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MAINTENANCE INTERVALS - Safety

1. For additional information about adding an extender see Operation and Maintenance Manual Caterpillar Extended Life Coolant ELC or consult your Caterpillar Dealer 125 Maintenance Section Cooling System Coolant Extender ELC Add 100823820 Cooling System Level Check SMCS Code 1350 535 FLV S N 6BK1 Up The cooling system pressure cap for the tractor is located on the top of the hood The pressure cap is directly above the radiator 00395997 Illustration 128 Typical example 1 Remove the cooling system pressure cap slowly in order to relieve the pressure 2 Maintain the coolant level at 13 mm 5 inch from the bottom of the filler pipe If it is necessary to add coolant daily check the system for leaks 3 If additional coolant is necessary remove the cooling system pressure cap and add the appropriate coolant mixture Install the pressure cap 126 Maintenance Section Cooling System Pressure Cap Clean Replace 100823942 Cooling System Pressure Cap Clean Replace SMCS Code 1382 070 1382 510 S N 6BK1 Up The cooling system pressure cap for the tractor is located on the top of the hood at the front of the machine 00395997 Illustration 129 1 Remove the cooling system pressure cap slowly in order to relieve the pressure 2 Inspect the cap for damage for foreign material and for deposits 3 Clean the cap with a clean cloth or replace the cap if necessary
2. 14 Inspect the steps the walkways and the handholds 14 Clean the steps the walkways and the handholds Make any necessary repairs Inspect the Rollover Protective Structure ROPS for damage If repair is necessary consult your Caterpillar Dealer Tighten any loose ROPS bolts 15 Inspect the operator compartment 15 for trash buildup Check for trash buildup under the floorplate and on top of the crankcase guard Keep these areas clean Inspect the instrument panel 15 for broken gauges and for broken indicators Replace any broken lenses and any broken indicator lights Adjust the mirrors for the correct rear view of the machine Clean the windows 16 Make sure that all covers and guards are securely attached Inspect the covers and the guards for damage 17 Inspect the lights for broken bulbs and for broken lenses Replace any broken bulbs and any broken lenses 18 Inspect the air brake system Replace any worn brake lines 19 Check all of the rollers for the scraper 20 Grease all of the fittings that need to be serviced on a daily basis 183 Maintenance Section Wheel Bearing Oil Change 100877318 Wheel Bearing Oil Change SMCS Code 4234 044 OC S N 5SG480 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any
3. 14 Run the engine and check dipstick 5 after the engine has been running for ten minutes Maintain the oil between the marks on the SAFE OPERATING RANGE side of the dipstick If necessary add oil 15 Close the engine access door and stop the engine 100078319 Engine Valve Lash Check SMCS Code 1105 535 S N 6BK1 Up Engine valve lash adjustments should be made at every 2000 hour interval Maintenance is recommended by Caterpillar for engine valve lash adjustments The maintenance for engine valve lash is part of the lubrication and preventive maintenance schedule in order to provide maximum engine life NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar Dealer for the complete engine valve lash adjustment procedure Be sure the engine cannot be started while this maintenance is being performed To prevent pos sible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting engine valve lash clearance NOTICE Operation of Caterpillar Engines with improper engine valve lash adjustments will reduce the engine efficien cy This reduced efficiency could result in excessive fuel usage and or shortened engine component life Measure the engine valve lash with the engine stopped To obtain an accurate measurement allow a
4. Shims may need to be removed from the top of the bracket when you are working in loose material The space that is between the cutting edge and the elevator flight will become narrower 1 Park the machine on level ground Lower the bowl Apply the parking brake 2 You should raise the front of the elevator with a jack or a hoist Place blocks or stands under the front of the elevator once the elevator has been raised Lower the elevator until the elevator is resting on the blocks or stands Note The front of the elevator must not be resting on the top plate 5 3 Remove the bolts 1 that hold the shims in place 4 Reposition the shims 2 3 5 Install the bolts 1 6 Follow Steps 3 through 5 in order to position the shims on the other side of the bowl 7 Lower the front of the elevator 100807343 Coolant Conditioner Element Replace SMCS Code 1352 510 FQ S N 6BK1 364 g00383172 Illustration 123 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids accordi
5. g00344219 Illustration 114 2 Apply the service brake pedal and hold down the service brake pedal 3 Stop the engine 4 The reading on the air pressure gauge should not drop by more than 35 kPa 5 psi after the engine is stopped for 10 minutes Repair the brakes if necessary i00768566 Brake Air System Warning Horn Test SMCS Code 7402 081 7408 081 The warning horn for the air brake system should sound when the air pressure gauge shows a reading below 450 kPa 65 psi 1 The parking brake should be in the ENGAGED position 2 The lever for the transmission control should be in the NEUTRAL N position 3 Start the engine 4 Watch the air pressure gauge The air pressure must be above 450 kPa 65 psi 5 Purge air from the air tanks by doing the following procedure e Engage and disengage the service brake until the air pressure drops below 450 kPa 65 psi The warning horn should sound Make repairs if the horn is not sounding 100773589 Brake Camshaft Bearing Lubricate SMCS Code 4251 086 BD The grease fittings for the brake camshaft can be reached from the back side of each wheel Wipe all of the grease fittings before you apply the grease The grease fittings may have a protective covering Remove the covers before applying grease Replace the covers after applying grease Illustration 115 g00355312 Typical Example g00355315 Illustration 116 Typical Example
6. 100814979 Cushion Hitch Accumulator Check SMCS Code 5077 535 S N 6BK1 Up g00388912 Illustration 131 Typical Example The cushion hitch accumulator is located on the right side of the machine near the center hitch Check the precharge pressure in the cushion hitch accumulator Add nitrogen if necessary Refer to the Systems Operation Testing and Adjusting SENR6825 621F 623F and 627F Wheel Tractor Scrapers Cushion Hitch Hydraulic System Testing and Adjusting Section for more information You may need to consult your Caterpillar Dealer for the checking procedure 100815172 Cutting Edges and End Bits Inspect Replace SMCS Code 6801 040 6801 510 6804 040 6804 510 Personal injury or death can result if the bowl is not blocked up Block the bowl before changing cutting edge NOTICE Do not attempt to increase wear life by welding on cutting edges This may result in premature failures Change or rotate the cutting edges or router bits be fore the mounting surfaces become worn g00389174 Illustration 132 Typical Example Note Any material that might fall on the worker should be removed from the apron and from the sides of the bowl 1 Park the machine on level ground 2 Engage the parking brake 3 Raise the bowl and block up the bowl Block the bowl on both sides Blocks should be of material that is suitable for carrying the weight of the bowl Only block up the bowl
7. 139 Maintenance Section Elevator Chain Idler Lubricate 100954378 Elevator Chain Roller Check Lubricate SMCS Code 6260 086 6260 535 S N 5SG480 Up g00486659 Illustration 155 The elevator chain rollers 1 are located at the lower end of the elevator frame One roller is located on each side of the elevator frame 1 Park the machine on level ground Apply the parking brake Lower the bowl 2 Position the filler plug 2 so that the plug is at the top of the roller 3 Clean the area around the filler plug Remove the filler plug 4 Maintain the oil level to the bottom of the filler hole Add oil if oil is needed 5 Clean the filler plug Install the filler plug 6 Repeat Steps 1 through 5 for the other elevator chain roller 140 Maintenance Section Elevator Drive Tube Roller Bearing Lubricate 100953430 Elevator Drive Tube Roller Bearing Lubricate SMCS Code 7551 086 ELV S N 5SG480 Up Illustration 156 g00486262 g00486491 Illustration 157 The roller bearing for the elevator drive tube 1 is located on the right side of the elevator drive tube Refer to Disassembly and Assembly SENR6809 Elevator Drive Sprockets amp Speed Reducer for further information on repacking the bearings Consult your Caterpillar Dealer for further information 100967258 Elevator Linkage Lubricate SMCS Code 6241 086 KL S N 5SG480 Up Illustration 158 g00492722 I
8. 6BK1 Up A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage KN j S Illustration 172 goo409464 The dipstick 1 for the tractor engine is located on the right side of the tractor 1 Park the machine on level ground Lower the bowl 2 Open the access cover that is on the right side of the machine 3 Check the SAFE OPERATING RANGE side of dipstick 1 while the engine is running Maintain the oil level between the ADD mark and the FULL mark Check the SAFE STARTING RANGE side of dipstick while the engine is stopped Maintain the oil level between the LOW mark and the FULL mark Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the FULL mark on the SAFE STARTING RANGE side of the dipstick 4 Clean the oil filler cap 2 Remove the oil filler cap If necessary add oil 5 Clean the oil filler cap and install the oil filler cap 6 Close the access cover 100127693 Engine Oil Sample Obtain SMCS Code 1000 008 7542 008 S N 6BK1 Up Refer to Operation and Maintenance Manual S O S Oil Analysis and Operation and Maintenance Manual Sampling Interval and Location of Sampling Valve for information that pertain
9. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates g00475892 Illustration 207 The suction screen 3 for the transmission is located at the rear of the transmission 1 Park the machine on level ground Lower the bowl Apply the parking brake Shut off the engine 2 Clean the area around the housing 8 for the screen 3 Remove the drain plug 1 Allow the oil to drain into a suitable container 4 Remove the bolts 2 for the cover of the screen 5 Remove the cover 3 6 Remove the screen Clean the screen in nonflammable solvent Inspect the screen for damage Replace the screen if the screen is damaged 7 Install the screen Inspect the seal for the cover Replace the seal if the seal is damaged 8 Clean the cover Install the cover 9 Clean the plug Install the plug 10 Start the engine 11 Check the area around the screen housing for leaks 12 Check the transmission oil level Add oil if oil is needed 13 Shut off the engine 100931685 Tire Inflation Check SMCS Code 4203 535 Al A WARNING Personal injury can result from improper tire infla ti
10. Clean the plug Install the plug 9 Perform the same procedure to the other rear wheel Note See Operation and Maintenance Manual Gear Oil for further information See Operation and Maintenance Manual Refill Capacities for further information 100877704 Wheel Bearing Oil Level Check SMCS Code 4234 535 FLV S N 5SG480 Up go0446989 Illustration 222 The oil filler plug 1 for checking the oil for the wheel bearing is located on the rear wheel The filler plug for the oil for the wheel bearing is not clearly shown in this picture The filler plug is shown in the DRAIN position The wheel must be rotated 90 degrees in order to place the plug in the CHECK position Do not confuse the oil filler plug 1 with the filler plug 2 for the antifreeze for the rear wheel 1 Park the machine with the oil filler plug in a horizontal position in relation to the axle 2 Lower the bowl Apply the parking brake Shut off the engine 3 Clean the area around the plug hole 4 Remove the oil filler plug Oil should be dripping from the bottom of the plug hole Add oil if oil is needed 5 Clean the plug Install the plug 6 Perform the same procedure to the other rear wheel Note See Operation and Maintenance Manual Gear Oil for further information 100878727 Wheel Coolant Level Check SMCS Code 4207 535 FLV S N 5SG480 Up A WARNING With a lack of wheel coolant personal injury or de
11. Damage to the vibration damper or failure of the vibration damper will increase torsional vibrations These vibrations will result in damage to the crankshaft and to the other engine components A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range Caterpillar recommends replacing the vibration damper for any of the following reasons e The engine has had a failure because of a broken crankshaft e The S O S analysis detected a worn crankshaft front bearing e The S O S analysis detected a large amount of gear train wear that is not caused by a lack of oil The vibration damper can be used again if none of the above conditions are found or if the vibration damper is not damaged In the vibration damper a wobble can occur on the outer ring Some of the wobble of the outer ring is normal If a wobble is present replacement of the vibration damper may not be necessary To confirm an acceptable wobble see the Service Manual for the procedure to check the vibration damper Marks of the vibration damper are on the hub and on the outer ring These marks will indicate the condition of the vibration damper If the marks are not in alignment the rubber seal between the outer ring and the hub has separated from the outer ring and or from the hub Install a new vibration damper if the marks are not in alignment Note Contact your Caterpillar Dealer for further information
12. Position the post covers Close the battery access cover 100757468 Battery Battery Cable or Battery Disconnect Switch Replace SMCS Code 1401 510 1402 510 1411 510 S N 6BK1 Up 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position Turn the battery disconnect switch to the OFF position Remove the key On machines which are equipped with supplemental steering remove the fuse for the supplemental steering At the battery disconnect switch disconnect the negative battery cable that is connected to the frame Note Do not allow the disconnected battery cable to contact the disconnect switch 5 9 Disconnect the negative battery cable from the terminals of the battery Perform the necessary repairs Replace the cable or the battery as needed Connect the negative battery cable to the terminals of the battery Connect the negative battery cable at the battery disconnect switch Install the fuse for the supplemental steering 10 Install the key for the battery disconnect switch Turn the key to the ON position 114 Maintenance Section Brake Air System Pressure Test 100767745 Brake Air System Pressure Test SMCS Code 4250 081 PX ESA Illustration 113 g00351052 Typical Example 1 Start the engine and look at the air pressure gauge Allow the brake system air pressure to reach 850 50 kPa 125 10 psi
13. Use a 4C 5084 Filter Cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage i00860147 Radiator Core Clean SMCS Code 1353 070 KO S N 6BK1 Up Se AN a AY va N AQ AN V WG Ve Y AY FS E V CW AW ANUS A AAi AIK ANY ii Y Ay LLL im NI SS x y Illustration 200 g00039503 You can use compressed air high pressure water o
