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MAINTENANCE INTERVALS - Safety

1. Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes before obtaining the oil sample This will thoroughly mix the differential oil for a more accurate sample 168 Maintenance Section Drive Shaft Spline Lubricate Illustration 164 g01264367 Front differential and final drive filler plug Illustration 165 g01264369 Rear differential and final drive filler plug 2 The differential and final drives are not equipped with sampling valves Obtaining an oil sample will require the use of a vacuum pump or equivalent in order to extract the oil from the component Extract the oil through the filler openings on the differential and final drives 3 Complete any additional required work Fill the differential and final drives with oil as required Install the dipstick fill plugs Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample SEBU8079 11 102926782 Drive Shaft Spline Lubricate SMCS Code 3253 086 SN Note For better access fully articulate the machine to the right or to the left Because the steering frame lock cannot be connected remove the engine start switch key and turn the batte
2. Block the bucket before changing bucket wear plates Illustration 126 g00879740 Inspect the wear plates Replace the wear plates before damage to the bottom of the bucket occurs Consult your Caterpillar dealer for replacement of wear plates 154 Maintenance Section SEBU8079 11 Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust Replace Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust Replace SMCS Code 6001 025 CLR 6001 040 CLR 6001 510 24 6119 025 CLR 6119 040 CLR 6119 510 24 Inspect the Linkage Illustration 127 g03003577 1 Lift Arm 2 Bucket 3 Inspection Points for the Bucket Hinge Periodically inspect the bucket linkage The gap between the bucket and the linkage should not exceed the thinnest shim that is available for the bucket assembly 1 Lower the lift arm assembly 1 to suitable blocking Rest the bucket 2 on the ground 2 Use a gauge to measure the gap at the hinge 3 If the measurement exceeds the required amount new shims must be installed Installing Shims for the Hinge on the Bucket Note Refer to the Disassembly and Assembly Manual Bucket Remove for the correct procedure for removing the pins in the linkage Illustration 128 g01345720 2 Bucket 4 Install washers on lift arm Install washers and pin assembly to the bucket When possible use washers on both sides of the lift arm to reduce the gap between the lift arm and the
3. Illustration 174 g01246185 1 Air Filter Service Indicator 2 Engine Oil Filler 3 Engine oil Dipstick 4 Fuel Filler 13 Reset the air filter service indicator 1 if necessary 14 Close the engine hood i01702009 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Service the air filter only with the engine stopped En gine damage could result NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Note Replace the secondary element when you service the primary element for the third time If a clean primary element has been installed and a warning for the air filter still occurs replace the secondary element Also if the exhaust smoke remains black and a clean primary element has been installed replace the secondary element 172 Maintenance Section Engine Air Filter Service Indicator Inspect 1 Remove the primary element Reference Refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace for the correct procedure 7 Illustration 175 g00845406 2 Remove the secondary element 3 Cover the air inlet opening Clean the inside of the air cleaner housing 4 Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged 5 Uncover the air inlet opening Install a new secondary element 6 Install
4. 1 Cover Latches for the Air Cleaner 2 Vacuator Valve 2 Empty the dirt from the vacuator valve 2 Loosen the cover latches 1 and remove the air cleaner cover Note The latches for the air cleaner housing may snap open when you release the latches SEBU8079 11 Illustration 171 g00101415 3 Remove the primary filter element from the air cleaner housing In order to remove the engine air filter primary element pull the element outward While you pull the element outward rock the element Use Steps 4 through 6 in order to clean the primary element 4 Inspect the primary element If the pleats the gaskets or the seals are damaged discard the element Replace a damaged primary element with a clean primary element Illustration 172 g00328468 5 If the primary element is not damaged clean the primary element Pressurized air can be used to clean a primary element that has not been cleaned more than two times Use filtered dry air at a maximum pressure of 207 kPa 30 psi Note Pressurized air will not remove deposits of carbon and oil 6 When you clean the primary element always begin in the inside of the element clean side This will force dirt particles toward the outside of the element dirty side SEBU8079 11 Direct the air along the length inside of the filter This will help prevent damage to the paper pleats Note Do not aim the stream of air directly at the primary element Di
5. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpil All Rights alana CATERPI LLAR CATERPILLAR ae LL Operation and Maintenance Manual 938H Wheel Loader and IT38H Integrated Toolcarrier JKM1 Up 938H LKM1 Up 938H MCC1 Up 938H MJC1 Up 938H JNJ1 Up IT38H SAFETY CAT COM SEBU8079 11 04876454 Maintenance Interval Schedule SMCS Code 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance All adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging are included Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals Note The aftertreatment system can be expected to function properly for the useful life of the engine emissions durability period as defined by regulation All prescribed maintenance requi
6. Program A Verification for an Oil Change Interval of 500 Hours This program consists of three oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine lf a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type in the Lubricant Viscosities for Ambient Temperatures Table in this Operation and Maintenance Manual Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each increment is an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above SEBU8079 11 References Reference Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations
7. SMCS Code 1071 070 Z3 1405 070 VN g01724456 Illustration 111 Air Inlet Screen 1 Inspect the air inlet screen for dirt and for trash 2 Remove the plug in the screen Loosen the hose clamp on the rain cap 3 Remove the rain cap Remove the screen 4 Use low pressure air in order to clean debris from the screen 5 Open the hood on the left side of the machine in order to access the alternator cover 143 Maintenance Section Alternator Air Vent Line and Screen Clean Illustration 112 g01733717 Alternator Cover 6 Remove the air supply line from the alternator cover Use low pressure compressed air in order to clean any debris from the air supply line and the alternator cover 7 Install the air supply line on the alternator cover 8 Install the screen and the rain cap 9 Install the plug in the screen NOTICE service the air screen only with the engine stopped Alternator damage could result if the screen is ser viced while the engine is running 144 Maintenance Section Articulation Bearings Lubricate 102594009 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD Ay WARNING Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Illustration 113 g01300288 Note On certain models th
8. ccccceceeeeeeeeeeeeeeees 199 Steering Column Play Check ccccceeceeees 203 Initial 500 Service Hours Engine Valve Lash Check cccccccceeeeeeeeeees 178 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 BaS re 1i A EEE E E E E AE E E T T 164 Every 500 Service Hours Cooling System Coolant Sample Level 1 ODIA caaan aaa a a aa 164 Differential and Final Drive Oil Sample Obtain 167 Hydraulic System Oil Sample Obtain 193 Open Crankcase Ventilation OCV Fumes Disposal Filter Replace eiteis Shs liesdd ccanteeetinnscieede dion vsene dence 195 Transmission Oil Sample Obtain 209 Every 500 Service Hours or 3 Months Engine Crankcase Breather Clean 173 Engine Oil and Filter Change cccee 176 Fuel System Primary Filter Water Separator Element Replace cccccecceecceeceeeeneeseeeeees 181 Fuel System Secondary Filter Replace 182 Fuel Tank Cap and Strainer Clean 183 Hydraulic System Biodegradable Oil Filter Element RODIACE inpo aa e Cian E dt uubuieties 188 Hydraulic System Oil Filter Replace 191 Transmission Oil Filter Replace 00 207 Every 1000 Service Hours or 6 Months Articulation Bearings Lubricate 00 144 Axle Oil Cooler Magnetic Fil
9. or ice Note For more information on WAVS refer to Operation and Maintenance Manual SEBU815 7 Work Area Vision System 160 Maintenance Section Circuit Breakers Reset 02884329 Circuit Breakers Reset SMCS Code 1420 529 Illustration 147 g01436009 Open the access door A on the left side of the machine Illustration 148 g01436010 in order to reset the circuit breaker The button will stay depressed if the circuit is working properly Check the appropriate electrical circuit if the button does not stay depressed GC Circuit Breaker Reset Push the button SEBU8079 11 102594018 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Ay WARNING Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Topping off or mixing Cat
10. Apply a light coat of clean transmission oil to the seal of the new filter element Install a new transmission oil filter hand tight until the seal of the transmission oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the transmission oil filter that are soaced 90 degrees or 1 4 or a turn away from each other When you tighten the transmission oil filter use the rotation index marks as a guide 4 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 5 Start the engine and apply the service brake Slowly operate the transmission controls in order to circulate the transmission oil 6 Move the transmission control to the NEUTRAL position and engage the parking brake Inspect the transmission oil filter for leaks 7 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure 03652442 Transmission Oil Level Check SMCS Code 3030 535 FLV Operate the
11. Bucket Upper Pivot Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD 1 Wipe off the fitting before you apply any lubricant x i gt gt gt i a ts i g00554978 Illustration 140 2 Apply lubricant through the fitting on the upper pivot bearing 158 Maintenance Section Bucket Wear Plates Inspect Replace 101709216 Bucket Wear Plates Inspect Replace SMCS Code 6120 040 6120 510 Ay WARNING Personal injury or death can result from the bucket falling Block the bucket before changing bucket wear plates Illustration 141 g00879740 Inspect the wear plates Replace the wear plates before damage to the bottom of the bucket occurs Consult your Caterpillar dealer for replacement of wear plates i02593767 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Note Clean the filter elements more often in dusty conditions If there is a noticeable reduction in the air flow from the air vents check the filter elements SEBU8079 11 aN SS 1 E AN ATE Illustration 142 g01300450 1 Remove the filter cover under the platform on the left side of the operator compartment Remove the filter elements Do not wash the filter elements while the filter elements are installed on the machine g01417275 Illustration 143 2 Raise the seat Remove the filter cover on the left side of the seat SEBU8079 11 Illust
12. g00101318 183 Maintenance Section Fuel Tank Cap and Strainer Clean Apply a thin coat of clean diesel fuel to the sealing surface of the new fuel filter element Install a new fuel filter hand tight until the seal of the fuel filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the fuel filter use the rotation index marks as a guide 6 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter Prime the fuel system Reference For more information refer to Operation and Maintenance Manual Fuel System Prime Close the engine hood 102837651 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 Z2 1273 070 STR Illustration 201 g01414869 184 Maintenance Section Fuel Tank Water and Sediment Drain A iN M i 1 i N Illustration 202 g01246185 1 Air Filter Service Indicator 2 Engine
