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MAINTENANCE INTERVALS - Safety

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1. o o DAA EEFE i L o o o f z E3 HE CEAT Y TREER O I OF Ci VY A Illustration 146 g00791863 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 The fuel filters are located on the right side of the machine in the engine compartment The water separator bowl 1 is located on the bottom of the primary fuel filter Attach a hose 3 to the bottom of the drain valve in order to catch the fuel Open the drain valve 2 on the bottom of the water separator bowl Allow the water and the fuel to drain into a suitable container 2 Close the drain valve Note The water separator is under suction during normal engine operation Tighten the drain valve securely in order to prevent air leakage into the fuel system 100 Maintenance Section SEBU7546 03 Fuel System Primary Filter Water Separator Element Replace 101524402 Fuel Syst
2. Illustration 102 g01064443 all rl k oS FE nh idee 2 i is h fe 2 a io Ae g01064448 Illustration 103 The cooling system pressure cap 2 is located under the access door 1 at the top rear of the machine SEBU7546 03 79 Maintenance Section Cooling System Water Temperature Regulator Replace Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer 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 101526355 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age NOTICE Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a ther mostat installed If the thermostat is installed wrong it will cause the engine to overheat Inspect gaskets before assembly and replace if worn or damaged B
3. Table 8 814F Wheel Tractor Engine Oil Change Interval Multigrade Operating Conditions Oil T eee Severe Normal High Fuel Altitude Load Sulfur above Factor from 1830 m above 0 3 to 6000 ft 40 L 11 0 5 US gal P per hr of fuel Cat DEO Preferred 500 hr 500 hr 500 hr 250 hr API CH 4 11 0 minimum 500 hr 500 hr 500 hr 250 hr TBN Preferred API CH 4 TBN 500 hr 500 hr 250 hr 250 hr below 11 0 API CG 4 500 hr 250 hr 250 hr 250 hr API CF 4 250 hr 250hr 250 hr 250 hr 1 The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines 2 Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments 3 High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination These fa
4. ef 0 4 g01152685 Illustration 166 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 101528271 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD S a OO 53 oe 3 Illustration 167 g00793224 Wipe all fittings before lubrication The rod end of the steering cylinders are lubricated by using a grease fitting that is located on the cylinder The head end of the steering cylinders are lubricated by using remote grease fittings These fittings 2 and 3 are located on the left side of the machine There is a total of four fittings 102305841 Tire Inflation Check SMCS Code 4203 535 Al S N BGF1 Up A A g01160201 Illustration 168 Always obtain proper tire inflation pressures and maintenance recommendations for the tires on your machine from your tire supplier Measure the tire pressure on each tire Inflate the tires with nitrogen if necessary Reference Refer to the Tire Inflation Information section of the
5. Illustration 107 g00287531 Location of filler plug 1 and drain plug 2 for the rear axle differential for the 814F Wheel Tractor and the 815F Soil Compactor Note The axle housings are equipped with ecology drain valves 1 Remove drain plugs 2 Attach a hose to a 126 7914 Oil Drain Coupling Install the threaded end of the coupling into the drain valve Allow the oil to drain into a suitable container 2 Clean drain plugs 2 and install drain plugs 2 3 Wipe off filler plugs 1 and the surfaces around filler plugs 1 4 Remove filler plugs 1 Fill the axles with oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the type of lubricant and quantity of lubricant for the refill capacity 5 Clean filler plugs 1 and install filler plugs 1 toa torque of 45 6 N m 33 4 Ib ft 816F Landfill Compactor Illustration 108 g01063707 Location of filler plug 1 for the front axle differential for the 816F Landfill Compactor Illustration 109 g01063943 Location of drain plug 2 for the front axle differential for the 816F Landfill Compactor Illustration 110 g01063938 Location of filler plug 1 for the rear axle differential for the 816F Landfill Compactor 82 Maintenance Section Differential and Final Drive Oil Level Check SEBU7546 03 2 AA Illustration 111 g01063
6. Illustration 165 g00932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 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 110 Maintenance Section Steering Cylinder Bearings Lubricate SEBU7546 03
7. 101524264 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR 1273 070 Z2 ye Fo Illustration 151 g00791803 102 Maintenance Section Fuel Tank Water and Sediment Drain SEBU7546 03 The fuel tank cap is located on the non engine end frame of the machine 1 Remove fuel tank cap 1 and strainer 3 from the fuel tank Remove seal 2 from the cap 2 Wash the strainer and the fuel tank cap in a clean nonflammable solvent 3 Install the strainer into the filler opening 4 Inspect the seal for damage Replace the seal if necessary Install the fuel tank cap 101524470 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S OR 2 Illustration 152 g00791926 The drain valve is located on the bottom right side of the fuel tank The drain valve is located in the non engine end frame of the machine Open the drain valve Allow the sediment to drain into a suitable container Close the fuel tank drain valve 101524559 Fuses Replace SMCS Code 1417 510 Illustration 153 g00792012 These fuses are located in the operator compartment Flood Lights Front 1 10 Amperes Flood Lights Rear 2 10 Amperes Transmission Shift Control 3 10 Amperes