14. consult your Caterpillar Dealer for an inspection of the machine 6 Reduce the engine speed to low idle and move the transmission control to the NEUTRAL position Engage the parking brake Lower the bowl to the ground and stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar Dealer Have the dealer inspect and if necessary repair the service brakes before returning the machine to operation 117 Maintenance Section Braking System Test Note If the friction material for the brakes needs to be replaced the new friction material may require burnishing for maximum performance Consult your Caterpillar Dealer or see Special Instruction SEHS9580 for the procedure for burnishing Parking And Secondary Brake Holding Ability Test Make sure that no people or obstacles are in the area around the machine Test the brakes on a dry level surface Fasten the seat belt before you test the brakes This test determines whether the parking brake is functional This test is not intended to measure the maximum brake holding effort 1 Start the engine and look at the air pressure gauge Allow the brake system air pressure to reach 850 50 kPa 125 10 psi 2 Apply the parking brake 3 Raise the bowl 4 While the engine is at an idle and the parking brake is applied move the transmission control to the SECOND SPEED position A WARNING If the machine begins to move reduce the en
15. tempt to reuse it by cleaning Engine damage could result Note Replace the engine air filter secondary element when you service the engine air filter primary element for the third time If a clean primary element has been installed and the engine air filter service indicator still enters the red zone replace the secondary element Also if the exhaust smoke remains black and a clean primary element has been installed replace the secondary element 1 Remove the air cleaner cover and the primary element Illustration 167 g00039214 2 Remove the nuts that hold the secondary element to the air cleaner housing Do not remove the two nuts that hold the air cleaner housing to the inlet manifold Remove the secondary element 3 Cover the air inlet opening Clean the inside of the air cleaner housing 4 Uncover the air inlet opening Install a new secondary element Tighten the nuts to a torque of 27 7N m 20 5 lb ft 5 Install the primary element and the air cleaner housing cover Use your fingers to tighten the cover bolts Do not use a tool to tighten the bolts 100832198 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 S N 6BK1 Up NOTICE Service the air cleaner only with the engine stopped Engine damage could result g00403438 Illustration 168 Typical Example The engine filter element indicator 1 for the tractor is located on the front of the hydraulic oil reservoir Use a towel to
16. 127 Crankshaft Vibration Damper Inspect 128 Every 6000 Service Hours or 6 Years Cooling System Coolant ELC Change 123 100744477 Air Conditioner Test SMCS Code 7320 081 S N 6BK1 Up A WARNING Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air condition ers or wherever refrigerant gas may be present 1 Start the engine Operate the engine at high idle 2 Set the heating and air conditioner control for maximum cooling Set the fan speed switch to HIGH SPEED position 3 Allow the air conditioning system to run for several minutes Poor cooling indicates a low refrigerant level Service of the air conditioner should be done by your Caterpillar dealer For proper cooling charge the air conditioning system with R 134a refrigerant Operate the air conditioner monthly in order to lubricate the compressor seals Set the controls on the maximum setting Operate the system for 5 minutes 109 Maintenance Section Air Conditioner Test 100745298 Air Dryer Check SMCS Code 4285 535 S N 6BK1 Up Illustration 106 g00335158 1 Open the drain valves for the air tanks on the tractor The air tanks should have air pressure 2 Check for moisture in the air tank Moisture will spray f
17. 14 Check the filter for leaks Check the magnetic screen for leaks 15 Shut off the engine 16 Check the oil level of the transmission Some oil may be needed Add oil if oil is needed 100892762 Transmission Oil Level Check SMCS Code 3030 535 FLV S N 6BK1 Up Illustration 214 g00389932 The sight gauge for transmission oil is located on the back right side of the transmission g00455511 Illustration 215 1 Park the machine on level ground 2 Lower the bowl Shut off the engine 3 Clean the sight gauge 1 and the oil filler cap 2 4 Maintain the oil level between the FULL and the ADD marks on the sight gauge 5 Remove the oil filler cap and add oil if it is necessary 6 Clean the oil filler cap and install the oil filler cap 179 Maintenance Section Transmission Oil Level Check Note Red dye is added to the transmission oil at the factory If the oil in the differential 8 has a red color transmission oil has leaked into the differential If oil is leaking from the transmission see your Caterpillar Dealer for further information 9U 5031 Red Oil Dye may be added to your transmission oil See your Caterpillar Dealer for further information 180 Maintenance Section Transmission Oil Sample Obtain i00916549 Transmission Oil Sample Obtain SMCS Code 3030 008 7542 008 S N 6BK1 Up Refer to Operation and Maintenance Manual S O S Oil Analysis and Operatio
18. 144 Maintenance Section Engine Air Filter Secondary Element Replace Illustration 166 g00102318 6 When you clean the inside pleats and the outside pleats direct the air along the pleats or direct the water along the pleats The primary element can be washed in a solution that consists of warm water and of nonsudsing household detergent Fully rinse the pleats Allow the primary element to air dry completely 7 Inspect the primary element after you clean the primary element Do not use a primary element if the pleats the gaskets or the seals are damaged 8 Cover the clean primary element Store the primary element in a clean dry location A primary element may be cleaned for a maximum of six times Also replace the primary element if the primary element has been in service for one year 9 Install a clean primary element 10 Clean the cover and install the cover Tighten the clips over the air cleaner cover 11 Reset the engine air filter service indicator Start the engine If the yellow piston in the engine air filter service indicator moves into the red zone install a new secondary element Also if the exhaust smoke is black install a new secondary element See the Operation and Maintenance Manual Engine Air Filter Secondary Element Replace i00060042 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE S N 6BK1 Up NOTICE Always replace the secondary element Do not at
19. Apply lubricant through the two fittings on the inside of each tractor wheel 115 Maintenance Section Brake Camshaft Bearing Lubricate g00355321 Illustration 117 Typical Example Apply lubricant through the two fitting on each scraper wheel There is a total of eight fittings 116 Maintenance Section Brake Shoes and Drums Inspect Replace 00803899 Brake Shoes and Drums Inspect Replace SMCS Code 4252 040 4252 510 4253 040 4253 510 g00380131 Illustration 118 Typical Example Note Check the brakes on all 4 wheels 1 Remove the wheel brake dust covers 2 Check the brake shoes for wear or for damage Measure the thickness of the brake linings If the thickness of the brake linings is less than 7 2 mm 28 inch replace the brake linings 3 Check the brake drum for wear or for damage Repair the brake drum or replace the brake drum if necessary 4 Install the wheel brake dust cover 100059383 Brakes Indicators and Gauges Test SMCS Code 4251 081 4267 081 7000 7450 081 7490 081 Before you operate the machine perform the following checks and make any necessary repairs e Look for broken lenses on the gauges broken indicator lights broken switches and other broken components in the cab e Start the engine e Look for inoperative gauges e Turn on all machine lights Check for proper operation e Sound the forward horn e Move the machine forward and test the s
20. Breaker Relief Valve Clean SMCS Code 5118 070 S N 6BK1 Up g00441328 Illustration 195 The hydraulic tank breaker relief valve is located on the top of the hydraulic tank near the hydraulic oil filter cover The relief valve controls the pressure in the tank The relief valve controls the vacuum in the tank 1 Clean the debris from the relief valve 1 2 Turn the relief valve counterclockwise in order to remove the relief valve Remove the relief valve slowly in order to relieve the pressure that is in the tank 3 Remove the retaining ring from the top of the relief valve 4 Remove the metal cover that is under the retaining ring A filter is under the metal cover 5 Wash the breaker relief valve in a clean nonflammable solvent Wash the filter in a clean nonflammable solvent 6 Dry the relief valve Dry the filter Use compressed air in order to speed the drying 7 Inspect the filter for damage Replace the filter if the filter is damaged 8 Inspect the O rings that are between the filter and the housing of the relief valve Replace the O rings if the O rings are damaged 9 Inspect the relief valve for damage Replace the relief valve if the relief valve is damaged 10 Apply a light coat of oil to the O rings Assemble the filter on the relief valve 11 Install the relief valve on the hydraulic tank 100813116 In Line Refrigerant Dryer Check Replace SMCS Code 7322 510 7322 535 S
21. Interval Schedule Engine Oil Level Check cccceeeeeeeseeeeeees 148 Floor Rollers Lubricate ccccccscessssseeeeeeees 152 Fuel Tank Water and Sediment Drain 157 Hydraulic Oil Cooler Clean ccccceeeeeeeeees 161 Hydraulic System Oil Level Check 0 164 Radiator Core Olean ccccccccccccccecceeeeeeeeeeeeenees 169 Seat Belt Inspect 02 eceeeeeeeeeeeeeeeteeeeeteeteeeees 171 Transmission Oil Level Check n 179 Walk Around Inspection cceceeeeeeeeeeeeeeteeeeeeeee 182 Every 50 Service Hours or Weekly Cab Air Filter Clean Replace c eeceee 118 Hitch Lubricate wo aie aaia 160 Tire Inflation Check ccccccceeeeceesseeaeeeeeeeees 175 Every 250 Service Hours or Monthly Air Conditioner Test cccceessceeeeeeeeeseeeeeneees 109 Air Dryer CHECK eeeecceeeeeeeeeeeeeeeeceeeeeeeneeeeneees 109 Brake Air System Pressure Test cceee 114 Braking System Test cccssceeeeteeeseeeseneeteeee 117 Coolant Conditioner Element Replace 121 Cooling System Coolant Additive DEAC Add 124 Cooling System Coolant Extender ELC Add 125 Elevator Chain Roller Check Lubricate 139 Elevator Speed Reducer Check Lubricate 141 Engine Oil High Speed and Oil Filter Change 146 Engine Oil Sample Obtain 00 ee 149 Engine Oil and Filter Change sses 149 F
22. N 6BK1 Up Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still under pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system g00389572 Illustration 196 Typical Example 167 Maintenance Section In Line Refrigerant Dryer Check Replace Check The in line refrigerant dryer 4 is located behind the panel 5 at the front of the cab Illustration 197 g00387392 Typical In line Refrigerant Dryer g00400323 Illustration 198 1 Remove the panel 5 at the front of the cab Check the moisture indicator 2 on the dryer If the moisture indicator is pink replace the dryer
23. Wipe all the grease fittings before lubricating Remove the covers on the fittings 3 Apply lubricant through fitting 1 for the fan drive bearing Apply lubricant through fitting 2 for the belt tightener 4 Replace the covers on the fittings 5 Close the engine access cover 00955145 Floor Rollers Lubricate SMCS Code 6228 086 S N 5SG480 Up g00486940 Illustration 177 The elevator floor rollers 1 are located on the door assembly Four rollers are located on each side of the assembly 1 Park the machine on level ground Apply the parking brake Lower the bowl 2 Clean the area around the grease fittings 2 for the rollers 3 Apply grease to the fittings 4 Follow Steps 2 and 3 for the other rollers i00850658 Fuel Injection Timing Check SMCS Code 1290 535 TM S N 6BK1 Up Note The correct fuel timing specification is found on the Engine Information Plate Fuel timing specifications may vary for different engine applications and or for different power ratings A qualified mechanic should adjust the fuel injector timing because special tools and training are required Refer to your Caterpillar dealer for the complete adjustment procedure for the fuel injector timing 153 Maintenance Section Fuel Injection Timing Check 100851367 Fuel System Prime SMCS Code 1250 548 S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of insp
24. adjusting nut 4 until the proper belt tension is reached To check the belt tension apply 110 N 25 Ib of force midway between the pulleys Correctly adjusted belts will deflect 13 to 19 mm 1 2 to 3 4 inch 4 Tighten the locking nut 7 to 150 20 N m 110 15 Ib ft 5 Tighten the pivot bolts 3 5 and 6 6 Close the access panels 182 Maintenance Section Walk Around Inspection 100936816 Walk Around Inspection SMCS Code 7000 040 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand Remove the cooling system pressure cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury NOTICE Accumulated grease and oil ona machine is a fire haz ard Remove this debris with steam cleaning or high pressure water at least every 1000 hours or each time any significant quantity of oil is spilled on a machine Note Watch closely for leaks If you observe a leak find the source of the leak and correct the leak If you suspect a leak or you observe a leak check the fluid levels more frequently g00477095 Illustratio
25. fuel enters the fuel tank 1 Remove the fuel tank cap 2 Remove the gasket that is part of the fuel cap Inspect the gasket for damage Replace the gasket if the old gasket is damaged 3 Disassemble the fuel tank cap Remove the filter elements Clean the filter elements in clean nonflammable solvent Apply a thin coat of oil to the filter elements Assemble the fuel tank cap Install the gasket 4 Remove the strainer Clean the strainer in clean nonflammable solvent Install the strainer 5 Install the fuel tank cap 100857073 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S S N 5SG480 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates g00428201 Illustration 181 The drain for the fuel system is located ahead of the rear push block The drain is located inside the rear frame A ball valve is at the end of the fuel line This ball valve is used for draining diesel fuel from the fuel tank 1 Move th
26. moderate pressure until all the dirt is removed Wipe off the cleaner with a clean towel Soap and Water Use a clean sponge or a towel Wash the windows with a solution of soap and water Rinse the windows thoroughly Dry the windows with a clean towel Stubborn Dirt and Grease Wash the windows with naphtha isopropyl alcohol or butyl cellosolve Then wash the windows with a solution of soap and water Dry the windows with a clean towel Note After you have washed the windows with a solution of soap and water you may want to clean the windows again with a commercially available glass cleaner Dry the windows with a clean towel Note A light covering of dust may be removed with a Clean towel