13. hinges on the bucket Note Refer to the Disassembly and Assembly Manual Bucket Install for the correct procedure for installing the pins in the linkage 101940922 Bucket Linkage and Loader Cylinder Bearings Lubricate SMCS Code 5102 086 BD 5104 086 BD 6107 086 BD Wheel Loader Illustration 129 g00873076 SEBU8079 11 1 Wipe off the fittings before you apply lubricant 2 Apply lubricant to the grease fittings Integrated Toolcarrier Illustration 130 g00923459 1 Wipe off the fittings before you apply lubricant 2 Apply lubricant to the grease fittings i01889917 Bucket Lower Pivot Bearings Lubricate SMCS Code 6101 086 BD 6107 086 BD 1 Wipe off the fittings before you apply any lubricant z d Illustration 131 g00554957 2 Apply lubricant through the fitting on each lower pivot bearing 155 Maintenance Section Bucket Lower Pivot Bearings Lubricate 03657242 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Ay WARNING Personal injury or death can result from the bucket falling Block the bucket before changing bucket tips Bucket Tips g00101352 Illustration 132 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 fr
14. 1 Remove the system filter 2 Discard the filter elements 3 Install the new filter elements 4 Check the hydraulic oil level Refer to Operation and Maintenance Manual Hydraulic Syatem Oil Level Check for more details about the hydraulic oil level SEBU8079 11 102896159 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Check the hydraulic system oil level while the machine is on a level surface Illustration 215 g01245607 1 Hydraulic Oil Filler Cap 2 Hydraulic Sight Gauge The hydraulic oil tank and the filler cap 1 are located behind the cab on the engine compartment The sight gauge 2 is located on the left side of the hydraulic oil tank behind the cab 1 Maintain the hydraulic oil level above the ADD COLD mark on the sight gauge 2 Remove the hydraulic tank filler cap and add hydraulic oil if necessary SEBU8079 11 3 Cle
15. 4 eo 5 Coa 3 A Ta Uh pa i 2 BT aaa A h nied Be i y f Se F ns ie E wie F A bh Ns 2 ats WETA I Dh Von gt T ji E ey l k al i FEJA 4 ff AES fo Se J ei Se a hl te Illustration 191 g01453131 1 Stop the engine and open the engine hood The fuel priming pump is located above the primary fuel filter on the right side of the machine This machine is equipped with an electric fuel priming pump The toggle switch for the pump is located on the filter base Operate the fuel pump for approximately 60 seconds 2 Start the engine Note Additional priming may be needed if you are priming because of the following circumstances 180 Maintenance Section Fuel System Primary Filter Water Separator Drain e The engine will not start e The engine starts but the engine continues to misfire e The engine starts but the engine continues to emit smoke e The engine has run out of fuel e The fuel injectors have been removed from the engine Operate an electric fuel pump for approximately 30 seconds for this additional priming 102926798 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disas
16. Axle Oil Cooler Pump If Equipped Your machine is equipped with a single serpentine belt Stop the engine Open the rear hood The belt is located at the rear of the engine Inspect the condition of the serpentine belt Replace the belt if the belt is cracked or frayed 150 Maintenance Section Belt Inspect Adjust Replace Illustration 123 View C is basic View D is with air conditioner 1 Alternator 3 Idler pulley 5 Crankshaft 2 Tensioner 4 Air Conditioner Compressor If Equipped 6 Axle Oil Cooler Pump A tensioner keeps the correct tension on the belt Insert a ratchet with a square drive into the hole Rotate the tensioner clockwise in order to relieve tension on the belt Remove the belt Install the new belt Be sure that the new belt is routed correctly as shown View C represents machines that are not equipped with an air conditioner View D represents machines that are equipped with an air conditioner Rotate the tensioner clockwise in order to install the new belt Release the tensioner when the new belt is installed The correct tension will automatically be applied SEBU8079 11 g01448276 SEBU8079 11 102837923 Brake Accumulator Check SMCS Code 4263 535 Illustration 124 1 Left Turn Signal 7 Parking Brake 2 Primary Steering 8 Applied Ride Control If 3 Secondary Steering If Equipped 9 Action Lamp 4 Applied Transmission Neutralizer 10 Electrical 5 Transm
17. ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant shortens coolant ser vice life and may cause premature wear to compo nents Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life Reference For information about adding Extender to the cooling system refer to Operation and Maintenance Manual Cooling System Coolant Extender ELC Add or consult your Caterpillar dealer SEBU8079 11 Illustration 149 g01300560 The cooling system pressure cap is located under the engine hood at the rear of the machine 1 Open the engine hood Slowly loosen cooling system pressure cap in order to relieve any system pressure Remove the cooling system pressure cap CASN ONTAN C g01310342 Illustration 150 Coolant drain valve The side frame and the tire are not shown for clarity 2 The drain valve is located on the bottom of the transmission cooler on the left side of the machine Open the drain valve Allow the coolant to drain into a suitable container 161 Maintenance Section Cooling System Coolant Extender ELC Add 3 If an Extended Life Coolant ELC was previously used flush the cooling system with clean water and close
18. Insert the pin through the bucket tooth b Place the Pin Master over the bucket tooth and locate the pin in the hole of holder 10 SEBU8079 11 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 137 gy ieeeaes Note Retainers are often damaged during the removal process Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced Illustration 138 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 157 Maintenance Section Bucket Upper Pivot Bearings Lubricate 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 139 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 i01889915
19. Oil Filler 3 Engine oil Dipstick 4 Fuel Filler The fuel cap 4 is located at the rear of the machine on the right side 1 Open the engine access door on the right side of the engine Lift the lever and turn the lever counterclockwise until the lever stops Remove the cap 2 Remove the seal from the cap Inspect the seal for damage 3 Remove the strainer from the fuel tank 4 Wash the strainer and the fuel tank cap in a clean nonflammable solvent 5 Install the strainer into the filler opening 6 Replace the seal if necessary 7 Install the fuel tank cap Close the engine access door SEBU8079 11 102593877 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note If the water separator bowl is full on a daily basis drain the fuel tank on a daily basis Illustration 203 g01309452 Location of the fuel tank drain valve The right rear wheel has
20. Reference Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Reference Special Publication PEDP7035 Optimizing Oil Change Intervals Reference Special Publication PEDP7036 S O S Fluid Analysis Reference Special Publication PEDP7076 Understanding the S O S Oil Analysis Tests Procedure for Changing the Engine Oil and Filter NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies Suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Open the engine hood 177 Maintenance Section Engine Oil and Filter Change NN l a l j nie Illustration 186 g01308805 Oil drain on the left side 2 The crankcase drain valve is on the left side of the oil pan Open the crankcase drain valve Allow the oil to drain into a suitable container Close the drain valve Rae 5 a SEN r a E Illustration 187 g01453122 3 Remove the filter element with a strap type wrench Reference Refer to Operation and Mainten
21. a clean primary element and the cover for the air cleaner housing 7 Close the access door 102594033 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 NOTICE Service the air cleaner only with the engine stopped Engine damage could result SEBU8079 11 Illustration 176 g01300560 l mn i l i Yl i a N Illustration 177 g01246185 1 Air Filter Service Indicator 2 Engine Oil Filler 3 Engine oil Dipstick 4 Fuel Filler 1 Open the access door on the right side of the machine The air filter service indicator 1 is located in the engine compartment on the right side of the machine 2 If the yellow piston in the air filter service indicator enters the red zone service the air cleaner 3 Check the condition of the air filter service indicator If the air filter service indicator is damaged then replace the air filter service indicator SEBU8079 11 4 Close the access door 02594029 Engine Air Filter Service Indicator Inspect Replace SMCS Code 7452 040 7452 510 Illustration 178 g01300560 L i N l N Illustration 179 g01246185 1 Air Filter Service Indicator 2 Engine Oil Filler 3 Engine oil Dipstick 4 Fuel Filler To check the condition of the service indicator 1 try resetting the service indicator This should require less than three pushes of the reset button 173 Maintenance Se
22. machine for a few minutes in order to warm the transmission oil Park the machine on level ground SEBU8079 11 Illustration 253 g01959954 1 Filler Cap 2 Cold transmission oil level 3 Warm transmission oil level and the engine at low idle The sight gauge for the transmission oil level is located on the left side of the machine near the articulation joint Note Before the machine is started the transmission oil level should be above MIN START mark 2 on the upper end of the sight gauge 1 Operate the machine for a few minutes in order to warm the transmission oil 2 Park the machine on a hard level surface Put the transmission control into the NEUTRAL position Lower the bucket to the ground with a slight downward pressure Engage the parking brake 3 Check the oil level while the engine is running at low idle While the engine is running at low idle the transmission oil level should be between the MIN mark and the MAX mark 3 4 If necessary remove the filler cap and add oil SEBU8079 11 02845175 Transmission Oil Sample Obtain SMCS Code 3080 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special
23. 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 SEBU8079 11 195 Maintenance Section Open Crankcase Ventilation OCV Fumes Disposal Filter Replace 104796940 1 Remove the OCV filter Use a Cat strap wrench Open Crankcase Ventilation A ene nl OCV Fumes Disposal Filter 2 Replace the OCV filter Follow the installation instructions on the filter Replace If E ui ed 3 Check the condition of the hoses Make sure that IARE the inside of the hose is unobstructed Replace SMCS Code 1317 510 FI the hose if a hose is damaged 4 Close the access door and the hood Illustration 220 g01300560 Open the hood on the rear of machine in order to access the engine compartment The Open Crankcase Ventilation OCV is located on the right side of the engine Illustration 221 g02914977 196 Maintenance Section Pallet Fork Inspect 104004068 Pallet Fork Inspect SMCS Code 6136 0
24. oil cooler 2 away from the radiator 3 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator fins The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi However the use of compressed air is preferred Refer to Operation and Maintenance Manual General Hazard Information for Safety information about using pressurized air and water Swing the condenser and the cooler into position Open the engine hood g01447730 6 Open the access panels on both sides in order to clean the front face of the radiator ot io Wal a OPATAN A os WO NA CAAA J tara GREE rE A ABA AA CAGA a A i ZE aNG it Oe le og POLL IAG Z CACAGASL AA A VAA it dt GBEAE Oa a wn a C iaa 7 Za N POE OAA g00101939 SEBU8079 11 7 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 8 Close the access panels 9 Close the engine hood i01708690 Refrigerant Accumulator With Desiccant Replace SMCS Code 7322 510 DSS Reference For the correct procedure refer to Air Conditioning and Heating Service Manual SENR5664 or the Disassembly and Assembly Manual for your machine Note A qualified mechanic should replace the components of