8. 2 Remove the cap 2 that protects the male coupler Connect an oil pump to the fitting The fitting on the machine is a male coupler 3 Turn on the oil pump and withdraw the engine oil from the engine oil pan SEBU7546 03 93 Maintenance Section Engine Oil Level Check 4 Use a strap type wrench to remove the filter element 1 Inspect the filter Reference Refer to Operation and Maintenance Manual Oil Filter Inspect 5 Clean the filter mounting base with a clean cloth Make sure that the used filter gasket has been completely removed Illustration 136 g00101318 6 Apply a thin film of clean engine oil to the sealing surface of the new filter element Note There are rotation index marks on each engine oil filter that are spaced 90 degrees or 1 4 turn away from each other Note the position of the marks on the filter in relation to a fixed point on the filter base 7 Install the engine oil filter element 1 hand tight until the seal of the engine oil filter element 1 contacts the oil filter base Note Note the position of the index marks on the filter in relation to a fixed point on the filter base 8 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide 9 Connect an oil pump to the male coupler for the high speed arrangement Fill the crankcase with new oil Reference Refer to Operation and Maintenance Manual Lu
9. Hydraulic System Oil Level Check SMCS Code 5056 535 FLV Illustration 158 g00792457 The hydraulic oil tank is located on the right side of the machine The sight glass is located on the side of the hydraulic oil tank Check the level of the hydraulic oil tank when the engine is not running and the oil is cold Maintain the oil above the ADD mark Add oil if necessary 102084311 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5056 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes before obtaining the oil sample Operate the hydraulic controls This will thoroughly mix the hydraulic oil for a more accurate sample g Illustration 159 g01063190 2 The hydraulic oil sampling valve 2 is located in the return
10. ommended multigrade oil types are met When these requirements are not met shorten the oil change interval to 250 hours or use an S O S oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine Caterpillar oil filters are recommended Recommended multigrade oil types are listed in Table 8 and Table 9 Do not use single grade oils Illustration 134 g00753767 API Trademark Commercial oils that are licensed by the American Petroleum Institute API bear this trademark Commercial oils that do not bear this trademark are not licensed and these oils are not recommended Oils that are not listed in Table 8 and in Table 9 are not recommended Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in the engine oil change interval from the recommendations in Table 8 and in Table 9 Also refer to Manual SEBU5898 Cold Weather Recommendations Poor maintenance of air filters or of fuel filters requires reduced oil change intervals See your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments SEBU7546 03 91 Maintenance Section Engine Oil High Speed and Oil Filter Change
11. 7310 070 Illustration 178 g00038949 Use commercially available window cleaning solutions in order to clean the windows Clean the outside windows from the ground unless handholds are available
12. Rotating Beacon 4 10 Amperes Autoshift 5 10 Amperes Monitoring System 6 10 Amperes Window Wiper 7 10 Amperes 00000090G SEBU7546 03 103 Maintenance Section Hydraulic System Oil Change Lighter 8 10 Amperes Lift Kickout 9 10 Amperes Illustration 154 g00792039 These fuses are located in the engine compartment te Horn 10 10 Amperes Tail Lights 12 10 Amperes 101690342 Hydraulic System Oil Change SMCS Code 5056 044 Selection of the Oil Change Interval Your machine may be able to use a 4000 hour interval for the hydraulic oil The hydraulic oil is in the system that is not integral to the service brakes the clutches the final drives or the differentials The standard change interval is 2000 hours The oil should be monitored during intervals of 500 hours The extended 4000 hour interval can be used if the following criteria are met Oil Filters Caterpillar oil filters are recommended The interval for changing the oil filter should be 500 hours Oil The 4000 hour interval for changing the oil is for the following oil types e Caterpillar Hydraulic Oil HYDO e Caterpillar Transmission and Drive Train Oil TDTO e Caterpillar TDTO TMS e Caterpillar Diesel Engine Oil e Caterpillar Biodegradable Hydraulic Oils HEES e Caterpillar Multipurpose Tractor Oil MTO e Heavy duty diesel engine oil with a minimum
13. The end bits are not reversible If both sides are worn install a new cutting edge 5 Install bolts 3 Tighten the bolts to the specified torque Reference Refer to Specifications SENR3130 Torque Specifications 6 Strike the bolt heads with a hammer Tighten the bolts again to the specified torque 7 Start the engine Raise the blade and remove the blocking Lower the blade to the ground 8 After a few hours of operation check the bolts for proper torque 102086258 Differential and Final Drive Oil Change SMCS Code 3278 044 4011 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 814F Wheel Tractor and 815F Soil Compactor Illustration 106 g00287529 Location of filler plug 1 and drain plug 2 for the front axle differential for the 814F Wheel Tractor and the 815F Soil Compactor SEBU7546 03 81 Maintenance Section Differential and Final Drive Oil Change