27. to a sufficient height for the removal of the cutting edges 4 Block the apron Refer to Operation and Maintenance Manual Warning Signs and Labels for information on blocking the apron 129 Maintenance Section Cutting Edges and End Bits Inspect Replace g00389294 Illustration 133 5 If the cutting edges 1 are worn remove the bolts for the cutting edges 1 If the opposite sides of the cutting edges are not worn rotate the cutting edges and install the opposite sides of the cutting edges outward Clean the contact surfaces before installing 6 Install new cutting edge sections if the cutting edges are worn on both sides 7 If the end bits 2 are worn remove the bolts for the end bits 2 If the opposite sides of the end bits are not worn rotate the end bits and install the opposite sides of the end bits outward Clean the contact surfaces before installing 8 Install new end bits if the end bits are worn on both sides 9 Install the bolts and tighten the bolts to the specified torque See Operation and Maintenance Manual Torque for Ground Engaging Tool Bolts 10 Raise the apron and remove the pin assembly from the pin holder Lower the apron and return the pin assembly to the pin s storage location 11 Raise the bowl and remove the blocking Lower the bowl to the ground 12 After a few hours of operation check the bolts for proper torque Tighten the bolts if necessary 130 M
28. which is located above the filter 6 Turn the filter to the left in order to loosen the filter Loosen the filter with a strap type wrench 156 Maintenance Section Fuel Tank Cap and Strainer Clean 7 Remove the filter Clean the bottom of the filter base Make sure that all of the old filter seal is removed 8 Apply clean diesel fuel to the seal of the new secondary filter 9 Install the new filter by hand When the seal contacts the base tighten the filter for an additional 3 4 turn Rotation index marks are positioned on the filters at 90 degree intervals Use these rotation index marks as a guide when you tighten the filter 10 Return the fuel valve to the OPEN position 11 Purge the air from the fuel system See the Operation and Maintenance Manual Fuel System Prime for further instructions Note The primary fuel filter should also be changed at this time See the Operation and Maintenance Manual Fuel System Primary Filter Replace for further instructions 12 Start the engine and check for leaks 100842136 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR 1273 070 Z2 S N 5SG480 Up The fuel tank cap is located on the top of the fuel tank The fuel cap has a filter element that is located within the cap The filter element filters the air that enters the fuel tank as the fuel level changes The strainer is located under the fuel cap The strainer will strain the fuel as the
29. 02 Illustration 163 The engine air filter primary element for the tractor is located behind the hydraulic reservoir The filter can be viewed from the right rear of the tractor Illustration 164 g00102316 1 Loosen the clips on the air cleaner cover Remove air cleaner cover 1 2 Remove the engine air filter primary element 2 from the air cleaner housing 143 Maintenance Section Engine Air Filter Primary Element Clean Replace Illustration 165 g00102317 3 Clean the inside of the air cleaner housing 4 Inspect the primary element If the pleats the gaskets or the seals are damaged discard the primary element Replace a damaged primary element with a clean primary element NOTICE Do not clean the primary element by bumping or tap ping them Do not use primary element with damaged pleats gaskets or seals Engine damage can result Make sure the cleaned primary element is completely dry before installing into the air cleaner housing Water remaining in the primary element can cause false in dications of contamination in Scheduled Oil Sampling test results 5 If the primary element is not damaged clean the primary element The primary element can be cleaned by using the following methods e Pressure air e Pressure water e Detergent washing When you use pressure air the maximum air pressure is 205 kPa 30 psi When you use pressure water the maximum water pressure is 280 kPa 40 psi
30. 4 Inspect the condition of the gasket in the cap Replace the gasket if necessary 5 Install a pressure cap 100820280 Cooling System Relief Valve Clean SMCS Code 1370 070 S N 6BK1 Up The cooling system relief valve for the tractor is located on the top of the radiator at the front of the machine The sheet metal that is covering the radiator will need to be removed in order for you to work on the relief valve 1 Remove the cooling system pressure cap slowly in order to relieve the pressure Illustration 130 g00102095 2 Remove the mounting bolts 1 Remove the cover 5 gaskets 2 plate 3 and valve assembly 4 3 Inspect the valve assembly 4 plate 3 and gaskets 2 Replace any of these components if necessary 4 Inspect valve cover 5 and mounting bolts 1 5 Inspect the components for damage and for foreign matter Replace the valve assembly if the valve assembly is damaged 6 Install the valve assembly 4 Install the plate 3 gaskets 2 cover 5 and the mounting bolts 1 7 Maintain the coolant level within 13 mm 5 inch of the bottom of the filler pipe 8 Install the cooling system pressure cap 100338284 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 S N 6BK1 Up A WARNING Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all li
31. 76 Maintenance Section Transmission Breather Clean i00903369 Transmission Breather Clean SMCS Code 3030 070 BRE S N 6BK1 Up Illustration 209 g00460707 The transmission breather 1 for the tractor is located on the top of the transmission and at the right rear of the tractor The breather with the hose is the breather for the differential and final drive Use the following procedure to clean the breather 1 Clean the area around the breather 2 Remove the breather 3 Wash the breather in clean nonflammable solvent 4 Allow the breather to dry 5 Install the breather 100894472 Transmission Oil Change SMCS Code 3030 044 S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin g00456570 Illustration 210 The drain plug 1 for the transmission is located under the tractor The drain p
32. Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Your machine may be equipped with a high speed arrangement for changing the engine oil The high speed arrangement allows the oil to be quickly withdrawn The high speed arrangement allows the oil to be quickly replaced The high speed arrangement has a hose which is attached to the oil pan at the drain hole The other end of the hose has a quick coupler 1 Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the crankcase The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with the new oil Park the machine on a level surface Shut off the engine Apply the parking brake goo484448 Illustration 171 Typical Example 2 Clean the area around the dust cover 1 for the male quick coupler that is on the hose Remove the dust cover Clean the male fitting 3 Remove the dust cover from female fitting of the suction hose Clean the female fitting Attach the suction hose to the male fitting Remove the oil from the engine 4 Remove the filter e
33. Inspect Replace 100872269 Router Bits Inspect Replace SMCS Code 6809 040 6809 510 S N 5SG480 Up A WARNING Personal injury or death can result if the bowl is not blocked up Block the bowl before changing router bits Note Any material that might fall on the worker should be removed from the bowl area Replace the router bits if the router bits are worn or damaged One router bit is on each side of the bowl 1 Park the machine on level ground 2 Raise the bowl and block up the bowl Block the bowl on both sides Blocks should be of material that is suitable for carrying the weight of the bowl Only block up the bowl to a sufficient height for the removal of the router bits 3 Block the apron Refer to Operation and Maintenance Manual Warning Signs and Labels for information on blocking the apron 4 Shut off the engine Engage the parking brake Release the hydraulic pressure on the hydraulic cylinders g00442403 Illustration 201 5 Remove the bolts and remove the router bits 1 6 Clean the contact surfaces 7 Use the opposite side of the router bits if the opposite side of the router bits are not worn Move the right side router bit to the left side of the bowl Move the left side router bit to the right side of the bowl 8 Install new router bits if both of the sides of the router bits are worn 9 Install the bolts for the router bits and tighten the bolts to the specified torqu
34. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved nS EBU6720 02 CATERPILLAR saute Operation ane Maintenance manual 623F Wheel Tractor Scraper 100845475 Maintenance Interval Schedule SMCS Code 1000 7000 Note All safety information warnings and instructions must be read and understood before you perform any operation or any maintenance procedure Before each consecutive interval is performed all of the maintenance requirements from the previous interval must also be performed When Required Battery Recycle o ee eeceeeceeeeseseceeeeseeeeeeeenenees 112 Battery Electrolyte Level Check ceeeeee 112 Battery Battery Cable or Battery Disconnect Switch Replace os danptieciitacenicunsndcneeee 113 Circuit Breakers Reset nenene 119 Clearance between Elevator Flight and Cutting Edge eCheck Adjust siieeft ds wreverevedrecrcatan annata a tenets 120 Cutting Edges and End Bits Inspect Replace 129 Draft Arm Wear Plates Check Adjust 133 Ejector Carrier Rollers Check Adjust 134 Ejector Guide Rollers Check Adjust 135 Ejector Support Rollers Check Adjust 136 Ejector Support Rollers Inspect Pack Replace 136 Elevator Chain Inspect Adjust eeeee 137 Engine Air Filter Primary Element Clean Replace cceecceceeeeeeeeeceeee
35. N position 17 Purge the air from the fuel system See the Operation and Maintenance Manual Fuel System Prime for further instructions Note The secondary fuel filter should also be changed at this time See the Operation and Maintenance Manual Fuel System Secondary Filter Replace for further instructions 18 Start the engine and check for leaks 155 Maintenance Section Fuel System Secondary Filter Replace 100855923 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates g00426839 Illustration 180 The secondary fuel filter for the tractor is mounted on the front of the hydraulic tank The hydraulic tank is to the right of the engine compartment 1 Park the machine on a level surface Lower the bowl Shut off the engine Move the fuel valve 3 to the CLOSED position Clean the secondary filter 2 Clean the filter base 1
36. The moisture indicator should always be checked at the end of the summer Use the following procedure in order to replace the dryer 168 Maintenance Section Oil Filter Inspect Replace 1 Stop the engine Allow the air conditioning system to remain inactive for five minutes in order to equalize the pressure 2 If the dryer is equipped with electrical connections disconnect the electrical connections 3 Disconnect the IN hose 1 from the old dryer Disconnect the hose at the quick coupler 4 Connect the IN hose 1 that was disconnected in Step 3 to the IN hose coupler on the new dryer 5 Start the engine and operate the air conditioning system for one minute in order to evacuate the refrigerant from the used dryer 6 With the air conditioning system in operation disconnect the OUT hose 3 from the old dryer Disconnect the hose at the quick coupler 7 Stop the engine The air conditioning system must be idle for five minutes in order to equalize the pressure 8 Connect the OUT hose 3 that was disconnected in Step 6 to the coupler on the new dryer 9 If the receiver is equipped with electrical connections install the electrical connections 10 Install the panel 100052234 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 S N 6BK1 Up Inspect A Used Filter for Debris Illustration 199 g00100013 The element is shown with debris
37. achine on level ground Lower the bowl and close the apron The ejector support rollers are located at the rear of the ejector There are 2 ejector support rollers These rollers support the rear portion of the ejector The rollers run in a track 3 A track is located on each side of the frame for the ejector Illustration 148 g00435120 Check the adjustment for the ejector support rollers Measure the clearance between the roller 1 and the inside wall of the track The clearance should be between 0 8 mm 03 inch and 3 3 mm 13 inch Shims will need to be used to establish the correct distance Refer to Disassembly and Assembly SENR6809 Ejector Support Rollers for additional information Refer to Specifications SENR6822 Ejector Group for additional information g00435120 Illustration 149 Remove the debris from the rollers in order to inspect the rollers Pack the bearings of the rollers Refer to Disassembly and Assembly SENR6809 Ejector Support Rollers for additional information Refer to Specifications SENR6822 Ejector Group for additional information on packing the bearings 100963198 Elevator Chain Inspect Adjust SMCS Code 6231 025 6231 040 S N 5SG480 Up Inspect the Elevator Chain g00490921 Illustration 150 Inspect the slack of the elevator chain Inspect the slack at the widest space that is between the arrows The upper arrow is located at the lower
38. aintenance Section Differential Thrust Pin Clearance Check 00995188 Differential Thrust Pin Clearance Check SMCS Code 3258 535 T9 S N 6BK1 Up 100839167 Differential and Final Drive Breather Clean SMCS Code 3258 070 BRE 4050 070 BRE S N 6BK1 Up Illustration 134 g00395022 Typical Example p g00395885 Illustration 135 The Differential Thrust Pin is located at the front left of the differential housing Refer to Specifications SENR6810 621F 623F and 627F Wheel Tractor Scrapers Power Train Differential and Bevel Gear for the correct procedure to adjust the differential thrust pin or contact your Caterpillar Dealer Illustration 136 g00410143 The differential and final drive breather for the tractor is located on the top of the transmission and at the right rear of the tractor Use the following procedure to clean the breather 1 Remove the breather 2 Wash the breather in clean nonflammable solvent 3 Allow the breather to dry 4 Install the breather 100925564 Differential and Final Drive Oil Change SMCS Code 3258 044 4050 044 S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Pub
39. an Drive Bearing and Belt Tightener LUDTIC ALS scoi an a dined ences 152 Hydraulic System Oil Sample Obtain 165 Transmission Oil Sample Obtain 0c 180 V Belts Inspect Adjust Replace 180 Wheel Bearing Oil Level Check 0 ce 184 Every 500 Service Hours or 3 Months Brake Camshaft Bearing Lubricate 115 Differential and Final Drive Oil Sample Obtain 133 Engine Crankcase Breather Clean 00 146 Fuel System Primary Filter Clean Inspect Replace oriras needa ited 154 Fuel System Secondary Filter Replace 155 Fuel Tank Cap and Strainer Clean 06 156 Hydraulic System Oil Filter Replace 163 Hydraulic Tank Breaker Relief Valve Clean 166 In Line Refrigerant Dryer Check Replace 167 Transmission Oil Filter and Magnetic Screen Replace Clean cccecccccceceesececeeeeesecaeeseeeeeees 177 Every 1000 Service Hours or 6 Months Air Dryer Desiccant Replace 110 Brake Air System Warning Horn Test 114 Differential and Final Drive Breather Clean 130 Rollover Protective Structure ROPS Inspect 169 Seat Suspension Lubricate cccecceenees 172 Suction Screen Transmission Scavenge ClO AM sid eavscs Qvteaiia a anit ave eevee 174 Transmission Breather Clean 0 ccccsceeeee 176 Transmission Oil Change cccceeeeeseeeeee
