MAINTENANCE INTERVALS - Safety
Contents
1. 153 Every 10 Service Hours or Daily Cooling System Coolant Level Check 135 Engine Air Filter Service Indicator Inspect 140 Engine Oil Level Check 140 Hydraulic System Oil Level Check 151 Indicators and Gauges Test 152 Seat Belt Inspect 154 Track Rubber Inspect Replace 155 Travel Alarm 22 158 Undercarriage 158 Every 10 Service Hours or Daily for Machines Used in Severe Applications Blade Linkage Lubricate 122 Bucket Linkage Lubricate 127 Quick Coupler Lubricate 153 Every 50 Service Hours Bucket Linkage Lubricate 127 Quick Coupler Lubricate 153 Initial 100 Service Hours Engine Oil and Filter Change 141 Every 100 Service Hours Swing Bearing Lubricate 155 Swing Gear Lubricate 155 Every 100 Service Hours or 2 Weeks for Machines Used in Severe Applications Boom and Stick Linkage Lubricate 123 Initial 250 Service Hours Engine Valve2. 101637979 Window Washer Reservoir Fill SMCS Code 7306 544 KE NOTICE When operating in freezing temperatures use Caterpillar or any commercially available nonfreezing window washer solvent SEBU7452 07 159 Maintenance Section Window Wiper Inspect Replace Illustration 280 g00847636 The washer fluid bottle is located in the engine compartment 1 Open the engine access door 2 Remove the filler cap 3 Fill the washer fluid bottle with washer fluid through the filler opening 4 Replace the filler cap 5 Close the engine access door Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 Inspect the wiper blade on the front window Replace the wiper blade if the wiper blade is worn or damaged Replace the wiper blade if the front window is streaked after use 101592019 Windows Clean SMCS Code 7310 070 7340 070 Use commercially available window cleaning solutions in order to clean the windows Note When you are cleaning the window above the front window you should use a soft cloth that is not abrasive This window can be easily scratched Wash polycarbonate windows with a mild soap and water Never use a cleaning solvent on poly carbonate windows Cleaning Methods Aircraft Windshield Cleaner Apply the cleaner with a soft cloth Rub the window with moderate pressure until all the dirt is removed Allow the cleaner to dry Wipe off t
3. Section B B From Illustration 199 A Side cutter C Shear ledge on a side cutter D Side plate on a bucket E 0 0 mm 0 0 inch 5 Make sure that there is not a gap between the side plate on the bucket and the shear ledge on the side cutter 6 Torque the mounting bolts to the correct specification 101650429 Circuit Breakers Reset SMCS Code 1420 529 Illustration 201 900852789 Circuit breaker for the alternator The circuit breaker for the alternator is located inside the access cover on the left front side of the seat support Open the access cover in order to inspect the circuit breaker or reset the circuit breaker The circuit breaker has a capacity of 60 Amperes In order to reset the circuit breaker push the button If the system is working properly the button will remain depressed If the button does not remain depressed check the appropriate electrical circuit Repair the electrical circuit if necessary 101631756 Cooling System Coolant ELC Change SMCS Code 1350 044 NOTICE Do not change the coolant until you read and under stand the cooling system information in Special Pub lication SEBU6250 Caterpillar Machine Fluids Rec ommendations Failure to do so could result in damage to the cooling system components NOTICE Mixing ELC with other products will reduce the effec tiveness of the coolant This could result in damage to cool
4. Code 7063 086 Illustration 269 900847450 The grease fitting for the swing gear is located on the right side of the machine 1 Lower all work tools to the ground 2 Wipe the grease fitting before you lubricate the grease fitting 3 Apply lubricant through fitting A 4 Rotate the upper structure for 90 5 Apply lubricant through fitting A 6 Repeat Step 3 and Step 4 until the upper structure has rotated 360 102183254 Track Rubber Inspect Replace If Equipped SMCS Code 4198 040 4198 510 Illustration 270 g01104638 Check the rubber tracks for the following conditions Steel cords that are cut Iron cores that are fractured Rubber flaking off to the point of showing steel cords or iron cores Loss of traction or grousers are worn down to approximately 5 mm 0 2 inch in height If any of the above conditions or a combination of the above conditions are observed replace the belt 156 Maintenance Section Track Adjustment Adjust SEBU7452 07 101637735 Track Adjustment Adjust SMCS Code 4170 025 Personal injury or death can result from grease under pressure Grease coming out of the relief valve under pres sure can penetrate the body causing injury or death Do not watch the relief valve to see if grease is es caping Watch the track or track adjustment cylin der to see if the track is being loosened Loosen the re
5. Engine Oil and Filter Change SMCS Code 1318 510 Note If the sulfur content in the fuel is greater than 1 596 by weight use an oil that has a TBN of 30 and reduce the oil change interval by one half Drain the crankcase while the oil is warm Ss Illustration 226 g00824782 142 Maintenance Section Engine Oil and Filter Change SEBU7452 07 1 Open the crankcase access cover that is under the rear of the machine Remove the bolts that secure the access cover Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 900824756 Illustration 227 2 Remove the crankcase drain plug Allow the oil to drain into a suitable container Note Discard any drained fluids according to local regulations 3 Clean the drain plug and install the drain plug 4 Install the crankcase access cover 5 Open the engine hood Illustration 228 900845868 6 Remove the filter element with a filter wrench Discard the used oil filter properly 7 Clean the filter housing base Make sure that all of the former filter gasket is removed Note This oil filter is a cartridge type filter This type of filter cannot be reused Note Always discard used filters according to local regulations Enc Illustration 229 900824766 8 Apply thin coat of clean engine oil t
6. Lash 143 Final Drive Oil Change 143 Hydraulic System Oil Filter Return Replace 151 Every 250 Service Hours Belt Inspect Adjust Replace 121 Cooling System Hoses Inspect 137 Engine Oil Sample Obtain 141 Engine Oil and Filter Change 141 Final Drive Oil Level Check 144 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 OMAT hot Rt s 137 Every 500 Service Hours Blade Linkage Lubricate 122 Boom and Stick Linkage Lubricate 123 Boom Stick and Frame Inspect 124 SEBU7452 07 119 Maintenance Section Maintenance Interval Schedule Cooling System Coolant Sample Level 1 ette Dee P ee ets 136 Engine Valve Lash 143 Final Drive Oil Sample Obtain 144 Fuel System Filter Replace 145 Fuel Tank and Strainer Clean 147 Hydraulic System Oil Filter Return Replace 151 Hydraulic System Oil Sample Obtain 152 Every 1000 Service Hours Battery Clean inseri 120 Battery Hold D