14. amp Va e e O t e o o 38 Ld Sol Illustration 104 g00792854 Replace the water temperature regulator in order to reduce the chance of problems with the cooling system Replace the water temperature regulator and the seals while the cooling system is completely drained or while the coolant is drained to a level that is below the water temperature regulator housing Note If you are only replacing the water temperature regulator drain the coolant to a level that is below the water temperature regulator housing Reference Refer to the Disassembly and Assembly Manual for the correct procedure for replacing the water temperature regulator 80 Maintenance Section Cutting Edges and End Bits Inspect Replace SEBU7546 03 101936280 Cutting Edges and End Bits Inspect Replace SMCS Code 6801 040 6801 510 6804 040 6804 510 OOO OO00 O an pay 2 3 Illustration 105 g00771980 Check the cutting edges and the end bits for wear and for damage Use the following procedure to service the cutting edges and the end bits if necessary 1 Raise the blade and place blocking under the blade Lower the blade onto the blocking Stop the engine 2 Remove bolts 3 cutting edges 2 and end bits 1 3 Clean all contact surfaces 4 If the opposite side of the cutting edge is not worn use the opposite side of the cutting edge
15. gauge 2 Install the filler cap Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 8 Start the engine and run the engine for at least ten seconds Then stop the engine and add hydraulic oil to the tank until the oil level is at the FULL mark on the sight gauge Install the filler cap 9 Start the engine and run the engine at low idle Cycle the implements so that all hydraulic systems are filled with oil Note If the alert indicator for a low oil level comes on stop the engine and immediately add oil to the hydraulic tank The oil level should not be below the suction ports in the hydraulic tank while the engine is running 10 Add hydraulic oil to the tank until the oil level is at the FULL mark on the sight gauge 11 Stop the engine Top off the hydraulic tank so that the oil level is at the FULL mark on the sight gauge Install the filler cap Note The oil must be free of air bubbles If air bubbles are present in the hydraulic oil air is entering the hydraulic system Inspect the hydraulic suction line and the hose clamps 102084372 Hydraulic System Oil Filter Replace SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the
16. samples e Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102086165 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates
17. 101517741 Brake Accumulator Check SMCS Code 4263 535 aO Sp Boa W Illustration 86 g00787525 1 Turn the engine start switch to the ON position The alert indicator for brake oil pressure should come on if the braking system is not at normal operating pressure 2 Start the engine Run the engine at half speed for two minutes in order to increase the accumulator pressure The alert indicator for brake oil pressure should go off 3 Stop the engine Apply the service brake pedal and release the service brake pedal until the alert indicator for brake oil pressure comes on This will decrease the accumulator pressure A minimum of five applications of the service brake pedal are required 4 If the alert indicator comes on after less than five applications of the brake measure the accumulator precharge pressure An authorized Caterpillar dealer can measure the nitrogen gas pressure in the accumulator Use only dry nitrogen gas for recharging 101690577 Brake Discs Check SMCS Code 4255 535 Reference For information about checking the thickness of the brake discs refer to Systems Operation Testing and Adjusting SENR1316 814F Wheel Tractor 815F Soil Compactor and 816F Landfill Compactor Braking System or consult your Caterpillar dealer 101520405 Braking System Test SMCS Code 4251 081 4267 081 e Park the machin
18. Operation and Maintenance Manual for more information SEBU7546 03 111 Maintenance Section Transmission Oil Change i01709890 Transmission Oil Change SMCS Code 3030 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate the machine for a few minutes in order to warm the transmission oil 2 Park the machine on a level surface Lower the attachment to the ground and apply slight downward pressure Engage the parking brake and stop the engine Illustration 169 g00793448 1 Breather 2 Bolts 3 Cover 4 Seal 5 Washer 6 Magnetic Tube Assembly 7 Screen 8 Drain Plug Note Remove the transmission guard from the bottom of the machine in order to access the magnetic screen assembly 3 Remove transmission oil drain plug 8 Allow the transmission oil to drain int
19. Years Cooling System Coolant Extender ELC Add 76 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccccceceeeeeeeeeeeeetteeeees 109 Every 4000 Service Hours or 2 Years Hydraulic System Oil Change ee 103 Every 6000 Service Hours or 4 Years Cooling System Water Temperature Regulator ELETO E saved s aetece aaecaere E 79 Every 6000 Service Hours or 6 Years Cooling System Coolant ELC Change 74 SEBU7546 03 67 Maintenance Section Articulation Bearings Lubricate 101514904 Articulation Bearings Lubricate SMCS Code 7057 086 BD 7065 086 BD 7066 086 BD mi Fo Illustration 79 g00786065 Wipe all fittings before lubricant is applied Apply grease to two fittings for the articulation bearings 101517222 Axle Oscillation Bearings Lubricate SMCS Code 3268 086 BD 3278 086 BD Illustration 80 g00787242 The oscillation bearings are lubricated by using two remote grease fittings These fittings are located behind the small access door on the left side of the machine Wipe all fittings before any lubricant is applied Fitting 1 lubricates the front oscillation bearing of the rear axle Fitting 2 lubricates the rear oscillation bearing of the