40. ath can result The brakes can generate enough heat to burn the tire bead A burning bead pro duces gases inside the tire that can explode en dangering personnel within 500 meters 1500 feet g00447783 Illustration 223 The filler plug 1 for checking the antifreeze solution for the rear wheel is located on the rear wheel 1 Park the machine with the plug in a horizontal position in relation to the axle 2 Lower the bowl Apply the parking brake Shut off the engine 3 Clean the area around the plug hole 4 Remove the plug Antifreeze should be dripping from the bottom of the plug hole Add antifreeze if antifreeze is needed A solution of 50 percent water and 50 percent Caterpillar antifreeze is preferable If Caterpillar antifreeze is not used commercially available ethylene glycol type antifreeze can be a substitute 5 Clean the plug Install the plug 6 Perform the same procedure to the other rear wheel 185 Maintenance Section Wheel Coolant Level Check i00879019 Wheel Coolant Level Check SMCS Code 4207 535 FLV S N 6BK1 Up A WARNING With a lack of wheel coolant personal injury or death can result The brakes can generate enough heat to burn the tire bead A burning bead pro duces gases inside the tire that can explode en dangering personnel within 500 meters 1500 feet g00453025 Illustration 224 DRIVEN WHEELS The check fill plug 1 for the wheel coolant is located o
41. ble container 4 Remove the bolts 3 from the filter housing and remove the cover from the filter housing 5 Remove the used filter element and discard the used filter element 6 Clean the inside of the filter housing with a clean towel 7 Insert a new filter element into the filter housing 8 Inspect the filter housing seal Replace the seal if the seal is damaged 9 Install the cover on the filter housing 10 Install the transmission filter housing drain plug in the filter housing g00468461 Illustration 213 The magnetic screen is located below the transmission oil filter The screen is located at the rear of the transmission housing 1 Remove the drain plug 4 Drain the oil into a suitable container Remove the bolts 5 Remove the cover 6 Remove the screen a A O N Separate the magnets from the screen Wash the screen and the magnets in a nonflammable solvent Note Do not rap the magnets on hard objects The magnets may be damaged Replace damaged magnets 6 Allow the cleaned parts to dry Use compressed air pressure in order to speed the drying of the parts 7 Clean the magnets with a towel or clean the magnets with a stiff brush 8 Install the magnets into the screen 9 Install the magnetic screen into the housing 10 Install the cover and the bolts 11 Install the drain plug 12 Start the engine Apply the parking brake 13 Run the engine at low idle
42. carrier rollers are located at the base of the ejector There are 2 ejector carrier rollers g00102197 Illustration 145 Remove the debris from the roller in order to inspect the roller Pack the bearings of the rollers Refer to Disassembly and Assembly SENR6808 Ejector Carrier Rollers for additional information Refer to Specifications SENR6820 Ejector for additional information on packing the bearings 100861271 Ejector Guide Rollers Check Adjust SMCS Code 6230 025 6230 535 S N 5SG480 Up Park the machine on level ground Lower the bowl and close the apron The ejector guide rollers are located at the middle of the ejector There are 2 ejector guide rollers These rollers prevent the ejector from contacting the sides of the bowl These rollers prevent the ejector from cocking Check the adjustment for the ejector guide rollers The ejector guide rollers are correctly adjusted if the ejector does not contact the sides of the bowl The rollers should be in a position that prevents the ejector from rising too far above the floor of the bowl g00432148 Illustration 146 Typical Example 1 Loosen roller shaft clamping bolt 1 2 Move eccentric roller shaft 2 to a position that allows the ejector to pass over the sides of the bowl 3 Tighten roller shaft clamping bolt 1 4 Repeat Step 1 through Step 3 in order to adjust the other ejector guide roller 5 Start the engine Mo
43. compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates go0446989 Illustration 221 184 Maintenance Section Wheel Bearing Oil Level Check The oil filler plug 1 for checking the oil for the wheel bearing is located on the rear wheel The filler plug for the oil for the wheel bearing is not clearly shown in this picture The filler plug is in the DRAIN position Do not confuse the oil filler plug 1 with the filler plug 2 for the antifreeze for the rear wheel 1 Park the machine with the oil filler plug in a vertical position in relation to the axle The oil plug should be at the lowest point for the plug 2 Lower the bowl Apply the parking brake Shut off the engine 3 Remove the plug Allow the oil to drain into a suitable container 4 Clean the area around the plug hole 5 Start the engine Release the parking brake Raise the bowl Move the machine until the filler plug hole is horizontal with the axle The filler plug hole should move 90 degrees from the lowest position 6 Lower the bowl Apply the parking brake Shut off the engine 7 Fill the wheel bearing with oil Oil should drip from the filler hole when the cavity for the bearing is full 8
44. cuit Repair the electrical circuit if necessary GQ Circuit Breaker Reset Push in the button Blower Motor 1 15 AMP Alternator 2 80 AMP D amp 2 120 Maintenance Section Clearance between Elevator Flight and Cutting Edge Check Adjust Clearance between Elevator Flight and Cutting Edge Check Adjust SMCS Code 6232 025 6232 535 S N 5SG480 Up g00493775 Illustration 122 The clearance between the elevator flights and the top of the cutting edge may be adjusted The distance between the top of the cutting edge and the elevator flights is set at the factory at approximately 61 mm 2 4 inches Two shims 3 are located on top of the welded bracket 6 when the machine is shipped from the factory The welded brackets 6 are located on each side of the bowl The shims must be equally placed on each of the brackets A special plate 5 is located above the removable shims 3 The top plate 5 must remain in the top position The top plate 5 prevents damage to the attaching bolts 1 Four shims 2 are located on the bottom of the welded bracket 6 when the machine is shipped from the factory Shims may need to be added to the top of the bracket when you are working in material which is compacted The space that is between the cutting edge and the elevator flight will become wider Shims may also need to be added to the top of the bracket when the components of the elevator become worn
45. djustment for the pulley that is spring loaded Replace the belts if the belts are worn or if the belts are damaged Alternator Belt Illustration 217 g00458855 The alternator belt 2 is located in the engine compartment of the tractor Open the access door on the right side of the engine in order to inspect the alternator belt Replace the belt if the belt is worn or if the belt is damaged 1 Loosen the pivot bolts 3 5 and 6 Note One pivot bolt 3 is located under the alternator 2 Loosen the locking nut 7 3 Move the adjusting nut 4 until the proper belt tension is reached To check the belt tension apply 110 N 25 Ib of force midway between the pulleys Correctly adjusted belts will deflect 13 to 19 mm 1 2 to 3 4 inch 4 Tighten the locking nut 7 to 150 20 N m 110 15 Ib ft 5 Tighten the pivot bolts 3 5 and 6 Air Conditioning Compressor Belt Illustration 218 g00459078 181 Maintenance Section V Belts Inspect Adjust Replace The air conditioning compressor belt 8 is located in the engine compartment of the tractor Open the access door on the top of the engine in order to inspect the air conditioning compressor belt Replace the belt if the belt is worn or if the belt is damaged 1 Loosen the pivot bolts 3 5 and 6 Note One pivot bolt 3 is located under the air conditioning compressor 2 Loosen the locking nut 7 3 Move the
46. e See Operation and Maintenance Manual Torques for Ground Engaging Tool Bolts 10 Start the engine Raise the apron and remove the pin assembly from the pin holder Lower the apron and return the pin assembly to the pin s storage location 11 Raise the bowl Remove the supporting block Lower the bowl to the ground After a few hours of operation check the bolts for proper torque i00061967 Seat Inspect SMCS Code 7312 040 S N 6BK1 Up Replace the tether straps after every three years g00102996 Illustration 202 Inspect the following components for leaks and or for damage shock absorber air valve and lines Repair these components if necessary Check the operation of the adjustment levers Lubricate the adjustment levers if necessary 171 Maintenance Section Seat Inspect i00062066 Seat Belt Inspect SMCS Code 7327 040 S N 6BK1 Up Always check the condition of the seat belt and the condition of the mounting hardware before you operate the machine Regardless of appearance replace the seat belt after every three years of use A date label for determining the age of the seat belt is attached to each seat belt Illustration 203 g00103047 Inspect the seat belt for webbing that is worn or frayed Carefully check the following components of the seat belt e Strap e Buckle e Anticreep Slides Replace the seat belt if the strap the buckle or the anticreep slides are
47. e The parking brake must be applied e The hydraulic oil must be warm e The engine must be running at low idle e The transmission control must be in NEUTRAL e The cushion hitch must be in the OFF position e The ejector must be moved forward e Apply slight downward pressure on the bowl g00439339 Illustration 194 If oil is needed add oil to the hydraulic tank The hydraulic oil filler cap 2 is located on top of the hydraulic tank 1 You should clean the cap before you remove the cap This cap is a locking cap You need to remove the padlock if a padlock is on the cap Raise the lever 3 in order to engage the lug Turn the cap counterclockwise in order to remove the cap Remove the cap slowly in order to relieve the air pressure 2 Add hydraulic oil until the oil level is at the full mark 3 Clean the cap Inspect the cap for damage to the seal Replace the seal if the seal is damaged 4 Install the oil filler cap 165 Maintenance Section Hydraulic System Oil Sample Obtain 100089529 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 7542 008 S N 6BK1 Up Refer to Operation and Maintenance Manual S O S Oil Analysis and Operation and Maintenance Manual Sampling Interval and Location of Sampling Valve for information that pertains to obtaining a sample of the hydraulic oil 166 Maintenance Section Hydraulic Tank Breaker Relief Valve Clean 100871335 Hydraulic Tank
48. e ball valve to the OPEN position 2 Collect the fuel in a suitable container A clear container is suitable 3 Move the ball valve to the CLOSED position in order to examine the fuel that is collected 4 Examine the fuel that is collected for water and for sediment Water collects below the diesel fuel If water is in the fuel collect additional fuel If sediment is in the fuel collect additional fuel If unwanted material is not found in the fuel discontinue draining of the fuel 157 Maintenance Section Fuel Tank Water and Sediment Drain 5 Move the ball valve to the CLOSED position 158 Maintenance Section Fuses Replace i00865846 Fuses Replace SMCS Code 1417 510 S N 6BK1 Up NOTICE Replace fuses with the same type and size only Oth erwise electrical damage can result If it is necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer g00436201 Illustration 182 The fuse box is located on the left side of the seat for the operator The fuse box is located on the floor Remove the 4 screws 18 which hold the cover on the fuse box in order to expose the fuses Note The front head lights the instrument lights the dome light and the red lights on the rear of the scraper are on an automatic breaker The automatic breaker is located inside the compartment for the fuses Note Your machine may not utilize all of the fuses that are listed he
49. e the pressure in the hydraulic system 1 Shut off the engine Apply the parking brake Lower the bowl 2 Move the control levers through the full travel strokes This will relieve any pressure that may be present in the pilot system 3 Slowly loosen the breather cap on the hydraulic oil tank 4 The pressure in the hydraulic system has now been released Lines and components can now be removed Remove the screen 1 Remove the hose 1 2 Loosen the nut 2 Remove the fitting 8 A wow Remove the screen which is located below the fitting 3 5 Clean the screen in nonflammable solvent Inspect the screen for damage Replace the screen if the screen is damaged 173 Maintenance Section Steering Pump Outlet Screen Clean 6 Install the clean screen 7 Inspect the O ring which is located under the nut 2 Replace the O ring if the O ring is damaged 8 Install the fitting 3 Position the fitting so that the hose 1 can be easily installed 9 Install the hose 1 10 Tighten the nut 2 11 Start the engine Check for oil leaks at the steering pump outlet screen 174 Maintenance Section Suction Screen Transmission Scavenge Clean 100934598 Suction Screen Transmission Scavenge Clean SMCS Code 3030 070 Z3 S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine
50. ection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates The fuel priming pump for the tractor is mounted on the front of the hydraulic tank The hydraulic tank is to the right of the engine compartment The pump is used when the following operations occur e Changing the fuel filters e Priming the fuel system e Changing the fuel lines e Purging air from the fuel system Note Do not attempt to start the engine until the fuel system is purged of air g00422959 Illustration 178 1 Open the purge screw 2 on the secondary filter base 154 Maintenance Section Fuel System Primary Filter Clean Inspect Replace 2 Turn the knob 1 of the priming pump plunger counterclockwise in order to unlock the plunger 3 Pull up and push down on the knob in order to pump fuel Note The pump will fill the filters Note If the pump will not pump fuel the pump may be defective or an air leak may occur on the suction side of the fuel system 4 Continue to prime the fuel system until the flow of fuel is free of air bubble s 5 C
51. ed in the rail 4 6 Shorten the jack in order to relieve the pressure on the mounting pins for the jack Remove the mounting pins in order to remove the jack 7 Repeat Steps 3 through 6 in order to adjust the other elevator chain 8 Install the mounting pins in the jack Install the jack in the storage area that is under the scraper 138 Maintenance Section Elevator Chain Adjustment Idler Lubricate Note Remove a half link from each elevator chain in order to obtain more adjustment of the chain 100954949 Elevator Chain Adjustment Idler Lubricate SMCS Code 6248 086 S N 5SG480 Up 00486818 Illustration 153 The elevator chain adjustment idlers 1 are located on the elevator frame One idler is located on each side of the frame 1 Park the machine on level ground Apply the parking brake Lower the bowl 2 Clean the area around the grease fitting 2 for the idler 3 Apply grease to the fitting 4 Follow Steps 2 and 3 for the other idler 100954823 Elevator Chain Idler Lubricate SMCS Code 6248 086 S N 5SG480 Up g00486735 Illustration 154 The elevator chain idlers 1 are located on the elevator frame One idler is located on each side of the frame 1 Park the machine on level ground Apply the parking brake Lower the bowl 2 Clean the area around the grease fitting 2 for the idler 3 Apply grease to the fitting 4 Follow Steps 2 and 3 for the other idler
