondary filter element appears dusty Always service the air cleaner from the right fend er only DO NOT stand on the undercarriage belt or ground to service the air cleaner Personal in jury could result g00401405 Illustration 283 1 Slowly release latches for the air cleaner housing Remove cover 1 Note The latches for the air cleaner ho
45. es crank the engine for a maximum of 30 seconds If the engine does not start you may need to prime the engine for an additional 25 pumps 100835532 Fuel System 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 machine Be prepared to collect the fluid with suitable containers before Opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates 192 Maintenance Section Fuel System Prime g00406659 Illustration 326 Water separator bowl 1 is located below primary filterwater separator 2 If water is present water will be visible at the bottom of the water separator bowl 1 Loosen the drain valve in order to drain the moisture into a suitable container Drain the water separator bowl until all of the moisture is removed 2 Close the drain valve Dispose of the moisture 100836242 Fuel System Prime SMCS Code 1258 NOTICE Do not crank the engine for more than 30 seconds Al low the starter to cool for two minutes before cranking again Turbocharger damage can result if the engine rpm is not kept low unti
46. es that protrude above the surface of the belt should be repaired Repair the cables by clipping or grinding the cable Clip or grind the cable so that the cable is below the surface of the belt This will prevent additional damage If you break in the belts in very wet conditions or you break in the belts in dry clean conditions the rubber may scuff The scuffing can last for 400 service hours The guide blocks may appear moderately worn or severely worn on the surface Some material may be removed Although scuffing affects the appearance of the belt the life of the guide blocks is not affected If scuffing occurs with high temperatures on the guide blocks consult any Caterpillar dealer Illustration 398 g00410518 Cuts gouges and minor wear on guide blocks 3 will not cause operational problems However a standard belt that is missing more than three consecutive guide blocks should be repaired A standard belt that is missing more than one third of the total guide blocks should be repaired A standard belt that is missing more than three consecutive guide blocks may come off the machine This could damage other components on the undercarriage A special application belt that is missing two or more consecutive guide blocks should be replaced A special application belt that is missing more than one fourth of the total guide blocks should be repaired Refer to Special Instruction REHS0151 Procedure For Reinforcing an
47. ethods e Pressure air e Pressure water e Detergent washing When you use pressure air the maximum air pressure is 205 kPa 30 psi When you use pressure water the maximum water pressure is 280 kPa 40 psi Illustration 277 g00039203 Illustration 278 g00328468 Illustration 279 g00039203 5 When you clean the inside pleats and the outside pleats direct the air along the pleats or direct the water along the pleats The element can be washed in a solution that consists of warm water and of nonsudsing household detergent Fully rinse the pleats Allow the filter to air dry completely Engine air filter primary elements may be wet for three days During this time install a new primary element or install a dry cleaned element Store the dry element for installation at the next service Illustration 280 g00328470 6 Inspect the filter element after you clean the filter element Do not use a filter if the pleats the gaskets or the seals are damaged Place a light bulb inside the filter element Discard the filter element if you find any of the following conditions e Holes of light that are pin hole size e Areas of paper that appear thin 7 Cover the clean filter elements Store the elements in a clean dry location A primary element may be cleaned for a maximum of six times Also replace the primary element if the primary element has been used for one year 8 Install a clean primary filter eleme
48. g system Note Thermostats can be reused if the thermostats meet certain test specifications The tested thermostats must not be damaged and the tested thermostats must not have an excessive buildup of deposits 1 Park the machine on a hard level surface Allow the engine to cool and allow the radiator to cool 2 Raise the hood in order to access the radiator Note See Operation and Maintenance Manual Engine Compartment Hood Raise Lower Illustration 250 g00387093 3 Slowly loosen the filler cap in order to relieve the pressure Remove the filler cap 4 Inspect the filler cap gasket Replace the filler cap if the gasket is damaged g00387852 Illustration 251 5 Attach a hose to the nipple on the drain valve Open the drain valve that is under the radiator Allow the coolant to drain into a suitable container Note Always discard drained fluids according to local regulations 6 Close the drain valve Fill the cooling system with clean water and with a 6 to 10 concentration of cooling system cleaner Install the filler cap 7 Start the engine Run the engine for 90 minutes 8 Stop the engine Drain the cleaning solution 9 Flush the cooling system with water until the draining water is transparent Fully drain the cooling system 165 Maintenance Section Cooling System Coolant DEAC Change 10 Close the drain valve 11 Add the coolant solution See Operation and Maintenance Ma
49. ht side of the right hydraulic coupler 1 Attach a hose to the drain valve 2 Open the drain valve in order to allow water and sediment to drain into a suitable container 3 Close the drain valve when clean fuel appears 01183104 Fuel Vent Breather Clean SMCS Code 1273 070 BRE Illustration 329 g00633546 The fuel tank breather is located on the right rear side of the operators compartment 1 Remove the breather 2 Wash the breather in a clean nonflammable solvent 3 Allow the breather to dry 4 Install the clean dry breather 193 Maintenance Section Fuel Vent Breather Clean 101183271 Fuses Circuit Breakers and Relays Replace Reset SMCS Code 1417 510 NOTICE Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result Fuses protect the electrical system from damage that is caused by overloaded electrical circuits Replace a fuse if the element separates If the fuse of a particular electrical system requires frequent replacement check the electrical circuit Repair the electrical circuit if necessary There are two fuse panels for the electrical system A decal is attached to the back of the cover of the fuse panel that is located on the right side console near the floor The decal provides a description of the fuses and the circuit breakers that are located in both the fuse panels The left side of the decal contains the i
50. ial screen is located at the lower front of the differential Access the differential screen The differential screen is located underneath the tractor 172 Maintenance Section Differential and Final Drive Oil Level Check Illustration 264 g00629606 10 Remove the breather cap from the filler tube Illustration 265 g00396318 Illustration 266 g00633534 11 Add oil until the oil level is above the center of the oil level sight gauge 12 Inspect the cap and the cap seal for damage for deposits or for foreign material Clean the cap with a clean cloth Replace a damaged cap 13 Install the cap 14 Start the engine and run the engine for at least five minutes Check for leaks 15 Stop the engine 16 The oil level should be just above the center of the oil level sight gauge Differential and Final Drive Oil Level Check SMCS Code 3258 535 FLV 4050 535 FLV 4070 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and