7. bolt 1 washer 2 and left cover 3 Illustration 249 900846715 150 Maintenance Section Hydraulic System Oil Change SEBU7452 07 n nun SUE Illustration 252 900825618 8 Remove spring 4 and screen 5 Note Do not allow spring 4 to fall into the hydraulic tank Illustration 253 900825626 9 Clean screen 5 and inspect screen 5 Replace the screen if the screen is damaged or badly contaminated 10 Inspect O ring seal 6 Replace the O ring seal if itis necessary 11 Install the screen by reversing steps 7 and 8 Note Make sure that the O ring seal and the spring are properly positioned during installation 12 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Capacities Refill Illustration 254 900101462 13 Inspect the pressure cap Clean the pressure Replace the pressure cap if damage is evident 14 Install the pressure cap 15 Start the engine and run the engine for a few minutes Slowly operate the control levers in order to cause the hydraulic oil to flow through the circuits Illustration 255 900825578 16 Extend the stick and the bucket fully Lower the boom so that the bucket is rested on the ground Lower the blade to the ground Illustration 256 900846755 SEBU7452 07 151 Maintenance
8. fitting at the joint that is between the boom and the stick LA Illustration 168 900844861 7 Apply lubricant through the following fittings e 1 The fitting at the stick cylinder rod end 2 The fitting at bucket cylinder head end Illustration 169 900844876 8 Apply lubricant through the fitting that is located at the swing cylinder rod end Illustration 170 900844880 9 Apply lubricant through the fitting at the swing cylinder head end The fitting is accessed through the filter element access cover on the right side of the machine 102860835 Boom Stick and Frame Inspect SMCS Code 6501 6502 6506 All earthmoving equipment is prone to a high degree of wear Regular inspections for structural damage are necessary The interval between these inspections depends on the factors that follow The age of the machine The severity of the application The loads that have been carried on the machine The amount of routine servicing that has been carried out If the machine has been involved in any kind of accident the machine must be inspected thoroughly Inspect the machine regardless of the date of the last inspection The machine must be clean before the machine is inspected Proper repair of frames and structures requires specific knowledge of the following subjects e Materials that have been us
9. of the angle blade SEBU7452 07 123 Maintenance Section Boom and Stick Linkage Lubricate 3 Apply lubricant to grease fitting 6 at the head end of the cylinder of the angle blade Apply lubricant to grease fitting 7 at the rod end of the cylinder of the angle blade 102181923 Boom and Stick Linkage Lubricate SMCS Code 6501 086 6502 086 Note Caterpillar recommends the use of 596 molybdenum grease for lubricating the boom and stick linkage Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Apply lubricant through all fittings after operation under water Wipe all fittings before you apply lubricant Illustration 162 900823721 1 Apply lubricant through the fittings at the swing post OT Ss cu Illustration 164 900844843 3 Apply lubricant through the fitting at the boom cylinder head end Illustration 163 900844838 2 Apply lubricant through the fitting at the base of the boom Illustration 165 900844846 4 Apply lubricant through the fitting at the rod end of the boom cylinder Illustration 166 900823737 5 Apply lubricant through the fitting at the stick cylinder head 124 Maintenance Section Boom Stick and Frame Inspect SEBU7452 07 Vi N Illustration 167 900844856 6 Apply lubricant through the
10. tap ping This could damage the seals Do not use ele ments with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result The air filter element can be cleaned by using the following methods pressure air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean air filter elements Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 216 900281692 Note When the air filter element is cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the air filter element Dirt could be forced further into the pleats Vacuum Cleaning Vacuum cleaning is another method for cleaning air filter elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Replace the air filter element after the air filter element has been cleaned six times Also replace the air filter element if the air filter element has been in service for 2000 hours Replacing the Air Filter Element The air filter e
11. to the ON position 900887679 Illustration 236 1 Air vent screw 2 Loosen air vent screw 1 in order to purge the air in the fuel injector pump 3 Once purging from air vent screw 1 is complete tighten air vent screw 1 Note Air in the fuel injector lines and injectors will be expelled automatically when the engine is cranked 4 Start the engine Further priming of the engine is necessary if the following problems occur The engine will not start The engine starts but the engine continues to misfire The engine starts but the engine continues to emit smoke Note If the engine starts but the engine runs rough continue to run the engine at low idle until the engine runs smoothly 101684866 Fuel System Filter Replace SMCS Code 1261 510 Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage Illustration 237 g00868854 The fuel filter is located on the right side of the machine inside the filter element access cover 1 Open the filter element access cover 2 Illustration 238 900868856 1 Fuel cock 2 Element 3 Case 4 Ring nut 2 Close fuel cock 1 3 Remove ring nut 4 4 Remove element 2 from case 3 Replace element 2 with a new element 146 Maint
12. 0845346 Check Air Filter indicator while the engine is running at high idle Service the air cleaner if the restricted Air Filter indicator on the monitor panel comes on Stop the engine before you service the air cleaner 101632740 Engine Oil Level Check SMCS Code 1000 535 NOTICE Do not overfill the crankcase Engine damage can re sult 1 Open the engine access door and lock the door open SEBU7452 07 141 Maintenance Section Engine Oil Sample Obtain Illustration 222 g00845693 Illustration 223 900824454 2 While the engine is stopped maintain the oil level in area A on the dipstick Illustration 224 900845717 3 If necessary remove the filler and add Allow the oil to drain into the crankcase before you check the oil level 4 Clean the oil filler cap and install the oil filler cap 5 Close the engine access door Engine Oil Sample Obtain SMCS Code 1000 008 1000 1348 008 1348 554 SM 7542 008 7542 554 OC SM Illustration 225 g01104147 Obtain the oil sample of the engine oil through the opening for the dipstick Refer to Special Publication SEBU6250 5 5 Oil Analysis for information that pertains to obtaining a sample of the engine oil Refer to Special Publication PEHP6001 How Take A Good Oil Sample for more information about obtaining a sample of the engine oil 101633083
13. 4170 040 Measuring Rubber Track Tension 1 Park the machine on a level surface Illustration 275 900696958 2 Position the upper frame over the tracks at a 90 angle 3 Lower the bucket to the ground with the stick in a vertical position 4 Chock the track that is not being lifted off the ground 5 Apply boom down pressure until the track that is on the same side as the bucket has cleared the ground 6 Chock the lower frame of the machine in this position 7 Clean the track rollers and the area around the skid plate Illustration 276 000484245 8 For a machine that is equipped with the rubber tracks locate the omega mark on the inside flat of the track 9 Locate the omega mark under the center track roller Eur oxy Illustration 277 900522663 The distance B should be 10 to 15 mm 0 4 to 0 6 inch 10 Measure the sag in the track The sag is measured from the bottom of the roller to the surface on the top of the track A properly adjusted track will have 10 to 15 mm 0 4 to 0 6 inch of sag Measuring Steel Track Tension Follow the same procedures for measuring rubber track tension There is not a omega mark on the steel tracks You do not need to align the steel tracks The proper amount of sag for steel tracks is 25 to 35 mm 1 0 to 1 4 inch 158 Maintenance Section Travel Alarm Test SEBU