52. edge of the frame assembly for the elevator The lower arrow is on the upper side of the elevator chain The widest space will be halfway between the upper sprocket and the lower idler The slack in the elevator chain should be 254 to 356 mm 10 to 14 inches Adjust the elevator chain when the distance between the arrows exceeds 356 mm 14 inches The elevator chain should be inspected for wear Measure the length of 10 chain links Replace the elevator chain if the 10 links measure more than 1079 mm 42 5 inches Refer to Disassembly and Assembly SENR6809 Elevator Flight Assemblies and Chain Assemblies for further information Note Failure to replace a worn elevator chain will result in excessive wear to the drive sprockets 137 Maintenance Section Elevator Chain Inspect Adjust Adjust the Elevator Chain g00490922 Illustration 151 1 Remove the jack 5 which is located under the scraper The jack is located near the push block Illustration 152 g00490923 Typical Example 2 Remove the pins 6 from the jack 3 Attach one end of the jack to the frame assembly for the elevator 1 Adjust the jack until the other end of the jack can be attached to the adjuster arm 2 4 Extend the jack until the pressure is off of the adjusting bolt 3 Remove the adjusting bolt 5 Extend the jack until the desired tension of the chain is achieved Install the adjusting bolt 3 The adjusting bolt must be secur
53. eeeeeeeeeneeees 143 Engine Air Filter Secondary Element Replace 144 Engine Air Precleaner Clean iccse 145 Ether Starting Aid Cylinder Replace 151 Fuel System Prime cccceeeeeceeesseeeeeeeeeeeeees 153 Fuel System Primary Filter Clean Inspect Replace enoii aeea Ea a Ei 154 Fuses Replace sssssesesrressrrnserirresrrrrnesrrnneens 158 Hydraulic Tank Breaker Relief Valve Clean 166 Oil Filter Inspect ee eee eee eeeeeeeeeteeeeeneeteeeees 168 Router Bits Inspect Replace eee 170 Seat Inspect ooo cece ceeeeceeeeeeeeeeseeaeeeeaeeeeneeees 171 Steering Pump Outlet Screen Clean 173 Window Washer Reservoir Fill l a 186 Window Wiper Inspect Replace n 187 Windows Clean 00 0 cee eeeececessteeeeeesseeeeeeesaeeeeeeaas 187 Every 10 Service Hours or Daily Air Tank Moisture and Sediment Drain 110 Backup Alarm Testne 111 Brakes Indicators and Gauges Test 4 116 Cooling System Level Check cccssceceeeeee 125 Differential and Final Drive Oil Level Check 132 Ejector Guide Rollers Inspect Lubricate RE Plae si a aa e sh TRAN 135 Elevator Chain Adjustment Idler Lubricate 138 Elevator Chain Idler Lubricate c0 139 Elevator Linkage Lubricate eceeeeeeees 140 Engine Air Filter Service Indicator Inspect 145 107 Maintenance Section Maintenance
54. erential and final drive oil is located on the back right side of the transmission g00390115 Illustration 142 1 Park the machine on level ground 2 Lower the bowl Shut off the engine 3 Clean the sight gauge 1 and the oil filler cap 2 4 Maintain the oil level between the FULL and the ADD marks on the sight gauge 5 Remove the oil filler cap and add oil if it is necessary 6 Clean the oil filler cap and install the oil filler cap Differential and Final Drive Oil Sample Obtain SMCS Code 3258 008 4050 008 7542 008 S N 6BK1 Up Refer to Operation and Maintenance Manual S O S Oil Analysis and Operation and Maintenance Manual Sampling Interval and Location of Sampling Valve for information that pertains to obtaining a sample of the differential and final drive oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the differential and final drive oil 133 Maintenance Section Differential and Final Drive Oil Sample Obtain i00059862 Draft Arm Wear Plates Check Adjust SMCS Code 6204 025 WK 6204 535 WK S N 5SG480 Up g00102145 Illustration 143 Check the clearance between shoe 1 and draft arm wear plate 2 The clearance should be 6 0 mm 24 inch or less Add shims if necessary Repeat the procedure for the draft arm wear plate that is on the other side of the bowl 134 Main
55. ervice brakes If the service brakes malfunction consult your Caterpillar Dealer for repairs e Engage the parking brake Move the machine forward in order to test the parking brake If the parking brake malfunctions consult your Caterpillar Dealer for repairs e Stop the engine i00798619 Braking System Test SMCS Code 4251 081 4267 081 Service Brake Holding Ability Test A WARNING 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 Make sure that the area around the machine is clear of personnel and of obstacles Test the brakes on a dry level surface Fasten the seat belt before you test the brakes The service brake holding ability test determines whether the service brake is functional This test is not intended to measure the maximum brake holding effort 1 Start the engine and look at the air pressure gauge Allow the brake system air pressure to reach 850 50 kPa 125 10 psi 2 Raise the bowl 3 Apply the service brake and release the parking brake 4 While the engine is at an idle and the service brake is applied move the transmission control to the SECOND SPEED position 5 Gradually increase the engine rom The service brake should prevent machine movement when the engine is running at 1200 100 rpm If the machine moves with the engine rom less than 1200 rom
56. f air The air dryer may need to be serviced Refer to Operation and Maintenance Manual Air Dryer Check for further information If oil is draining from the tanks consult your Caterpillar dealer Two valves are on the left side of the tractor The valves are located in the recess for the step Illustration 109 g0033606 1 Typical Example g00335158 Illustration 110 Open the valves Allow the moisture and the sediment to drain into a suitable container Close the valves The air tank for the scraper is on the right rear side of the scraper Illustration 111 g00336028 Typical Example g00336138 Illustration 112 Open the drain valve Allow the moisture and the sediment to drain into a suitable container Close the drain valve 111 Maintenance Section Backup Alarm Test 100993421 Backup Alarm Test SMCS Code 7406 081 The backup alarm is on the rear of the machine Turn the engine start switch to the ON position in order to perform the test Apply the service brake Move the transmission control lever to the REVERSE position The backup alarm should start to sound immediately The backup alarm will continue to sound until the transmission control lever is moved to the NEUTRAL position or to the FORWARD position To adjust the volume level turn the three position adjustment knob on the back of the backup alarm The three position adjustment knob is set to the HIGH setting when
57. gine speed immediately and engage the parking brake 5 Gradually increase the engine rom The parking brake should prevent machine movement when the engine is running at 1000 100 rom If the machine moves with the engine rom less than 1000 rpm consult your Caterpillar Dealer for an inspection of the machine 6 Reduce the engine speed and move the transmission control to the NEUTRAL position Lower the bowl to the ground and stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar Dealer Have the dealer inspect and if necessary repair the service brakes before returning the machine to operation 118 Maintenance Section Cab Air Filter Clean Replace Note If the friction material for the brakes needs to be replaced the new friction material may require burnishing for maximum performance Consult your Caterpillar Dealer or see Special Instruction SEHS9187 for the procedure for burnishing i00804039 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 S N 6BK1 Up Cleaning the Filters Outside Filters Note Clean the air filters more often during dusty conditions CATERPILLAR Illustration 119 g00380452 Typical Example 1 Open the access cover 1 that is located at the front of the cab 2 Remove the thumb screws 2 which hold the filter element in place 3 Remove the filter element 3 Clean the filter element with pressure air or wash the f
58. id with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates g00425658 Illustration 179 The primary fuel filter for the tractor is mounted on the front of the hydraulic tank The hydraulic tank is to the right of the engine compartment 1 Park the machine on a level surface 2 Lower the bowl 3 Shut off the engine 4 Move the fuel valve 3 to the CLOSED position 5 Clean the primary filter 2 Clean the filter base 1 which is located above the filter 6 Loosen the filter housing retaining bolt 1 which is located at the top of the filter base 7 Remove the housing 2 8 Remove the element from the housing 9 Wash the element and wash the housing in clean nonflammable solvent 10 Dry the element by using pressure air 11 Inspect the element for damage Replace the element if the element is damaged 12 Install the clean element into the housing 13 Inspect the seal which is located inside the bottom of the filter base Replace the seal if the seal is damaged 14 Install the housing on the filter base 15 Tighten the retaining bolt to 24 4 N m 18 3 Ib ft 16 Move the fuel valve to the OPE
59. ids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates The elevator speed reducer 1 is located at the top of the elevator The elevator speed reducer is on the left side of the elevator 1 Park the machine on level ground Lower the bowl Apply the parking brake 2 Clean the area around the filler plug 2 3 Clean the area around the drain plug 3 Remove the drain plug 4 Allow the oil to drain into a suitable container 5 Clean the drain plug Install the drain plug 6 Remove the filler plug Fill the gear case with oil Refer to Operation and Maintenance Manual Refill Capacities for further information Refer to Operation and Maintenance Manual Lubricant Viscosities for further information Oil should drip out of the filler hole when the gear case is full of oil Add oil if oil is needed 7 Clean the filler plug Install the filler plug 100833575 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY S N 6BK1 Up g004045
60. iller pipe 124 Maintenance Section Cooling System Coolant Additive DEAC Add 10 Inspect the gasket of the cooling system pressure cap If the gasket is damaged replace the gasket 11 Install the cooling system pressure cap 12 Stop the engine 100993304 Cooling System Coolant Additive DEAC Add SMCS Code 1352 544 S N 6BK1 Up See the appropriate topics in your machine s Operation and Maintenance Manual for all cooling system requirements Use 8T 5296 Test Group to check the concentration of the Diesel Engine Antifreeze Coolant DEAC If necessary add supplemental coolant additive NOTICE Do not exceed the recommended six percent sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temperature components Excessive supplemental coolant additive concentration could also result in ra diator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supple mental coolant additive and the spin on element if equipped at the same time The use of those addi tives together could result in supplemental coolant additive concentration exceeding the recommended six percent maximum 1 Slowly loosen the cooling system
61. ilter element in warm water Use a nonsudsing household detergent Rinse the filter element in clean water and air dry the filter element thoroughly 4 After you clean the filter element inspect the filter element Do not use a filter element with damaged pleats or a damaged seal If the filter element is damaged replace the filter element 5 Install the filter element Close the access cover Inside Filter g00382090 Illustration 120 1 Remove the access cover The access cover is on the inside of the cab 2 Remove the filter element Clean the filter element with pressure air or wash the filter element in warm water Use a nonsudsing household detergent Rinse the filter element in clean water and air dry the filter element thoroughly 3 After you clean the filter element inspect the filter element Do not use a filter element with damaged pleats or a damaged seal If the filter element is damaged replace the filter element 4 Install the filter element Install the access cover 119 Maintenance Section Circuit Breakers Reset i00806608 Circuit Breakers Reset SMCS Code 1420 529 S N 6BK1 Up g00382972 Illustration 121 The circuit breakers are located at the left side of the operator s seat in order to reset the circuit breaker If the electrical system is working properly the button will remain depressed If the button does not remain depressed check the appropriate electrical cir
62. iper Inspect Replace SMCS Code 7305 040 7305 510 S N 6BK1 Up One window wiper is located at the cab front window One window wiper is located at the cab rear window The window wipers have replacable wiper blades Replace the wiper blades when the following conditions occur e The wiper blades streak the windows of the cab e The wiper blades are damaged e The wiper blades are worn Note Damaged wiper blades may cause permanent damage to the glass of the cab windows 187 Maintenance Section Window Wiper Inspect Replace 00881851 Windows Clean SMCS Code 7310 070 S N 6BK1 Up g00449946 Illustration 226 Typical Example If it is at all possible you should clean the windows while you are standing on the ground Use the handhold assemblies 1 2 and 4 when you are cleaning the windows Skid resistant materials 3 and 5 are provided for better footing Handhold assemblies and skid resistant materials are also found on other parts of the machine Illustration 227 g00449964 Typical Example Use a bottle which is made of plastic Use a bottle which is equipped for spraying a cleaning solution Fill the bottle with a commercially available glass cleaner 188 Maintenance Section Windows Clean Cleaning Methods Spray the windows with the cleaner Rub the windows with a clean towel If a container for spraying is not available apply the cleaner with a clean towel Rub the window with
63. lean the oil cooler in the same manner as you Clean the radiator You can use compressed air high pressure water or steam to remove dust and other debris from the radiator core However the use of compressed air is preferred Note Care must be taken when you are using high pressure water High pressure water can cause damage to the radiator Use of a water spray nozzle on the pressure washer which will disperse the water pressure is preferred Note At the same interval clean the air conditioner condenser 161 Maintenance Section Hydraulic Oil Cooler Clean 100870315 Hydraulic System Oil Change SMCS Code 5056 044 S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates goo440444 Illustration 189 The drain for the hydraulic tank is located under the hydraulic tank The drain is ahead of the right tractor wheel Note The machine must meet the following conditions before you change the hydraulic tank oil e The