51. 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 Obtain the sample of the differential and final drive oil as close as possible to the recommended sampling interval The recommended sampling interval is every 250 service hours In order to receive the full effect of S O S oil analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced 1 Before you obtain an S O S oil sample operate the machine until the oil is warm and the oil is well circulated Then obtain the S O S oil sample NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead to customer and dealer concerns 174 Maintenance Section Drawbar Wearplates
52. ir cleaner if the yellow piston in the filter element indicator moves into the red zone Always service the air cleaner from the right fend er only DO NOT stand on the undercarriage belt or ground to service the air cleaner Personal in jury could result g00401405 Illustration 275 1 Slowly release the latches for the air cleaner housing Remove cover 1 Note The latches for the air cleaner housing may snap open when you release the latches 176 Maintenance Section Engine Air Filter Primary Element Clean Illustration 276 g00401441 2 Remove primary filter element 2 from the air cleaner housing In order to remove the engine air filter primary element pull the element outward While you pull the element outward rock the element 3 Inspect the primary element If the pleats the gaskets or the seals are damaged discard the element Replace a damaged primary element with a clean primary element NOTICE Do not clean the filter elements by bumping or tapping them Do not use filter elements with damaged pleats gaskets or seals Engine damage can result Make sure the cleaned filter elements are completely dry before installing into the filter housing Water re maining in the elements can cause false indications of contamination in Scheduled Oil Sampling test results 4 If the primary element is not damaged clean the primary element The filter elements can be cleaned by using the following m
53. is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes 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 Mixing ELC with other products reduces the effective ness of the ELC and shortens the ELC service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for premixed or concentrate coolants Use only Caterpillar ELC Extender with Caterpillar ELC Failure to follow these recommendations can result in shortened cool ing system component life
54. isher 101191116 Front Axle Lubricate SMCS Code 3259 3268 3282 086 NOTICE Do not use pneumatic or otherwise powered lubrica tion equipment This causes damage to the seals Use a manual grease gun only 185 Maintenance Section Fire Extinguisher Inspect Note Lubricate the front axle with Caterpillar Multipurpose Molybdenum Grease MPGM See Operation and Maintenance Manual Lubricating Greases Illustration 306 g00403833 Illustration 307 g00403861 Lubricate the fitting that is located at the bottom of the center of the front axle housing 101191148 Front Idler Hubs Oil Change SMCS Code 4159 510 HU 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 186 Maintenance Section Front Idler Hubs Oil Change Ma Illustration 308 g00408680 Perform this procedure on the left side and the right side idler hubs after recently using the machine g00408682 Illustration 30
55. k that is on the sight gauge 4 Check the engine cooling system for leaks and for faulty hoses As required repair the components or replace the components Inspect the engine air filter indicator 11 Service the air cleaner if the yellow piston in the filter element indicator moves into the red zone Inspect the condition of the following components e Alternator belt e Air conditioning compressor belt Make sure that the screens for the alternator are clean Operation of an alternator with plugged screens can reduce the service life of the alternator As required tighten the belts or replace the belts 10 Inspect the three point hitch linkage for damage and for excessive wear As required repair the components 11 Inspect the following components for damage or for excessive wear e Three point hitch linkage e Drawbar e Drawbar support e Drawbar wearplate 224 Maintenance Section Walk Around Inspection e Drawbar pin e Swing stops As required repair the components or replace the components 12 Inspect the operation of dash lamps Also inspect the operation of all external lamps 10 As required repair any nonfunctional lamps or replace any nonfunctional lamps 13 Inspect all hose clamps As required tighten the clamps 14 Check the horn for proper operation Illustration 396 g00410352 15 Inspect the condition and the cleanliness of the following components e S
56. l filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts The primary filter water separator extends the life of the secondary fuel filter The primary filter water separator also removes water from the fuel In normal conditions replace the fuel filter elements after every 250 service hours Severe conditions that cause dirt rust or other contamination may shorten the life of the filters 189 Maintenance Section Fuel System Primary Filter Water Separator Clean Replace NOTICE Fuel system damage may result if engine power loss is used to indicate when fuel filters need to be replaced A fuel pressure sensor will indicate low fuel pressure when either filter is plugged The engine status lamp will flash a code 63 See Operation and Maintenance Manual Engine Status Lamp If a code 63 occurs replace both fuel filters before you begin the next day s work If the filter plugs early check your fuel supply for contaminants Illustration 320 g00407223 1 Shut off the fuel at the primary filter with the shutoff valve NOTICE Protect the rubber engine mounts from fuel spillage Contact with fuel will damage the rubber engine mounts g00407259 Illustration 321 2 Drain the primary filter Unscrew the water separator bowl in order to remove the water separator bowl from the primary filter element 190 Maintenance Section Fuel System Secondary Filter
57. l the oil gauge display verifies that the oil pressure is sufficient If the engine does not start air may be trapped in the fuel lines to the engine Use the following procedure in order to purge air from the fuel lines Illustration 327 g00406649 The fuel priming pump is located above the secondary fuel filter on the right side of the engine 1 Unlock the priming pump plunger Operate the plunger until you feel resistance 2 Push in the plunger Hand tighten the plunger 3 Start the engine If the engine does not start you may need to prime the engine for an additional 25 pumps Some misfiring may occur However the engine will not be damaged 4 Run the engine at low idle speed until the engine runs smoothly 100835616 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Illustration 328 g00406799 The drain for the fuel tank is mounted to the rig
