MAINTENANCE INTERVALS - Safety
Contents
1.2. Illustration 117 2 Apply lubricant to the three grease fittings for the lift arm linkage on the right side of the machine amu m ss 2 r3 A N A Illustration 118 g00474200 3 Apply lubricant to the grease fittings for the tilt linkage on each side of the machine 102021756 Bucket Pivot Bearings Lubricate SMCS Code 6107 086 BD SIN PDF1 Up 1 Wipe off the grease fittings before you apply lubricant 94 Maintenance Section Bucket Tips Inspect Replace SEBU7781 02 g00391443 Illustration 119 2 Apply lubricant to grease fittings 1 for the lower pivot pins of the bucket There is a grease fitting for each side of the bucket r N 3 Apply lubricant to grease fitting 2 for the upper pivot pin of the bucket Illustration 120 g00392317 103657242 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Personal injury or death can result from the bucket falling Block the bucket before changing bucket tips Bucket Tips g00101352 Illustration 121 1 Usable 2 Replace the tip 3 Replace the tip Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip 1 Remove the pin from the bucket tip The pin can be removed by one of the following methods e Use a hammer and a punch from the retainer side of the bucket to drive out the pin e Use a Pin Master Follow Step 1 a through Step 1
3. Pressurized Air Pressurized air can be used to clean a primary air filter element that has not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 147 g00281692 Note When the primary air filter element is cleaned always begin with the inside of the filter in order to force dirt particles toward the outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air filter element Dirt could be forced further into the pleats Vacuum Cleaning Vacuum cleaning is another method for cleaning a primary air filter element which requires daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Inspecting the Primary Air Filter Elements Illustration 148 g00281693 Inspect the clean dry primary air filter element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air filter element Rotate the primary air filter element Inspect the primary air filter element for tears and or holes Inspect the primary air filter element for light that may show through the filter material If it is neces
4. 1 The sight gauge is located on the right side of the machine Maintain the hydraulic oil level between lines 1 and 3 on the sight gauge 2 Remove the hydraulic tank filler cap and add hydraulic oil if necessary i02006885 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 008 7542 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 1 Operate the machine for a few minutes before obtaining the oil sample Operate the hydraulic controls This will thoroughly mix the hydraulic oil for a more accurate sample M Illustration 170 901038684 2 Use the sampling valve in order to obtain a sample of the hydraulic oil The sampling valve is located on the left side of the machine behind the engine compartment Reference For more information re
5. e f the engine is not equipped with a drain valve remove oil drain plug 1 in order to allow the oil to drain into a suitable container 2 After the oil has drained the oil drain plug should be cleaned and installed If necessary replace the O ring seal on the drain plug Replace 1 Use a strap type wrench to remove the filter Inspect the filter Reference For more information refer to Operation and Maintenance Manual Oil Filter Inspect Illustration 158 g0 1003628 2 Filter Mounting Base 3 O ring Seal 2 Clean the sealing surface of Filter Mounting Base 2 Make sure that the used O ring seal has been completely removed 3 Apply a thin film of clean engine oil to O ring seal 3 of the new oil filter NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 4 Install the new oil filter by hand When O ring seal 3 contacts filter mounting base 2 tighten the filter by an additional 3 4 turn Fill AO die ERA ei a LI b i PY Ae Ol B i o o mms i HOKA Lf Tey ZZ 0 ORo Lo i ms ES PARU f RU S O e ms 901039557 Illustration 159 1 Remove the oil filler cap Fill the crankcase w
6. Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Illustration 136 901039025 SEBU7781 02 101 Maintenance Section Cooling System Water Temperature Regulator Replace 1 Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Reference Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant 2 Submit the sample for Level 2 analysis Reference For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age NOTICE Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a ther mostat installed If the thermostat is
7. Inspect Replace SMCS Code 6120 040 6120 510 Personal injury or death can result from falling bucket When working under or around the bucket or link age with the bucket raised proper support must be provided for the bucket and or the linkage Replace the wear plates before damage to the bottom of the bucket occurs 1 Raise the bucket and block up the bucket 2 Loosen bolts and remove wear plates 3 Install new wear plates Tighten the bolts to the specified torque Reference For more information refer to Specifications SENR3130 Torque Specifications 102003823 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Note Clean the filters more often in dusty conditions If there is a noticeable reduction in the airflow from the air vents check the filters 10 Illustration 129 g01036552 The external cab filter is located on the left side of the operator compartment under the steps SEBU7781 02 97 Maintenance Section Circuit Breakers Reset Illustration 130 g01036553 The internal cab filter is located near the left side of the operator seat 1 Remove the filter covers 2 Remove the filters Note Raise the operator seat in order to remove the internal cab filter 3 Clean the filters with compressed air You can also wash t
8. 9 Start the engine and run the engine for a few minutes 10 Maintain the hydraulic oil level between lines 2 and 3 on the sight gauge Add oil if necessary Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction hoses and hose clamps 11 Stop the engine 102006859 Hydraulic System Oil Level Check SMCS Code 5095 535 FLV 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 Check the hydraulic system oil level with the machine on a level surface El B S qn im e U Illustration 169 g01038375 1 Maximum 2 Normal 3 Minimum 116 Maintenance Section Hydraulic System Oil Sample Obtain SEBU7781 02
9. Alarm Test SMCS Code 7406 081 N e i J e E g01034357 Illustration 106 The backup alarm is located at the rear of the machine 1 Turn the engine start switch to ON 2 Apply the service brakes 3 Disengage the parking brake 4 Move the directional control to REVERSE The backup alarm should sound immediately The backup alarm should continue to sound until the directional control is moved to the NEUTRAL position or to the FORWARD position SEBU7781 02 89 Maintenance Section Battery Clean 101999170 Battery Clean SMCS Code 1401 070 7 20 o g01034366 Illustration 107 The batteries are located at the right rear side of the machine 1 Open the engine access door on the back side of the machine Use the prop rod to hold the engine access door open 2 Clean the battery surface with a clean cloth Keep the terminals clean and keep the terminals coated with petroleum jelly Install the post cover after you coat the post with petroleum jelly Make sure that the battery cables are installed securely 3 Remove the prop rod Close the engine access door 101586700 Battery Hold Down Tighten SMCS Code 7257 527 Tighten the hold downs for the battery in order to prevent the batteries from moving during machine operation 103747851 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 1 Turn the engine start swi