64. lement 2 with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect 5 Clean the filter mounting base with a clean towel Make sure that the old filter gasket has been removed 6 Apply a thin film of clean engine oil to the sealing surface of the new filter element 7 Install the new filter elements hand tight When the gasket contacts the filter base turn the filter by 270 degrees more This will tighten the filter sufficiently 8 Every new oil filter has marks which are for determining the rotation index These marks are spaced at 90 degree increments Use the rotation index marks as a guide for tightening the oil filter 9 Pump new oil into the engine See the following topics e Operation and Maintenance Manual Lubricant Viscositites e Operation and Maintenance Manual Refill Capacities 10 Remove the hose from the male coupler Install the dust cover 147 Maintenance Section Engine Oil High Speed and Oil Filter Change 11 Start the engine and allow the oil to warm Check the engine for leaks Check the male fitting for leaks Check the filter for leaks Shut off the engine 12 Check the oil level on the dipstick 3 Maintain the oil between the marks on the SAFE OPERATING RANGE side of the dipstick If necessary add oil 148 Maintenance Section Engine Oil Level Check 100839534 Engine Oil Level Check SMCS Code 1000 535 FLV S N
65. lication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin g00456570 Illustration 137 The drain plug for the differential 2 is located under the transmission of the tractor The drain plug for the transmission 1 is located behind the drain plug for the differential 2 The drain plug for the differential is located closer to the front of the machine Operate the machine until the differential oil is warm Park the machine on a level surface Lower the bowl 1 Engage the parking brake Stop the engine 131 Maintenance Section Differential and Final Drive Oil Change 2 Clean the area around the drain plug 3 Engage the parking brake Stop the engine 4 Remove the differential drain plug and drain the oil into a suitable container 5 Clean the plug Install the plug Note The drain plug 3 for the final drive is located on the hub of the wheel The plug must be at the lowest point for the plug in order to drain the final drive Ado Illustration 138 g00472907 6 Clean the area around the drain plug 3 7 Remove the plug Drain the oil into a suitable container 8 Clean the plug Install the plug 9 Repeat this p
66. lizes 9 Maintain the coolant level within 13 mm 5 inch of the bottom of the filler pipe 10 Inspect the gasket of the cooling system pressure cap If the gasket is damaged replace the gasket 11 Install the cooling system pressure cap 12 Stop the engine 100812639 Cooling System Coolant ELC Change SMCS Code 1350 044 NL S N 6BK1 Up NOTICE Do not change the coolant until you read and under stand the material found in the Operation and Mainte nance Manual Cooling System Specifications sec tion Failure to do so could result in damage to the cooling systems components NOTICE Mixing ELC with other products reduces the effec tiveness of the coolant and shortens coolant life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specifications for pre mixed or concentrate coolants Use only Caterpillar Extender with Caterpillar ELC Failure to follow these recommendations could result in the damage to cooling systems components If ELC cooling system contamination occurs see the topic ELC Cooling System Contamination of this op eration and maintenance manual NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before Opening any compartment or disassembling any component containing fluids Refer t
67. llustration 159 g00492724 g00492727 Illustration 160 The elevator linkage 1 supports the elevator on the machine The elevator linkage is located on each side of the elevator There are 4 grease fittings to grease for the elevator linkage 1 Park the machine on level ground Apply the parking brake Lower the bowl 2 Clean the area around the grease fittings 2 3 3 Remove the dust caps from the grease fittings 2 3 4 Apply grease to the fittings 5 Install the dust caps 141 Maintenance Section Elevator Speed Reducer Check Lubricate i00953669 Elevator Speed Reducer Check Lubricate SMCS Code 6236 086 ELV 6236 535 ELV S N 5SG480 Up Illustration 161 g00486360 The elevator speed reducer 1 is located at the top of the elevator The elevator speed reducer is on the left side of the elevator 1 Park the machine on level ground Lower the bowl Apply the parking brake 2 Clean the area around the filler plug 2 3 Remove the filler plug Oil should drip out of the filler hole Add oil if oil is needed Refer to Operation and Maintenance Manual Lubricant Viscosities for further information 4 Clean the filler plug Install the filler plug 142 Maintenance Section Elevator Speed Reducer Oil Change 100954244 Elevator Speed Reducer Oil Change SMCS Code 6236 044 ELV S N 5SG480 Up go0486588 Illustration 162 NOTICE Care must be taken to ensure that flu
68. lose the purge screw If you have only changed the fuel filters go to Step 8 If you have air in the fuel system for some other reason continue with Step 6 6 Prime the injector nozzle by first opening the fuel inlet line The injector nozzle must be held in order to open the fuel line The line may need to be wiggled slightly in order to allow the fuel to flow from the line 7 Continue to prime the fuel system until the flow of fuel from the line is free of air bubble s Close the line Follow this procedure for all of the injectors 8 Continue pumping the knob The fuel system is primed when resistance is felt in the system 9 Push in on the knob for the pump Turn the knob clockwise in order to lock the knob 10 Start the engine If the engine will not start further priming is necessary If the engine starts but the engine continues to misfire further priming is necessary If the engine starts but the engine continues to emit smoke further priming is necessary 11 If the engine starts but the engine runs rough continue to run the engine at low idle Continue to run the engine at low idle until the engine runs smoothly 100854741 Fuel System Primary Filter Clean Inspect Replace SMCS Code 1260 510 1260 571 S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the flu
69. lug 2 for the differential is located ahead of the drain plug for the transmission The drain plug for the differential is closer to the front of the machine Operate the machine until the transmission oil is warm Park the machine on a level surface Lower the bowl Engage the parking brake Stop the engine 1 Clean the area around the drain plug 1 177 Maintenance Section Transmission Oil Filter and Magnetic Screen Replace Clean 2 Remove the transmission drain plug and drain the oil into a suitable container 3 Clean the transmission drain plug and install the transmission drain plug g00460507 Illustration 211 4 Clean the area around the filler cap Remove the filler cap 3 Fill the transmission with oil through the filler tube 3 Fill the transmission to the FULL mark 4 in the sight glass Refer to the Operation and Maintenance Manual Refill Capacities and the Operation and Maintenance Manual Lubricant Viscosities Note Red dye is added to the transmission oil at the factory If the oil in the differential 5 has a red color transmission oil has leaked into the differential If oil is leaking from the transmission see your Caterpillar Dealer for further information 9U 5031 Red Oil Dye may be added to your transmission oil See your Caterpillar Dealer for further information 5 Clean the oil filler cap Install the oil filler cap 6 Start the engine Run the engine at lo
70. machine must be level e The parking brake must be applied e The hydraulic oil must be warm e The transmission control must be in NEUTRAL e The bowl must be lowered 162 Maintenance Section Hydraulic System Oil Change g00440583 Illustration 190 The hydraulic oil filler cap 8 is located on top of the hydraulic tank 1 Loosen the hydraulic oil filler cap in order to relieve any pressure in the tank You should clean the cap before you remove the cap This cap is a locking cap You need to remove the padlock if a padlock is on the cap Raise the lever 4 in order to engage the lug Turn the cap counterclockwise in order to remove the cap Remove the cap slowly in order to relieve the air pressure 2 Remove the drain plug 1 which is located at the bottom of the hydraulic tank 3 Open the tank drain valve 2 Allow the oil to drain into a suitable container 4 Change the hydraulic system filters See Operation and Maintenance Manual Hydraulic System Oil Filter Replace for further information 5 Close the drain valve Clean the drain plug Install the drain plug 6 A screen is located under the oil filler cap 3 Remove the oil filler cap Remove the screen 7 Wash the screen in clean nonflammable solvent Inspect the screen for damage Replace the screen if the screen is damaged 8 Install the screen 9 Fill the hydraulic tank to the proper level See Operation and Maintenance Ma
71. n 219 1 Inspect the engine air precleaner 1 for dirt buildup Remove dirt from the precleaner screen Make sure that the air filter service indicator is not in the red zone 2 Inspect the hitch components 2 for cracks for worn hitch pins and for damaged stops Make any necessary repairs 3 Inspect the steering linkage 3 for cracks Check for steering components that are worn or damaged 4 Inspect the draft frame gooseneck 4 for cracks for damage and for distortion 5 Inspect the draft arms 5 and the cross tube for cracks or for damage 6 Inspect the bowl and the ejector 6 for damage and for distortion 7 Inspect the elevator chain 7 for tension and for damage Check the oil level of the gear box for the elevator drive 8 Inspect the engine compartment 8 for debris Inspect the radiator for debris Remove debris from the radiator and from the engine Check the oil level of the engine Check the fluid level of the radiator Check the cooling system for leaks 9 Inspect oil levels of the transmission 9 and of the differential 9 10 Inspect the oil level of the hydraulic tank 10 g00477131 Illustration 220 11 Inspect the hydraulic system 11 for leaks 12 Inspect the final drives 12 for leaks Inspect the inside areas of the wheels for leaks Make any necessary repairs 13 Inspect the tires 13 for any damage and for proper inflation Replace any missing valve caps
72. n and Maintenance Manual Sampling Interval and Location of Sampling Valve for information that pertains to obtaining a sample of the transmission oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the transmission oil 100899143 V Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 1359 025 BE 1859 040 BE 1359 510 BE 1405 025 BE 1405 040 BE 1405 510 BE 7320 025 BE 7320 040 BE 7320 510 BE S N 6BK1 Up Inspect the belts for cracks Inspect the belts for missing pieces Inspect the belts for frayed areas Inspect the belts for wear A worn belt will ride in the bottom of the pulley Replace the belts if any of these conditions exist Replace the belts if the belts are stretched beyond the limits of the adjuster Note If new belts are installed recheck the belt adjustment after 30 minutes of operation If two belts or more are required for an application replace the belts in belt sets that are matched If only one belt of a matched set is replaced the new belt will carry more load Belts of the same part number are not necessarily matched belts Fan Belts go0458843 Illustration 216 The fan belts 1 are located in the engine compartment of the tractor Open the access door on the right side of the engine in order to inspect the fan belts The fan belts run on a pulley that is spring loaded There is no a
73. n the battery retainers 3 Clean the top of the batteries with a clean towel Do not allow dirt to build up on the battery Conductive paths may develop Under dusty conditions clean the tops of the batteries often Buildup of dirt may lead to the following electrical problems e Electrical charge may be drained from the batteries e The Engine Monitoring System may function with the disconnect switch in the OFF position A film of acid may be on the battery To neutralize the acid one of the following solutions may be used 113 Maintenance Section Battery Battery Cable or Battery Disconnect Switch Replace e Baking soda solution may be made by mixing 100 grams 4 0 oz with 1 liter 1 quart of clean water e Ammonia solution may be made by mixing 100 grams 4 0 oz with 1 liter 1 quart of clean water The caps of the battery cells must be in place before using one of the above solutions Rinse the batteries with clean water after using one of the above solutions Lift the post covers in order to remove the cable from the battery terminal Clean the battery terminals A fine grade of sandpaper may be used for cleaning Petroleum jelly may be used as protection against corrosion Apply corrosion inhibitors after you connect the cables to the battery post A battery saver and cleaner is available from your Caterpillar dealer Use these products to improve battery performance Install the cables
74. n the outer edge of the wheel The check fill plug is easily confused with the drain plug 2 for the final drive The drain plug for the final drive has the word DRAIN next to the plug 1 The check fill plug for the wheel coolant must be horizontal with the center line of the axle in order to check the coolant level 2 Clean the area around the plug hole 186 Maintenance Section Window Washer Reservoir Fill 3 Remove the plug Antifreeze should be dripping from the hole 4 Add antifreeze if antifreeze is needed A solution of 50 percent water and 50 percent Caterpillar antifreeze is preferable If Caterpillar antifreeze is not used commercially available ethylene glycol type antifreeze can be a substitute 5 Clean the plug Install the plug 6 Install the final drive 7 Perform the same procedure to the other driven wheels 100874049 Window Washer Reservoir Fill SMCS Code 7306 544 S N 6BK1 Up NOTICE Use Caterpillar nonfreezing window washer solvent or a commercially available windshield washer fluid in order to prevent freezing of the windshield washer system g00444266 Illustration 225 The window washer reservoir is located on the front of the machine The reservoir is located below the left side of the cab front window 1 Remove the cap 1 of the reservoir 2 Fill the window washer reservoir through the filler opening 3 Replace the cap of the reservoir 100874176 Window W
75. nes to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes Replace the cooling system water temperature regulator on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system The water temperature regulator should be replaced after the cooling system has been cleaned Replace the water temperature regulator while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the water temperature regulator housing assembly NOTICE Failure to replace the engine s water temperature reg ulator on a regularly scheduled basis could cause se vere engine damage Note If you are only replacing the water temperature regulator drain the cooling system coolant to a level that is below the water temperature regulator housing assembly 1 Loosen the hose clamp and remove the hose from the elbow 2 Remove the bolts from the elbow and remove the elbow 127 Maintenance Section Cooling System Water Temperature Regulator Replace 3 Remove the turbocharger water line from the c