20. a primary element with damaged pleats gaskets or seals 9 If it is necessary compare the primary element to a new primary element Use a new primary element that has the same part number This may be necessary in order to confirm the results of the inspection 10 Discard a damaged primary element Use Steps 11 through 13 to install a clean primary element NOTICE Do not use a filter if the pleats the gaskets or the seals are damaged SEBU7546 03 87 Maintenance Section Engine Air Filter Secondary Element Replace 11 Install a clean primary filter element over the engine air filter secondary element Apply firm pressure to the end of the primary element as you gently rock the filter element This seats the primary element 12 Clean the cover for the air cleaner housing Align the slot on the cover with the pin on the air cleaner housing Install the cover 13 Close the engine hood 101693619 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Service the air filter only with the engine stopped En gine damage could result NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Note Replace the secondary element when you service the primary element for the third time If a clean primary element has been installed and a warning for the air filter still occurs replace the secondary element A
21. discard the water separator bowl 4 Inspect the O ring seal in the water separator bowl for damage Replace the O ring seal if necessary 5 Lubricate the O ring seal with clean diesel fuel or with engine oil Place the O ring seal in the water separator bowl 6 Install the water separator bowl onto the new filter element by hand Do not use tools to tighten the water separator bowl Illustration 148 g00101318 7 Lubricate the gasket of the new filter element with clean diesel fuel 8 Install the new filter on the filter mounting base When the filter gasket contacts the filter mounting base tighten the filter by an additional 3 4 turn 9 Tighten the drain valve on the water separator bowl Note The water separator element is under suction during normal engine operation The drain valve must be tightened in order to prevent air leakage into the fuel system 10 Prime the fuel system in order to fill the filter element with fuel Reference Refer to Operation and Maintenance Manual Fuel System Prime for the correct procedure SEBU7546 03 101 Maintenance Section Fuel System Secondary Filter Replace 101524455 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containe
22. fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 2 Illustration 156 g01063216 3 4 aA gE mt 5 _ _ l UF a a db g00792496 Illustration 157 The hydraulic oil filters are located in the hydraulic oil tank The hydraulic oil tank is located behind the platform on the right side of the machine 1 Remove the bolt 2 and swing the platform 1 away from the machine 2 Remove the four bolts 3 from each of the covers 4 Remove both of the covers 3 Remove the filter elements Discard the old elements 4 Clean the covers Inspect the condition of the seals Replace the seals if necessary 106 Maintenance Section Hydraulic System Oil Level Check SEBU7546 03 5 Install new filter elements and install the covers Tighten the bolts to 58 4 N m 42 8 2 9 Ib ft 6 Check the level of the hydraulic oil tank Add oil if necessary 7 Close the platform and install the bolt 101525484
23. key 3 Disconnect the negative battery cable from the disconnect switch Note Do not allow the disconnected battery cable to contact the disconnect switch 4 Disconnect the negative battery cable at the battery 5 Disconnect the positive battery cable at the battery 6 Inspect the battery terminals for corrosion Inspect the battery cables for wear or damage 7 Make any necessary repairs If necessary replace the battery cables or the battery 8 Connect the positive battery cable at the battery 9 Connect the negative battery cable at the battery 10 Connect the battery cable at the battery disconnect switch 11 Install the key and turn the battery disconnect switch ON 101520294 Belt Inspect Adjust Replace SMCS Code 1397 025 1397 040 1397 510 Illustration 85 g00789533 1 Compressor 2 Fan Pulley 3 Alternator 4 Tensioner 5 Belt 6 Drive Pulley Your machine is equipped with a serpentine belt Inspect the belt for damage Replace the belt if necessary Insert a ratchet with a square drive into the square hole that is located in the tensioner 4 Rotate the tensioner counterclockwise in order to relieve tension on the belt Remove the belt Install the new belt correctly as shown The correct tension will automatically be applied Be sure that the belt is fully seated on the pulleys 70 Maintenance Section Brake Accumulator Check SEBU7546 03