10. Analysis Illustration 135 901039025 Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer 1 Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system 2 Submit the sample for Level 1 analysis Reference For additional information about coolant analysis refer to Special Publication SEBUG250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102009631 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE
11. any metal section of the ROPS 102429589 Seat Belt Inspect SMCS Code 7327 040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 188 900932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension SEBU7781 02 123 Maintenance Section Seat Belt Replace 102429594 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation or within five years
12. cap 3 Inspect the sealing surface for damage Replace the fuel tank cap if necessary 4 Remove the strainer from the filler opening 5 Inspect the strainer for damage Replace the strainer if necessary 6 Use a clean nonflammable solvent to wash the strainer and the fuel tank cap T Install the strainer 8 Install the fuel tank cap 102006830 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Illustration 166 g01043163 The fuel tank is located on the left side of the machine 1 Slowly remove fuel tank cap 1 in order to relieve pressure 2 Loosen drain plug 2 Allow the water and sediment to drain into a suitable container Tighten drain plug 2 Reference Your machine may be equipped with an ecology drain For more information refer to Parts Manual SEBP3757 914G Wheel Loader or Parts Manual SEBP4016 IT14G Integrated Toolcarrier 3 Replace fuel tank cap 1 102006844 Fuses Replace SMCS Code 1417 510 NOTICE Replace the fuses with the same type and size only Otherwise electrical damage can result If itis necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer 114 Maintenance Section Hydraulic System Oil Change SEBU7781 02 1 2 3 14 5 6 7 8 9 10 11 1
13. installed wrong it will cause the engine to overheat Inspect gaskets before assembly and replace if worn or damaged Replace the water temperature regulator and the seals while the cooling system is completely drained or while the coolant is drained to a level that is below the regulator housing Reference For the correct procedure refer to Engine Supplement RENR7769 Disassembly and Assembly 3054C Tier Il Emissions 102005234 Differential and Final Drive Oil Change SMCS Code 3278 044 OC 4011 044 OC NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 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 Wipe the covers and surfaces around openings before you check the oil and before you add oil Illustration 137 900493398 Front Differential and Final Drive Drain Plug 900393958 Illustration 138 Rear Differential and Final Drive Drain Plug 102 Maintenance Section Differential and Final Drive Oil Level Check SEBU7781 02 1 Remove the drain
14. of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 elie RTE 4 901152685 Illustration 189 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 102005182 Service Brake Disc Wear Check SMCS Code 4255 535 Reference For information on checking the service brake discs refer to Systems Operation Testing and Adjusting RENR6495 914G Wheel Loader and IT14G Integrated Toolcarrier Braking System Service Brake Discs Check 102005450 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD 1 Wipe off the grease fittings before you apply any lubricant Illustration 190 900412742 2 Apply lubricant to grease fitting 1 for the head end of the steering cylinder There is a grease fitting on each side of the machine 3 Apply lubricant to remote grease fitting 2 for the rod end of the steering cylin
15. 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 Mixing ELC with other products will reduce the effec tiveness of the coolant This could result in damage to cooling system compo nents If Caterpillar products are not available and com mercial products must be used make sure they have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants and Caterpillar Extender Use Caterpillar Extended Life Coolant ELC when you add coolant to the cooling system Reference Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for all cooling system requirements 1 Stop the engine and allow the engine to cool 2 Open the engine access door on the back side of the machine Use the prop rod to hold the engine access door open Remove the cooling System pressure cap slowly in order to relieve the pressure 3 Use a Coolant Conditioner Test Kit in order to check the concentration of the coolant Note It may be necessary to drain some coolant from the radiator so that Caterpillar Extender can be added to the cooling system Note Discard drained fluids according to local regulations 4
16. 2 13 14 15 16 17 18 1e 20 21 22 FWD g01038179 Illustration 167 The fuse panel is located inside the cab on the side of the right console Fuses protect the electrical system from damage that is caused by overloaded circuits Replace the fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary 1 Lights Flood 15 Amp 2 Lighter 10 Amp 3 Wipers 10 Amp 4 Transmission 10 Amp 5 Steering 10 Amp 6 24 Volt to 12 Volt Converter 10 Amp 7 Starting Aid or Air Seat 15 Amp 8 Engine Speed 10 Amp 9 Indicator Gauge Group 10 Amp 10 Window Defroster Rear 15 Amp 11 Beacon or Seat Heater 10 Amp 12 Joystick 10 Amp 13 A C 25 Amp 14 Kickout or Ride Control 10 Amp 15 Blower Fan 15 Amp 16 Turn Signals 10 Amp 17 Stop Lights 10 Amp 18 Dome Light or Hour Meter 10 Amp 19 Spare 10 Amp 20 Horn 10 Amp 21 Key 10 Amp 22 Spare 10 Amp 102005832 Hydraulic System Oil Change SMCS Code 5095 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 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 bef
17. 3 070 KO Illustration 181 901037452 FWL1 Up and KZN1 Up g00387726 Illustration 183 SEBU7781 02 121 Maintenance Section Ride Control Accumulator Check Illustration 184 g00448380 1 Open the engine access door on the back side of the machine Use the prop rod to hold the engine access door open The radiator assembly is located on the left side of the engine compartment rex a v o Illustration 185 901043952 Rear View of the Machine 2 Unlatch two latches 1 for hydraulic oil cooler 2 Swing the hydraulic oil cooler away from radiator 3 in order to clean the radiator and the hydraulic oil cooler Illustration 186 g00101939 3 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator fins However the use of compressed air is preferred 4 Swing the hydraulic oil cooler back into the operating position and latch the two latches 5 Close the engine access door 102005499 Ride Control Accumulator Check SMCS Code 5077 535 R6 When the ride control accumulator is properly charged the fore and aft motion of the machine is reduced by the ride control accumulator Special tools and equipment are required in order to test the accumulator Reference For more information refer to Systems Operation Testing and Adjusting RENR6493 914G Wheel Loader and IT14G I