14. 7452 07 Travel Alarm Test If Equipped SMCS Code 7429 081 The travel alarm will sound when the machine is moved forward or backward You must move the machine in order to test the travel alarm 1 Start the engine Move the hydraulic control console to the LOWERED position 2 Raise the work tool Make sure that there is adequate overhead clearance Illustration 278 900832965 3 Use the travel levers to move the machine forward The travel alarm should sound 4 Release the travel levers in order to stop the machine 5 Use the travel levers to move the machine backward The travel alarm should sound 6 Release the travel levers in order to stop the machine Lower the work tool to the ground Deactivate the hydraulic controls by placing the hydraulic control console in the RAISED position Stop the engine i01722112 Undercarriage Check SMCS Code 4150 535 Illustration 279 900885424 1 Check the carrier rollers the track rollers and the idler wheels for possible leakage 2 Check the surface of the track the carrier rollers the track rollers the idler wheels the track shoes and the drive sprockets Look for signs of wear and loose mounting bolts 3 Listen for any abnormal noises while you are moving slowly in an open area 4 If abnormal wear exists or abnormal noises or leaks are found consult your Caterpillar dealer
15. 9 Final assembly of pin into bucket tip e Strike the end of the tool until the pin is fully inserted Illustration 190 901092808 Bucket With Side Cutters A Side cutters 1 Remove the mounting bolts and the side cutters 2 Clean the mounting surface of the side plate on the bucket and of the side cutter Remove any burrs or protrusions on the mating surfaces Illustration 191 901092810 Side cutter Note Some side cutters may be rotated for additional wear 3 Install the side cutter Note Certain bolts may require thread compound 4 Hand tighten the bolts SEBU7452 07 131 Maintenance Section Bucket Tips Inspect Replace Illustration 192 901092812 Section B B From Illustration 191 A Side cutter C Shear ledge on a side cutter D Side plate on a bucket E 0 0 mm 0 0 inch 5 Make sure that there is not a gap between the side plate on the bucket and the shear ledge on the side cutter 6 Torque the mounting bolts to the correct specification Bucket Tips Inspect Replace Vertical Retention System for a Round Hole Tip SMCS Code 6805 040 6805 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket tips or side cutters Bucket Tips Illustration 193 g00101352 1 Usable 2 Replace this bucket tip 3 Overworn Check the bucket tips for wear If the bucket tip has a hole
16. Amp 14 Work Lights 10 Amp 101635713 Hydraulic System Oil Change SMCS Code 5056 044 1 Park the machine on level ground SEBU7452 07 149 Maintenance Section Hydraulic System Oil Change 4 Relieve the internal pressure from the hydraulic tank by loosening the hydraulic oil filler cap After the pressure is relieved remove the hydraulic oil filler cap Illustration 247 900825578 2 Extend the stick and the bucket fully Lower the boom so that the bucket is rested on the ground Lower the blade to the ground Illustration 250 900825581 The hydraulic oil drain plug is located on the bottom of the hydraulic oil tank Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 5 Remove the hydraulic oil drain plug Allow the oil to drain into a suitable container 6 Clean the drain plug and the O ring Inspect the drain plug and the O ring Replace the drain plug p or replace the O ring if the drain plug or the O ring ge is damaged or worn Reinstall the plug 900846708 Illustration 248 3 The hydraulic tank is located under the access cover on the right side of the machine Open the access cover for the hydraulic tank Clean the area around the hydraulic oil filler cap in order to prevent dirt from entering the hydraulic tank Illustration 251 900846733 7 Remove
17. Block the bucket before changing the bucket teeth To prevent possible injury to the eyes wear a pro tective face shield when striking the pin The pin when struck can fly out and cause injury to nearby personnel Bucket Tips g00101352 Illustration 183 1 Usable 2 Replace this bucket tip 3 Overworn Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip 1 Remove the pin from the bucket tip The pin can be removed by one of the following methods e Use a hammer and a punch from the retainer side of the bucket to drive out the pin e Use a Pin Master Follow Step 1 a through Step 1 c for the procedure SEBU7452 07 129 Maintenance Section Bucket Tips Inspect Replace E C SS OF ZI c 252 b Illustration 184 a Place the Pin Master on the bucket tip 2 7 900590670 4 Back of Pin Master 5 Extractor b Align extractor 5 with the pin c Strike the Pin Master at the back of the tool 4 and remove the pin Note Discard the old pin and the retainer assembly When you change tips use a new pin and a new retainer assembly Refer to the appropriate parts manual for your machine Illustration 185 901194448 6 Retainer assembly 7 Adapter 2 Clean the adapter and the pin 3 Fit retainer assembly 6 into the counterbore that is in the side of adapter 7 Make sure that the fac
18. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved SEBU7452 07 AATERPILLAR ded Operation and Maintenance Manual 303 CR Mini Hydraulic Excavator DMA1 Up Machine 118 Maintenance Section Maintenance Interval Schedule SEBU7452 07 102853668 Maintenance Interval Schedule SMCS Code 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed When Required Air Conditioner Cab Heater Filter Recirculation Inspect Replace 120 Battery Recycle 120 B
19. Section Hydraulic System Oil Filter Return Replace 17 Maintain the hydraulic oil level between mark A and mark B of the sight gauge 18 Close the right access door i01636092 Hydraulic System Oil Filter Return Replace SMCS Code 5068 510 RJ NOTICE Hot oil can cause personal injury Remove the hy draulic oil filler cap only when the engine is stopped Allow time for the hydraulic system to cool Remove hydraulic oil filler cap slowly in order to relieve pres sure The hydraulic oil tank is located under the access cover on the right side of the machine 1 Open the right access cover 2 Clean the area thoroughly in order to prevent dirt from entering the hydraulic oil tank 3 Slowly loosen the hydraulic oil filler cap in order to relieve the pressure in the hydraulic oil tank Os S Illustration 257 900846912 Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 4 Remove bolt 1 washer 2 and right cover 3 5 Remove spring 5 valve 6 and element 7 from the case 6 Inspect O ring 4 Replace the O ring if the O ring is worn or damaged 7 Reverse steps 4 and 5 in order to install the new element 8 Tighten the hydraulic oil filler cap 9 Close the right access cover 101636660 Hydraulic System Oil Level Check SMCS Code 5050 535 Note Check the hydraulic s