76. ng to local regulations and mandates 1 Open the access cover on the right side of the machine 2 Close inlet valve 1 and outlet valve 2 3 Remove coolant conditioner element 3 with your hand or with a strap type wrench Properly discard coolant conditioner element 3 4 Clean the base for the element Make sure that all of the old gasket is removed 5 Replace the used element with a new Caterpillar maintenance element 6 Coat the gasket of the new element with a thin film of clean engine oil 121 Maintenance Section Coolant Conditioner Element Replace 7 Install the new element by hand When the gasket contacts the element assembly base turn the element by 270 degrees more This will tighten the element sufficiently 8 Open inlet valve 1 and outlet valve 2 9 Start the engine and check for leaks Allow the coolant level to stabilize Check the coolant level of the radiator If necessary add premixed coolant 10 Close the access cover Stop the engine 122 Maintenance Section Cooling System Coolant DEAC Change i00830098 Cooling System Coolant DEAC Change SMCS Code 1350 044 S N 6BK1 Up NOTICE Do not change the coolant until you read and under stand the material found in the Operation and Mainte nance Manual Cooling System Specifications sec tion Failure to do so could result in damage to the cooling systems components NOTICE Care must be taken to ensure tha
77. ns Illustration 184 g00438543 Inspect the upper hitch pin 1 for wear Inspect the lower hitch pin 2 for wear Replace the pins if it is necessary amga g00438583 Illustration 185 Inspect the two horizontal hitch pins 3 for wear or for damage Replace the horizontal hitch pins if necessary Note Only one of the horizontal hitch pins is shown 160 Maintenance Section Hitch Lubricate g00438643 Illustration 186 There are six pins 4 5 6 7 8 and 9 in the links for the steering Inspect the pins for wear or for damage Replace the pins in the links for the steering if it is necessary Note See Disassembly and Assembly SENR6808 Steering Link Assemblies for further information i00868953 Hitch Lubricate SMCS Code 7107 086 7113 086 g00438663 Illustration 187 Note Clean all of the fitting before you apply grease Twenty four grease fittings are located near the cushion hitch accumulator Illustration 188 g00438664 Five grease fittings are located on the draft frame These fittings are accessible from the back of the tractor Note If any of the remote lines are damaged replace the damaged lines Fill the new lines with grease 100881441 Hydraulic Oil Cooler Clean SMCS Code 1374 070 S N 6BK1 Up The hydraulic oil cooler is located in front of the radiator for the tractor Clean the oil cooler and clean the radiator at the same time C
78. ns and mandates Hydraulic Tank Filters go0440164 Illustration 191 The oil filter cover 1 is located on top of the hydraulic tank Two oil filters and a screen are located under the oil filter cover The hydraulic tank is located ahead of the right tractor wheel 1 Park the machine on level ground Lower the bowl Shut off the engine 2 The hydraulic oil filler cap 2 is located on top of the hydraulic tank You should clean the cap before you remove the cap This cap is a locking cap You need to remove the padlock if a padlock is on the cap Raise the lever 3 in order to engage the lug Turn the cap counterclockwise in order to remove the cap Remove the cap slowly in order to relieve the air pressure 163 Maintenance Section Hydraulic System Oil Filter Replace 3 Clean the filter cover 1 Remove the 4 capscrews 4 that hold the filter cover in place 4 Remove the two oil filters Discard the oil filters in a proper manner 5 Remove the screen 6 Wash the screen in clean nonflammable solvent Inspect the screen for damage Replace the screen if the screen is damaged 7 Install the screen Install 2 new filters 8 Clean the filter cover Inspect the O ring seal for the filter cover Replace the O ring seal if the O ring is damaged 9 Install the filter cover In line Filter Illustration 192 g00485046 The in line filter 5 for the hydraulic system is on the right side of the tran
79. nual Hydraulic System Oil level Check for further information See Operation and Maintenance Manual Lubricant Viscosities for further information See Operation and Maintenance Manual Refill Capacities for further information 10 Clean the cap Inspect the cap for damage to the seal Replace the seal if the seal is damaged 11 Install the oil filler cap 12 Start the machine Run the machine at a low idle Check the hydraulic oil level The oil level should be above the ADD level in the sight gauge Add oil if it is necessary Note The oil must be free from bubbles If there are bubbles in the oil then air is entering the hydraulic system Inspect the suction hoses and the clamps 13 Stop the engine If necessary tighten any loose clamps and any loose connections Replace any damaged hoses i00995909 Hydraulic System Oil Filter Replace SMCS Code 5068 510 S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulatio
80. o Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates If the coolant in the machine is changed to Extended Life Coolant from another type of coolant see Operation and Maintenance Manual Extended Life Coolant ELC Cooling System Maintenance 1 Allow the engine to cool 2 Loosen the pressure cap slowly in order to release pressure Remove the pressure cap 123 Maintenance Section Cooling System Coolant ELC Change Illustration 126 g00400065 3 The radiator drain 1 is located behind the oil drain 2 g00400068 Illustration 127 4 Remove the bolt 3 in order to remove the cover plate for the radiator drain Open the drain valve 5 Flush the cooling system with clean water until the draining water is transparent 6 Close the drain valve Install the cover plate and the bolt 7 Add the Extended Life Coolant Refer to the following topics e Operation and Maintenance Manual Cooling System Specifications e Operation and Maintenance Manual Refill Capacities 8 Start the engine Operate the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes 9 Maintain the coolant level within 13 mm 5 inches of the bottom of the f
81. on A tire blowout or rim failure can result from im proper or misused equipment Use a self inflating chuck and stand behind the tread when inflating a tire Proper inflating equipment and training in using the equipment are necessary to avoid overinflat ing Before inflating tire install on the machine or put tire in a restraining device g00474917 Illustration 208 Typical Example Measure the pressure of each tire with a tire gauge A regular tire gauge will work on tires that are inflated with nitrogen Note Scraper tires should be inflated with nitrogen gas in order to prevent the tires from exploding 1 Park the machine on level ground Apply the parking brake Lower the bowl Shut off the engine 2 Clean the area around the valve stem 1 for the tire 3 Remove the dust cover 1 for the valve stem 4 Measure the pressure of each tire with a tire gauge Add nitrogen gas if the pressure is low 5 Install the dust cover on the valve stem 175 Maintenance Section Tire Inflation Check Refer to the following additional information about tire inflation e Operation and Maintenance Manual Tire Inflation with Nitrogen e Operation and Maintenance Manual Tire Shipping Pressure e Operation and Maintenance Manual Tire Inflation Pressure Adjustment Consult your Caterpillar Dealer for further information on the correct operating pressures and the correct load ratings 1
82. over assembly 4 Remove the bolts from the the water temperature regulator housing and remove the water temperature regulator housing 5 Remove the water temperature regulator from the water temperature regulator housing Remove the gasket from the water temperature regulator housing Remove the seal from the water temperature regulator housing NOTICE Former water temperature regulators may be used if they meet test specifications and are not damaged or have excessive buildup or deposits NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a water temperature regulator Depending on load failure to operate with a water tem perature regulator could result in either an overheating or an overcooling condition NOTICE If the water temperature regulator is installed incor rectly it will cause the engine to overheat 6 Install a new seal in the water temperature regulator housing Install a new water temperature regulator and a new gasket Install the water temperature regulator Install the water temperature housing 7 Install the elbow and the hose Tighten the hose clamp 8 Add the cooling system coolant Maintain the coolant level within 13 mm 50 inch of the bottom of the filler tube 128 Maintenance Section Crankshaft Vibration Damper Inspect 100815039 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 S N 6BK1 Up
83. pressure cap in order to relieve the pressure Remove the cap 2 Add supplemental coolant additive Drain some coolant from the radiator into a suitable container in order to allow space for the extra coolant additive Note Always discard drained fluids according to local regulations 3 Add 0 24 L 50 pint of supplemental coolant additive for every 38 L 10 US gal of engine cooling capacity 4 Inspect the gasket for the cooling system pressure cap Replace the gasket if the gasket is damaged 5 Install the cooling system pressure cap 100993313 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL S N 6BK1 Up When a Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval The amount of extender is determined by the cooling system capacity Table 30 Amounts of the Caterpillar ELC Extender Recommended Amount of Caterpillar Extender Cooling System Capacity 22 to 30 L 6 to 8 US gal 0 57 L 20 oz 30 to 38 L 8 to 10 US gal 0 71 L 24 oz 38 to 49 L 10 to 13 US gal 0 95 L 32 oz 49 to 64 L 13 to 17 US gal 1 18 L 40 02 64 to 83 L 17 to 22 US gal 1 60 L 54 02 83 to 114 L 22 to 30 US gal 2 15 L 72 o2 114 to 163 L 30 to 43 US gal 3 00 L 100 oz 163 to 242 L 43 to 64 US gal 4 40 L 148 0z
84. r steam to remove dust and other debris from the radiator core However the use of compressed air is preferred Note Care must be taken when you are using high pressure water High pressure water can cause damage to the radiator Use of a water spray nozzle on the pressure washer which will disperse the water pressure is preferred Note At the same interval clean the air conditioner condenser See Special Publication SEBD0518 Know Your Cooling System for the complete procedure for cleaning the radiator core 169 Maintenance Section Radiator Core Clean 100872161 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 S N 6BK1 Up 1 Inspect the ROPS for loose bolts Inspect the ROPS for damaged bolts Replace the damaged bolts and the missing bolts with original equipment parts only Torque the bolts to 1050 35 N m 772 26 lb ft Note Apply oil to all ROPS bolt threads before you install the bolt Failure to apply oil can result in improper bolt torque 2 Run the machine on a rough surface Replace the ROPS mounting supports if the ROPS makes a noise or if the ROPS rattles 3 Do not attempt to straighten the ROPS structure Do not repair the ROPS by welding reinforcement plates to the structure If there are any cracks in the welds in the castings or in any metal section of the ROPS consult your Caterpillar Dealer for repairs 170 Maintenance Section Router Bits
85. re Fuses The fuses protect the electrical system from damage that is caused by overloaded circuits If the element inside the fuse separates replace the fuse Check the circuit if the element is separated in the new fuse Repair the circuit if necessary Note All of the fuses in this fuse box are 10 ampere fuses You should only replace these fuses with 10 ampere fuses of the same type Illustration 183 g00436360 The fuses are numbered left to right The fuses are numbered from the top to the bottom A pictograph 17 is located to the right of the fuse holder The location of the fuse matches the location of the pictograph EMS 1 10 AMP Front Wiper Washer 2 10 AMP Air Dryer 3 10 AMP Radio 4 10 AMP Engine Start 5 10 AMP Turn Signals 6 10 AMP Rear Wiper Washer 7 10 AMP OOOB E O O yi Or LESS k we A gt O Rear Lights 8 10 AMP Solenoids 9 10 AMP Electronic Transmission Controls 10 10 AMP Optional Front Flood Lights 11 10 AMP Optional Electric Fuel Pump 12 10 AMP Horn 13 10 AMP Backup Alarm 14 10 AMP Engine Solenoid 15 10 AMP Cushion Hitch and or Bail Control 16 10 AMP 159 Maintenance Section Hitch Inspect i00868657 Hitch Inspect SMCS Code 4305 040 7107 040 7113 040 Consult your Caterpillar Dealer for the allowable tolerance of all the pi
86. remove the dust which has collected on the indicator Examine the indicator The machine may be operated when the indicator is yellow The machine should not be operated when the indicator is red The air cleaner will need to be cleaned or the air cleaner will need to be replaced Once the air cleaner has been checked the indicator should be reset Push in on the bottom of the indicator 2 The indicator will return to the yellow color Note See the Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace See the Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 145 Maintenance Section Engine Air Filter Service Indicator Inspect 100830433 Engine Air Precleaner Clean SMCS Code 1055 070 S N 6BK1 Up NOTICE Service the air cleaner only with the engine stopped Engine damage could result E S gt Illustration 169 g00402547 The engine air precleaner is on the right front side of the tractor Under most conditions cleaning the screen 1 with a brush or cleaning with a towel will be sufficient Under extreme conditions the precleaner should be removed 1 Loosen the clamp 2 at the bottom of the precleaner 2 Remove the precleaner Inspect the opening in the tube for dirt Clean the tube if the tube is dirty 3 Clean the precleaner screen 4 Install the precleaner and tighten the clamp 146 Maintenance Sec
87. rocedure for the other wheel Note The filler tube 5 for the differential is located at the right rear of the tractor g00473367 Illustration 139 10 Clean the area around the filler cap 5 Remove the cap 132 Maintenance Section Differential and Final Drive Oil Level Check 11 Fill the differential with oil through the filler tube Fill the differential to the FULL mark in the sight glass 6 Refer to the Operation and Maintenance Manual Refill Capacities and the Operation and Maintenance Manual Lubricant Viscosities for further information 12 Clean the filler cap Install the filler cap Note The differential and the final drives share a common reservoir However the oil level of the final drives should be checked The filler plug for the final drive must be horizontal with the center of the final drive in order to check the oil level of the final drive The drain plug 3 will be at the bottom of the wheel A g00472907 Illustration 140 13 Clean the area around the filler plug 4 Remove the plug 14 Add oil to the final drive if oil is needed Oil should be dripping out of the filler hole when the final drive is full of oil 15 Clean the filler plug Install the filler plug 100816738 Differential and Final Drive Oil Level Check SMCS Code 3258 535 FLV 4050 535 FLV S N 6BK1 Up Illustration 141 g00389932 Typical Example The sight gauge for the diff