18. Add Caterpillar Extended Life Coolant ELC to the cooling system 5 Inspect the gasket of the cooling system pressure cap If the gasket is damaged replace the pressure cap 6 Install the cooling system pressure cap 7 Remove the prop rod Close the engine access door 102005165 Cooling System Coolant Level Check SMCS Code 1350 535 FLV 1 Open the engine access door on the back side of the machine Use the prop rod to hold the engine access door open meses el Illustration 134 901037092 2 Maintain the coolant level between the FULL mark and the ADD mark on the coolant overflow reservoir Note If you need to add coolant daily check the cooling system for leaks 3 Remove the prop rod Close the engine access door 100 Maintenance Section Cooling System Coolant Sample Level 1 Obtain SEBU7781 02 102009624 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2
19. Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Note Never replace one belt Always replace two belts if equipped Air Conditioner Belt Illustration 111 901037188 Inspect 1 Stop the engine 2 Inspect the condition of the air conditioner belt Check the tension of the belt If the air conditioner belt requires adjustment or replacement proceed to the Adjust procedure Adjust 1 Loosen mounting bolt 2 Loosen adjustment bolt 1 2 Insert a ratchet with a square drive into hole 3 Use the ratchet as a lever in order to rotate the compressor until the correct belt tension is achieved Note The tension of a belt with more than 30 minutes of operation at rated speed should be 445 44 N 100 x 10 Ib The tension of a belt with 30 minutes of operation or less at rated speed should be 578 111 N 130 x 25 Ib 3 Tighten adjustment bolt 1 Tighten mounting bolt 2 4 Recheck the belt tension If the tension is incorrect repeat the Adjust procedure SEBU7781 02 91 Maintenance Section Brake Accumulator Check Replace 1 Loosen mounting bolt 2 Loosen adjustment bolt 1 2 Insert a ratchet with a square drive into hole 3 Use the ratchet as a lever in order to rotate the compressor until the belt is loose 3 Remove the belt 4 Replace the belt with a new belt 5 Insert a ratchet with a square drive into hole 3 Use the ratchet as a
20. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR S ILL Operation and Maintenance Manual 914G Wheel Loader and IT14G Integrated Toolcarrier PDF1 Up 914G FWL1 Up IT14G KZN1 Up IT14G SAFETY CAT COM 86 Maintenance Section Maintenance Interval Schedule SEBU7781 02 103661280 Maintenance Interval Schedule SMCS Code 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced 10 hydraulic oil is used the hydraulic oil change interval is extended to 3000 hours S O S services may extend the oil change even lon
21. MCS Code 3253 086 SN Note Fully articulate the machine before lubricating the drive shaft spline dip Illustration 145 g01040464 1 Wipe off the grease fitting 2 Apply lubricant through the grease fitting on the drive shaft spline i02005692 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY 1 Open the access door for the air filter housing 104 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU7781 02 Illustration 146 g00102316 2 Remove cover 1 3 Remove primary filter element 2 4 Clean the inside of the air filter housing 5 Install a clean primary air filter element For more information refer to Cleaning the Primary Air Filter Element 6 Install cover 1 7 Reset the engine air filter service indicator Reference For more information refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect Replace 8 Close the access door Cleaning the Primary Air Filter Element NOTICE Caterpillar recommends certified air filter cleaning ser vices available at participating Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not was
22. OTICE The water separator is not a filter The water separa tor separates water from the fuel The engine should never be allowed to run with the water separator more than half full Engine damage may result 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 Open the engine access door on the back side of the machine Use the prop rod to hold the engine access door open The water separator element is located on the right side of engine compartment F3 NM ull MULT Illustration 163 901037713 2 Open drain valve 4 Allow the water and fuel to drain into a suitable container 3 Support the water separator element and rotate locking ring 1 counterclockwise Remove the locking ring 4 Remove the water separator element from the mounting base 5 Remove water separator bowl 3 from the filter element Cl
23. ay vary for different engine applications and or for different power ratings A qualified mechanic should adjust the fuel injection timing because special tools and training are required Refer to the Service Manual for the complete adjustment procedure for the fuel injection timing Refer to your Caterpillar dealer for the complete adjustment procedure for the fuel injection timing 102006070 Fuel System Filter and Water Separator Drain SMCS Code 1261 543 1263 543 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE The water separator is not a filter The water separa tor separates water from the fuel The engine should never be allowed to run with the water separator more than half full Engine damage may result 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 reg
24. c for the procedure S np SSD Illustration 122 4 Back of Pin Master 5 Extractor 7 C 0 900590670 a Place the Pin Master on the bucket tooth b Align extractor 5 with the pin c Strike the Pin Master at the back of the tool 4 and remove the pin SEBU7781 02 95 Maintenance Section Bucket Tips Inspect Replace Illustration 123 g00590819 6 Retainer 7 Retaining washer 8 Adapter 2 Clean the adapter and the pin 3 Fit retainer 6 into retaining washer 7 Install this assembly into the groove that is in the side of adapter 8 Illustration 124 g00101359 4 Install the new bucket tip onto the adapter Note The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration 5 Drive the pin through the bucket tip The pin can be installed by using one of the following methods e From the other side of the retainer drive the pin through the bucket tip the adapter and the retainer e Use a Pin Master Follow Step 5 a through Step 5 e for the procedure Note To correctly install the pin into the retainer the pin must be driven in from the right side of the tooth Improper installation of the pin can result in the loss of the bucket tip g00590666 Illustration 125 4 Back of Pin Master 9 Pin setter 10 Pin holder a Insert the pin through the bucket tooth b P