58. lect 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 g00633494 Illustration 237 The drain line for the air conditioner is located on the left side of the engine compartment 158 Maintenance Section Air Spring Pressure Check Remove any debris or dirt in the drain line for the air conditioner This line removes condensate from the air conditioner coils A plugged line can cause water to accumulate The accumulated water will soak the air filter 101191067 Air Spring Pressure Check SMCS Code 4193 535 Use a self attaching inflation chuck and stand behind the belt when inflating springs to prevent possible personal injury Proper inflation equipment and training in using the equipment are necessary to avoid overinfla tion A blowout can result from improper or misused equipment NOTICE Set the inflation equipment regulator at no more than 140 kPa 20 psi over the recommended pressure to prevent air spring damage A inflated spring in an enclosed shop at a temperature of 19 5 1 5 C 67 2 7 F is underinflated if the machine works in freezing temperatures Inflate the suspension spring
59. lose as possible to the recommended sampling interval The recommended sampling interval is every 250 service hours In order to receive the full effect of S 0 S oil analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced 1 Before you obtain an S O S oil sample operate the machine until the oil is warm and the oil is well circulated Then obtain the S O S oil sample NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead to customer and dealer concerns g00409704 Illustration 302 The sampling valve for the engine is located on the right side of the engine 2 Use a sampling gun in order to obtain the oil sample from the sampling valve Do not take the oil sample from the drain stream because a stream of dirty oil from the bottom of the compartment will contaminate the sample Likewise never dip an oil sample from an oil container or pour a sample from a used filter Consult any Caterpillar Dealer for complete information and assistance about the S O S oil analysis
60. lug A considerable number of strokes may be required in order to fill the fuel lines and the fuel filters 4 Tighten air bleed plug 3 Continue to operate the priming pump until you feel a strong resistance Listen for an audible click from the fuel filter base The click indicates that the valve is opened and the system is pressurized Lock the handle on the hand priming pump 5 Crank the engine If the engine starts but the engine runs rough operate the engine at low idle speed until the engine runs smoothly 101183747 Fuel System Primary Filter Water Separator Clean Replace SMCS Code 1260 070 PY 1260 510 PY 1261 Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Personal injury can result when using cleaner sol vents To help prevent personal injury follow the instruc tions and warnings on the cleaner solvent contain er before using Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Do not fill fue
61. ly for use in extremely muddy underfoot conditions Note The cast slotted drive wheel should not be used in applications when the machine is pulling a scraper go0410346 C 12 3 mm 0 50 0 12 inch initial D 8 3 mm 0 30 0 12 inch initial Adjust scraper 1 to an initial Dimension A of 5 0 0 5 mm 0 17 0 02 inch by using 155 1557 Cast Driver Gauge Adjust scraper 2 to an initial Dimension B of 3 2 0 5 mm 0 13 0 02 inch Dimension A will increase as scraper 1 wears When Dimension A wears to 9 0 mm 0 35 inch readjust the scrapers to the original Dimension A of 5 0 0 5 mm 0 17 0 02 inch Scrapers may be inverted in order to provide additional service life If a scraper is severely worn the scraper should be replaced Scraper 3 is installed in order to provide a clean groove for the guide blocks Adjust scraper 3 in order to provide a Dimension C of 12 3 mm 0 50 0 12 inch Dimension C is between the center of the drive wheel and the end of the scraper The Dimension D between scraper 3 and the edge of the drive wheel should be 8 3 mm 0 30 0 12 inch Scrapers that are missing or scrapers that are not adjusted properly can severely shorten the life of the belt Make sure that the scrapers are adjusted correctly and that the bolts are tight If a scraper is severely worn the scraper should be replaced 100838958 Slotted Cast Drive Wheel Scrapers Che
62. mark on sight glass 1 Note See Operation and Maintenance Manual Lubricant Viscosities for the correct type of hydraulic oil c Clean the hydraulic oil filler cap 2 Install hydraulic oil filler cap 2 d Maintain the oil level between the ADD mark and the FULL mark on sight glass 1 100837288 Hydraulic System Oil Return Filter Replace SMCS Code 5068 510 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Note The hydraulic oil tank must be drained in order to change the implement return oil filter See Operation and Maintenance Manual Hydraulic System Oil Change go0408685 Illustration 348 An indicator on the dash panel will illuminate when the implement return oil filter is plugged 1 Place an oil pan below the filter that will be replaced You may lose a small amount of oil
63. n 372 g00623209 4 Engage the parking brake g00391145 Illustration 373 5 Depress the service brake pedal at two second intervals Depress the pedal until the system recharges A slight decrease in engine speed indicates that the system is recharging 6 Fully apply the brakes at one minute intervals until the system recharges 213 Maintenance Section Slotted Cast Drive Wheel Scrapers Adjust 7 Record the number of applications before the system recharges 8 If the system recharges prior to three full brake applications the brake system should be inspected Consult any Caterpillar dealer for more information 101456920 Slotted Cast Drive Wheel Scrapers Adjust SMCS Code 4199 025 Table 54 Required Tool Part Number Part Description Qty 155 1557 Cast Driver Gauge 214 Maintenance Section Slotted Cast Drive Wheel Scrapers Adjust Illustration 374 Equipped with Sealed and Lubricated Undercarriage A 5 0 0 5 mm 0 17 0 02 inch initial adjustment B 3 2 0 5 mm 0 13 0 02 inch initial adjustment adjustment adjustment Note Make sure that the adjustment is made while the machine is on a flat floor The belt must be properly tensioned Also make sure that the part number that is stamped on the slotted drive wheel is lined up with the scraper Note The slotted drive wheel is recommended on
64. nd Maintenance Manual Engine Compartment Hood Raise Lower g00388695 Illustration 249 164 Maintenance Section Cooling System Coolant DEAC Change 3 Coolant should be visible in the coolant recovery bottle Drain some coolant from the radiator into a suitable container in order to allow space for the extra coolant additive Add supplemental coolant additive Note Always discard drained fluids according to local regulations 4 Add 0 24 L 50 pint of supplemental coolant additive 5 Inspect the filler cap gasket Replace the filler cap if the gasket is damaged 6 Install the filler cap 101191059 Cooling System Coolant DEAC Change SMCS Code 1352 1395 044 A WARNING Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing
65. nd Maintenance Manual Engine Compartment Hood Raise Lower 210 Maintenance Section Radiator Core Clean Illustration 359 g00377898 2 Unlatch cooler latches 1 Illustration 360 g00378017 3 Raise air cooler 2 4 Secure air cooler 2 with support 3 Illustration 361 5 Use the handles on each side The condenser core moves on slides 5 Pull out air conditioning condenser core 4 6 Direct pressurized air or direct pressurized water at the radiator Clean the radiator core of foreign material The use of compressed air is preferred Blow out the debris from the fan side first Then clean debris from the front compartment Note Use pressurized air with a maximum pressure of 205 kPa 30 psi Use pressurized water with a maximum pressure of 280 kPa 40 psi 7 After cleaning push condenser core 4 against the mounting plates Engage latches Illustration 362 g00378017 8 In order to disengage support 3 lift the support Lower air cooler 2 Secure air cooler 2 with the rubber latches g00377172 Illustration 363 9 Lower the hood Note See Operation and Maintenance Manual Engine Compartment Hood Raise Lower 100839204 Radiator Pressure Cap Clean Replace SMCS Code 1353 070 CAP 1353 510 CAP Illustration 364 g004 10698 The relief valve should be cleaned or replaced if the system overheats or if loss of coolant is observed 1 Remove the radia
66. nd Radiator 17 to 22 Challenger US gal 95E 1 Park the machine on a hard level surface Allow the engine to cool and allow the radiator to cool Illustration 256 g00387093 2 Raise the hood in order to access the radiator Note See Operation and Maintenance Manual Engine Compartment Hood Raise Lower 3 Coolant should be visible in the coolant recovery bottle If necessary drain some of the coolant from the radiator into a suitable container in order to allow space for the Extender Note Always discard drained fluids according to local regulations 169 Maintenance Section Cooling System Level Check Illustration 257 g00393145 4 Slowly loosen the filler cap in order to relieve the pressure Remove the filler cap 5 Inspect the filler cap gasket Replace the filler cap if the gasket is damaged 6 Add the recommended amount of Caterpillar Extender to the cooling system 7 Install the filler cap 101191079 Cooling System Level Check SMCS Code 1350 535 FLV 1395 535 FLV A WARNING Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is c
67. nd warnings on the cleaner solvent contain er before using Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts In normal conditions replace the fuel filter elements after every 250 service hours Severe conditions that cause dirt rust or other contamination may shorten the life of the filters NOTICE Fuel system damage may result if engine power loss is used to indicate when fuel filters need to be replaced A fuel pressure sensor will indicate low fuel pressure when either filter is plugged The engine status lamp will flash a code 63 See Operation and Maintenance Manual Engine Status Lamp If a code 63 occurs replace both fuel filters before you begin the next day s work If the filter plugs early check your fuel supply for contaminants NOTICE When replacing the secondary fuel filter use only the 1R 0762 Fuel Filter Assembly or equivalent Use of any other Caterpillar filter or a filter from another man ufacturer can result in fuel injector damage due to ac celerated wear of close toleranced fuel system parts The s
68. nformation for the fuse panel for the dash panel The right side of the decal contains the information for the fuse panel for the right hand console Fuse Panel for the Dash Panel g00403425 Illustration 330 The fuse panel for the dash panel is located below the dashboard and behind the inching pedal 194 Maintenance Section Fuses Circuit Breakers and Relays Replace Reset FRONT DASH _m Illustration 331 g00633661 195 Maintenance Section Fuses Circuit Breakers and Relays Replace Reset Table 47 Fuses Number Rating Color Description 1 15 Amp Blue Front wiper 2 15 Amp Blue Rear wiper 3 20 Amp Yellow Front floodlights 4 15 Amp Blue Dimmer for high beam 5 20 Amp Yellow Rear floodlights 6 10 Amp Red Dome Lights 6 10 Amp Red Parking lights 6 10 Amp Red Lights for the rocker switches 6 10 Amp Red Lights for the right hand console 6 10 Amp Red Courtesy lights for the cab 7 15 Amp Blue Auxiliary trailer connector pin 7 8 15 Amp Blue Auxiliary trailer connector pin 4 9 10 Amp Red Stop lamp 10 20 Amp Yellow Partial floodlights 11 10 Amp Red Radio if equipped 12 20 Amp Yellow Backlighting 13 15 Amp Blue Spare 14 10 Amp Red Air conditioning clutch 15 20 Amp Yellow Air conditioner blower 16 10 Amp Red Ignition 17 10 Amp Red Low beam headlamps 18 10 Amp Red High beam headlamps
69. nt level stabilizes 10 As needed add coolant Maintain the coolant level to the bottom of the filler pipe 11 Install the filler cap i00816008 Cooling System Extended Life Coolant Extender Add SMCS Code 1350 1352 544 NL 1395 544 NL A WARNING Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before Opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates NOTICE Mixing ELC with other produ
70. nt over the engine air filter secondary element Apply firm pressure to the end of the primary element as you gently rock the filter element This seats the primary element 9 Clean the cover for the air cleaner housing Align the slot on the cover with the pin on the air cleaner housing Install the cover 10 Reset the air cleaner service indicator If the yellow piston in the filter element indicator moves into the red zone after starting the engine or the exhaust smoke is still black after installation of a clean primary filter element install a new primary filter element After six cleanings the primary element should be replaced Replace the element annually 177 Maintenance Section Engine Air Filter Primary Element Replace 101260415 Engine Air Filter Primary Element Replace SMCS Code 1054 510 PY Regardless of the condition replace the engine air filter primary element at an interval of one year Always service the air cleaner from the right fend er only DO NOT stand on the undercarriage belt or ground to service the air cleaner Personal in jury could result Illustration 281 g00411498 1 Slowly release the latches for the air cleaner housing Remove cover 1 Note The latches for the air cleaner housing may snap open when you release the latches go0411499 Illustration 282 2 Remove primary filter element 2 from the air cleaner housing In order to remove the engine air filt
71. ntenance Section Hydraulic System Oil Change g00408 143 Illustration 344 10 Remove the screen from the housing Discard the screen 11 Install a new screen into the housing Make sure that the screen is seated and make sure that the seal is in the groove 12 While the hydraulic tank is drained change the implement return oil filter See Operation and Maintenance Manual Hydraulic System Implement Return Oil Filter Replace 13 Fill the hydraulic tank Note See Operation and Maintenance Manual Lubricant Viscosities for the correct type of hydraulic oil 14 Inspect the gasket on the filler cap If necessary replace the gasket 15 Make sure that the oil is at the FULL mark on the sight glass Install the filler cap 16 Start the engine Run the engine for a few minutes Inspect the machine for leaks If necessary refill the hydraulic oil tank g00408099 Illustration 345 204 Maintenance Section Hydraulic System Oil Level Check 17 Maintain the oil level between the ADD mark and the FULL mark on sight glass 1 i00836619 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV 7479 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be p