24. oil filter contacts the base 6 Tighten the oil filter element 1 according to the instructions that are printed on the filter Use the index marks as a guide 7 Open the crankcase drain valve 2 Allow the oil to drain into a suitable container Close the crankcase drain valve o o AA a l i I o ti o o 3 T il i 4 5 fae at ry H O O O 7 aN Illustration 141 g00791396 8 Open the access door that is located on the right side of the machine Remove oil filler plug 3 Fill the crankcase with new oil Reference Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 9 Clean the oil filler plug and install the oil filler plug 10 Start the engine and allow the oil to warm Check for leaks 11 Check the engine oil level in dipstick 4 Reference Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure 12 Stop the engine Close the engine access doors 101181536 Engine Valve Lash Check SMCS Code 1105 535 For the correct procedure refer to the appropriate Service Manual module for your machine s engine or consult your Caterpillar dealer Note A qualified mechanic should adjust the engine valve lash because special tools and training ar
25. oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type in Table 10 Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each increment is an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above References Reference Form PEDP7035 Optimizing Oil Change Intervals Reference Form PEDP7036 S O S Fluid Analysis Reference Form PEDP7076 Understanding the S 0 S Oil Analysis Tests Procedure for Changing the Engine Oil and Filter NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid wi
26. or the seals are damaged discard the element Replace a damaged primary element with a clean primary element To avoid personal injury always wear eye and face protection when using pressurized air Illustration 125 g00328468 5 If the primary element is not damaged clean the primary element Pressurized air can be used to clean a primary element that has not been cleaned more than two times Use filtered dry air at a maximum pressure of 207 kPa 30 psi Note Pressurized air will not remove deposits of carbon and oil 6 When you clean the primary element always begin in the inside of the element clean side This will force dirt particles toward the outside of the element dirty side Direct the air along the length inside of the filter This will help prevent damage to the paper pleats Note Do not aim the stream of air directly at the primary element Dirt could be forced further into the pleats Use Steps 7 through 10 in order to inspect the primary element Illustration 126 g00328470 7 Place a light bulb inside the filter element Use a 60 watt blue light in a dark room or in a similar facility Inspect the primary element for light that may show through the filter material 8 Inspect the primary element while you rotate the element Inspect the primary element for tears and or holes Do not use a primary element that has any tears and or holes in the filter material Do not use
27. rear axle 101713195 Backup Alarm Test SMCS Code 7406 081 1 Turn the engine start switch key to the ON position in order to perform the test 2 Apply the service brake Q fae lt Illustration 81 g00783907 3 Move the transmission direction control lever to the REVERSE position 68 Maintenance Section Battery Clean SEBU7546 03 TEE o 2 Illustration 82 g00782208 The alarm should start to sound immediately The alarm will continue to sound until the transmission direction control lever is moved to the NEUTRAL position or to the FORWARD position Reference For more information refer to Operation and Maintenance Manual Backup Alarm 101517509 Battery Clean SMCS Code 1401 070 C O O Io Illustration 83 g00787365 One battery is located on each side of the machine under the access door Clean the battery terminals and the surfaces of the batteries with a clean cloth Coat the battery terminals with petroleum jelly Make sure that the battery cables are installed securely 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
28. refer to Operation and Maintenance Manual Cooling System Coolant Extender ELC Add or consult your Caterpillar dealer If an Extended Life Coolant was previously used flush the cooling system with clean water No other cleaning agents are required Use the following procedure to change the Extended Life Coolant Illustration 97 g00792796 The cooling system pressure cap 2 is located under the access door 1 at the top rear of the machine 1 Slowly loosen the cooling system pressure cap in order to relieve system pressure Remove the cooling system pressure cap 2 Place the drain hose 4 into a suitable container Open the drain valve 5 on the bottom of the radiator Allow the coolant to drain into a suitable container Note The Landfill Compactor is equipped with bottom guards The radiator guard needs to be lowered in order to access the drain valve 3 Flush the cooling system with clean water until the draining water is clean Close the drain valve 4 Replace the water temperature regulator Reference Refer to Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the correct procedure 5 Add the Extended Life Coolant Reference Refer to Operation and Maintenance Manual Capacities Refill for the refill capacity of the cooling system 6 Start the engine Run the engine without the cooling system pres
29. the bolt on clamp 6 to a torque of 24 7 N m 18 5 lb ft Install hose 5 and tighten clamp 4 Install hood assembly 1 Tighten the bolt on clamp 2 101720842 Engine Crankcase Breather Clean SMCS Code 1317 070 o o A oj DA sod 1M ae OUt tI Cy Illustration 133 g00791169 The crankcase breather is located on the top of the engine on the right side 1 Remove the four bolts that hold the breather onto the cover Remove the breather Check the condition of the cover seal Replace the seal if the seal is damaged Wash the breather and the filter element in a clean nonflammable solvent Shake the breather or use pressure air in order to dry the breather Inspect the hose for damage Replace the hose if it is necessary Install the breather assembly Install the hose and install the hose clamp Close the access door 90 Maintenance Section Engine Oil High Speed and Oil Filter Change SEBU7546 03 Engine Oil High Speed and Oil Filter Change If Equipped SMCS Code 1318 510 HZ Selection of the Oil Change Interval NOTICE This machine is equipped with an engine that meets EPA Tier 2 Euro Stage Il or MOC Step 2 emission regulations A 500 hour engine oil change interval is available provided that operating conditions and rec