25. ce indicator that is faulty SEBU7781 02 107 Maintenance Section Engine Air Filter Service Indicator Inspect Replace i02005700 Engine Air Filter Service Indicator Inspect Replace SMCS Code 7452 040 7452 510 Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises Inspect Illustration 153 g00103777 The air filter service indicator is located near the air filter housing Observe the air filter service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone The red piston locks in the visible position Test 1 Check for ease of resetting The service indicator should reset in less than three pushes 2 Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is attained 3 If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset th
26. 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 176 900402638 The hydrostatic drive box is located on the underside of the machine 1 Operate the machine for a few minutes before obtaining the oil sample This will thoroughly mix the oil for a more accurate sample 900402618 Illustration 177 2 Use the fill port in order to obtain a sample of the hydrostatic drive oil Note Remove the oil level fill plug slowly in order to release pressure SEBU7781 02 119 Maintenance Section Oil Filter Inspect Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample 3 Clean the oil level fill plug and install the oil level fill plug 102106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 Inspect a Used Filter for Debris Illustration 178 900100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An exc
27. ct 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 Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain ands Illustration 157 1 Oil Drain Plug g01003623 1 After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine oil e If the engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to drain the oil After the oil has drained into a suitable container turn the drain valve knob clockwise in order to close the drain valve 110 Maintenance Section Engine Oil and Filter Change SEBU7781 02
28. der There is a grease fitting on each side of the machine 103589859 Steering Column Play Check SMCS Code 4310 535 4338 535 Illustration 191 901408466 1 Hold the steering wheel with both hands 2 Try to move the steering wheel from one side to the other side The maximum allowed movement in the steering column should not exceed 25 mm 1 0 inch If the value is not within the limit perform the following steps 124 Maintenance Section Steering Column Spline HMU Steering Lubricate SEBU7781 02 a Inspect the pivot joint for loose bolts b Tighten the bolts if the bolts are loose Note Apply 9S 3263 Thread Lock Compound to the bolts before tightening c Inspect the pivot joint for excessive wear d Replace the bushings if there is excessive wear Failure to perform this inspection and repair may cause loss of steering control which may result in personal injury or death Do not operate the machine until the inspection and repair are completed Contact your Caterpillar dealer for any other required service Steering Column Spline HMU Steering Lubricate SMCS Code 4310 086 JF 4310 086 SN 4338 086 SN 4343 086 SN 4343 086 JF Illustration 192 g01477014 The metering pump is located under the front of the cab Crushing Hazard Connect the steering frame lock between front and rear frames before servicing the machine in the articulation area Disconnect the steeri
29. ds 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 155 g01039231 1 Open the engine access door The engine oil dipstick 2 is located near the engine oil filter 2 Remove engine oil dipstick 2 and wipe the dipstick with a clean cloth Then insert the dipstick and remove the dipstick again This will ensure a more accurate measurement of the engine oil level 3 Maintain the oil level between the marks on the dipstick 4 If necessary remove oil filler plug 1 and add oil through the oil filler tube 5 Clean the oil filler plug and install the oil filler plug 6 Close the engine access door Engine Oil Sample Obtain SMCS Code 1348 008 7542 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 o
30. e air line for the service indicator may be plugged Replace Replace the service indicator if the following conditions exist e The machine is used in a severely dusty environment The engine is overhauled e Major components are replaced Replace the service indicator annually regardless of the operating conditions Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 102010496 Engine Air Precleaner Clean SMCS Code 1055 070 NOTICE Service the air cleaner only with the engine stopped Engine damage could result M UL KO Illustration 154 g01039697 1 Remove the precleaner 2 Inspect the air inlet screen for dirt and for trash Remove the screen Clean the screen if the screen is dirty 3 Inspect the precleaner tube openings Remove dirt and debris 4 Clean the precleaner with compressed air or wash the precleaner in warm water Dry all the parts 5 Install the precleaner screen 108 Maintenance Section Engine Oil Level Check SEBU7781 02 i02009900 Engine Oil Level Check SMCS Code 1000 535 FLV NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage NOTICE Care must be taken to ensure that flui
31. e nere i 100 Every 500 Service Hours Cooling System Coolant Sample Level 1 leor a E 100 Differential and Final Drive Oil Sample Obtain 103 Hydraulic System Oil Sample Obtain 116 Hydrostatic Drive Oil Sample Obtain 118 Every 500 Service Hours or 3 Months Engine Oil and Filter Change 109 Fuel System Filter and Water Separator Element Repl ce s eH v eo aa 112 Fuel Tank Cap and Strainer Clean 113 Every 1000 Service Hours Battery Hold Down Tighten sse 89 SEBU7781 02 87 Maintenance Section Maintenance Interval Schedule Every 1000 Service Hours or 6 Months Hydraulic System Oil Change 114 Power Train Oil Filter Replace 119 Rollover Protective Structure ROPS Inspect 122 Every 1000 Service Hours or 1 Year Engine Valve Lash Check ssssss 111 Every 2000 Service Hours or 1 Year Differential and Final Drive Oil Change 101 Engine Air Filter Service Indicator Inspect Replace ssssssssssssesee 107 Fuel Injection Timing Check 111 Hydrostatic Drive Oil Change 116 Service Brake Disc Wear Check 123 Every Year Cooling System Coolant Sample Level 2 Obtain ec ee eere i ans feuds on Re
32. ean the bowl and clean the O ring groove Note The bowl is reusable Do not discard the bowl 6 Inspect the O ring seal of the bowl for damage Replace the O ring seal if necessary 7 Lubricate the O ring seal with clean diesel fuel or lubricate the O ring seal with motor oil Place the O ring seal in the bowl 8 Spin the bowl by hand onto fuel system filter 2 until the bowl is snug Do not use tools to tighten the fuel system filter 9 Install the new water separator element Rotate the locking ring clockwise in order to fasten the water separator element to the mounting base Note The fuel system does not need to be primed manually The fuel system is primed automatically by an electric fuel priming pump Refer to the following step in order to activate the electric fuel priming pump SEBU7781 02 113 Maintenance Section Fuel Tank Cap and Strainer Clean Illustration 164 g00395819 10 Turn the key switch to the START 3 position and release the key switch This process will activate the relay for the fuel pump which allows power to reach the fuel priming pump 102006773 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR 1273 070 Z2 Illustration 165 901040225 1 Open the engine access door on the back side of the machine Use the prop rod to hold the engine access door open The fuel tank cap is located on the left side of the engine compartment 2 Remove the fuel tank