25. retractable belts SEBU8079 11 04421974 Seat Belt Replace SMCS Code 7327 510 The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts Illustration 240 g01152685 Typical Example 1 Date of installation retractor 2 Date of installation buckle 3 Year of manufacture tag fully extended Web 4 Year of manufacture underside buckle Consult your Cat dealer for the replacement of the seat belt and the mounting hardware Determine age of new seat belt before installing on seat A manufacture label is on belt webbing and imprinted on belt buckle Do not exceed install by date on label Complete seat belt system should be installed with new mounting hardware Date of installation labels should be marked and affixed to the seat belt retractor and buckle Note Date of installation labels should be permanently marked by punch retractable belt or stamp non retractable belt lf your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension SEBU8079 11 103694709 Secondary Steering Test SMCS Code 4300 081 SE 4300 081 SST 4324 081 43
26. system filter 2 Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Replace 6 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 7 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary 8 Install the hydraulic tank filler cap 9 Start the engine and run the engine at low idle for ten to fifteen seconds 10 Shut off the engine 11 Refill the hydraulic tank to the full mark on the sight gauge 12 Restart the engine and run the engine at low idle Cycle all the implements until all the systems are refilled Note If the warning light for a low oil level comes on during the cycling stop the engine immediately and refill the hydraulic tank If the filling procedure is done correctly the warning light should never come on 13 After you have cycled the implements again stop the engine and refill the hydraulic tank to the full mark on the sight gauge Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check 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 14 If necessary tighten any loose clamps and any loose connections Replace any damaged hoses 15 Close the service center 191 Maint
27. the drain valve No other cleaning agents are required If you change from another type of coolant to an Extended Life Coolant close the drain valve Fill the cooling system with a solution that consists of water with a 6 to 10 percent concentration of Caterpillar cleaning agent Run the engine for 90 minutes Then drain the solution After you drain the solution thoroughly flush the cooling system with clean water All of the cleaning agent must be removed from the cooling system 4 Replace the water temperature regulator Reference Refer to Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the correct procedure 5 Add the Extended Life Coolant Reference Refer to Operation and Maintenance Manual Capacities Refill for the proper amount 6 Start the engine Run the engine without the cooling system pressure cap until the thermostat opens and the coolant level stabilizes 7 Stop the engine Maintain the coolant level in gauge on the coolant overflow reservoir 8 Inspect the cooling system pressure cap and the cap seal Clean the cooling system pressure cap with a clean cloth If necessary replace the cooling system pressure cap 9 Install the cooling system pressure cap Close the engine hood 102594021 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Ay WARNING Pressurized system Hot coolant can cause seri ous burn To open ca
28. the refrigerant system since special tooling and training are required 101699743 Ride Control Accumulator Check SMCS Code 5077 535 R6 The ride control accumulator reduces the pitching of the machine If the machine seems to be bouncing excessively check the charge in the ride control accumulator Note Special tools and equipment are required to test the accumulator Reference For more information refer to Testing and Adjusting RENR6078 938G Series II Wheel Loader and IT38 Integrated Toolcarrier Hydraulic System or consult your Caterpillar dealer 03657286 Roading Fender Hinges Lubricate If Equipped SMCS Code 7252 086 HNG Wipe off the fitting before any lubricant is applied 201 Maintenance Section Refrigerant Accumulator With Desiccant Replace Illustration 237 g01963400 Open the roading fender Apply lubricant through one fitting on the hinge There is one hinge on each side of the machine 101886437 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 1 Inspect the ROPS for bolts that are loose or damaged Use original equipment parts only to replace bolts that are damaged or missing Illustration 238 g00979102 2 Tighten the four cab mounting bolts to a torque of 850 100 N m 629 74 Ib ft Note Apply oil to all bolt threads before installation Failure to apply oil can result in improper bolt torque Do not repair the ROPS by wel
29. 24 Ay WARNING The service brake must be checked in order to en sure proper operation before you test the supple mental steering system Personal injury death or property damage could occur if the supplemental steering system is test ed and the service brake is not operational Test the service brake before you test the supple mental steering system Perform the following procedure if your machine is equipped with a ground driven supplemental steering and if the procedure is required by local regulations Ensure that there are no hazards in the test area The test area must be unobstructed and level Operate the machine in second gear Ensure that all air tanks and accumulators are properly charged Ensure that there is no load in the work tool Position the machine with the bucket or the work tool in the carry position with the machine in neutral Release the parking brake Apply the service brakes and put the engine at low idle Ensure that The area around the machine is clear of personnel Shift the transmission to second gear forward and slowly release the service brakes Moderately increase the engine speed to high idle Shift the transmission to neutral Turn the ignition to the OFF position Allow the machine to coast While the machine is in motion turn the machine to the left and to the right If the machine responds to the steering input the supplemental steering system is operating Stop the machine with the ser
30. 40 Descriptions of the Fork Tine Parts Illustration 222 1 Blade The horizontal part of the fork tine that supports the load 2 Heel The radius on the fork tine that connects the blade to the shank 3 Shank The vertical part of the fork tine that has the hooks that support the fork tines attached 4 Hook or Hanger Carriers that mount the fork tines to the carriage 5 Tip The free end of the blade Surfaces Illustration 223 6 Upper Face of the Blade The upper surface of the blade that carries the load SEBU8079 11 5 g01598401 9 11 11 9 g01598403 7 Bottom of Heel The lower surface of the blade that includes the tapers SEBU8079 11 197 Maintenance Section Pallet Fork Inspect 8 Front Face of Shank The distance for the load center is measured from the front face of the shank and the face of the shank contacts the load 9 Flanks The side faces of the blade and the shank 10 Blade Bevel The upper and lower surfaces of the tip on the blade that are tapered for easy insertion of the fork tines 11 Tip Flanks The side surfaces of the tip on the blade that are tapered for easy insertion of the fork tines 12 Top of Shank The upper surface on the shank 13 Shaft The tubes that are mounted on the fork tines for mounting the fork tines to the carriage Dimensions W E j Section A A Illus
31. Air Filter Secondary Element Replace 171 Ether Starting Aid Cylinder Replace 179 Fuel System Prime ccccccecceeeceeeeeeeeeeeeeeees 179 FUSES REDIACC inaron sieke na 185 High Intensity Discharge Lamp HID Replace 187 OIN FINersINSDCGCE os sicescci sect siawhacliieioeiddueeedscekin ues 194 Pallet Fork Inspect ccccscceeeceeeseeeeeeeeeeees 196 Radiator Core Clean cccccecccsseceeeceeeseeeeees 200 Ride Control Accumulator Check 00 201 Secondary Steering Test ccccceeceeeeeeeeeeeees 203 Window Washer Reservoir Fill 0 0008 210 Window Wiper Inspect Replace 00008 210 Every 10 Service Hours or Daily Backup Alarm Test ccccccseeseeeeeeeeeeneeeeeeeees 146 Cooling System Coolant Level Check 162 Engine Air Filter Service Indicator Inspect 172 Engine Oil Level Check cccccscceeeeeeeeees 174 Fuel System Primary Filter Water Separator EGAN aaan a ch eseabendaccys ote shan seach eeaseeeae tock 180 Hydraulic System Oil Level Check 192 Quick Coupler Check cccseccceeeeeeeeeeeeeeees 199 Seat Belt Inspect cece eccseeeceeeeeeeeeeeenaees 202 Transmission Oil Level Check c cccee 208 Windows Clean seinniceihaethelewssssmin Sihadautelidbetasreten 210 Every 50 Service Hours or Weekly Buck
32. Differential and Final Drive Filler Plug Note Wipe the covers and surfaces around openings before you remove the filler plug 7 Remove the filler plugs for both differentials Fill the differentials with oil Maintain the oil level at the bottom of the filler plug hole 8 Install the filler plugs for each differential Operate the machine for a few minutes and allow the oil to flow completely through the axles Remove the filler plugs and check the oil level Add oil if necessary Reference Refer to Operation and Maintenance Manual Lubricant Viscosities for the proper oil Reference Refer to Operation and Maintenance Manual Capacities Refill for the amount of oil 9 Clean the filler plugs and install the filler plugs 102910320 Axle Oscillation Bearings Lubricate SMCS Code 3268 086 BD 3278 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death SEBU8079 11 Oo O 0 UG j Illustration 119 g01448235 Wipe off the fittings before you apply any lubricant Apply lubricant through two remote fittings near the articulation hitch on the right side of the machine i01698523 Backup Alarm Test SMCS Code 7406 081 Turn the engine start switch key to ON in order to perform the test Apply the serv
33. Forward Horn Axle Oil Cooler Shifter Brake Pedal Sensor and Articulation Angle Sensor 23 Hazard Flashers 24 Hazard Flashers 25 Beacon and Heated Mirrors 26 Secondary Steering and Autolube 27 Breaker for the HVAC Blower Replace the fuse if the element separates Use a fuse of the same size If the element of a new fuse separates check the circuit Repair the circuit if necessary g01414515 28 Implement Lockout and Quick Coupler 29 MSS and Product Link 30 Messenger 31 Radio 32 Reversing Fan 33 Spare 34 Payload Control System 35 Window Wipers 36 Spare 37 Backlight Diode 37 Right Hand Turn Signal 38 ECM 39 Seat 40 Spare SEBU8079 11 102245859 High Intensity Discharge Lamp HID Replace If Equipped SMCS Code 1434 510 Ay WARNING HID lamps operate at very high voltages To avoid electrical shock and personal injury disconnect power before servicing HID lamps HID bulbs become very hot during operation Before servicing remove power from lamp for at least five minutes to ensure lamp Is cool NOTICE Although HID bulb materials may change over time HID bulbs produced at the time of the printing of this manual contain mercury When disposing of this com ponent or any waste that contains mercury please use caution and comply with any applicable laws h Remove the electrical power from the high intensity discharge lamp HID The elect
34. HP6001 How To Take A Good Oil Sample 103650025 Engine Oil and Filter Change SMCS Code 1318 510 Selection of the Oil Change Interval NOTICE A 500 hour engine oil change interval is available pro vided that the operating conditions and recommend ed multigrade oil types are met When these require ments are not met shorten the oil change interval to 250 hours or use an S O S Services oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine The normal engine oil change interval is listed in this Operation and Maintenance Manual Maintenance Interval Schedule SEBU8079 11 Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals Also refer to Special Publication SEBU5898 Cold Weather Recommendations for All Caterpillar Machines Poor maintenance of air filters or of fuel filters requires reduced oil change intervals Consult your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Cat oil filters are recommended
35. Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes before obtaining the oil sample This will thoroughly mix the transmission oil for a more accurate sample Illustration 254 g01245845 209 Maintenance Section Transmission Oil Sample Obtain Ae ee aaa L a meen Mi cee ee ad an Sy ee el WT i ene fa ee IR 4 T T T R DA CE ee Illustration 255 ane eho 1 Hydraulic Case Drain Filter 2 Hydraulic System Filter 3 Transmission Oil Filter 4 Brake Accumulator 5 5 Hydraulic Oil Tank Drain Illustration 256 g01246739 The sampling valve is located on the top of the transmission oil filter in the hydraulic service center on the right side of the machine 2 Use the sampling valve in order to obtain a sample of transmission oil 210 Maintenance Section Window Washer Reservoir Fill Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PEHP6001 How To Take A Good Oil Sample 02594042 Window Washer Reservoir Fill SMCS Code 306 544 NOTICE When operating in freezing temperatures use Caterpillar nonfreezing windo
36. an the hydraulic tank filler cap Install the hydraulic tank filler cap 102492082 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes before obtaining the oil sample Operate the hydraulic controls This will thoroughly mix the hydraulic oil for a more accurate sample Illustration 216 g01245845 2 Open the door for the hydraulic service center on the right side of the machine The sampling valve is located on the base of the hydraulic system filter 193 Maintenance Section Hydraulic System Oil Sample Obtain 4 cae Uaa fea A a e Er ee i IE r ll A man e a AR i Illustration 217 g01246554 3 Use the sampling valve in order to obtain a sample of hydraulic oil 4 Close the door for the hydraulic service center 02615782 Hydraulic Tank Breaker Relief Valve Clean SMCS Code 5118 070 Th
37. ance Manual Oil Filter Inspect for information about inspecting used filter elements for metal and for other debris 4 Clean the filter housing base Make sure that the used filter gasket is completely removed 178 Maintenance Section Engine Valve Lash Check Illustration 188 g00101318 5 Apply a thin coat of clean engine oil to the seal on the new filter Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 or a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 6 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter SEBU8079 11 liy N Illustration 189 g01246185 1 Air Filter Service Indicator 2 Engine Oil Filler 3 Engine oil Dipstick 4 Fuel Filler Note The oil filler cap 2 and the dipstick 3 are on the right s
38. ank If the difference in measurements is less than 10 the fork tine can remain in service If the difference in measurements is greater than 10 the fork tine must be taken out of service Fork tine wear that is greater than 10 represents a 20 reduction in the capacity of the fork tine Consult your Cat dealer for additional information Angle of the Heel Illustration 227 1 g01600075 Place a measuring device in the top inside area of the heel on top of the blade Ensure that the measuring device is held flat against the blade in order to acquire an accurate measurement SEBU8079 11 Illustration 228 2 g01600076 Move the upper arm of the measuring device toward the face of the shank Ensure that the measuring device is held flat against the face of the shank in order to acquire an accurate measurement Check the angle that was measured with the device for the angle of the heel If the angle is between 87 degrees and 93 degrees the fork tine can remain in service If the angle is less than 87 degrees or greater than 93 degrees the fork tine must be taken out of service The fork tines must be inspected for the following conditions e permanent deformation e stress cracks e other defects Consult your Cat dealer for additional information SEBU8079 11 199 Maintenance Section Pallet Fork Lubricate 03082842 101362822 Pallet Fork Lubricate Quick Coupler Ch
39. ay 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 02837728 Steering Column Spline HMU Steering Lubricate SMCS Code 4310 086 SN 4343 086 SN Illustration 242 g01414912 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 steering frame lock and secure it in the stored po sition before resuming operation Failure to do so could result in serious injury or death Refer to Operation and Maintenance Manual Steering Frame Lock before entering the articulation joint Note Do not disconnect any hydraulic lines from the metering pump Use the following steps to lubricate the splines on the steering column SEBU8079 11 Illustration 243 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 PNN g01311464 Illustration 244 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 s
40. battery disconnect switch ON SEBU8079 11 Recycle the Battery Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 102910353 Belt Inspect Adjust Replace SMCS Code 1397 025 1397 040 1397 510 Your machine is equipped with a single serpentine belt Stop the engine Open the rear hood The belt is located at the rear of the engine Inspect the condition of the serpentine belt Replace the belt if the belt is cracked or frayed SEBU8079 11 149 Maintenance Section Belt Inspect Adjust Replace Illustration 122 g01448273 View A is basic View B is with air conditioner 1 Alternator 3 Idler pulley 5 Crankshaft 2 Tensioner 4 Air Conditioner Compressor If Equipped A tensioner keeps the correct tension on the belt Insert a ratchet with a square drive into the hole Rotate the tensioner clockwise in order to relieve tension on the belt Remove the belt Install the new belt Be sure that the new belt is routed correctly as shown View A represents machines that are not equipped with an air conditioner View B represents machines that are equipped with an air conditioner Rotate the tensioner clockwise in order to install the new belt Release the tensioner when the new belt is installed The correct tension will automatically be applied Belt for the
41. been removed for clarity The fuel tank drain valve is located under the rear of the machine on the right side Slowly remove the fuel tank cap in order to relieve pressure Remove the cover plate SEBU8079 11 185 Maintenance Section Fuses Replace Illustration 204 g01309448 Open the fuel tank drain valve Allow the water and sediment to drain into a suitable container Close the fuel tank drain valve Install the cover plate 102833606 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 Fuses protect the electrical system from damage that is caused by overloaded circuits Illustration 205 g01414881 Open the cab door on the right side of the machine in order to access the fuse panel 186 Maintenance Section Fuses Replace SEBU8079 11 Illustration 206 Backlight Diode Transmission ECM Converter Circuit STD Unused Left Hand Tail Light Forward Horn Unused Hood Actuator Right Hand Tail Light 0 Spare 1 Spare 2 Front Lights 3 Running Lamps 4 2 3 4 5 6 T 8 9 1 1 1 1 14 AUTOLUBE 1 Tilt Hood Actuator Switch Ignition Switch Engine ECM Rear Lights Stop Lights and Start Relay
42. collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes This will allow all of the oil to reach a common level 2 Park the machine on level ground Lower the attachment and apply slight downward pressure Engage the parking brake Stop the machine Illustration 162 g01264367 Front differential and final drive filler plug 167 Maintenance Section Differential and Final Drive Oil Level Check Illustration 163 g01264369 Rear differential and final drive filler plug 3 Remove the filler plug for the differential Maintain the oil level at the bottom of the filler plug hole Add oil if necessary 4 Install the filler plug 102527335 Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4011 008 4070 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500
43. ction Engine Air Filter Service Indicator Inspect Replace Next check the movement of the yellow piston in the service indicator Start the engine and accelerate the engine to high idle for a few seconds After the governor control pedal is released the yellow piston should remain at the highest position that was achieved during acceleration If either of these conditions are not met replace the service indicator 104796938 Engine Crankcase Breather Clean If Equipped SMCS Code 1317 070 Illustration 180 g01300560 Open the engine hood The crankcase breather is located on the top of the engine Note If the engine is equipped with a fumes disposal filter refer to Operation and Maintenance Manual Open Crankcase Ventilation OCV Fumes Disposal Filter Replace for details about replacing the filter 174 Maintenance Section Engine Oil Level Check g01453119 Illustration 181 1 Remove the heat shield from the top of the engine 2 Loosen the breather outlet hose clamp Remove the breather hose from the breather cover 3 Remove the breather element cover assembly 4 Check the condition of the cover seal If the used seal is damaged replace the seal with a new seal 5 Wash the element and the cover assembly in clean nonflammable solvent 6 To dry the element shake the element or use air pressure 7 Inspect the breather hose for damage Replace the breather hose if necessar
44. d on the right side of the engine below the ECM module 2 Loosen retaining clamp 1 and unscrew ether starting aid cylinder 2 3 Remove the gasket Install the new gasket that is provided with each new ether starting aid cylinder 4 Install new ether starting aid cylinder 2 hand tight Tighten retaining clamp 1 securely 5 Close the engine hood 179 Maintenance Section Ether Starting Aid Cylinder Replace 103900803 Fuel System Prime SMCS Code 1250 548 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note The volume of air in the water separator is small Usually it is not necessary to prime the fuel system if only the water separator element has been changed i 1 s pei b _ _ f a a T OF n l ui C F E Ai ee fi t ri a oat i rel 4 ae r a h a r fA e i tet A I re oes ER aba ont an m i ff z a p edl T 4 sy Ja e Hl as o n roa L 5 a EA Ad A piy A at l
45. ding reinforcement plates to the ROPS Consult your Caterpillar dealer for repair of cracks in any welds in any castings or in any metal section of the ROPS 202 Maintenance Section Seat Belt Inspect 04423622 Seat Belt Inspect SMCS Code 7327 040 Always inspect the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 239 g02620101 Typical example Inspect buckle 1 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect seat belt 2 for webbing that is worn or frayed Replace the seat belt if the webbing is worn or frayed Inspect all seat belt mounting hardware for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension Contact your Cat dealer for the replacement of the seat belt and the mounting hardware Note The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non
46. e If a different brand of grease is used check for combatability If the new grease is not combatable with the grease in the reservoir the system must be purged Refer to System Operation RENR 6331 for more information about purging the system 5 Remove the filler assembly and install the dust cap 2 02593765 Axle Oil Cooler Magnetic Filter Clean Replace SMCS Code 3004 070 MGS 3004 510 MGS The magnetic filters are located on the right side of the machine Illustration 115 g01384680 1 Front Magnetic Oil Filter 2 Rear Magnetic Oil Filter 145 Maintenance Section Axle Oil Cooler Magnetic Filter Clean Replace Illustration 116 g01448141 Magnetic Oil Filter 1 Remove the two magnetic filters from the axle oil cooler lines 2 Wash the filters in a clean nonflammable solvent Inspect the filters for damage Replace the filters if the filters are damaged Note If the oil samples for the differential oil show a particle count that is higher than normal clean the filters for the axle oil cooler at an earlier interval 3 Install the two filters for the axle oil cooler 4 Close the engine hood 5 Start the engine Operate the machine in order to circulate the oil 6 Stop the engine Tamy pl g E Illustration 117 g01264367 Front Differential and Final Drive Filler Plug 146 Maintenance Section Axle Oscillation Bearings Lubricate Illustration 118 g01264369 Rear