30. the machine for a few minutes before obtaining the oil sample Operate the hydraulic controls This will thoroughly mix the hydraulic oil for a more accurate sample x ie E o o Illustration 175 g01063364 2 The sampling valve for the transmission oil 1 is located on the transmission oil filter base 2 3 Use the sampling valve for the transmission oil 1 in order to obtain a sample of the transmission oil Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis and Special Publication PEHP6001 How To Take A Good Oil Sample i01528989 Window Washer Reservoir Fill SMCS Code 7306 544 Jh H me Po Illustration 176 g00793722 The window washer reservoir is located behind the operator compartment on the firewall Open the cover in order to access the reservoir 101529015 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 a 7M g00793752 Illustration 177 Inspect the condition of the wiper blades Replace the wiper blades if the blades are worn or damaged 115 Maintenance Section Windows Clean SEBU7546 03 i00037755 Windows Clean SMCS Code
31. when the yellow diaphragm enters the red zone or the red piston locks in the visible position If the service indicator 1 appears red at any time clean the air cleaner element or install a new air cleaner element Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes e Check the movement of the yellow core when the engine is accelerated to the engine rated rpm The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are severely dusty Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 102084827 Engine Air Filter Service Indicator Inspect Replace SMCS Code 7452 040 7452 510 NOTICE Service the air cleaner only with the engine stopped Engine damage c
32. zinc content of 900 ppm Use heavy duty oils with the following classification CF CF 4 CG 4 and CH 4 Note Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems These oils are more likely to cause corrosion and excessive wear Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours Caterpillar s standard S O S Fluids Analysis or an equivalent oil sampling program should be used The current guidelines for cleanliness of the oil should be observed Refer to Measured Data If an oil sampling program is not available the standard 2000 oil change interval should be used Measured Data The following information should be monitored by using a program for sampling the oil e Significant changes in wear metals should be monitored These metals include iron copper chromium lead aluminum and tin Significant changes in additives should be monitored These metals zinc calcium magnesium and phosphorus e Contaminants should not be present These contaminants include fuel and antifreeze Water content should be 5 percent or less e The silicon level should not exceed 15 parts per million for new oil The particle counts should be monitored 104 Maintenance Section Hydraulic System Oil Change SEBU7546 03 e The recommended level of cleanliness for Caterpillar machines that are operated in the field is ISO 18 15 or cleaner The cleanlin
33. 250 hr 250 hr API CF 4 250 hr 250 hr 250 hr 250 hr 1 The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines 2 Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments 3 High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption of your 814F Wheel Tractor exceeds 40 L 11 US gal per hour follow the High Load Factor recommendations in Table 10 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change 4 For sulfur content above 0 5 refer to Operation and Maintenance Manual SEBU6250 To
34. 3 The axles are not equipped with sampling valves Obtaining a sample of the differential and final drive oil will require a vacuum pump or an equivalent Withdraw the oil through filler plug opening 1 on the front axle and through filler plug opening 2 on the rear axle Reference Refer to Special Publications SEBU6250 Caterpillar Machine Fluid Recommendations for more information about obtaining a fluid sample 101522600 Drive Shaft Spline Center Lubricate SMCS Code 3253 086 SN H g00790972 Illustration 120 Wipe all fittings before lubricant is applied Apply lubricant to fitting 1 until the lubricant is expelled from fitting 2 101522681 Drive Shaft Support Bearing Lubricate SMCS Code 3267 086 BD hoe poe PG Illustration 121 g00791051 Wipe all fittings before lubricant is applied The support bearing is lubricated by a remote grease fitting that is located near the center hitch above the drive shaft in the non engine end frame of the machine Apply grease to this fitting 102061807 Electronic Unit Injector Inspect Adjust SMCS Code 1251 025 1251 040 1290 025 1290 040 The Electronic Control module produces high voltage To prevent p