33. ese 100 Every 3000 Service Hours Steering Column Spline HMU Steering l bfiCate 2 3 ncc oir or ERR 124 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace sssssssssssssss 123 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 99 Cooling System Water Temperature Regulator Replace cnr rene ee dne eau 101 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 97 88 Maintenance Section Articulation Bearings Lubricate SEBU7781 02 102019196 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD m de 3 F g01043245 Illustration 103 1 Wipe off the grease fittings before you apply lubricant 2 Apply lubricant to the grease fittings for the pivot bearings 100802472 Axle Oscillation Bearings Lubricate SMCS Code 3268 086 BD 3278 086 BD Wipe the remote grease fittings before you apply lubricant to the remote grease fittings 900389098 Illustration 104 The remote grease fittings for the axle oscillation bearings are located in the center of the machine on the left side 900389099 Illustration 105 Apply lubricant to the remote grease fittings for the axle oscillation bearings 101999141 Backup
34. essive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 102006806 Power Train Oil Filter Replace SMCS Code 3004 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 product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Pub
35. f 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 Operate the machine for a few minutes before you obtain the fluid sample This will thoroughly mix the fluid for a more accurate sample SEBU7781 02 109 Maintenance Section Engine Oil and Filter Change Illustration 156 g01039493 Location of the Oil Sample Port Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample i02009652 Engine Oil and Filter Change SMCS Code 1318 510 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to colle
36. fer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample 102005329 Hydrostatic Drive Oil Change SMCS Code 4350 044 OC n 900475532 Illustration 171 Allow the machine to cool before you change the hydrostatic drive oil Oil could spray when you remove the plug The hydrostatic drive box is located on the underside of the machine SEBU7781 02 117 Maintenance Section Hydrostatic Drive Oil Level Check Illustration 172 g00433956 1 Remove oil level fill plug 1 slowly in order to release pressure Illustration 173 g00402578 2 Remove drain plug 2 and allow the oil to drain into a suitable container 3 Clean the drain plug and install the drain plug 4 Add oil until the oil is level with the bottom of the plug threads Reference For more information refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities 5 Clean the oil level fill plug and install the oil level fill plug i02005680 Hydrostatic Drive Oil Level Check SMCS Code 4350 535 OC 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 col
37. ger Consult your Caterpillar dealer for details When Required Battery or Battery Cable Inspect Replace 89 Bucket Cutting Edges Inspect Replace 92 Bucket Tips Inspect Replace 94 Bucket Wear Plates Inspect Replace 96 Circuit Breakers Reset ssssssssssss 97 Engine Air Filter Primary Element Clean Replace a ids ete ia eat n iem 103 Engine Air Filter Secondary Element Replace 106 Engine Air Precleaner Clean 107 Fuel Tank Water and Sediment Drain 113 Fuses Replace sss 113 Oil Filter Inspect eee eee ceeeeeeeeeeeeeectteeeeeeeees 119 Radiator Core Clean ce ecceeseeceeceeeeeeeneees 120 Ride Control Accumulator Check 121 Windows Clean sesssesseeeeeee 125 Windshield Washer Reservoir Fill 125 Windshield Wipers Inspect Replace 126 Every 10 Service Hours or Daily Backup Alarm Test ssessssssssssssss 88 Cab Air Filter Clean Replace 96 Cooling System Coolant Level Check 99 Engine Air Filter Service Indicator Inspect 106 Engine Air Filter Service Indicator Inspect Replace cccscceceeceeeeeeteeeeeteeeaeees 107 Engine Oil Level Check sssssss
38. h the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The primary air filter element can be used up to six times after the element is properly cleaned and inspected When the primary air filter element is cleaned check for rips or tears in the filter material The primary air filter element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings NOTICE Do not clean the air filter elements by bumping or tap ping This could damage the seals Do not use ele ments with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air filter element before cleaning Inspect the air filter element for damage to the seal the gaskets and the outer cover Discard any damaged air filter elements There are two common methods that are used to clean the primary air filter element e Pressurized air e Vacuum cleaning SEBU7781 02 105 Maintenance Section Engine Air Filter Primary Element Clean Replace
39. he filters with a solution of warm water and of a nonsudsing household detergent Note Do not wash the filters while the filters are installed on the machine Do not spray water into the cab air filter when you are washing the machine 4 Rinse the filters in clean water Air dry the filters thoroughly 5 Replace any filters that are worn or damaged 6 Install the filters and replace the covers Note Face the seal toward the parking brake lever when you install the internal cab filter 102003893 Circuit Breakers Reset SMCS Code 1420 529 Illustration 131 g01041385 The circuit breakers are located on the right side of the machine Alternator Circuit Breaker 1 60 Amp Depress the button in order to reset the circuit breaker If the circuit is functioning properly the button will remain depressed If the button will not remain depressed check the electrical circuit Main Circuit Breaker 2 60 Amp Depress the button in order to reset the circuit breaker If the circuit is functioning properly the button will remain depressed If the button will not remain depressed check the electrical circuit 102005104 Cooling System Coolant ELC Change SMCS Code 1395 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure If an Extended Life Coolant was previously used flush
40. ith new oil Reference For more information refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities 2 Clean the oil filler cap and install the oil filler cap 3 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 4 Stop the engine for a minimum of ten minutes E 3 Illustration 160 Y ADD mark X FULL mark X 900998024 SEBU7781 02 111 Maintenance Section Engine Valve Lash Check 5 Remove the engine oil dipstick in order to check the oil level Maintain the oil level between the ADD and FULL marks on the engine oil dipstick 103661727 Engine Valve Lash Check SMCS Code 1105 025 Reference For the complete procedure refer to Systems Operation RENR2410 Testing and Adjusting Engine Valve Lash Inspect Adjust A qualified mechanic should adjust the engine valve lash and the fuel injector timing because special tools and training are required Crankcase Breather Clean the engine crankcase breather on the valve cover before you install the valve cover 100916186 Fuel Injection Timing Check SMCS Code 1251 531 Note The correct fuel timing specification is found on the Engine Information Plate Fuel timing specifications m