88. rom the drain valves if moisture is present Close the drain valves g00335233 Illustration 107 3 If there is moisture in the air tank replace the desiccant cartridge or rebuild the desiccant cartridge Consult your Caterpillar dealer for information about replacing the desiccant cartridge and for instructions for rebuilding the desiccant cartridge Note Small amounts of moisture may be in the system due to condensation in the system Moisture may also be in the system if an air dryer is installed on a machine that has been operating without an air dryer Several weeks may be required in order to completely dry the system 110 Maintenance Section Air Dryer Desiccant Replace i00746501 Air Dryer Desiccant Replace SMCS Code 4285 510 DSS S N 6BK1 Up Air lines to and from the air dryer must be at atmo spheric pressure Release the air pressure from the air system completely before performing main tenance g00335233 Illustration 108 Replace the air dryer desiccant cartridge or rebuild the air dryer desiccant cartridge if water cannot be absorbed Consult your Caterpillar Dealer for service or for replacement parts 100747822 Air Tank Moisture and Sediment Drain SMCS Code 4272 543 M amp S The air tanks should have some air pressure Check the air tanks at the end of the shift for moisture and for sediment Moisture and sediment can accumulate in the air tank This can lead to a low reserve o
89. s 176 108 Maintenance Section Maintenance Interval Schedule Wheel Coolant Level Check 00 c eee 185 Wheel Coolant Level Check 00 cee 185 Every 2000 Service Hours or 1 Year Cushion Hitch Accumulator Check 0 06 128 Differential Thrust Pin Clearance Check 130 Differential and Final Drive Oil Change 131 Ejector Carrier Rollers Check Adjust 134 Ejector Carrier Rollers Inspect Pack Replace 134 Ejector Guide Rollers Check Adjust 04 135 Ejector Support Rollers Check Adjust 136 Ejector Support Rollers Inspect Pack Replace 136 Fuel Injection Timing Check cccceeeeeeee 153 Hitch Inspect i eel eee cae eee teens 159 Hydraulic System Oil Change ceeee 161 In Line Refrigerant Dryer Check Replace 167 Wheel Bearing Oil Change ccceeeeeeeees 183 Every 2000 Service Hours or Yearly Brake Shoes and Drums Check Replace 116 Elevator Drive Tube Roller Bearing Lubricate 140 Elevator Speed Reducer Oil Change 142 Engine Valve Lash Check 0 00 ceeeeeseeeeeeeenees 151 Every 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 122 Cooling System Pressure Cap Clean Replace 126 Cooling System Relief Valve Clean 00 126 Cooling System Water Temperature Regulator Replace Avice a acti TETEN E EEE
90. s to obtaining a sample of the engine oil 149 Maintenance Section Engine Oil Sample Obtain 100841310 Engine Oil and Filter Change SMCS Code 1318 510 S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before Opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Illustration 173 g00411318 g00411738 Illustration 174 150 Maintenance Section Engine Oil and Filter Change The oil drain for the tractor engine is located on the engine oil pan A guard covers the oil pan The oil filter for the tractor is on the right side of the engine Note Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the crankcase The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with
91. smission 1 Clean the area around the filter 2 Remove the filter with a strap type wrench See Operation and Maintenance Manual Oil Filter Inspect Discard the used oil filter properly 3 Clean the filter base Check for any pieces of the seal from the old filter Remove any pieces of the seal from the old filter 164 Maintenance Section Hydraulic System Oil Level Check 4 Apply a thin coat of hydraulic oil to the gasket of the new filter 5 Install the new filter by hand When the gasket contacts the filter base turn the filter by 270 degrees more This will tighten the filter sufficiently 6 Every new oil filter has marks which are for determining the rotation index These marks are spaced at 90 degree increments Use the rotation index marks as a guide for tightening the oil filter 7 Start the machine Check for leaks 8 Check the oil level for the hydraulic system Add oil if oil is needed See Operation and Maintenance Manual Hydraulic System Oil Level Check for further information 9 Install the hydraulic oil filler cap 100869343 Hydraulic System Oil Level Check SMCS Code 5050 535 FLV S N 6BK1 Up Illustration 193 The hydraulic tank is located ahead of the right tractor wheel Clean the sight gauge 1 in order to view the oil level Note The machine must meet the following conditions before you check the hydraulic tank oil level e The machine must be level
92. t fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates If the Diesel Engine Antifreeze Coolant DEAC is dirty or if you observe any foaming in the cooling system drain the coolant before the recommended interval 1 Stop the engine and allow the engine to cool 2 Loosen the pressure cap slowly in order to release pressure Remove the pressure cap p Illustration 124 g00400065 3 The radiator drain 1 is located behind the oil drain 2 g00400068 Illustration 125 4 Remove the bolt 3 in order to remove the cover plate for the radiator drain open the drain valve 5 Flush the cooling system with clean water until the draining water is transparent 6 Close the drain valve Replace the cover 7 Add the coolant solution Refer to Operation and Maintenance Manual Refill Capacities 8 Remove the cooling system pressure cap Start the engine and run the engine Leave the pressure cap off until the water temperature regulator opens and the coolant level stabi
93. t least 20 minutes for the valves to cool to engine cylinder head and block temperature 151 Maintenance Section Engine Valve Lash Check 100850047 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD S N 6BK1 Up The ether starting aid cylinder is mounted on the right side of the engine compartment The ether cylinder is ahead of the engine access door g00421358 Illustration 175 The ether cylinder is not shown in the illustration 1 Remove the 2 bolts 1 that hold the access door closed Open the access cover for the ether cylinder 2 Loosen the ether cylinder retaining clamp 2 Unscrew the ether cylinder 3 Remove the used gasket 3 Install the new gasket A new gasket is provided with each new ether cylinder 4 Install the new ether cylinder Tighten the ether cylinder hand tight Tighten the cylinder retaining clamp with your fingers 5 Close the access cover Install the bolts for the cover 152 Maintenance Section Fan Drive Bearing and Belt Tightener Lubricate i00820688 Fan Drive Bearing and Belt Tightener Lubricate SMCS Code 1358 086 1359 086 BD S N 6BK1 Up g00393178 Illustration 176 The lubricant fitting for the fan drive and the lubricant fitting for the belt tightener is located on the right side of the engine for the tractor 1 Open the engine access cover on the right side of the engine These grease fittings are located near the oil filler plug 2
94. tenance Section Ejector Carrier Rollers Check Adjust i00860625 Ejector Carrier Rollers Check Adjust SMCS Code 6229 025 6229 535 S N 5SG480 Up Park the machine on level ground Lower the bowl and close the apron The ejector carrier rollers are located at the base of the ejector There are 2 ejector carrier rollers These rollers prevent the ejector from contacting the floor of the bowl Check the adjustment for the ejector carrier rollers The ejector carrier rollers are correctly adjusted if the ejector does not contact the bottom of the bowl g00102197 Illustration 144 1 Loosen roller shaft clamping bolt 1 2 Move eccentric roller shaft 2 to a position that allows the ejector to pass over the bottom of the bowl The ejector carrier rollers must be adjusted so that the clearance between the bottom of the ejector and the bottom of the bowl is between 10 to 13 mm 40 to 51 inch 3 Tighten roller shaft clamping bolt 1 4 Repeat Step 1 through Step 3 in order to adjust the other ejector carrier roller 5 Start the engine Move the ejector forward and backward Stop the engine 6 Check for drag between the ejector and the bottom of the bowl Repeat the adjustment procedure if necessary i00860885 Ejector Carrier Rollers Inspect Pack Replace SMCS Code 6229 040 6229 086 6229 510 S N 5SG480 Up Park the machine on level ground Lower the bowl and close the apron The ejector
95. the machine is shipped from the factory The three position adjustment knob should remain at the HIGH setting unless the job site requires a lower volume level 112 Maintenance Section Battery Recycle i00993589 Battery Recycle SMCS Code 1401 561 S N 6BK1 Up 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 100758975 Battery Electrolyte Level Check SMCS Code 1401 535 FLV S N 6BK1 Up Table 29 Battery Electrolyte Level Battery Interval Conventional 100 Hours Low Maintenance 250 Hours Premium High Output 1000 Hours Maintenance Free No Interval Note Do not attempt to add water to maintenance free batteries Many Caterpillar machines are now sold with maintenance free batteries A battery should not require more than 30 cc 1 oz of water per cell per week Maintain the electrolyte level to the bottom of the filler openings Use distilled water to bring up the level of the electrolyte The electrolyte should always be above the plates of the battery If distilled water is not available use clean drinking water During hot weather check the level of the electrolyte weekly All batteries must have the following maintenance at every 1000 hours 1 Open the battery access cover 2 Check the battery retainers Tighte
96. the new oil 1 Park the machine on a level surface and engage the parking brake Stop the engine 2 Remove the drain plug through the access hole 1 3 Insert a wrench through the access hole 2 which is on the side of the guard in order to open the crankcase drain valve 4 Allow the oil to drain into a suitable container 5 Close the crankcase drain valve Install the drain plug 6 Open the access door on the right side of the engine 7 Remove the oil filter 3 with a strap type wrench See Operation and Maintenance Manual Oil Filter Inspect Discard the used oil filter properly 8 Clean the filter housing base Make sure that all of the old filter gasket is removed 9 Apply a thin coat of engine oil to the gasket of the new filter 10 Install the new filter by hand When the gasket contacts the filter base turn the filter by 270 degrees more This will tighten the filter sufficiently 11 Every new oil filter has marks which are for determining the rotation index These marks are spaced at 90 degree increments Use the rotation index marks as a guide for tightening the oil filter 12 Clean the oil filler cap 4 Remove oil filler cap Fill the crankcase with new oil See Operation and Maintenance Manual Refill Capacities Clean the oil filler cap and install the oil filler cap 13 Start the engine and allow the oil to warm Check the engine for leaks Check the filter for leaks
97. tion Engine Crankcase Breather Clean 100837864 Engine Crankcase Breather Clean SMCS Code 1317 070 S N 6BK1 Up g00409171 Illustration 170 The engine crankcase breather 1 for the tractor is located on top of the engine valve cover Open the engine access cover on top of the engine in order to service the crankcase breather 1 Loosen the breather outlet hose clamp Remove the hose from the breather cover 2 Loosen the breather inlet hose clamp Remove the engine crankcase breather 3 Check the condition of the breather seal Replace the seal if the seal is damaged 4 Wash the breather in a clean nonflammable solvent 5 Shake the breather until the breather is dry You may also use pressure air to dry the breather 6 Check the condition of the hose Replace the hose if the hose is damaged 7 Install the breather Tighten the breather inlet hose clamp 8 Install the hose and the breather outlet hose clamp 9 Close the access cover Engine Oil High Speed and Oil Filter Change SMCS Code 1318 510 HZ S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products
98. ve the ejector forward and backward Stop the engine 6 Check for drag between the ejector and the sides of the bowl Repeat the adjustment procedure if necessary 135 Maintenance Section Ejector Guide Rollers Check Adjust i00863992 Ejector Guide Rollers Inspect Lubricate Replace SMCS Code 6230 040 6230 086 6230 510 S N 5SG480 Up Park the machine on level ground Lower the bowl and close the apron The ejector guide rollers are located at the middle of the ejector There are 2 ejector guide rollers g00434601 Illustration 147 Remove the debris from the roller in order to inspect the roller Clean the grease fittings 1 Attach a grease gun to the fittings Apply grease to the rollers Refer to Disassembly and Assembly SENR6809 Ejector Guide Rollers for additional information 136 Maintenance Section Ejector Support Rollers Check Adjust 100864496 Ejector Support Rollers Check Adjust SMCS Code 6230 025 6230 535 S N 5SG480 Up Park the machine on level ground Lower the bowl and close the apron The ejector support rollers are located at the rear of the ejector There are 2 ejector support rollers These rollers support the rear portion of the ejector The rollers run in a track 3 A track is located on each side of the frame for the ejector 100864776 Ejector Support Rollers Inspect Pack Replace SMCS Code 6230 040 6230 086 6230 510 S N 5SG480 Up Park the m
99. w idle Inspect the transmission for leaks 7 Slowly operate the transmission control in order to circulate the oil 8 Maintain the oil level between the FULL and ADD OIL marks on the sight glass Add oil through the filler tube if necessary 9 Stop the engine 100916920 Transmission Oil Filter and Magnetic Screen Replace Clean SMCS Code 3030 070 MGS 3067 510 S N 6BK1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates g00468264 Illustration 212 The transmission oil filter housing 1 is located on the top left side of the transmission case The transmission oil filter housing is located at the left rear of the tractor 1 Park the machine on level ground Apply the parking brake Lower the bowl 2 Clean the filter housing 178 Maintenance Section Transmission Oil Filter and Magnetic Screen Replace Clean 3 Remove the transmission filter housing drain plug 2 Allow the oil to drain into a suita
100. worn or damaged Illustration 204 g00103048 172 Maintenance Section Seat Suspension Lubricate Inspect the belt mounting hardware Replace any hardware that is damaged or worn Keep the mounting bolts tight If the bolt that holds the two parts of the seat belt mounting hooks and the nut that holds the two parts of the seat belt mounting hooks are not correctly installed the hooks can separate This allows the seat belt to separate from the belt mounting Inspect the hooks on each half of the seat belt in order to make sure that the bolt and the nut are correctly installed Remove the old bolt and the old nut if the bolt and the nut are not correctly installed Install a new bolt and a new nut 00873671 Seat Suspension Lubricate SMCS Code 7324 086 S N 6BK1 Up g00443449 Illustration 205 The seat moves forward and the seat moves backward on 4 plastic slides which are located on the rails Lubricate the plastic slides with extreme pressure grease in order to keep the seat moving freely See Service Manual SENR8556 Suspension Seat for Wheel Tractor Scrapers for further information i00907683 Steering Pump Outlet Screen Clean SMCS Code 4306 070 Z3 S N 6BK1 Up Illustration 206 g00463080 The steering pump outlet screen is located inside the right frame rail of the tractor Clean the screen after a pump failure Clean the screen after the new pump has been installed Releas

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