20. al time for the engine to cool before mea suring adjusting valve lash clearance NOTICE Only qualified service personnel should perform this maintenance Refer to the Systems Operation Testing and Adjusting Manual Valve Lash and Valve Bridge Adjustment article or consult your Caterpillar dealer for the complete valve lash adjustment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life Refer to Service Manual RENR5578 Mitsubishi Diesel Engines SL Series S3L S3L2 SAL 5412 in order to perform the complete procedure for the valve lash adjustment 101633148 Final Drive Oil Change SMCS Code 4050 044 FLV Illustration 232 900845941 1 Oil filler plug 2 Oil level plug 3 drain plug 1 Position one final drive so that the three plugs are aligned vertically Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 2 Remove oil filler plug 1 level plug 2 and drain plug 3 Allow the oil to drain into a suitable container 3 Clean the plugs and inspect the plugs Replace a worn plug or a damaged plug 4 Apply pipe sealant to oil filler plug 1 level plug 2 and drain plug 3 5 Install drain plug 3 6 Add oil through the o
21. attery or Battery Cable Inspect Replace 121 Bucket Linkage Inspect Adjust 126 Bucket Tips Inspect Replace 128 Bucket Tips Inspect Replace 128 Bucket Tips Inspect Replace 131 Circuit Breakers 133 Cooling System Pressure Cap Clean Replace 138 Engine Air Filter Element Clean Replace 139 Fuel System Prime 145 Fuel System Water Separator Drain 146 Fuel Tank Water and Sediment Drain 147 Fuses Replace 148 Oil Filter 20222222 153 Radiator Core Clean 154 Track Adjustment 156 Track Adjustment Inspect 157 Window Washer Reservoir Fill 158 Window Wiper Inspect Replace 159 Windows Clean 2 2222222 159 Every 10 Service Hours or Daily for First 100 Hours Blade Linkage Lubricate 122 Boom and Stick Linkage Lubricate 123 Bucket Linkage Lubricate 127 Quick Coupler Lubricate
22. e of the retainer assembly with the marking OUTSIDE is visible Illustration 186 g00101359 4 Install the new bucket tip onto the adapter Note The bucket tips can be rotated by 180 degrees in order to allow the tip to wear evenly You may also move the tips from the outside teeth to the inside teeth Check the tips often If wear is present on the tips rotate the tips The outside teeth generate the most wear 5 Drive the pin through the bucket tip The pin can be installed by using one of the following methods From the same side of the retainer drive the pin through the bucket tip the retainer assembly and the adapter Use a Pin Master Follow Step 5 a through Step 5 e for the procedure Illustration 187 901209166 8 a Insert 8 through the bucket tip 130 Maintenance Section Bucket Tips Inspect Replace SEBU7452 07 Illustration 188 901209140 4 Back of Pin Master 9 Pin holder 10 Pin setter b Place the Pin Master over the bucket tips so that the pin will fit into the counterbore of the pin holder 9 c Strike the Pin Master with a hammer at the back of the tool 4 in order to insert the pin d Slide pin holder 9 away from the pin and rotate the tool slightly in order to align pin setter 10 with the pin Side Cutters Illustration 189 90120915
23. ed on the bottom of the hydraulic oil tank Refer to Special Publication SEBU6250 5 5 Oil Analysis for information that pertains to obtaining a sample of the hydraulic oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the hydraulic oil 101710484 Indicators and Gauges Test SMCS Code 7450 081 7490 081 Illustration 262 900880299 1 Check the cab for the following problems Broken lenses on the gauges Broken indicator lights SEBU7452 07 153 Maintenance Section Oil Filter Inspect Broken switches Other broken components 2 Turn the engine start switch key to the ON position 3 Verify that all of the indicators on the instrument panel are illuminated for approximately 2 5 seconds The alarm should also sound 4 Start the engine 5 Look for inoperative gauges 6 Turn on all machine lights Check for proper operation 7 Turn off all machine lights 8 Stop the engine 9 Make any repairs that are required before operating the machine 102106227 Oil Filter Inspect SMCS Code 1308 507 5068 507 Inspect a Used Filter for Debris Illustration 263 900100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can ind
24. ed to manufacture the frame members Frame member construction SEBU7452 07 125 Maintenance Section Boom Stick and Frame Inspect Repair techniques that are recommended by the manufacturer Consult your Caterpillar dealer if repairs are necessary Your Caterpillar dealer is qualified to carry out repairs on your behalf All repairs should be carried out by a Caterpillar dealer If you carry out your own repairs contact your Caterpillar dealer for advice about proper repair techniques Particular attention should be given to all welded structures The following items should be thoroughly inspected for cracks and for defects Boom e Stick Blade e Lifting points e Upper frame Lower frame Stick Illustration 172 901425293 Check all welded joints and check the mounting points for the cylinder Blade NOTICE The areas highlighted are of particular importance but other areas must not be neglected The entire struc ture must be carefully examined Boom a Illustration 173 g01425286 Check all welded joints and check the mounting points for the cylinder Lifting Points Illustration 171 901425291 Check all welded joints and check the mounting points for the cylinder Illustration 174 901425213 126 Maintenance Section Bucket Linkage Inspect Adjust SEBU7452 07 Il
25. el The oil should be near the bottom of the opening of oil level plug 2 4 Add oil through the opening of oil filler plug 1 if necessary Note Overfilling the final drive will cause the seals on the travel motor to allow hydraulic oil or water to enter the final drive This may contaminate the final drive 5 Clean oil level plug 2 and oil filler plug 1 6 Apply pipe sealant to oil level plug 2 and oil filler plug 1 7 Install oil level plug 2 8 Install oil filler plug 1 9 Repeat the procedure for the other final drive 102182193 Final Drive Oil Sample Obtain SMCS Code 4011 008 4050 008 4050 SM 7542 008 Illustration 234 900845941 1 Oil filler plug 2 Oil level plug 3 drain plug Remove oil level plug 2 for the final drive Obtain a sample of the final drive oil by pulling a sample through the opening for oil level plug 2 Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 5 5 Oil Analysis for information that pertains to obtaining a sample of the final drive oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the final drive oil SEBU7452 07 145 Maintenance Section Fuel System Prime 101728476 Fuel System Prime SMCS Code 1250 548 900817949 Illustration 235 1 Turn the engine start switch
26. enance Section Fuel System Water Separator Drain SEBU7452 07 Note This type of element cannot be reused Note Always discard used elements according to local regulations 5 Check for water in case 3 If water is found clean case 3 6 Reinstall case 3 and ring nut 4 7 Open fuel cock 1 101685213 Fuel System Water Separator Drain SMCS Code 1263 Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage Illustration 239 900869068 The fuel system water separator is located on the right side of the machine inside the filter element access cover Drain the water and the sediment if the level ring is positioned near the reference line on the case 1 Open the filter element access cover Illustration 240 900869069 1 Fuel cock 2 Element 3 Level ring 4 Case 5 Ring nut 2 Close fuel cock 1 3 Remove ring nut 5 and case 4 4 Allow water and sediment to drain into a suitable container 5 Remove element 2 and level ring 3 from case 4 Replace element 2 with a new element Note Always discard used elements according to local regulations 6 Reinstall level ring 3 7 Reinstall case 4 and ring nut 5 8 Open fuel cock 1 SEBU7452 07 147 Maintenance Section F