41. lace the Pin Master over the bucket tooth and locate the pin in the hole of holder 10 c Strike the tool with a hammer at the back of the tool 4 in order to start the pin d Slide pin holder 10 away from the pin and rotate the tool slightly in order to align pin setter 9 with the pin e Strike the end of the tool until the pin is fully inserted 6 After you drive the pin make sure that the retainer fits snugly into the pin groove K Series Tip Removal Illustration 126 g01389463 Note Retainers are often damaged during the removal process Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced 96 Maintenance Section Bucket Wear Plates Inspect Replace SEBU7781 02 Illustration 127 g01175361 1 Use a pry bar in order to disengage retainer 5 2 Use the pry bar in order to remove retainer 5 from bucket tip 4 3 Remove bucket tip 4 from adapter 6 with a slight counterclockwise rotation 4 Clean adapter 6 Installation 1 Clean the adapter and the area around the latch if necessary 2 Install the new bucket tip onto the adapter with a slight clockwise rotation Illustration 128 g01124736 3 Install the retainer Make sure that the retainer s latch catches under the tip pocket 4 Make sure that the latch is properly seated by trying to remove the bucket tip 102003771 Bucket Wear Plates
42. 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 Illustration 174 900402638 The hydrostatic drive box is located on the underside of the machine 1 Allow the machine to cool before you check the hydrostatic drive oil level Oil could spray when you remove the plug 118 Maintenance Section Hydrostatic Drive Oil Sample Obtain SEBU7781 02 g00402618 Illustration 175 2 Remove the oil level fill plug slowly in order to release pressure The oil should be level with the bottom of the plug threads 3 Add oil if necessary Reference For more information refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities 4 Clean the oil level fill plug and install the oil level fill plug 102005818 Hydrostatic Drive Oil Sample Obtain SMCS Code 4350 008 7542 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
43. lever in order to rotate the compressor until the correct belt tension is achieved 6 Tighten adjustment bolt 1 Tighten mounting bolt 2 Alternator Belts Illustration 112 g01039887 Inspect 1 Inspect the condition of the alternator belt If the alternator belt requires adjustment or replacement proceed to the Adjust procedure Adjust 1 Loosen mounting bolts 1 Loosen adjustment bolt 2 2 Move the alternator until the correct belt tension is achieved Note The tension of a belt with more than 30 minutes of operation at rated speed should be 355 N 80 Ib 3 Tighten adjustment bolt 2 Tighten mounting bolts 1 4 Recheck the belt tension If the tension is incorrect repeat the Adjust procedure Replace 1 Loosen mounting bolts 1 Loosen adjustment bolt 2 2 Move the alternator until the belt is loose 3 Remove the old belt 4 Install a new belt 5 Move the alternator until the correct belt tension is achieved 6 Tighten adjustment bolt 2 Tighten mounting bolts 1 i01999668 Brake Accumulator Check SMCS Code 4263 535 1 Turn the engine start switch to the ON position The alert indicator for brake oil pressure should illuminate if the braking system is not at normal operating pressure 2 Start the engine Run the engine at half speed for two minutes in order to increase the accumulator pressu
44. lication 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 om on on zu T g01038158 Illustration 179 120 Maintenance Section Quick Coupler Lubricate SEBU7781 02 1 The power train oil filter is located on the left side of the machine behind the engine compartment 2 Remove the oil filter with a strap type wrench 3 Clean the filter mounting base Remove any part of the oil filter gasket that remains on the filter mounting base 4 Apply a light coat of oil to the gasket of the new oil filter 5 Install the new oil filter by hand When the gasket contacts the filter mounting base tighten the oil filter for an additional three quarters of a turn 102005661 Quick Coupler Lubricate SMCS Code 6129 086 Illustration 180 901037450 PDF1 Up A grease fitting is located on each side of the quick coupler Illustration 182 901037453 FWL1 Up and KZN1 Up 1 Wipe off all grease fittings before you apply lubricant 2 Apply lubricant through each fitting Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 102021513 Radiator Core Clean SMCS Code 135
45. new cutting edge if both edges are worn 7 Install the bolts Tighten the bolts to the specified torque 8 Raise the bucket Remove the blocks 9 Lower the bucket to the ground 10 After a few hours of operation check the bolts for proper torque 102001470 Bucket Linkage and Loader Cylinder Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD 914G Tilt Cylinder and Bucket Linkage 1 Wipe off the grease fittings before you apply lubricant g00414605 Illustration 114 2 Lubricate the grease fittings for the tilt cylinder 1 Lubricate the grease fittings for the tilt linkage 2 Lift Arm and Cylinder Linkage 1 Wipe off the grease fittings before you apply lubricant SEBU7781 02 93 Maintenance Section Bucket Pivot Bearings Lubricate Illustration 115 900403621 2 Apply lubricant to grease fittings 1 for the frame and for the lift arm of the machine There is a grease fitting for each side of the machine 3 Apply lubricant to grease fittings 2 for the head end of the lift cylinders of the machine There is a grease fitting for each side of the machine 900403638 Illustration 116 4 Apply lubricant to grease fittings 3 for the rod ends of the lift cylinders There is a grease fitting for each side of the machine IT14G Attachment Arm and Cylinder Linkage 1 Wipe off the grease fittings before you apply lubricant sm oni Ae g00474190
46. ng and for the correct operating pressures 2 Inflate the tires if necessary Reference For more information refer to Operation and Maintenance Manual Tire Inflation with Air 101921569 Windows Clean SMCS Code 7310 070 Use commercially available window cleaning solutions in order to clean the windows Clean the outside windows from the ground unless handholds are available Note Use a damp cloth to clean the windows Using a dry cloth will damage the surface of the window 102009134 Windshield Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solvent or equivalent System damage can result from freezing Illustration 195 900387726 1 Open the engine access door on the back side of the machine 900448380 Illustration 196 126 Maintenance Section Windshield Wipers Inspect Replace SEBU7781 02 2 Use the prop rod to hold the engine access door open g00394757 Illustration 197 The window washer reservoir is located on the left side of the machine 3 Fill the reservoir with window washer solvent 4 Close the engine access door 102005598 Windshield Wipers Inspect Replace SMCS Code 7305 040 7305 510 1 Inspect the condition of the wiper blades 2 Replace the wiper blades if the wiper blades are worn or damaged Replace the wiper blades if streaking occurs