47. e fittings will be accessible from the left side of the machine Wipe off the fittings before any lubricant is applied Apply lubricant through fittings on the articulation hitches SEBU8079 11 04155776 Automatic Lubrication Grease Tank Fill Autolube If Equipped SMCS Code 7540 544 TNK The Automatic TWIN Greasing System Reference Refer to System Operation RENR 6331 for more information on the Automatic TWIN Greasing System A pressure hazard is present Severe personal in jury or death can result from removing hoses or fittings that are under pressure Relieve the pres sure in the system before you remove hoses or fittings Illustration 114 g01068678 1 Reservoir 2 Dust Cap 3 Fill Location Grease reservoir 1 is located near the rear fender on the right side of the machine Filling the Reservoir 1 Remove the dust cap 2 from the grease reservoir 1 2 Clean the filler tube assembly 3 and the coupling on the filler assembly Clean the filter located behind the coupling Refer to Operation and Maintenance Manual Automatic Lubrication Filler Filter Clean 3 Install the filler assembly onto the filler tube assembly 3 SEBU8079 11 4 Fill the grease reservoir 1 with grease to the maximum level which is indicated on the grease reservoir 1 Reference For the correct type of grease refer to Operation and Maintenance Manual Lubricant Viscosities Not
48. e hydraulic tank breaker relief valve is located on the hydraulic tank The hydraulic tank is located behind the cab Use the steps and the handholds in order to reach the hydraulic tank breaker relief valve The steps and handholds are located on the left side of the machine 194 Maintenance Section Oil Filter Inspect g01309730 Illustration 218 1 Hydraulic tank cap 2 Hydraulic tank breaker relief valve 1 Relieve the pressure in the hydraulic tank by pressing the button on the top of the hydraulic breaker Remove the hydraulic tank breaker relief valve 2 Clean the hydraulic tank breaker relief valve in a clean nonflammable solvent Shake dry or use pressure air 3 Install the hydraulic tank breaker relief valve SEBU8079 11 02106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 9068 507 Inspect a Used Filter for Debris Illustration 219 g00100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure lf metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as
49. e 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 in order to warm the hydraulic system oil Park the machine on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine The hydraulic tank filler cap is located behind the cab on the top of the engine compartment Use the steps and the handholds in order to reach the hydraulic tank filler cap The steps and handholds are located on both sides of the machine 1 Remove the hydraulic tank filler cap 2 The hydraulic tank drain valve is located on the right side of the machine in the hydraulic service center SEBU8079 11 Illustration 211 g01245845 E am or a _ e a ON je a lf l R Re 4 i Illustration 212 PARS 1 Hydraulic Case Drain Filter 2 Hydraulic System Filter 3 Transmission Oil Filter 4 Brake Accumulator 5 Hydraulic Oil Tank Drain 3 Open the drain valve 5 and allow the hydraulic oil to drain into a suitable container SEBU8079 11 NOTICE Never start the engine while the hydraulic oil tank is being drained or while the hydraulic oil tank is empty Excessive wear and damage to the hydraulic compo nents can occur 4 Close the drain valve 5 Replace the case drain filter 1 Replace the hydraulic
50. eck SMCS Code 6136 086 SMCS Code 6129 535 Illustration 231 g00718871 When you install a work tool on the quick coupler inspect the engagement of the coupler pins If there is play between the coupler pins and the corresponding bores inspect the coupler pins and the bores for 01563105 damage or wear Illustration 229 typical example 1 Coat the shafts with grease g00718876 Illustration 232 If there is play between the quick coupler and the hooks of the work tool inspect the quick coupler and the hooks for wear or for damage Make any necessary repairs before you operate the work tool Illustration 230 g01563115 typical example 2 Coat the mounting holes for the quick coupler with grease Reference Refer to Operation and Maintenance Manual SEBU6250 Caterpillar Machine Lubricant Recommendations for information on lubricants 200 Maintenance Section Quick Coupler Lubricate Quick Coupler Lubricate SMCS Code 6129 086 Illustration 233 Wipe off the coupler pins Coat the coupler pins with new grease Radiator Core Clean SMCS Code 1353 070 KO Ensure that the engine is off before you perform this procedure 1 Open the radiator grill Illustration 234 1 Air Conditioner Condenser 2 Hydraulic Oil Cooler 3 Radiator Core Illustration 235 Illustration 236 SEBU8079 11 Open the latch and swing the air conditioner condenser 1 and hydraulic
51. ed for clarity 1 Front Magnetic Oil Filter 2 Rear Magnetic Oil Filter Illustration 159 g01448141 3 Remove the magnetic plug on the front filter Clean the magnetic plug with a clean nonflammable solvent Install the magnetic plug Repeat the process for the rear magnetic filter Illustration 160 g01264367 Front differential and final drive filler plug Illustration 161 g01264369 Rear differential and final drive filler plug Note Wipe the covers and surfaces around openings before you remove the filler plug 4 Remove the filler plugs for both differentials Fill the differentials with oil Maintain the oil level at the bottom of the filler plug hole SEBU8079 11 Reference Refer to Operation and Maintenance Manual Lubricant Viscosities for the proper oil Reference Refer to Operation and Maintenance Manual Capacities Refill for the amount of oil 5 Install the filler plugs for each differential Operate the machine for a few minutes and allow the oil to flow completely through the axles Remove the filler plugs and check the oil level Add oil if necessary 6 Clean the filler plugs and install the filler plugs 102527321 Differential and Final Drive Oil Level Check SMCS Code 3278 535 FLV 4011 535 FLV NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to
52. ed to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill the fuel filters with fuel before installing the fuel filters The fuel will not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts Illustration 198 g01300434 Open the engine hood The secondary fuel filter is located on the right side of the machine SEBU8079 11 Illustration 199 1 Illustration 200 x N g01453467 Place a suitable container under the drain valves Open a drain valve Drain the fuel into a suitable container When the fuel stops draining keep the drain valve open As the filter is loosened additional fuel may drain from the drain valve When the fuel stops draining loosen the filter for an additional 1 4 turn Close the drain valves Properly dispose of the fuel Remove the filter Inspect the fuel filter element for debris by cutting the filter open Discard the used fuel filter element properly Clean the mounting base of the fuel filter Make sure that all of the old seal is removed from the mounting base of the fuel filter
53. electing the proper grease SEBU8079 11 5 Push the pump into position 6 Tighten the four bolts that hold the pump 7 Test the steering system 102926801 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD Crushing Hazard Insure that the machine ignition switch is in the OFF position and that the parking brake is engaged before entering the articulation area Failure to do so could result in serious injury or death Wipe off the fittings before you apply any lubricant Illustration 245 g01453090 1 Rear Trunnion 2 Front Trunnion 3 Tilt Cylinder 4 Head End of the Left Steering Cylinder 5 Head End of the Right Steering Cylinder 6 Rod End of Steering Cylinder Apply lubricant through the remote fittings for the head end of the steering cylinders The remote fittings are located in the articulation joint on the right side of the machine Apply lubricant through one fitting on the rod end 6 of each steering cylinder 205 Maintenance Section Steering Cylinder Bearings Lubricate 02305841 Tire Inflation Check SMCS Code 4203 535 Al N N Illustration 246 g01160201 Always obtain proper tire inflation pressures and maintenance recommendations for the tires on your machine from your tire supplier Measure the tire pressure on each tire Inflate the tires with nitrogen if necessary Reference Refer to the Tire Inflation Information section of the Operatio
54. em Coolant Sample Level 1 Obtain i02908607 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 Analysis ue iB lt JHON mG yy 2 AE Illustration 154 g01447361 Coolant Sample Port Above Alternator Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags SEBU8079 11 e Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location e Keep the lids on empty sampling bottles u
55. enance Section Hydraulic System Oil Filter Replace 02845357 Hydraulic System Oil Filter Replace SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 213 g01245845 1 Remove hydraulic tank filler cap that is located behind the cab on the top of the engine compartment Use the steps and handholds that are located on the right side of the machine in order to reach the hydraulic tank filler cap All hydraulic filters are located in the hydraulic service center on the right side of the machine behind the ladder 192 Maintenance Section Hydraulic System Oil Level Check Le e a y og oe ahd a Py em ll QT Tee Rey 4 ee E f SL A A 0 Tm E T TT I DA W Illustration 214 g01418755 1 Hydraulic Case Drain Filter 2 Hydraulic System Filter 3 Transmission Oil Filter 4 Brake Accumulator 5 Hydraulic Oil Tank Drain 2 Remove the case drain filter
56. ers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them The fuel will not be filtered and could be contaminated Contaminated fuel will cause accelerated wear to fuel system parts The fuel system should be primed prior to starting the engine Illustration 195 g01300560 The water separator element is located in the engine compartment on the right side of the machine 1 Open the engine hood COU im g01453559 g01309761 Illustration 197 1 Drain Valve 2 Water Separator 2 Open the drain valve 1 on the water separator bowl 2 Allow the water and fuel to drain into a suitable container 3 Support the water separator element and rotate the filter counterclockwise Remove the filter 4 Remove the water separator bowl 2 from the filter element Clean the water separator bowl and clean the O ring groove 182 Maintenance Section Fuel System Secondary Filter Replace Note The water separator bowl 2 is reusable Do not discard the water separator bowl 5 Inspect the O ring seal of the water separator bowl for damage Replace the O ring seal if
57. erval for changing the oil is for the following oil types e Caterpillar Hydraulic Oil HYDO e Caterpillar Transmission and Drive Train Oil TDTO e Caterpillar TDTO TMS e Caterpillar Diesel Engine Oil 189 Maintenance Section Hydraulic System Oil Change e Caterpillar Biodegradable Hydraulic Oils HEES e Caterpillar Multipurpose Tractor Oil MTO e Heavy duty diesel engine oils with a minimum zinc content of 900 ppm If Caterpillar oils cannot be used use heavy duty oils with the following classification Caterpillar ECF 1 API CG 4 API CF and TO 4 These oils must have a minimum zinc additive of 0 09 percent 900 ppm Note Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours Caterpillar s standard SOS Fluids Analysis or an equivalent oil sampling program should be used The current guidelines for cleanliness of the oil should be observed Refer to Measured Data If an oil sampling program is not available the standard 2000 oil change interval should be used Measured Data The following information should be monitored through sampling of the oil e Significant changes in wear metals should be monitored These metals include iron copper chromium lead aluminum and tin e Significant changes in the following additives should be monitored zinc calcium magnesium and pho
58. et Lower Pivot Bearings Lubricate 155 Cab Air Filter Clean Replace ccccceee 158 Fuel Tank Water and Sediment Drain 184 Tire Inflation CNeCK risser aea n 205 Every 100 Service Hours or 2 Weeks Axle Oscillation Bearings Lubricate 146 Bucket Linkage and Loader Cylinder Bearings LUDTICATE zaienei ona hae tien ved uu ea ena 154 Bucket Upper Pivot Bearings Lubricate 157 Steering Cylinder Bearings Lubricate 205 Initial 250 Service Hours Transmission Oil Filter Replace 00 207 Every 250 Service Hours Drive Shaft Support Bearing Lubricate 168 Engine Oil Sample Obtain cee eeeees 175 Every 250 Service Hours or Monthly Belt Inspect Adjust Replace cecceece scenes 148 142 Maintenance Section Maintenance Interval Schedule Brake Accumulator Check ccccseeeeeeeeees 151 Braking System Test cccceccecceseeeeeeeseeeeeees 151 Differential and Final Drive Oil Level Check 167 Drive Shaft Spline Lubricate ee 168 Engine Air Filter Service Indicator Inspect Replace ceccecccseecseeceseeseeeseeeeesseeees 173 Quick Coupler Lubricate cccccsseceeeeeeees 200 Every 250 Service Hours or 3 Months Engine Oil and Filter Change cceee 176 Pallet Fork Lubricate