27. et clearance 3 is still correct 102182155 Bucket Linkage Lubricate SMCS Code 6513 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the bucket control linkage Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe all grease fittings before you apply lubricant Illustration 180 g01104220 Note Completely fill all cavities of the bucket control linkage with grease when you initially install a bucket 1 Apply lubricant through the grease fittings 128 Maintenance Section Bucket Tips Inspect Replace SEBU7452 07 Note Service the above grease fittings after you operate the bucket under water 102869831 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket tips or side cutters Bucket Tips Illustration 181 g00101352 1 Usable 2 Replace this bucket tip 3 Overworn Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip Illustration 182 g01429324 1 Block the bucket 2 Remove mounting bolts 6 and nuts 5 Remove bucket tip 4 3 Clean the mounting surfaces 4 Install the new bucket tip onto the adapter 102798352 Bucket Tips Inspect Replace J200 Tips SMCS Code 6805 040 6805 510
28. he cleaner with a clean soft cloth Soap and Water Use a clean sponge or a soft cloth Wash the windows with a mild soap or with a mild detergent Also use plenty of lukewarm water Rinse the windows thoroughly Dry the windows with a moist chamois or with a moist cellulose sponge Stubborn Dirt and Grease Wash the windows with a good grade of naphtha or isopropyl alcohol or of Butyl Cellosolve Then wash the windows with soap and with water
29. he recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Submit the sample for Level 2 analysis Reference For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer i01631766 Cooling System Hoses Inspect SMCS Code 1380 040 1380 510 Pd 900824300 Illustration 210 1 Open the engine hood Illustration 211 900824313 2 Inspect all hoses for leaks due to cracking for softness next to the clamps and for loose clamps 3 Replace hoses that are cracked or soft and tighten any loose clamps Use Steps 3 a through 3 f to replace the hoses 138 Maintenance Section Cooling System Pressure Cap Clean Replace SEBU7452 07 Illustration 212 g00845211 a Slowly loosen the cooling system pressure cap in order to relieve system pressure Remove the pressure cap Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage Illustration 213 900845225 b Open the drain valve that is located on the bottom of the radiator Drain the coolant from the cooling system to a level that is below the hose that is being replaced Note Dispose of the drained fluids according
30. icate 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 102306981 Quick Coupler Lubricate If Equipped SMCS Code 6129 086 1 Lower all work tools to the ground 2 Wipe off the fitting before you lubricate the fitting Illustration 264 900509006 3 Apply grease to the fitting for the quick coupler 154 Maintenance Section Radiator Core Clean SEBU7452 07 101637493 Radiator Core Clean SMCS Code 1353 070 1 Open the engine access cover LH 44 UT 900847373 Illus
31. ing system compo nents If Caterpillar products are not available and com mercial products must be used make sure they have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants and Caterpillar Extender Note This machine was filled at the factory with Caterpillar Extended Life Coolant If the coolant in the machine is changed to Extended Life Coolant from another type of coolant see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 1 Open the engine hood 134 Maintenance Section Cooling System Coolant ELC Change SEBU7452 07 Illustration 202 g00845211 2 Slowly loosen the cooling system pressure cap in order to relieve cooling system pressure Remove the pressure cap Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 2 900845225 Illustration 203 3 Open the drain valve that is under the radiator Allow the coolant to drain into a suitable container 4 Close the drain valve Fill the system with a solution that consists of clean water and of cooling system cleaner 5 Start the engine Run the engine for approximately ten minutes in order to raise the coolant temperature 6 Stop the engine Open the drain valve and allow the cleaning solution to drain into a suitable container 7 Flush the cooling sys
32. inside the access cover on the left front side of the seat support Open the access cover for fuse access Fuses Fuses protect the electrical System from damage that is caused by overloaded circuits Change a fuse if the element separates If the element of a new fuse separates check the circuit and or repair the circuit NOTICE Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result NOTICE If itis necessary to replace fuses frequently an elec trical problem may exist Contact your Caterpillar dealer To replace a fuse use a puller that is stored in the fuse panel The following spare fuses are contained in the fuse panel e 10 Amperes e 20 Amperes 30 Amperes The following list identifies the circuits that are protected by each fuse The amperage for each fuse is included with each circuit e 10A a A na 30A 2 5 A Q 20A 20A 10 08 10 D 14 Illustration 246 g00825420 1 Horn 10 Amp 2 Spare 10 Amp 3 Travel Alarm 10 Amp 4 Dome Light and Radio 20 Amp 5 Hydraulic System and Fuel Shutoff 10 Amp 6 Engine Start 30 Amp 7 Heater and Air Conditioner 20 Amp 8 Windshield Washer and Lighter 20 Amp 9 Engine Speed 20 Amp 10 Beacon 10 Amp 11 Panel Dimmer 10 Amp 12 Spare 20 Amp 13 Spare 30
33. lean the filter element with a mild solution of soap and warm water Note Do not use organic solvents in order to clean the filter element 3 The filter element may also be cleaned with a maximum of 200 kPa 30 psi pressure air Note Refer to Operation and Maintenance Manual General Hazard Information before using pressure air to clean the filter element 4 After you clean the filter element inspect the filter element If the filter element is damaged or badly contaminated use a new filter element 5 Make sure that the filter element is dry Install the filter element into the filter housing Make sure that the filter element is seated in the bottom of the filter housing before the system is operated 101586674 Battery Clean SMCS Code 1401 070 Clean the battery surface with a clean cloth Keep the terminals clean and keep the terminals coated with petroleum jelly Install the post cover after you coat the terminal post with petroleum jelly 100993589 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations battery supplier An authorized battery collection facility Recycling facility i01586700 Battery Hold Down Tighten SMCS Code 7257 Tighten the hold downs for the battery in order to prevent the batteries from moving during machine operation SEBU7452 07 121 Maintenance Section Bat