72. nual Refill Capacities Note At this time do not add any supplemental coolant additive if you are using Caterpillar Extended Life Coolant that contains some additive 12 Start the engine Operate the engine until the coolant reaches the normal operating temperature and until the coolant level stabilizes Illustration 252 g00388695 13 Coolant should be visible in the coolant recovery bottle As needed add coolant 14 Install the filler cap 15 Stop the engine Clean Cooling System Relief Valve Illustration 253 g00388704 Clean the relief valve or replace the relief valve if the system overheats or loss of coolant is observed 1 Remove the radiator cap slowly in order to relieve the pressure 166 Maintenance Section Cooling System Coolant Sample Obtain 2 Inspect the relief valve and the gasket in the radiator cap Replace the radiator cap if the valve or the gasket are worn or damaged 101218018 Cooling System Coolant Sample Obtain SMCS Code 1350 008 1350 554 SM 1352 008 1395 008 1395 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 an
73. on Caterpillar products Dispose of all fluids according to local regulations and mandates General Inspection g00410198 Illustration 394 Illustration 395 1 Make sure that covers and guards are securely in place Inspect the machine for damage 2 Remove the following debris from the machine trash rocks and buildup of mud Pay special attention to the following areas e Stairs e Cab 3 e Engine compartment 2 e Radiator 1 e Cooler cores 1 e Radiator screen 1 e Three point hitch linkage 6 e The area between the belts and the main structure of the machine e Idlers 9 e Midwheels 8 e Drive wheels 7 3 Check for oil leaks Correct any oil leaks Pay special attention to the following areas e Belt tension cylinders e Idlers 9 e Midwheels 8 e Drive wheels 7 e Final Drives 7 e Engine compartment 2 g00410318 223 Maintenance Section Walk Around Inspection e Transmission case and transmission solenoids e Lift cylinders for the three point hitch 6 e Implement control valve bank 6 e Hydraulic oil filters e Hydraulic pumps e Hydraulic motors Check the fuel tank 5 and the fuel lines for leaks Correct fuel leaks before you start the engine Maintain the fuel level at the bottom of the filler neck in order to prevent moisture condensation in the fuel tank Maintain the hydraulic oil level between the ADD mark and the FULL mar
74. onsole is located on the front of the right side console near the floor 200 Maintenance Section Fuses Circuit Breakers and Relays Replace Reset RH CONSOLE _m SPARE 30A SPARE 63 20A 10A 20A 10A o o o o ololojo L Illustration 335 g00633734 Table 50 Relays Number Description 62 Suspension seat 63 Three point hitch 64 Subwoofer 65 Lamp test g00411732 Illustration 336 Circuit Breakers FRONT DASH _ m siwe Qs 9 l Y Illustration 337 000633736 Table 51 Circuit Breakers Number Rating Description 66 15 Amp Running lamps 67 20 Amp Engine start switch 1 Reset the circuit breaker by turning off the lights Then turn on the lights There could be an overload condition in the electrical circuit if the lights blink and or the circuit breakers reset continuously 201 Maintenance Section Fuses Circuit Breakers and Relays Replace Reset Auxiliary Circuit Breakers and Main Circuit Breakers Illustration 338 g00655633 The circuit breakers are located on the air conditioner case on the left side of the machine Table 52 Circuit Breakers Number Rating Description 68 150 Amp Main 69 80 Amp Auxiliary Circuit Breaker for the Engine and Relay for the Engine g00655637 Illustration 339 A 20 ampere circuit breaker 70 i
75. ool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes 170 Maintenance Section Differential and Final Drive Oil and Screens Change Clean 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 use a conventional coolant to top off a cooling system using Extended Life Coolant Do not use supplemental coolant additives SCA oth er than Extender in cooling systems filled with Extend ed Life Coolant See the appropriate topics in your machine s Operation and Maintenance Manual for all cooling system requirements g00388695 Illustration 258 This machine uses a coolant recovery bottle that is similar to the coolant recovery bottles that are used in automotive applications Once the engine is turned off and the coolant is cold the coolant should
76. p Red Pin 2 from No 1 power plug 39 20 Amp Yellow Spare 40 15 Amp Blue Suspension seat 41 10 Amp Red Subwoofer 42 30 Amp Green Pin 1 from No 1 power plug 43 30 Amp Green Spare 1 This pair is switched by the engine start switch key 2 This is switched by the engine start switch key The pair can also be controlled with the rocker switch on the right side console 3 This pin has unswitched power Relays for the Dash Panel The fuse panel for the dash panel is located below the dashboard and behind the inching pedal 198 Maintenance Section Fuses Circuit Breakers and Relays Replace Reset FRONT DASH _m Illustration 334 g00654495 199 Maintenance Section Fuses Circuit Breakers and Relays Replace Reset Table 49 Relays Number Description 44 Left turn signal for the machine 45 Left turn signal for the trailer 46 Horn 47 Right turn signal for the machine 48 Right turn signal for the trailer 49 Lights for the rocker switches 50 Dimmer 51 Front flood lights 52 Front windshield wiper 53 Partial flood lights 54 Right flood lights 55 Front windshield wiper 56 Radio 57 Relay that enables the front windshield wiper 58 Switch for the belt tensioner 59 Work lights for the trailer 60 Air conditioner 61 Turn signal Relays for the Right Side Console The fuse panel for the right side c
77. program 101472340 Engine Valve Lash Check SMCS Code 1102 1209 535 Consult any Caterpillar dealer in order to adjust the engine valve lash setting Caterpillar dealers have the tools and the trained personnel for this service The initial valve lash check can be performed with any of the other maintenance interval items between 250 and 1000 hours 100837840 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD Illustration 303 g00409282 g00409283 Illustration 304 The cylinder retaining clamp is located in the front left of the engine compartment 1 Raise the hood 2 Loosen the cylinder retaining clamp Unscrew the empty ether cylinder Remove the empty ether cylinder NOTICE When removing the ether cylinder you may need to hold the ether valve mechanism in order to prevent the mechanism from turning The ether line and tube may be damaged if they are allowed to turn 3 Remove the used gasket Install the new gasket that is provided with each new cylinder 4 Install the new cylinder Tighten the cylinder hand tight Tighten the cylinder clamp securely 5 Lower the hood 100838915 Fire Extinguisher Inspect SMCS Code 7419 040 go0410340 Illustration 305 A bracket for the fire extinguisher is mounted on the left side of the machine in front of the stairs Make sure that the fire extinguisher is charged and undamaged If necessary recharge or replace the fire extingu