59. 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates tn A IPren T a a z A Pa D F ee Ad ipa oe PT e tat e 1 u i bp k I A ry j Hh a Eii ae pe an bre E h A FAJ Re a 1 ri bd Illustration 250 g01245845 The transmission oil filter is located in the hydraulic service center on the right side of the machine 207 Maintenance Section Transmission Oil Filter Replace Ae ee aaa L a meen Mi cee ee ad an Sy ee el WT i ene fa ee IR 4 ATT T 3 I DA Illustration 251 g01418755 1 Hydraulic Case Drain Filter 2 Hydraulic System Filter 3 Transmission Oil Filter 4 Brake Accumulator 5 Hydraulic Oil Tank Drain 1 Use a strap type wrench to remove the filter element 3 Dispose of the used filter element properly 2 Clean the filter mounting base Make sure that all of the used gasket is completely removed Illustration 252 g00101318 208 Maintenance Section Transmission Oil Level Check 3
60. f necessary remove the engine oil filler cap 2 and add oil 4 Clean the engine oil filler cap and install the engine oil filler cap 5 Close the access door 175 Maintenance Section Engine Oil Sample Obtain Engine Oil Sample Obtain SMCS Code 1348 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes before obtaining the oil sample This will thoroughly mix the engine oil for a more accurate sample Illustration 184 g01300560 2 Open the engine hood 176 Maintenance Section Engine Oil and Filter Change Illustration 185 g01453124 3 Use the sampling valve in order to obtain a sample of engine oil The sampling valve is located on the engine oil filter base on the right side of the engine 4 Close the engine hood Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations and Special Publication PE
61. for the hydraulic oil The hydraulic oil is in the system that is not integral to the service brakes the clutches the final drives or the differentials The standard change interval is 2000 hours The oil should be monitored during intervals of 500 hours The extended 4000 hour interval can be used if the following criteria are met HYDO Advanced 10 Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic and hydrostatic transmission systems when ambient temperature is between 20 C 4 F and 40 C 104 F Cat HYDO Advanced 10 has an SAE viscosity grade of 10W Cat HYDO Advanced 10 has a 50 increase in the standard oil drain interval up to 3000 hours for machine hydraulic systems over second and third choice oils when you follow the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual 6000 hour oil drain intervals are possible when using S O S Services oil analysis When you switch to Cat HYDO Advanced 10 cross contamination with the previous oil should be kept to less than 10 Consult your Cat dealer for details about the benefits from the improved performance designed into Cat HYDO Advanced 10 Oil Filters Caterpillar oil filters are recommended The interval for changing the oil filter should be 500 hours Oil The 6000 hour interval for changing the oil is specific to HYDO Advance 10 The 4000 hour int
62. he rear of the housing Remove the magnets the tube and the screen from the housing NOTICE Do not drop or rap the magnets against any hard ob jects Replace any damaged magnets 6 Wash the tube and the screen in a clean nonflammable solvent Use a cloth a stiff bristle brush or pressure air to clean the magnets 7 Install the magnets and the tube into the screen Install the magnetic screen 8 Clean the magnetic strainer cover and inspect the seal Replace the seal if the seal is damaged Install the magnetic strainer cover and tighten the bolts Illustration 249 g01453622 9 Remove the filler cap and fill the transmission with transmission oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 10 Install the filler cap 11 Start the engine and run the engine at low idle Apply the service brake Slowly operate the transmission control in order to circulate the oil 12 Move the transmission control lever to the NEUTRAL position Inspect the transmission for leaks SEBU8079 11 13 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the correct procedure 102845173 Transmission Oil Filter Replace SMCS Code 3067 510 NOTICE Care must be taken to ensure that fluids are contained during performance o
63. ice brake Move the transmission direction control lever to REVERSE position The backup alarm should immediately sound The backup alarm will continue to sound until the transmission direction control lever is moved to the NEUTRAL position or to the FORWARD position The backup alarm is mounted in the back of the machine behind the rear grill SEBU8079 11 02926777 Battery Clean SMCS Code 1401 070 rad TT C a i OC Illustration 120 g01452689 The batteries are located in the battery compartment on the left side of the machine Your machine may have a set of batteries that are located below the top compartment If equipped ensure that all batteries are cleaned Clean the battery surfaces with a clean cloth Keep the terminals clean and keep the terminals coated with petroleum jelly Install the post covers after you coat the terminal posts with petroleum jelly 147 Maintenance Section Battery Clean i02926778 Battery Hold Down Tighten SMCS Code 7257 527 ra TTT SOTT T Gyre ee Illustration 121 g01452689 The batteries are located in the battery compartment on the left side of the machine Your machine may have a set of batteries that are located below the top compartment If equipped ensure that all batteries are checked Tighten the hold downs for the battery in order to prevent the batteries from moving during machine operation 148 Maintenance Section Batte
64. ide of the machine 7 Remove oil filler cap 2 Fill the crankcase with new oil Clean the filler cap and install the filler cap Reference Refer to Operation and Maintenance Manual Capacities Refill in order to determine the correct amount of oil 8 Start the engine and allow the oil to warm Check the engine for leaks 9 While the engine is running check the LOW IDLE side of dipstick 3 Maintain the oil between the ADD mark and the FULL mark If necessary add oil 10 Close the engine hood and stop the engine 04538255 Engine Valve Lash Check SMCS Code 1105 535 In order to perform the valve lash adjustment refer to Systems Operation Testing and Adjusting Engine Valve Lash Inspect Adjust Note A qualified mechanic should adjust the engine valve lash because special tools and training are required SEBU8079 11 102926773 Ether Starting Aid Cylinder Replace If Equipped SMCS Code 1456 510 CD te e TH as fr me a aag l I A A qg k oa a i NIN te Se A EA At aa e EF a _ a a a E Sree y 7 E ha A Z Car Nf i a i i i M D AAAA aA Y d s a n 4 x 5 i a A We i X NA ae Ke rat T i 1 TA Aj my E m A ll e m a ZX 4 Illustration 190 g01453126 i il 0 4 rai da to K a hey 1 Open the engine hood The ether starting aid cylinder is mounte
65. ids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life Illustration 152 g01300560 The sight gauge is located on the right side of the machine 163 Maintenance Section Cooling System Coolant Level Check Illustration 153 g01447051 1 Maintain the coolant level within the gauge on the side of the coolant reservoir 2 If the coolant level is low slowly remove cooling system pressure Cap 3 Add the required coolant in order to maintain the coolant level within the sight gauge Note If it is necessary to add coolant daily check for leaks 4 Inspect the cooling system pressure cap and the cap seal Clean the cap and install the cap If the cap is damaged install a new cooling system pressure cap 5 Inspect the radiator core for debris Clean the radiator core if necessary Reference Refer to Operation and Maintenance Manual Radiator Core Clean for more information 164 Maintenance Section Cooling Syst
66. ission 11 Engine 6 Service Brake 12 Turn Signal for Bucket 1 Turn the engine start switch to the ON position The alert indicator 9 should come on if the braking system is not at normal operating pressure Start the engine Run the engine at half speed for two minutes in order to increase the accumulator pressure The alert indicator 9 should go off 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 five applications of the service brake pedal are required Note The parking brake indicator light 7 will be on when the alert indicator for brake oil pressure comes on 4 If the alert indicator comes on after less than five applications of the brake measure the accumulator precharge pressure An authorized Caterpillar dealer can measure the nitrogen gas pressure in the accumulator Use only dry nitrogen gas for recharging 151 Maintenance Section Brake Accumulator Check FN wmr r el Us km mies g01413930 High Beam Equipped Hydraulic Starting Aid Machine Security System If Equipped 13 14 15 16 17 Right Turn signal i01732078 Brake Discs Check SMCS Code 4255 535 Reference For the correct procedure refer to the Testing and Adjusting Service Manual of the braking system for your machine or consult your Cater
67. n and Maintenance Manual for more information 102926803 Transmission Oil Change SMCS Code 3030 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes in order to warm the transmission oil 206 Maintenance Section Transmission Oil Change 2 Park the machine on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine Illustration 247 g01301886 Illustration 248 g01453626 1 Magnetic Strainer Cover 2 Magnets Tube and Screen 3 Drain Plug 3 Remove the transmission oil drain plug Allow the transmission oil to drain into a suitable container Clean the drain plug and install the drain plug 4 Replace the transmission oil filter Reference Refer to Operation and Maintenance Manual Transmission Oil Filter Replace for the correct procedure SEBU8079 11 5 Remove the magnetic strainer cover on t
68. necessary 6 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 water separator bowl 7 Install the water separator bowl onto the new filter element by hand until the filter element is snug Do not use tools to tighten the filter element 8 Install the new filter assembly Rotate the filter clockwise in order to fasten the filter to the mounting base 9 Tighten the drain valve 1 on the water separator bowl Note The water separator element is under suction during normal engine operation Tighten drain valve in order to prevent air leakage into the fuel system 10 Prime the fuel system in order to fill the water separator element with fuel Refer to Operation and Maintenance Manual Fuel System Prime 11 Close the engine hood 102926797 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Ay WARNING Personal injury or death may result from failure to adhere to the following procedures Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters SEBU8079 11 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 prepar
69. not move 6 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Engage the parking brake Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation Parking Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move reduce the engine speed immediately and apply the service brake pedal SEBU8079 11 This test is performed when the parking brake is engaged If the machine begins to move compare the engine rpm to the engine rpm of a prior test This will indicate the amount of system deterioration 1 Start the engine Raise the implement slightly Engage the parking brake 2 Make sure that the autoshift control is in the OFF position 3 Move the transmission control to THIRD SPEED FORWARD Then move the transmission control to NEUTRAL and back to THIRD SPEED FORWARD This will override the transmission neutralizer The parking brake indicator light should come on 4 Gradually increase the engine speed to high idle The machine should not move 5 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Lower the implement to the ground Stop the engine If the machine moved during the test cons