47. ng frame lock and secure it in the stored po sition before resuming operation Failure to do so could result in serious injury or death When you check the compact wheel loaders perform the following step first e Remove the plastic cone shaped nose in order to reach the steering valve HMU steering Refer to Operation and Maintenance Manual Steering Frame Lock before entering the articulation joint Note Do not disconnect any hydraulic lines from the metering pump Use the following steps to lubricate the splines on the steering column Illustration 193 g01311462 1 Metering Pump 2 Hose Coupling 3 Bolts 1 Support the metering pump 1 Loosen the four bolts 3 that hold the pump Do not loosen the hose couplings 2 SEBU7781 02 125 Maintenance Section Tire Inflation Check Illustration 194 g01311464 4 Splines 2 Lower the pump in order to expose the splines 4 3 Clean the male splines on the steering column Clean the female splines in the pump 4 Apply proper grease to the splines Refer to Operation and Maintenance Manual Lubricant Viscosities for selecting the proper grease 5 Push the pump into position 6 Tighten the four bolts that hold the pump 7 Test the steering system 102005573 Tire Inflation Check SMCS Code 4203 535 Al 1 Measure the tire pressure on each tire Consult your Caterpillar dealer for the correct load rati
48. ntegrated Toolcarrier Hydraulic System Ride Control Accumulator Test and Charge 122 Maintenance Section Rollover Protective Structure ROPS Inspect SEBU7781 02 102005410 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 N Nc 901037257 Illustration 187 1 Remove the access covers from both sides of the ROPS 2 Inspect the ROPS for loose bolts or for damaged bolts Replace any damaged bolts or missing bolts with original equipment parts only Note Apply oil to all ROPS bolt threads before you install the bolts Failure to apply oil to the bolt threads can result in improper bolt torque Tighten the bolts that hold the platform to the frame to a torque of 530 70 N m 400 50 Ib ft Tighten the bolts that hold the ROPS to the platform to a torque of 460 60 N m 340 45 Ib ft Once you have torqued all the bolts torque the bolts again 3 Operate the machine on a rough surface Replace the ROPS mounting supports if the ROPS emits a noise Replace the ROPS mounting supports if the ROPS rattles 4 Install the access covers Do not straighten the ROPS Do not repair the ROPS by welding reinforcement plates to the ROPS Consult your Caterpillar dealer for repair of cracks in any welds in any castings or in
49. ore open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes in order to warm the hydraulic system oil 2 The machine should be level Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine SEBU7781 02 115 Maintenance Section Hydraulic System Oil Level Check 1 Zeon T o o Illustration 168 901038716 3 Hydraulic tank filler cap 1 is located on the right side of the machine 4 Remove hydraulic tank filler cap 1 5 Hydraulic tank drain valve 4 is located at the bottom of the hydraulic tank Remove the bottom guard in order to access the drain valve Open the drain valve and allow the hydraulic oil to drain into a suitable container 6 Close drain valve 4 7T Fill the hydraulic system oil tank Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities 8 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary Install the hydraulic tank filler cap
50. p the strap on the air filter housing so that the air filter housing can be moved for better access 3 Remove primary element 2 from the air filter housing Reference Refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace Z Illustration 151 g00882913 4 Clean the inside of the air filter housing Then remove the secondary element from the air filter housing 5 Inspect the gasket between the air inlet pipe and the air filter housing Replace the gasket if the gasket is damaged 6 Install a new secondary element Note A secondary element should never be cleaned Always install a new secondary element filter 7 Install a clean primary element 8 Install cover 1 9 Make sure that the air filter housing is secure 10 Close the engine hood i02005699 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 1 Start the engine 2 Run the engine at high idle 3 Open the left side engine compartment door Illustration 152 g00103777 4 If the yellow piston in the engine air filter service indicator enters the red zone service the air cleaner Reference For more information refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace 5 Stop the engine Note Refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect Replace in order to check an engine air filter servi
51. plugs for the front differential and for the rear differential Allow the oil to drain into a suitable container sy ey oe Illustration 139 g00475408 Dipstick Fill Plug for the Front Differential and Final Drive g00393646 Illustration 140 Dipstick Fill Plug for the Rear Differential and Final Drive 2 Remove the dipstick fill plug for the front differential and the dipstick fill plug for the rear differential 3 Clean the drain plugs and install the drain plugs 4 Add 0 47 L 0 50 qt of 1U 9891 Hydraulic Oil Additive 5 Fill the axles with oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities 6 Install the dipstick fill plugs for each differential Operate the machine for a few minutes and allow the oil to flow completely through the axles 7 Remove the dipstick fill plugs Maintain the oil between the ADD mark and the FULL mark on the dipstick fill plug of each differential 8 Clean the dipstick fill plugs and install the dipstick fill plugs for each differential Differential and Final Drive Oil Level Check SMCS Code 3278 535 FLV 4011 535 FLV Wipe the area around the dipstick fill plugs for the differential and final drives before you remove the plugs Illustration 141 900475408 Dipstick Fill Plug for the Front Differential and Final Drive 900393646 Illustration 142 Dipstick Fill Plug for
52. re The alert indicator for brake oil pressure should go off 3 Stop the engine Apply the service brake pedal and release the service brake pedal until the alert indicator for brake oil pressure comes on This will decrease the accumulator pressure A minimum of three applications of the service brake pedal are required 4 If the alert indicator illuminates before three applications of the brake pedal measure the accumulator precharge pressure Your authorized dealer can measure the nitrogen gas pressure in the accumulator Use only dry nitrogen gas for recharging 92 Maintenance Section Braking System Test SEBU7781 02 102010604 Braking System Test SMCS Code 4011 081 4267 081 Reference For the correct procedure refer to Systems Operation Testing and Adjusting RENR6495 Brake System 101920076 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges Raise the bucket Place a block under the bucket 2 Lower the bucket to the blocking Do not block up the bucket too high Block up the bucket so that the bucket is high enough to remove the cutting edges and the end bits 3 Remove the bolts Remove the cutting edge and the end bits 4 Clean the contact surfaces 5 Use the opposite side of the cutting edge if this side is not worn 6 Install a