34. lement should be replaced immediately if the element is damaged ESS Illustration 217 g00845637 The air filter is located under the engine access door 1 Open the engine access door 140 Maintenance Section Engine Air Filter Service Indicator Inspect SEBU7452 07 Illustration 218 g00845647 1 Clamp 2 Cover 3 Air cleaner housing 2 Remove clamp 1 and remove cover 2 from air cleaner housing 3 4 Illustration 219 g00845650 4 Air filter element 3 Remove air filter element 4 from air cleaner housing 3 Illustration 220 g00845656 5 Air inlet port 4 Cover air inlet port 5 in order to prevent dirt from getting inside the engine 5 Inspect air filter element 4 If the pleats the gaskets or the seals are damaged discard the air filter element Replace the damaged air filter element with a new air filter element 6 Wipe dust from the interior of air cleaner housing 3 Remove the cover from air inlet port 5 7 Put the clean air filter element into air cleaner housing 3 and push the air filter element into position 8 Install cover 2 and clamp the access cover 9 Close the engine access door i01632010 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 DJ Illustration 221 g0
35. lief valve one turn only If track does not loosen close the relief valve and contact your Caterpillar dealer Tightening the Tracks Illustration 271 900847600 1 Remove the cover plate for the track adjustment valve Illustration 272 900847604 2 Wipe fitting 1 before you add grease 3 Add grease through fitting 1 until the correct tension is reached 4 Operate the track back and forth in order to equalize the pressure 5 Check the amount of sag Adjust the track as needed 6 Replace the cover plate for the track adjustment valve 7 Repeat the same procedure for the other track Loosening the Track Illustration 273 900847600 1 Remove the cover plate for the track adjustment valve Illustration 274 900847604 2 Loosen fitting 1 carefully until the track begins to loosen One turn should be the maximum 3 Tighten fitting 1 to 34 N m 25 Ib ft when the desired track tension is reached 4 Operate the track back and forth in order to equalize pressure SEBU7452 07 157 Maintenance Section Track Adjustment Inspect 5 Check the amount of sag in the track Adjust the track as needed 6 Replace the cover plate for the track adjustment valve 7 Repeat the same procedure for the other track 101592560 Track Adjustment Inspect SMCS Code
36. lustration 175 g00309343 Check the approved lifting points carefully Check the welds Check that the plates are not excessively bent Check that the lifting holes are not deformed Upper Frame Illustration 176 g01425289 Check for damaged panels Specifically look for any damage to the cab or damage to the canopy that might invalidate the certification The cab or the canopy is a safety device that must be maintained in good condition Check for loose hardware or missing hardware Lower Frame Illustration 177 g01425287 Check the weld joints in the lower structure Check for loose hardware or missing hardware Check the ring of bolts that secure the swing gear i01995001 Bucket Linkage Inspect Adjust SMCS Code 6513 025 6513 040 Unexpected machine movement can cause injury or death To avoid possible machine movement move the hydraulic lockout control to the locked position and attach a Special Instruction SEHS7332 Do Not Operate or similar warning tag to the hy draulic lockout control NOTICE Improperly adjusted bucket clearance could cause galling on the contact surfaces of the bucket and stick resulting in excessive noise and or damaged O ring seals SEBU7452 07 127 Maintenance Section Bucket Linkage Lubricate Illustration 178 900101687 The clearance of the bucket linkage on this machine can be adjusted by shimming If the ga
37. nch Illustration 159 900823546 1 Adjusting bolt 2 Water pump pulley 3 Alternator pulley 4 Alternator mounting bolt 5 Belt 6 Crankshaft pulley 4 If the deflection is not correct loosen alternator mounting bolt 4 and adjusting bolt 1 Move the alternator forward and backward in order to adjust belt 5 to the specified tension 5 When the adjustment is correct tighten adjusting bolt 1 and mounting bolt 4 securely 6 Check the deflection of the belt again Note If a new belt is installed check the belt adjustment again after 30 minutes of engine operation at the rated engine speed 102304927 Blade Linkage Lubricate SMCS Code 6060 086 KL Lower all the work tools and the blade to the ground Wipe all grease fittings before lubricating Illustration 160 900823677 1 Apply lubricant to grease fitting 2 at the head end of the blade cylinder Apply lubricant to grease fitting 1 at the rod end of the blade cylinder 2 Apply lubricant to grease fittings 3 and 4 for the blade linkage Angle Blade If Equipped Illustration 161 901154347 1 Apply lubricant to grease fitting 2 at the head end of the blade cylinder Apply lubricant to grease fitting 1 at the rod end of the blade cylinder 2 Apply lubricant to grease fittings 3 and 4 for the blade linkage Apply lubricant to grease fittings 5 for the center pin
38. ng Fluid Spillage 3 If additional coolant is necessary remove the filler cap for the coolant reservoir and add the appropriate coolant mixture Install the filler cap 136 Maintenance Section Cooling System Coolant Sample Level 1 Obtain SEBU7452 07 Illustration 207 g00845211 4 If the coolant reservoir is empty open the engine hood in order to gain access to the radiator Remove the cooling system pressure cap slowly in order to relieve pressure Add coolant to the radiator Illustration 208 900102170 5 Inspect the condition of the cap gasket If necessary replace the cap 6 Install the cooling system pressure cap 7 Close the engine hood 102182199 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1395 008 1395 554 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Illustration 209 900845211 Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis
39. o the gasket of the new filter 9 Install the new filter element by hand When the gasket contacts the filter base tighten the filter for an additional three quarters of a turn Illustration 230 900845875 10 Remove the oil filler cap 11 Fill the crankcase with new oil Refer to Operation and Maintenance Manual Capacities Refill and Operation and Maintenance Manual Lubricant Viscosities 12 Clean the oil filler cap and install the oil filler cap 13 Start the engine and operate the engine at low idle for several minutes While the engine is running check the filter base for oil leaks 14 Stop the engine Wait for thirty minutes in order to allow the oil to drain back into the crankcase 15 Remove the dipstick and wipe off the oil 16 Reinsert the dipstick SEBU7452 07 143 Maintenance Section Engine Valve Lash Check 17 Remove the dipstick and check the oil level on the dipstick 2 18 Maintain the within area A on the dipstick Illustration 231 900824779 19 Close the engine access door 102860521 Engine Valve Lash Check SMCS Code 1102 082 1102 535 1102 1105 025 1105 535 1121 535 1209 082 1209 535 1209 7527 Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow addition