78. r fluid bottle When you are standing next to the machine the bottle is visible through the slit in the fender g00401983 Illustration 404 Remove the cap in order to fill the washer fluid bottle with commercially available windshield washer fluid NOTICE Use Caterpillar nonfreezing window washer solvent or a commercially available windshield washer fluid in order to prevent freezing of the windshield washer system Note In order to find information about the refill capacity of the washer fluid bottle see Operation and Maintenance Manual Refill Capacities Window Wipers Inspect Replace SMCS Code 7305 040 7305 510 g00402285 Illustration 405 Inspect the windshield wiper blades at the front and the rear of the cab Replace any wiper blades that are damaged or worn Replace any wiper blades that streak the windshield 227 Maintenance Section Window Wipers Inspect Replace
79. reen and wash the magnets in a clean nonflammable solvent Allow the screen and the magnets to dry 7 Install the magnets into the screen Install the screen the cover and the bolts Illustration 385 g00409258 8 Remove the filler cap Add the correct type of oil Add oil until the oil level is between the ADD mark and the FULL mark on the sight glass Note See Operation and Maintenance Manual Lubricant Viscosities for the correct type of oil g00409239 Illustration 386 9 Check the oil level The oil level should be between the ADD mark and the FULL mark on the sight glass 10 Start the engine Run the engine for a few minutes in order to check for leaks 11 Stop the engine 12 Maintain the oil level between the ADD mark and the FULL mark on the sight glass 219 Maintenance Section Transmission Oil Filter Replace 100837909 Transmission Oil Filter Replace SMCS Code 3067 510 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Product
80. repared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates 1 Park the machine on a hard level surface Stop the engine before you check the hydraulic system oil level Allow the oil to cool for five minutes before you check the hydraulic system oil level Note Because of the numerous sizes of hydraulic cylinders on implements the position of the implement can affect the hydraulic oil level Always check the hydraulic oil with the implement in the position that the implement is normally stored Illustration 346 g00408099 2 Sight glass 1 is located on the front of the hydraulic oil tank The oil level should be between the ADD mark and the FULL mark on sight glass 1 3 If the oil level is low add hydraulic oil g00408101 Illustration 347 a Remove hydraulic oil filler cap 2 NOTICE Do not overfill the hydraulic oil tank Leaving all im plements in their existing unhooked positions will min imize the possibility of overfilling b Add the correct type of hydraulic oil Add hydraulic oil until the hydraulic system oil level is between the ADD mark and the FULL
81. rface If you cannot access the windows from the platform or from the stairs use a squeegee with a long handle in order to clean the windows Use the access ladder on the right side of the machine in order to access the windows on the right side of the machine Use commercially available window cleaning solutions in order to clean the windows 226 Maintenance Section Window Washer Reservoir Fill 101191358 Window Washer Reservoir Fill SMCS Code 7306 544 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 401 g00401978 The bottle for the windshield washer fluid is located in the left fender in front of the hydraulic tank g00401980 Illustration 402 Illustration 403 g00401982 There are two sight gauges for the washer fluid bottle One sight gauge is located in front of the washer fluid bottle When you are underneath the fender the bottle is visible The other sight gauge is located on the side of the washe
82. s Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates 1 Place an oil pan below the filter that will be replaced You may lose a small amount of oil when you replace each filter g00409360 Illustration 387 2 The transmission filter is located on the right side of the machine The filter is located below the cab in front of the midbeam Access the transmission filter below the machine Remove the filter element Inspect the filter for debris See Operation and Maintenance Manual Oil Filter Inspect 3 Wipe the sealing surface of the filter base Make sure that you remove all of the former filter seal 220 Maintenance Section Transmission Oil Level Check 4 Apply a thin coat of oil to the seal on the new filter Install the filter by hand When the filter seal contacts the filter base tighten the filter element by an additional turn of 270 degrees Rotation marks are spaced at 90 degree intervals Use these rotation marks as a guide for proper tightening Illustration 388 g00409239 5 Check the oil level with cold oil and a stopped engine The oil level should be between the ADD mark and the FULL mark on the sight glass 6 Start the engine Run the engine for a few minutes in order to check for leaks 7 If the oil level is low add oil go0409258 Illustration 389 a
83. s 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 312 g00409043 Maintain the oil level so that the oil touches line 1 in the sight glass in the center of the idler Note Check the oil level for the idler hub on both sides of the machine g00409053 Illustration 313 187 Maintenance Section Front Idler Hubs Oil Level Check If the oil level is low remove hub s center plug 2 Add the necessary amount of oil and replace the plug Note There is a vent hole in the center of plug 2 A small amount of dust that collects around the vent is normal This is not a sign of abnormal leakage See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities for proper oil quantities 101191225 Fuel System Fill SMCS Code 1250 544 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 NE
84. s located on the right frame rail The circuit breaker will automatically reset after an overload condition Relay 71 that is for the engine is located near the circuit breaker 202 Maintenance Section Hydraulic System Oil Change Table 53 Circuit Breaker and Relay Number Rating Description 70 20 Amp Circuit breaker for engine 71 Relay for engine i01457690 Hydraulic System Oil Change SMCS Code 5050 044 A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar 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 If the machine is equipped with a three point hitch the draft arms should be lowered before you change the hydraulic oil 1 Park the machine on a hard level surface Stop the engine before you check the hydraulic system oil level Allow the oil to cool for five minutes before you check the hydraulic system Illustration 3
85. s to the usual operating temperature of the machine Illustration 238 g00406898 Table 45 Inflation Operating Weight Inflation Pressure 14075 kg 31000 Ib 448 34 kPa 65 5 psi 15450 kg 34000 Ib 517 34 kPa 75 5 psi 552 34 kPa 80 5 psi 17025 kg 37500 Ib 586 34 kPa 85 5 psi 18600 kg 41000 Ib Note An increase in the air pressure increases the percentage of the machine weight to the midwheels Increasing the air pressure offers the following benefits e The performance of the steering can be increased especially while the machine is under load e The quality of the ride improves because the midwheels absorb a greater amount of the shock loads An air spring with insufficient pressure can cause poor turning performance under load and an increased roughness of ride The ideal pressure for the air springs can vary between 414 to 621 kPa 60 to 90 psi The ideal pressure will depend on the following conditions type of equipment condition of the soil and performance requirements Various pressures should be tried in order to find the ideal setting for the particular situation Do not exceed 650 kPa 95 psi 01183061 Alternator and Fan Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspect Belt Tension Illustration 239 g00375611 1 Raise the hood in order to access the alternator belt Note S