70. nt Clean Replace SMCS Code 1054 070 PY 1054 510 PY Ay WARNING To avoid personal injury always wear eye and face protection when using pressurized air NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the 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 Clean the engine air filter primary element when the clogged air filter indicator is displayed on the Caterpillar controller Clean the engine air filter primary element as soon as convenient 170 Maintenance Section Engine Air Filter Primary Element Clean Replace Illustration 169 g01300434 1 Open the engine hood The air cleaner is located on the right side of the engine compartment F Tri Ani Illustration 170 g01453793
71. ntil you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination e Never collect samples from expansion bottles e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 02911182 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a Separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers i 7 tb Bii i i Bs Ys a rat x g Illustration 155 g01447361 SEBU8079 11 Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis Reference For additional information about coolant analysis refe
72. nting bases Make sure that all of the used seals are completely removed Illustration 209 g00101318 3 Apply a thin coat of hydraulic oil to the seals on the new filters Install each new hydraulic oil filter hand tight until the seals of the hydraulic oil filters contact each filter base Note the position of the index marks on each filter in relation to a fixed point on each filter base Note There are rotation index marks on each hydraulic oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the hydraulic oil filters use the rotation index marks as a guide 4 Tighten each filter according to the instructions that are printed on each filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 5 Start the engine and run the engine at low idle Inspect the hydraulic system for leaks Illustration 210 g01185406 6 Maintain the oil level above the ADD COLD mark on the sight gauge Add hydraulic oil if necessary SEBU8079 11 103296763 Hydraulic System Oil Change SMCS Code 5056 044 Selection of the Oil Change Interval Your machine may be able to use a 4000 hour interval
73. om the retainer side of the bucket to drive out the pin e Use a Pin Master Follow Step 1 a through Step 1 c for the procedure 156 Maintenance Section Bucket Tips Inspect Replace Sa of Illustration 133 g00590670 4 Back of Pin Master 5 Extractor 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 Illustration 134 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 SEBU8079 11 Illustration 135 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 d g00590666 Illustration 136 4 Back of Pin Master 9 Pin setter 10 Pin holder a
74. p stop engine wait until ra diator is cool Then loose the cap slowly to relieve the pressure 162 Maintenance Section Cooling System Coolant Level Check NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant shortens coolant ser vice life and may cause premature wear to compo nents Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life When a Caterpillar Extended Life Coolant ELC is used an Extender must be added to the cooling system Use a 8T 5296 Coolant Test Kit to check the concentration of the coolant Reference For additional information about adding Extender refer
75. pillar dealer i02880091 Braking System Test SMCS Code 4251 081 4267 081 e Park the machine on a dry level surface Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles Make sure that the steering frame lock is in the unlocked position Fasten the seat belt before you test the brakes 152 Maintenance Section Bucket Cutting Edges Inspect Replace The following tests are used to determine whether the braking system is functional These tests are not intended to measure the maximum brake holding effort The required brake holding effort for sustaining a machine at a specific engine rpm varies from one machine to another machine The variations include differences in the engine setting the power train efficiency the brake holding ability etc Service Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake 1 Start the engine Raise the implement slightly Apply the service brake Release the parking brake 2 In the Messenger enable the override for the transmission neutralizer 3 Make sure that the autoshift control is in the OFF position 4 Move the transmission control to THIRD SPEED FORWARD while the service brakes are applied 5 Gradually increase the engine speed to high idle The machine should
76. r to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 104606857 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Replace the water temperature regulator thermostat according to the Maintenance Interval Schedule The thermostat should be replaced after the cooling system has been cleaned Replace the thermostat and seals while the cooling system is drained Note If you are only replacing the thermostat drain the cooling system coolant to a level that is below the thermostat housing 165 Maintenance Section Cooling System Water Temperature Regulator Replace NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basi
77. ration 144 g01417276 Oo Remove the filter element A Clean the filter elements with compressed air You can also wash the filter elements in a solution of warm water with a nonsudsing household detergent Rinse the filter elements in clean water Air dry the filter elements thoroughly Ol Install the filter element and the filter cover Replace any filter elements that are worn or damaged Note Make sure that the seals on the filter elements next to the seat are facing toward the parking brake lever when you install the filter elements 102816405 Camera Clean If Equipped SMCS Code 348 070 In order to maintain sufficient vision keep the Work Area Vision System WAVS camera lens and the display clean 159 Maintenance Section Camera Clean Display FEES SOTSOSG Illustration 145 g01223034 WAVS display Use a soft damp cloth in order to clean the display The display has a soft plastic surface that can be easily damaged by an abrasive material The display is not sealed Do not immerse the display with liquid Camera Illustration 146 g01223051 The WAVS camera is located on the rear of the machine in the center of the fan guard Use a damp cloth or water spray in order to clean the camera lens The camera is a sealed unit The camera is not affected by high pressure spray The camera is equipped with an internal heater to help counteract the effects of condensation snow
78. rements must be followed Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended substantially S O S services may extend the oil change even longer Consult your Cat dealer for details The following guidlines shoud be followed if the service hours are not met Items listed between 10 and 100 service hours should be performed at least every 3 months Items listed between 250 and 500 service hours should be performed at least every 6 months ltems listed between 1000 service hours and 2500 service hours should be performed at least every year When Required Alternator Air Vent Line and Screen Clean 143 Automatic Lubrication Grease Tank Fill 144 Battery or Battery Cable Inspect Replace 148 141 Maintenance Section Maintenance Interval Schedule Bucket Cutting Edges Inspect Replace 152 Bucket Hinge and Lift Arm Clearance Shims Inspect Adjust ReEplace cccceceeeeeeeeeeeeeeees 154 Bucket Tips Inspect Replace cceeeee eee 155 Bucket Wear Plates Inspect Replace 158 Camera Clean scsaieineetunatuhorei ier urerk aie ite eive 159 Circuit Breakers Reset cccceccseeceeeseeeeees 160 Engine Air Filter Primary Element Clean FRE DIAC CY nyana a aaa aR 169 Engine
79. rical power must be removed from the HID lamp for at least five minutes in order to ensure that the bulb is cool N Disassemble the housing for the HID lamp in order to have access to the bulb Note On some HID lamps the bulb is an integral part of the lens assembly The bulb is not removed separately from the lens assembly Replace the entire lens assembly on these HID lamps 3 Remove the bulb from the HID lamp 4 Install the replacement bulb in the HID lamp If the bulb is an integral part of the lens assembly install the replacement lens assembly in the HID lamp Note In order to avoid failure to the bulb that is premature avoid touching the bulb s surface with your bare hands Clean any fingerprints from the bulb with alcohol prior to operation 5 Reassemble the housing for the HID lamp Ensure that any printing on the lens is oriented correctly with respect to the HID lamp s mounting position on the machine 187 Maintenance Section High Intensity Discharge Lamp HID Replace 6 Reattach the electrical power to the HID lamp 7 Check the HID lamp for proper operation Note Consult your Caterpillar dealer for additional information on HID lamps 102926770 Hood Tilt Actuator Lubricate SMCS Code 7275 086 f 2 EREN 7y i nate C5 es Illustration 207 g01453083 Hood Tilt Actuator Please note that some parts are removed for clarity 1 Raise the engine hood The hood tilt act
80. rt could be forced further into the pleats Use Steps 7 through 10 in order to inspect the primary element Illustration 173 g00328470 7 Place a light bulb inside the filter element Use a 60 watt blue light in a dark room or in a similar facility Inspect the primary element for light that may show through the filter material 8 Inspect the primary element while you rotate the element Inspect the primary element for tears and or holes Do not use a primary element that has any tears and or holes in the filter material Do not use a primary element with damaged pleats gaskets or seals 9 If it is necessary compare the primary element to a new primary element Use a new primary element that has the same part number This may be necessary in order to confirm the results of the inspection 10 Discard a damaged primary element Use Steps 11 through 14 to install a clean primary element NOTICE Do not use a filter if the pleats the gaskets or the seals are damaged 11 Install a clean primary filter element over the engine air filter secondary element Apply firm pressure to the end of the primary element as you gently rock the filter element This seats the primary element 171 Maintenance Section Engine Air Filter Secondary Element Replace 12 Clean the cover for the air cleaner housing Align the slot on the cover with the pin on the air cleaner housing Install the cover L RNS i i N
81. ry disconnect switch to the OFF position in order to keep the machine from being articulated _ See mm Illustration 166 g01453068 Wipe off the fitting before any lubricant is applied Lubricate all the splines on the drive shaft Apply lubricant through the fittings on the drive shaft spline Refer to Operation and Maintenance Manual Lubricant Viscosities for the proper grease 102926787 Drive Shaft Support Bearing Lubricate SMCS Code 3267 086 BD Note For better access articulate the machine to the right or to the left Because the steering frame lock cannot be connected remove the engine start switch key and turn the battery disconnect switch to the OFF position in order to keep the machine from being articulated SEBU8079 11 Illustration 167 g01453068 Wipe off the fitting before any lubricant is applied Apply lubricant through the fitting on the drive shaft support bearing Refer to Operation and Maintenance Manual Lubricant Viscosities for the proper grease 102880032 Drive Shaft Universal Joints Lubricate SMCS Code 3251 086 Illustration 168 g01433505 1 Wipe off the grease fittings before lubricating 2 Lubricate all grease fittings on the universal joints Refer to Operation and Maintenance Manual Lubricant Viscosities for the proper grease 169 Maintenance Section Drive Shaft Universal Joints Lubricate 102926789 Engine Air Filter Primary Eleme
82. ry or Battery Cable Inspect Replace i 03657099 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 Ay WARNING Personal injury may occur from failure to properly service the batteries Batteries give off flammable fumes that can ex plode Electrolyte is an acid and can cause per sonal injury if it contacts the skin or eyes Prevent sparks near the batteries Sparks could cause vapors to explode Do not allow jumper ca ble ends to contact each other or the engine Im proper jumper cable connections can cause an ex plosion Always wear protective glasses when working with batteries 1 Turn the engine start switch key OFF Turn all of the switches OFF 2 Turn the battery disconnect switch OFF Remove the key 3 Disconnect the negative battery cable from the disconnect switch Note Do not allow the disconnected battery cable to contact the disconnect switch 4 Disconnect the negative battery cable at the battery 5 Disconnect the positive battery cable at the battery 6 Inspect the battery terminals for corrosion Inspect the battery cables for wear or damage 7 Make any necessary repairs If necessary replace the battery cables or the battery 8 Connect the positive battery cable at the battery 9 Connect the negative battery cable at the battery 10 Connect the battery cable at the battery disconnect switch 11 Install the key and turn the