53. s 108 Hydraulic System Oil Level Check 115 Seat Belt Inspect eessssssss 122 Tire Inflation Check sssssssssssss 125 Every 50 Service Hours or Weekly Bucket Linkage and Loader Cylinder Bearings Lubricate iie cette etie pee tdt 92 Bucket Pivot Bearings Lubricate 93 Fuel System Filter and Water Separator Drain 111 Quick Coupler Lubricate 120 Every 100 Service Hours or 2 Weeks Articulation Bearings Lubricate 88 Axle Oscillation Bearings Lubricate 88 Steering Cylinder Bearings Lubricate 123 Every 250 Service Hours Engine Oil Sample Obtain 108 Every 250 Service Hours or Monthly Battery Clean sse 89 Belts Inspect Adjust Replace 90 Brake Accumulator Check ssssssuse 91 Braking System Test ssssssesss 92 Differential and Final Drive Oil Level Check 102 Drive Shaft Spline Center Lubricate 103 Hydrostatic Drive Oil Level Check 117 Every 250 Service Hours or 3 Months Steering Column Play Check 123 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 ODI e nett
54. sary in order to confirm the result compare the primary air filter element to a new primary air filter element that has the same part number Do not use a primary air filter element that has any tears and or holes in the filter material Do not use a primary air filter element with damaged pleats gaskets or seals Discard damaged primary air filter elements Storing Primary Air Filter Elements If a primary air filter element that passes inspection will not be used the primary air filter element can be stored for future use Illustration 149 900281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air filter elements in Volatile Corrosion Inhibited VCI paper Place the primary air filter element into a box for storage For identification mark the outside of the box and mark the primary air filter element Include the following information Date of cleaning e Number of cleanings Store the box in a dry location 106 Maintenance Section Engine Air Filter Secondary Element Replace SEBU7781 02 101921521 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE 1 Open the engine hood The air filter is located on the left side of the machine Illustration 150 g00281967 2 Remove cover 1 from the air filter housing Note If necessary unclam
55. tch to the OFF position Turn all switches to the OFF position Illustration 108 900387726 2 Open the engine access door on the back of the machine Use the prop rod to hold the engine access door open 3 Turn the battery disconnect switch to the OFF position Remove the battery disconnect switch key Illustration 109 900389326 1 Off 2 ON 4 90 Maintenance Section Belts Inspect Adjust Replace SEBU7781 02 mc 900389632 Illustration 110 NOTICE Do not allow the disconnected battery cable to contact the disconnect switch 5 Disconnect the negative battery cable from the disconnect switch 6 Disconnect the negative battery cable at the battery 7 Disconnect the positive battery cable at the battery 8 Inspect the battery terminals for corrosion Inspect the battery cables for wear or damage 9 Make any necessary repairs If necessary replace the battery cables or the battery 10 Connect the positive battery cable at the battery 11 Connect the negative battery cable at the battery 12 Connect the battery cable at the battery disconnect switch 13 Install the key and turn the battery disconnect Switch ON Recycle the Battery Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility i01999569
56. the Rear Differential and Final Drive 1 Remove the dipstick fill plug for the front differential and final drive in order to check the oil level 2 The oil level should be between the ADD mark and the FULL mark on the dipstick fill plug Add oil if necessary 3 Clean the dipstick fill plug and install the dipstick fill plug for the front differential and final drive 4 Repeat step 1 to step 3 for the rear differential SEBU7781 02 103 Maintenance Section Differential and Final Drive Oil Sample Obtain 102005244 Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4011 008 4070 008 7542 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin 1 Operate the machine for a few minutes before you obtain the fluid sample This will thoroughly mix the fluid for a more accurate sample Illustration 143 900475408 Dipstick Fill Plug for the Front Differential and Final Drive 900393646 Illustration 144 Dipstick Fill Plug for the Rear Differential and Final Drive 2 Obtaining a sample will require a vacuum pump or an equivalent Withdraw the oil through the filler opening Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample 102012010 Drive Shaft Spline Center Lubricate S
57. the cooling system with clean water No other cleaning agents are required Use the following procedure to change the Extended Life Coolant 98 Maintenance Section Cooling System Coolant ELC Change SEBU7781 02 Illustration 132 g01037085 1 Slowly loosen cooling system pressure cap 1 in order to relieve system pressure Remove the cooling system pressure cap 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 2 Place drain hose 3 into a suitable container Open drain valve 2 on the bottom of the radiator Allow the coolant to drain into a suitable container 3 Flush the cooling system with clean water until the draining water is clean Close the drain valve NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial prod
58. ucts that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life 4 Add the Extended Life Coolant Reference For the refill capacity of the cooling system refer to Operation and Maintenance Manual Capacities Refill Reference For information about adding Extender to your cooling system refer to Special Publication SEBU6250 or consult your Caterpillar dealer 5 Start the engine Run the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes Illustration 133 g01037092 6 Maintain the coolant level between the FULL and ADD marks on the coolant overflow reservoir 7 Install the cooling system pressure cap Close the engine hood SEBU7781 02 99 Maintenance Section Cooling System Coolant Extender ELC Add 102005135 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL 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
59. ulations and mandates i EE i q Illustration 161 g01037688 Location of the Fuel System Filter 1 Open the engine access door Illustration 162 901037695 1 Cap 2 Drain Valve 2 Slowly open cap 1 112 Maintenance Section Fuel System Filter and Water Separator Element Replace SEBU7781 02 3 Attach a hose to the bottom of drain valve 2 Place the end of the hose in a suitable container 4 Open drain valve 2 on the bottom of the water separator bowl To open the drain valve turn the drain valve clockwise as you are looking at the top of the water separator 5 Allow the water and the fuel to drain into a suitable container 6 Close the drain valve Note The water separator is under suction during normal engine operation The drain valve must be tightened in order to prevent air leakage into the fuel system 7 Close cap 1 8 Close the engine access door 102064929 Fuel System Filter and Water Separator Element Replace SMCS Code 1261 510 1263 510 FQ Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately N
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