86. s worn or information and assistance about the S O S oil damaged analysis program 100826141 Electronic Unit Injectors Test SMCS Code 1290 081 Illustration 273 g00398338 The recommended maintenance interval for performing preventive maintenance on the electronic unit injectors is based on experience and accumulated information regarding the expectant life of the engine and related components The electronic unit injectors should be tested prior to failure in order to identify improper operating electronic unit injectors Test the electronic unit injectors at regularly scheduled intervals See the Special Instructions Using the 1N 6661 Pop Injector Tester SEHS8867 and 1 1 Lite Fuel Injection Test Specifications SEHS8884 for information and procedures to test the injectors Test the fuel injectors for the following factors e Spray Test e Valve Opening Pressure VOP e External Leakage e Leakdown Rate Note Do not use a fuel injector in the engine without testing All test results are required to be within test specifications Caterpillar dealers have the tools and the trained personnel for this test 175 Maintenance Section Electronic Unit Injectors Test Engine Air Filter Primary Element Clean SMCS Code 1051 1054 070 PY NOTICE Service the air cleaner only with the engine stopped Engine damage could result Illustration 274 g00401159 Run the engine at high idle Service the a
87. sample from an oil container or pour a sample from a used filter Consult any Caterpillar Dealer for complete information and assistance about the S O S oil analysis program 101172214 Walk Around Inspection SMCS Code 7000 040 Personal injury or death can result from escaping fluid under pressure Escaping fluid under pressure even a very small pin hole size leak can penetrate body tissue causing serious injury and possible death Always use a board or cardboard when checking for a leak Do not check for pin hole leaks in pump or motor hoses during a steer stall condition If fluid is injected into your skin it must be treated by a doctor familiar with this type of injury imme diately NOTICE Accumulated grease and oil on an engine is a fire haz ard Remove this debris with steam cleaning or high pres sure water each time any significant quantity of oil or other fluid is spilled on or near the engine Wipe clean all fittings caps and plugs before servic ing 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
88. scsiscaresdertianccdevelsteerebedncentines 193 Oil Filter Inspect oe eee eee cece ee ceeeeeeeneeteneees 207 Radiator Core Clean c ccceeeeeeeseeeeceeeeeeeeeeeees 209 Right Side Access Ladder Install Remove 211 Window Washer Reservoir Fill l a 226 Window Wipers Inspect Replace e 227 Every 10 Service Hours or Daily Air Conditioner Condenser Clean 06 156 Braking System Test cccsceeeereeesseeeeeteeeeees 160 Brakes Indicators and Gauges Test 0 161 Cooling System Level Check sses 169 Engine Oil Level Check ccccceteeeeeseeeeeees 182 Fire Extinguisher Inspect seeen 185 Hydraulic System Oil Level Check 0004 204 Quick Hitch Lubricate cceeeeeeeeeeeeeeeeees 209 Slotted Cast Drive Wheel Scrapers Check 215 Three Point Hitch Lubricate 2 0 0 0 eee eects 217 Transmission Oil Level Check s s 220 Walk Around Inspection ccceeeeeeeeeeeeeenteeeeeeeee 222 Windows Clean 00 0 eee cceecceceesseeeeeessteeeeeseseeeeesaes 225 Every 50 Service Hours Cassette Player Head Clean cccsceeeeeees 162 Parking Brake Adjust 0 eeeeeeeeeeeeeeeeeeeeeeees 208 Every 100 Service Hours Air Spring Pressure Check sessies 158 Differential and Final Drive Oil Level Check 172 153 Maintenance Section Maintenance Interval Schedule Front Idler Hubs Oil Level Check 187 Every
89. t 101286267 Air Conditioner Belt Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Illustration 228 g00375599 1 Raise the hood in order to access the air conditioner belts 2 Inspect the condition and adjustment of the belts If the belts are damaged replace the belts in sets g00376232 Illustration 229 3 Loosen mounting bolt 1 4 Loosen strap bolt 2 5 Rotate the compressor in order to adjust belt tension Use a 1 2 inch breaker bar in square hole 3 156 Maintenance Section Air Conditioner Condenser Clean Illustration 230 g00375611 6 Apply approximately 110 N 25 Ib force midway between the pulleys Measure the deflection of the belt Correctly adjusted belts will deflect 14 to 20 mm 0 56 to 0 81 inch 7 Tighten strap bolt 2 and mounting bolt 1 8 Measure the belt tension If the belt deflection is not correct repeat this procedure i00799701 Air Conditioner Condenser Clean SMCS Code 7320 070 g00377172 Illustration 231 1 Raise the hood Note See Operation and Maintenance Manual Engine Compartment Hood Raise Lower Illustration 232 g00377898 2 Unlatch cooler latches 1 g00378017 Illustration 233 3 Raise air cooler 2 4 Secure air cooler 2 with support 3 IR Illustration 234 g00378152 5 Use the handles on each side The condenser core moves on the slides 5 Pull out air conditioning con
90. tairs 12 e Handholds 13 e Platform 14 16 Inspect the Rollover Protective Structure ROPS for damage Consult any Caterpillar dealer for any necessary repairs 17 Inspect the cab for cleanliness Remove any heavy unsecured objects from the cab 18 Inspect all hydraulic lines and hydraulic hoses for the following conditions damage excessive wear and looseness As required repair the hydraulic lines or replace the hydraulic lines 19 Drain any accumulated water from the fuel tank Also drain accumulated water from the water separator Inspection of the Belts and Undercarriage 00300858 Illustration 397 The rubber belt is composed of several layers of cable The cables are similar to the cables in automotive tires The most important set of cables is located approximately 8 mm 3 inch beneath the inside surface of the belt These cables are called zero degree cables 1 The zero degree cables withstand the track tension Other sets of cables are located between the zero degree cables and the outside surface of the belt These cables are called breaker cables 2 Breaker cables lie in various angles in order to provide lateral support Also breaker cables protect the zero degree cables When any of the cables are exposed to moisture by cuts or gouges in the rubber the cables can rust Any exposed cables should be repaired as soon as possible Consult any Caterpillar dealer Any damaged zero degree cabl
91. ting 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 Park the machine on a hard level surface Stop the engine Allow the oil to cool for five minutes Note The engine oil should be warm when you change the engine oil g00409708 Illustration 293 2 The engine is equipped with an ecology drain valve Attach a hose to the nipple on the drain valve The hose prevents the oil from splashing 181 Maintenance Section Engine Oil and Filter Change 3 Turn the handle counterclockwise in order to drain the engine oil Drain the engine oil into a suitable container Illustration 294 g00409709 4 Use a 2P 8250 Strap Wrench Assembly in order to remove oil filter 1 Note An additional oil filter can be installed on filter base 2 Consult any Caterpillar dealer for more information 5 Inspect the engine oil filter See Operation and Maintenance Manual Oil Filter Inspect Illustration 295 g004097 10 6 Wipe the sealing surface of the mounting base Make sure that you remove all of the oil filter seal 182 Maintenance Section Engine Oil