40. own Tighten 120 Final Drive Oil Change 143 Every 2000 Service Hours Engine Air Filter Element Clean Replace 139 Hydraulic System Oil Change 148 Every Year Cooling System Coolant Sample Level 2 Obtain iie emere beet 137 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace 154 Every 3000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 135 Every 6000 Service Hours or 6 Years Cooling System Coolant ELC Change 133 120 Maintenance Section SEBU7452 07 Air Conditioner Cab Heater Filter Recirculation Inspect Replace 102788833 Air Conditioner Cab Heater Filter Recirculation Inspect Replace SMCS Code 1054 040 A C 1054 510 A C NOTICE An air recirculation filter element plugged with dust will result in decreased performance and service life to the air conditioner or cab heater To prevent decreased performance clean the filter el ement as required 2m 72 Illustration 156 901213860 The filter element is located on the lower right side of the cab 1 In order to remove the filter element slide the filter element outward 2 Inspect the filter element If the filter element is dirty c
41. p between the bucket and the stick becomes excessive adjust bucket clearance 3 to 0 5 to 1 mm 02 to 04 inch Two shims of different thickness are used at location 9 The thicknesses of the shims are 0 5 mm 0 02 inch and 1 0 mm 0 04 inch Illustration 179 900428258 Area for linkage adjustment 1 Position the machine on a level surface and lower the bucket to the ground 2 Slowly operate the swing control lever until stick boss 2 and bucket boss 11 are in full face contact at no gap 1 This will help to determine the total clearance of the connection point of the stick and the bucket 3 Move the hydraulic lockout control to the LOCKED position Stop the engine 4 Measure bucket clearance 3 which is the existing total clearance 5 Determine the number of shims that need to be removed from shims 4 by using the following calculation Subtract 0 5 mm 0 02 inch or 1 0 mm 0 04 inch from bucket clearance 3 6 Remove the appropriate number of shims at location 9 in order to meet the above thickness Make sure that you use a minimum of three 0 5 mm 02 inch shims To remove the shims remove bolts 7 washers 8 and plate 6 7 After the correct number of shims have been removed and pin 5 is aligned with the pin hole install plate 6 washers 8 and bolts 7 Tighten bolts 7 to a torque of 100 20 N m 70 15 lb ft 8 After installation make sure that buck
42. pening of filler plug 1 7 Fill the final drive to the bottom of the opening for level plug 2 Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities 8 Install level plug 2 and filler plug 1 9 Perform Step 1 to Step 8 on the other final drive Do not use the same container for the oil from the final drives The oil samples from the final drives must be separate 10 Completely remove any oil that has spilled 11 Start the engine and allow the final drives to operate through several cycles 144 Maintenance Section Final Drive Oil Level Check SEBU7452 07 12 Stop the engine 13 Check the oil level 14 Maintain the oil level to the bottom of the opening for level plug 2 15 Check the drained oil for metal chips or for particles If there are any chips or particles consult your Caterpillar dealer Note Dispose of drained fluids according to local regulations 101633360 Final Drive Level Check SMCS Code 4050 535 FLV off M wi Illustration 233 1 filler plug 2 Oil level plug 3 drain plug 900845941 1 Position one final drive so that the three plugs are aligned vertically Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 2 Remove oil level plug 2 3 Check the oil lev
43. perly could cause damage to the belt and or to the air conditioner compressor Your engine can be equipped with a water pump with a fan drive and with an alternator Your engine can also be equipped with accessory drive belts For maximum engine performance and maximum utilization of your engine inspect the belts for wear and for cracking Check the belt tension Adjust the belt tension in order to minimize belt slippage Belt slippage will decrease the belt life Belt slippage will also cause poor performance of the alternator and of any driven equipment 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 If only one belt of a pair is replaced the new belt will carry more load This is due to the fact that the older belts are stretched The additional load on the new belt could cause the new belt to break Water Pump Belt Fan Drive Belt and Alternator Belt 900880036 Illustration 157 The access cover is located behind the right side of the operator seat 1 Remove three bolts and washers 1 in order to gain access to the belt 122 Maintenance Section Blade Linkage Lubricate SEBU7452 07 Illustration 158 900823530 2 Apply approximately 98 N 22 Ib of force midway between the pulleys 3 Measure the deflection of the belt The belt should deflect 10 to 12 mm 7 16 to 1 2 i
44. procedure for the seat belt extension 102429594 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 elie ioe 4 901152685 Illustration 267 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware SEBU7452 07 155 Maintenance Section Swing Bearing Lubricate If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 101637513 Swing Bearing Lubricate SMCS Code 7063 086 1 Lower all work tools to the ground Illustration 268 900847399 The grease fitting for the swing bearing is located the right side of the machine 2 Wipe the grease fitting before you lubricate the grease fitting 3 Apply lubricant through fitting A until the old lubricant is pushed out from the seal surface 101637553 Swing Gear Lubricate SMCS
45. replace the bucket tip Illustration 194 g00823856 1 Block the bucket Illustration 195 g00823857 2 Remove the pin from the bucket tip Use a hammer and a punch in order to drive the pin from the bucket tip 132 Maintenance Section Bucket Tips Inspect Replace SEBU7452 07 T ee 2 27 S 5 Illustration 196 g01198006 4 Tip 5 Adapter 6 Pin 3 Clean the adapter and the pin When you replace tip 4 also replace pin 6 Side Cutters Illustration 197 900823892 4 Install the new bucket tip onto the adapter Note The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration 5 Drive pin 6 through tip 4 6 After you drive pin 6 make sure that the pin fits snugly into the groove Illustration 198 901092808 Bucket With Side Cutters A Side cutters 1 Remove the mounting bolts and the side cutters 2 Clean the mounting surface of the side plate on the bucket and of the side cutter Remove any burrs or protrusions on the mating surfaces Illustration 199 901092810 Side cutter Note Some side cutters may be rotated for additional wear 3 Install the side cutter Note Certain bolts may require thread compound 4 Hand tighten the bolts SEBU7452 07 133 Maintenance Section Circuit Breakers Reset A C E D 901092812 Illustration 200
46. tem with water until the draining water is transparent 8 Close the drain valve 9 Add the Extended Life Coolant Refer to the following topics Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Operation and Maintenance Manual Refill Capacities 10 Start the engine Leave the cooling system pressure cap off Run the engine in order to expel any air from the system 11 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe 12 Install the cooling system pressure cap after the thermostat and the coolant level stabilizes 13 Stop the engine NN QAR QALY Illustration 204 g00824033 A FULL level LOW level 14 Check the coolant level of the coolant reservoir Maintain the coolant level between the FULL mark and the LOW mark 15 If additional coolant is necessary remove the reservoir cap and add the appropriate coolant solution 16 Install the reservoir cap 17 Close the engine hood Note Drained fluids should always be disposed of according to local regulations SEBU7452 07 135 Maintenance Section Cooling System Coolant Extender ELC Add i01278063 Cooling System Coolant Extender ELC Add SMCS Code 1352 1353 1395 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loose the cap slowly to relie