35. 940 Location of drain plug 2 for the rear axle differential for the 816F Landfill Compactor 1 Repeat steps 1 through 5 in order to change the differential and final drive oil in the front axle differential and the rear axle differential for the 816F Landfill Compactor 102088246 Differential and Final Drive Oil Level Check SMCS Code 3278 535 FLV 4011 535 FLV Note Before you measure the oil level operate the machine for a few minutes in order to equalize the oil level Front Axle Sth g01063905 Illustration 112 The location of the filler plug 1 for the front axle differential for the 814F Wheel Tractor and the 815F Soil Compactor Illustration 113 g01063707 The location of the filler plug 1 for the front axle differential for the 816F Landfill Compactor 1 Remove the front differential filler plug 1 The positions of the plugs are shown in the above illustrations 2 Fill the front axle with oil and maintain the oil level to the bottom of the filler plug Refer to Operation and Maintenance Manual SEBU7546 02 Capacities Refill for information on the capacities of the axles 3 Install the front differential filler plug 1 Tighten to a torque of 45 6 N m 33 4 Ib ft Rear Axle iH g01063913 Illustration 114 The location of the filler plug 1 for the rear axle differential for the 814F Wheel Tractor and the 815F Soil Compactor SEB
36. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR area LL Operation and Maintenance Manual 816F Landfill Compactor 815F Soil Compactor and 814F Wheel Dozer BGF1 Up Machine BKL1 Up Machine BMR1 Up Machine SEBU7546 03 65 Maintenance Section Maintenance Interval Schedule i02711921 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 Battery RECYCl ss uci a aaia aaea 68 Battery or Battery Cable Inspect Replace 69 Circuit Breakers Reset cese
37. U7546 03 83 Maintenance Section Differential and Final Drive Oil Sample Obtain Illustration 115 g01063709 The location of the filler plug 2 for the rear axle differential for the 816F Landfill Compactor 1 Remove the rear differential filler plug 2 The positions of the plug is shown in the above illustrations 2 Fill the rear axle with oil and maintain the oil level to the bottom of the filler plug Refer to Operation and Maintenance Manual SEBU7546 02 Capacities Refill for information on the capacities of the axles 3 Install the front differential filler plug 1 Tighten to a torque of 45 6 N m 33 4 Ib ft Differential and Final Drive Oil Sample Obtain SMCS Code 3278 008 4011 008 4070 008 7542 Front Axle Illustration 116 g01063905 The location of filler plug 1 for the front axle differential for the 814F Wheel Tractor and the 815F Soil Compactor Illustration 117 g01063707 The location of filler plug 1 for the front axle differential for the 816F Landfill Compactor Rear Axle g Illustration 118 g01063913 The location of filler plug 1 for the rear axle differential for the 814F Wheel Tractor and the 815F Soil Compactor Illustration 119 g01063709 The location of filler plug 2 for the rear axle differential for the 816F Landfill Compactor 84 Maintenance Section Drive Shaft Spline Center Lubricate SEBU7546 0
38. al or change to a preferred multigrade oil type in the listing above References Reference Form PEDP7035 Optimizing Oil Change Intervals Reference Form PEDP7036 S O S Fluid Analysis Reference Form PEDP7076 Understanding the S 0 S Oil Analysis Tests Procedure for Changing the Engine Oil and Filter NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates qJ co fee yO LY P Pe 2 g00791274 Illustration 135 Your machine may be equipped with a high speed arrangement for changing the engine oil The high speed arrangement allows service personnel to change the oil from the engine access door on the right side of the machine The high speed arrangement allows the oil to be changed faster than conventional methods 1 The high speed arrangement is located on the right side of the engine
39. and the condenser Close the radiator guard Reference Refer to Special Publication SEBD0518 Know Your Cooling System for more information i02711933 Refrigerant Dryer Replace SMCS Code 7322 510 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 un der 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 NOTICE If the refrigerant system has been open to the outside air without being plugged for more than 30 minutes the receiver dryer must be replaced Moisture will en ter an open refrigerant system and cause corrosion which will lead to component failure Re
40. arting aid cylinder 2 hand tight Tighten retaining clamp 1 securely 5 Close the engine hood 101523459 Fan Drive Bearing Lubricate SMCS Code 1359 086 BD U Fw Illustration 144 g00791507 Wipe all bearings before lubrication The fan drive bearing is lubricated by a fitting that is located near the serpentine belt Apply grease to this fitting SEBU7546 03 99 Maintenance Section Fuel System Prime 101524005 Fuel System Prime SMCS Code 1250 548 i g QO oO ONO OO slg o 2 5 dA Illustration 145 g00791684 The priming pump is located on the right side of the machine in the engine compartment 1 Your machine is equipped with an electric fuel pump The toggle switch 1 for the electric fuel pump is located near the fuel filter on the right side of the engine 2 A plug 2 is located on the secondary filter The plug is used in order to purge air from the fuel lines 3 Use the toggle switch in order to operate the electric fuel pump Open the plug Operate the fuel priming pump until no air bubbles are present from the plug 4 Tighten the plug when air bubbles are no longer present Turn off the fuel priming pump If the engine does not start or the engine misfires further priming is necessary Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543