92. tor cap slowly in order to relieve pressure 2 Inspect the relief valve and the gasket in the radiator cap Replace the radiator cap if the valve or the gasket are worn or damaged 100836504 Right Side Access Ladder Install Remove SMCS Code 7254 010 Access to the right side of the machine is accomplished through the use of the ladder Use the following procedure in order to install the ladder g00407978 Illustration 365 211 Maintenance Section Radiator Pressure Cap Clean Replace 1 In order to remove the ladder from the storage location on the right fender release latch 1 Pull the ladder outward Illustration 366 g00407998 2 Insert hook 2 into slots 3 on the right fender Make sure that the ladder is secure before you use the ladder 3 In order to remove the ladder reverse the procedure 100837489 Rollover Protective Structure ROPS Inspect SMCS Code 7325 040 4 Illustration 367 g00408946 Front ROPS mounting bolts are located on each side of the front of the cab Lift the floormat in order to access the front ROPS mounting bolts 212 Maintenance Section Seat Belt Inspect go0408947 Illustration 368 Rear ROPS mounting bolts are located on both sides at the rear of the cab One of the bolts is located inside of the trainer seat Remove the trainer seat in order to access this bolt 1 Inspect the ROPS for the following items loose bolts missing bolts
93. transmission oil as close as possible to the recommended sampling interval The recommended sampling interval is every 250 service hours In order to receive the full effect of S 0 S oil analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced 1 Before you obtain an S O S oil sample operate the machine until the oil is warm and the oil is well circulated Then obtain the S O S oil sample NOTICE Do not use the same vacuum sampling pump for ex tracting oil samples that is used for extracting coolant samples A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken Always use a designated pump for oil sampling and a designated pump for coolant sampling Failure to do so may cause a false analysis which could lead to customer and dealer concerns 222 Maintenance Section Walk Around Inspection g00408058 Illustration 393 The sampling valve for the transmission is located on a tee in the hydraulic line for the transmission oil cooler Access the sampling valve from the right side of the machine 2 Use a sampling gun in order to obtain the oil sample from the sampling valve Do not take the oil sample from the drain stream because a stream of dirty oil from the bottom of the compartment will contaminate the sample Likewise never dip an oil
94. uids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates g00409444 Illustration 382 Front view The drain plug for the transmission is located at the front of the transmission case Access the drain plug below the machine 1 Park the machine on a hard level surface Stop the engine Allow the oil to cool for five minutes However the transmission oil should be warm for this procedure 2 Thoroughly clean the drain plug before you remove the plug Remove the plug Drain the oil into a suitable container 3 Clean the drain plug and install the drain plug Illustration 383 g00409519 Front view Note Remove the transmission screen Then clean the transmission screen This should be done whenever the transmission is drained The transmission screen is located at the lower front of the transmission behind the access cover 4 Remove bolts 1 and cover 2 g00409521 Illustration 384 5 Remove transmission screen 3 Remove the magnets from the screen 6 Wash the sc
95. using may snap open when you release the latches Ses Illustration 284 g00401441 2 Remove primary filter element 2 from the air cleaner housing In order to remove the primary filter element pull the primary filter element outward While you pull the primary filter element outward rock the primary filter element Note See Operation and Maintenance Manual Engine Air Filter Primary Element Clean g00403878 Illustration 285 3 Remove the secondary element 4 Cover the air inlet opening Clean the inside of the air cleaner housing 5 Inspect the gasket between the air inlet and the housing If the gasket is damaged replace the gasket 6 Uncover the air inlet opening Install a new secondary filter element Apply firm pressure to the end of the secondary filter element as you gently rock the secondary filter element This seats the secondary filter element 7 Install the primary filter element Apply firm pressure to the end of the primary filter element as you gently rock the primary filter element This seats the primary filter element 8 Clean the cover for the air cleaner housing Align the slot on the cover with the pin on the air cleaner housing Install the cover 9 Reset the air cleaner service indicator 101191101 Engine Compartment Hood Raise Lower SMCS Code 7251 009 A WARNING Weak or inoperative hood lift assist struts could cause the hood to lower unexpectedly possi
96. when you replace each filter 205 Maintenance Section Hydraulic System Oil Return Filter Replace g00408686 Illustration 349 2 The implement return oil filter is located on the right side of the machine The filter is located below the cab behind the axle Access the implement return oil filter below the machine Remove the filter element Inspect the filter for debris See Operation and Maintenance Manual Oil Filter Inspect 3 Wipe the sealing surface of the filter base Make sure that you remove all of the former filter seal 4 Apply a thin coat of oil to the seal on the new filter Install the filter by hand When the filter seal contacts the filter base tighten the filter element by an additional turn of 270 degrees Rotation marks are spaced at 90 degree intervals Use these rotation marks as a guide for proper tightening 100831540 Main Drive Shaft Slip Spline Lubricate SMCS Code 3253 086 Note Lubricate the slip spline for the main drive shaft with Caterpillar Multipurpose Molybdenum Grease MPGM Refer to Operation and Maintenance Manual Lubricating Greases 206 Maintenance Section Midwheel Hub Oil Level Check F Illustration 350 g00404066 Lubricate one fitting that is on the spline This is located on the drive shaft that is between the transmission and the differential Access the fitting from the location underneath the machine 101183563 Midwheel Hub Oil Level
97. wn with debris Use a 4C 5084 Filter Cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure 208 Maintenance Section Parking Brake Adjust If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe damage to the engine and or the hydraulic system Engine bearings the crankshaft pumps valves cylinders and other parts may be damaged This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 100834910 Parking Brake Adjust SMCS Code 4267 025 g00406502 Illustration 353 The parking brake caliper has an automatic adjustment that always functions when full stroke is used In order to check the adjustm

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