47. tery or Battery Cable Inspect Replace 101999587 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1401 561 1401 1402 040 1402 510 Personal injury can result from battery fumes or explosion Batteries give off flammable fumes that can ex plode Electrolyte is an acid and can cause per sonal injury if it contacts the skin or eyes Prevent sparks near the batteries Sparks could cause vapors to explode Do not allow jumper ca ble ends to contact each other or the engine Im proper jumper cable connections can cause an ex plosion Always wear protective glasses when working with batteries 1 Turn the engine start switch key to the OFF position Turn all of the switches to the OFF position Remove the key 2 Disconnect the negative battery cable at the battery 3 Disconnect the positive battery cable at the battery 4 Disconnect the battery cables from the machine if new cables are needed 5 Make necessary repairs or replace the battery 6 Connect the battery cables to the machine if the battery cables were removed 7 Connect the positive battery cable of the battery 8 Connect the negative battery cable of the battery 9 Install the key into the engine start switch 101709766 Belt Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 1397 025 1397 040 1397 510 NOTICE The V belt must be tensioned correctly Failure to ten sion the belt pro
48. to local regulations c Loosen the hose clamps and disconnect the damaged hose d Replace the damaged hose with a new hose e Replace the hose clamps and tighten the hose clamps f Add the appropriate coolant solution to the cooling system Refer to the Operation and Maintenance Manual Cooling System Level Check 4 Close the engine hood 101631931 Cooling System Pressure Clean Replace SMCS Code 1382 070 1382 510 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure Illustration 214 900845211 The cooling system pressure is located under the engine hood 1 Remove the cooling system pressure cap slowly in order to relieve pressure Illustration 215 900102170 2 Inspect the cooling system pressure the seal on the cooling system pressure cap for debris for foreign material or for damage SEBU7452 07 139 Maintenance Section Engine Air Filter Element Clean Replace 3 Clean the cooling system pressure cap with a clean cloth If necessary replace the cooling system pressure cap 4 Install the cooling system pressure cap 102183081 Engine Air Filter Element Clean Replace SMCS Code 1054 070 1054 510 Cleaning the Air Filter Element NOTICE Do not clean the air filter elements by bumping or
49. tration 265 2 Inspect radiator core 1 for dust or debris 3 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator fins However the use of compressed air is preferred 4 Close the engine access cover 102429589 Seat Belt Inspect SMCS Code 7327 040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 266 900932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection
50. uel Tank Cap and Strainer Clean 101633615 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR Illustration 241 900846099 1 Remove the fuel and the fuel fill screen Illustration 242 900846117 2 Inspect the cap Replace the cap if the cap is damaged Illustration 243 900104239 3 Wash the fuel fill screen in a clean nonflammable solvent and dry the fuel fill screen 4 Install the fuel fill screen 5 Put a light coating of fuel oil on the cap gasket 6 Install the fuel cap 101633568 Fuel Tank Water Sediment Drain SMCS Code 1273 543 8 Illustration 244 900846073 Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 1 Open the drain valve that is located under the fuel tank Allow the water and the sediment to drain into a suitable container Note Discard the drained fluids according to local regulations 2 Close the drain valve Fill the Fuel Tank You can now add fuel to the fuel tank if necessary Remove the fuel tank cap and pump fuel through the opening Make sure that you securely tighten the fuel tank cap after the refueling is complete 148 Maintenance Section Fuses Replace SEBU7452 07 101633841 Fuses Replace SMCS Code 1417 510 Illustration 245 900846309 The fuse panel is located
51. ve the pressure When a Caterpillar Extended Life Coolant 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 33 RECOMMENDED AMOUNT OF EXTENDER BY COOLING SYSTEM CAPACITY Recommended Amount of Extender 2 L 0 19 qt Cooling System Capacity 4 to 8L 1 1 to 2 1 US gal For additional information on the addition of extender see Operation and Maintenance Manual SEBU6250 Caterpillar Coolant Recommendations or consult your Caterpillar dealer 102182933 Cooling System Coolant Level Check SMCS Code 1350 040 1350 535 FLV 1395 535 FLV Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure Illustration 205 900879749 The coolant reservoir is located under the access cover on the right rear of the machine 1 Open the access cover and lock the access cover open POL QAR QALY Illustration 206 g00824033 2 Maintain the coolant level between FULL mark A on the coolant reservoir and LOW mark B on the coolant reservoir Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containi
52. you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant Complete the information on the label for the sampling bottle before you begin to take the samples Keep the unused sampling bottles stored in plastic bags e Obtain coolant samples through the filler pipe of the radiator Keep the lids on empty sampling bottles until you are ready to collect the sample SEBU7452 07 137 Maintenance Section Cooling System Coolant Sample Level 2 Obtain e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102049802 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1395 008 1395 554 7542 Reference Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Obtain the sample of the coolant as close as possible to t
53. ystem oil level with the machine on a level surface Illustration 258 900825529 1 Extend the stick and the bucket fully Lower the boom so that the bucket is rested on the ground Lower the blade to the ground 152 Maintenance Section Hydraulic System Oil Sample Obtain SEBU7452 07 Illustration 259 g00847296 2 The sight gauge is located on the side of the hydraulic tank 3 Maintain the hydraulic system oil level between top mark A and bottom mark B on the sight gauge 4 If additional hydraulic oil is needed the hydraulic filler cap is located under the access door on the right side of the machine Illustration 260 900847298 NOTICE Never remove the hydraulic tank filler cap from the hydraulic tank if the oil is hot Hot oil can cause burns Air can enter the system Air in the system can cause pump damage 5 Remove the hydraulic tank filler cap slowly in order to relieve any pressure Add hydraulic oil if necessary 6 Inspect the gasket on the hydraulic tank filler cap If the gasket is damaged replace the hydraulic tank filler cap 7 Install the hydraulic tank filler cap 102182230 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 OC 5095 008 5095 5 7542 008 7542 Illustration 261 g01104159 Obtain a sample of the hydraulic oil from the hydraulic oil sampling valve The hydraulic oil sampling valve is locat
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