83. s could cause severe engine dam age Reference For information on replacing the water temperature regulator refer to the Service Manual Disassembly and Assembly 102767684 Differential and Final Drive Oil Change SMCS Code 3278 044 4011 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 156 g01264364 Front differential and final drive drain plugs 166 Maintenance Section Differential and Final Drive Oil Change SEBU8079 11 Illustration 157 g01433537 Rear differential and final drive drain plugs 1 Remove the drain plugs for both differentials Allow the oil to drain into a suitable container 2 Clean the drain plugs and install the drain plugs Note If your machine is equipped with the axle oil cooler there are 2 magnetic filters that need to be cleaned If your machine is not equipped with the axle oil cooler skip the next step Illustration 158 g01384680 Note that parts are remov
84. sembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 192 g01300560 SEBU8079 11 The water separator is located in the engine compartment on the right side of the machine 1 Open the engine hood COU im g01453559 g01309761 Illustration 194 1 Drain Valve 2 Water Separator 2 Loosen the drain valve 1 on the bottom of the water separator 2 Allow the water and the sediment to drain into a suitable container 3 Tighten the drain valve Note The water separator is under suction during normal engine operation Tighten the drain valve in order to prevent air leakage into the fuel system SEBU8079 11 181 Maintenance Section Fuel System Primary Filter Water Separator Element Replace 4 If the engine fails to start change the fuel filter If there is a power loss change the fuel filter 5 Close the engine hood 102926799 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 1263 510 FQ NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable contain
85. sphorus e Contaminants should not be present These contaminants include fuel and antifreeze Water content should be 5 percent or less e The silicon level should not exceed 15 parts per million for new oil The particle counts should be monitored e The recommended level of cleanliness for Caterpillar machines that are operated in the field is ISO 18 15 or cleaner The cleanliness should be monitored by particle count analysis The levels of contamination should not exceed the normal by more than two ISO codes Action should be taken in order to determine the cause of the contamination The system should be returned to the original levels of contamination e There should not be significant changes in sodium silicon copper and potassium 190 Maintenance Section Hydraulic System Oil Change e The allowable level of oxidation is 40 percent 0 12 Abs units e The kinematic viscosity of 100 C 212 F oil should not exceed a change of more than 2 cSt from new oil Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitabl
86. ter Clean Replace 145 Battery Clean sactsci anced gninatieasenedtomacucicennet 147 Battery Hold Down Tighten ccccceeeeeeeee 147 Drive Shaft Universal Joints Lubricate 169 Roading Fender Hinges Lubricate 201 Rollover Protective Structure ROPS Inspect 201 Transmission Oil Change ccccseceeeeeeeeeees 205 Every 2000 Service Hours or 1 Year Brake Discs Check ccccsceseeeeeeeeceeeeeeeeaees 151 Differential and Final Drive Oil Change 165 Engine Valve Lash Check cccceccceeeeneeeees 178 SEBU8079 11 Hood Tilt Actuator Lubricate cceeeeeeee 187 Hydraulic System Oil Change 0cc0eee 189 Hydraulic Tank Breaker Relief Valve Clean 193 Refrigerant Accumulator With Desiccant TS DIAC C adna cua deth bimnaun a inet anieehs 201 Service Brake Wear Indicator Check 203 Every 3000 Service Hours Steering Column Spline HMU Steering LUDIC kaane a 204 Every 3 Years Seat Belt Replace cc ccecceecceeceeeeseeseeeeees 202 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 161 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 160 Cooling System Water Temperature Regulator RODIACE wilcn aea a OS E 165 SEBU8079 11 03348945 Alternator Air Vent Line and Screen Clean
87. to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer SEBU8079 11 Illustration 151 g01300560 The cooling system pressure cap is located under the engine hood at the rear of the machine 1 Open the engine hood Slowly loosen cooling system pressure cap in order to relieve any system pressure Remove the cooling system pressure cap 2 If necessary drain enough coolant from the cooling system in order to allow the addition of the Extender 3 Add one bottle of 111 2372 ELC Extender to the coolant system 4 Maintain the coolant level in the gauge on the coolant overflow reservotr 5 Install the cooling system pressure cap Close the engine hood 102594046 Cooling System Coolant Level Check SMCS Code 1350 535 FLV Ay WARNING Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure SEBU8079 11 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain flu
88. tration 224 993903 T Thickness The thickness of the blade at the Check the fork tines for wear or for damage Inspect closest point to the heel the welds the locks the shafts and the fork tines for damage If the components are damaged consult W Width The width of the blade at the closest your Cat dealer Refer to Daily Inspection for point to the heel additional information BH Back Height The distance from the bottom Blade Thickness of the blade to the top of the shank BL Length The length of the blade is measured from the front face on the shank to the tip on the blade A Angle The angle from the upper surface of the a blade to the front face of the shank a Inspection of the Fork Tines Check the fork tines daily for any twisting or bending of the fork tines If any twisting or bending is observed the fork tines should be changed prior to any lifting operation If the fork tines are damaged TREET 01600073 consult your Cat dealer 198 Maintenance Section Pallet Fork Inspect Illustration 226 2 Measure the thickness of the shank Ensure that the measuring device is held square across the shank in order to acquire an accurate measurement g01600074 Measure the blade of the fork tine near the heel Ensure that the measuring device is held square across the blade in order to acquire an accurate measurement Compare the measurement of the blade and the measurement of the sh
89. uator is located on the right side of the machine 2 Fully extend the cylinder and wipe off the inner post with a clean cloth Then lubricate the entire length of the inner post 3 Wipe off both fittings on the cylinder Then apply lubricant through the two fittings until the lubricant escapes back through each fitting 4 Close the engine hood 188 Maintenance Section SEBU8079 11 Hydraulic System Biodegradable Oil Filter Element Replace 03657272 Hydraulic System Biodegradable Oil Filter Element Replace If Equipped SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 208 g01108153 The hydraulic filters are located on the right side of the machine under the platform There are two hydraulic oil filters Each filter must be replaced during this procedure 1 Use a strap type wrench to remove each filter element Dispose of the used filter elements properly 2 Clean the filter mou
90. ult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation 03657238 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 SEBU8079 11 Illustration 125 g00764365 1 Bolts for Cutting Edge 2 Cutting Edge Check the cutting edges and the end bits for wear and for damage Use the following procedure to service the cutting edges and the end bits 1 Raise the bucket and place blocking under the bucket 2 Lower the bucket onto the blocking Stop the engine 3 Remove bolts 1 cutting edge 2 and the end bits 4 Clean all contact surfaces 5 If the opposite side of the cutting edge is not worn use the opposite side of the cutting edge The end bits are not reversible If both sides are worn install a new cutting edge 6 Install bolts 1 Tighten the bolts to the specified torque Reference Refer to Specifications SENR3130 Ground Engaging Tool G E T Fasteners 7 Start the engine Raise the bucket and remove the blocking Lower the bucket to the ground 8 After a few hours of operation check the bolts for proper torque 153 Maintenance Section Bucket Cutting Edges Inspect Replace Bucket Wear Plates Ay WARNING Personal injury or death can result from the bucket falling
91. vice brakes Apply the parking brake The machine can then be returned to normal operation If there is no response to the steering input the supplemental steering system is not operating Stop the machine immediately Repair the supplemental steering system before returning the machine to service 203 Maintenance Section Secondary Steering Test 101801632 Service Brake Wear Indicator Check SMCS Code 4255 535 Reference For information about checking the service brake wear indicator refer to Testing and Adjusting Braking System for the machine that is being serviced or consult your Caterpillar dealer 103589859 Steering Column Play Check SMCS Code 4310 535 4338 535 Illustration 241 g01408466 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 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 204 Maintenance Section Steering Column Spline HMU Steering Lubricate Ay WARNING Failure to perform this inspection and repair may cause loss of steering control which m
92. w washer solvent or equivalent System damage can result from freezing RN Illustration 257 g01308848 The window washer reservoir is located on the left side of the machine under the cab Fill the reservoir with window washer solvent SEBU8079 11 102837739 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 peony d so E J T m a i Ba Bi ai LoS i am Illustration 258 g01414919 Inspect the condition of the wiper blades Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs 104412316 Windows Clean SMCS Code 7310 070 Clean the outside of the windows from the ground unless handholds are available Illustration 259 g00566124 Typical example SEBU8079 11 Cleaning Methods Commercial Window Cleaner Apply the cleaner with a soft cloth Rub the window with moderate pressure until all the dirt is removed Allow the cleaner to dry Wipe off the cleaner with a clean soft cloth Soap and Water Use aclean sponge or a soft cloth Wash the windows with a mild soap or with a mild detergent Also use plenty of lukewarm water Rinse the windows thoroughly Dry the windows with a moist chamois or with a moist cellulose sponge Stubborn Dirt and Grease Wash the windows with a good grade of naphtha of isopropyl alcohol or of Butyl Cellosolve Then wash the windows with soap and with water Polycarbonate Windo
93. ws If equipped Wash polycarbonate windows with a mild soap or detergent Never use a cleaning solvent on polycarbonate windows Wash polycarbonate windows with warm water and a soft sponge or damp cloth Never use a dry cloth or paper towels on polycarbonate windows Rinse the windows with a sufficient amount of clean water 211 Maintenance Section Windows Clean
94. y 8 Install the breather element Install the breather element cover assembly 9 Install the breather hose and breather outlet hose clamp 10 Install the heat shield on the top of the engine 11 Close the engine hood SEBU8079 11 102594048 Engine Oil Level Check SMCS Code 1000 535 FLV NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage Illustration 182 g01300560 1 Open the access door on the right side of the machine SEBU8079 11 l i Ls ot y i d N Illustration 183 g01246185 1 Air Filter Service Indicator 2 Engine Oil Filler 3 Engine oil Dipstick 4 Fuel Filler 2 The engine oil dipstick 3 is located on the right side of the machine While the engine is stopped maintain the oil level at the FULL mark on the engine oil dipstick 3 I

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