41. bricant Viscosities and Refill Capacities for the correct type of oil and for the correct amount of oil 10 Clean the end of the male coupler Clean the cap that covers the male coupler and install the cap 11 Start the engine and allow the oil to warm Check the machine for oil leaks 12 Check the engine oil level Reference Refer to Operation and Maintenance Manual Engine Oil Level Check for the correct procedure 13 Stop the engine Close the engine access door and the engine hood i02709400 Engine Oil Level Check SMCS Code 1000 535 FLV NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Qaio Illustration 137 g00791374 1 Open the engine access door on the right rear side of the machine The engine oil dipstick is located
42. csei casi it eae ated 77 Engine Crankcase Breather Clean 005 89 Engine Oil High Speed and Oil Filter Change 90 Engine Oil and Filter Change s es 94 Fuel System Primary Filter Water Separator Element Replace eceececeeeeeeeeeteeeeees 100 Fuel System Secondary Filter Replace 101 Fuel Tank Cap and Strainer Clean 08 101 Hydraulic System Oil Filter Replace 105 Transmission Oil Filter Replace 066 112 Every 1000 Service Hours or 6 Months Articulation Bearings Lubricate 0 ceee 67 Battery Hold Down Tighten n 68 Drive Shaft Support Bearing Lubricate 84 Rollover Protective Structure ROPS Inspect 109 Transmission Oil Change ccceeeeeeeeeeeeentees 111 66 Maintenance Section Maintenance Interval Schedule SEBU7546 03 Every 2000 Service Hours Refrigerant Dryer Replace s in 108 Every 2000 Service Hours or 1 Year Brake Discs Check 0 ccceccececeeeeeeeeeeeeeeeeneeees 70 Cooling System Coolant Sample Level 2 OD AIR eretan rne aE NE EATER 78 Differential and Final Drive Oil Change 80 Electronic Unit Injector Inspect Adjust 84 Engine Valve Lash Check essees 97 Engine Valve Rotators Inspect eeen 97 Hydraulic System Oil Change n 103 Refrigerant Dryer Replace s is 108 Every 3000 Service Hours or 2
43. ctors deplete the oil additives more rapidly If the average fuel consumption of your 814F Wheel Tractor exceeds 40 L 11 US gal per hour follow the High Load Factor recommendations in Table 8 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change 4 For sulfur content above 0 5 refer to Operation and Maintenance Manual SEBU6250 Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines 5 In order to verify an oil change interval of 500 hours refer to Program A below 6 Use Program B below to determine an appropriate interval Table 9 815F Soil Compactor 816F Landfill Compactor Engine Oil Change Interval Operating Conditions Severe Normal High Fuel Altitude Multigrade Load Sulfur above Oil Type Factor from 1830 m above 0 3 to 6000 ft 47L 12 0 5 US gal per hr of fuel Cat DEO 500 hr 500hr 500 hr 250 hre Preferred API CH 4 11 0 minimum 500 hr 500 hr 500 hr 250 hr TBN Preferred API CH 4 TBN 500 hr 500 hr 250 hr 250 hr below 11 0 API CG 4 500 hr 250 hr 250 hr 250 hr API CF 4 250 hr 250 hr 250 hr 250 hr 1 The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine i
44. e correct procedure 101528752 Transmission Oil Level Check SMCS Code 3030 535 FLV za z Illustration 174 g00793593 The oil level sight gauge is located near the center hitch of the machine Maintain the oil above the MIN mark 2 on the sight gauge when the engine is off Maintain the oil between the MAX mark 3 and the MIN mark 4 when the engine is at idle Landfill Compactors are also equipped with an oil level dipstick 1 that is located behind the operator s cab Maintain the oil level within the LOW and FULL marks when the engine is at low idle and the oil is warm 114 Maintenance Section Transmission Oil Sample Obtain SEBU7546 03 i02084671 Transmission Oil Sample Obtain SMCS Code 3080 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Operate
45. e required 101935374 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to prevent being burned by hot oil or spray Caterpillar recommends replacing valve rotators that are operating improperly An improperly operating valve rotator will shorten valve life because of accelerated wear on the valves Also metal particles from a damaged valve rotator could fall into the cylinder and damage to the piston head and to the cylinder head may result 98 Maintenance Section Ether Starting Aid Cylinder Replace SEBU7546 03 Illustration 142 g00882731 Start the engine and run the engine at low idle Watch the top surface of each valve rotator Whenever an inlet valve closes or an exhaust valve closes each valve rotator should turn If a valve rotator fails to turn consult your Caterpillar dealer for service 101524144 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD ue Illustration 143 g00791745 1 Open the access door The ether starting aid cylinder is mounted on the right side of the machine 2 Loosen retaining clamp 1 and unscrew ether starting aid cylinder 2 3 Remove the gasket Install the new gasket that is provided with each new ether starting aid cylinder 4 Install new ether st
46. e A battery supplier e An authorized battery collection facility e Recycling facility 101517613 Battery Hold Down Tighten SMCS Code 7257 527 Illustration 84 g00787432 Open the battery compartment on both sides of the machine Over time the vibration of an operating machine can cause the battery hold downs to loosen To help to prevent loose batteries and the possibility of loose cable connections tighten the eight nuts on the two hold downs to a torque of 12 3 N m 8 9 2 2 Ib ft SEBU7546 03 69 Maintenance Section Battery or Battery Cable Inspect Replace 102517652 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 Personal injury may occur from failure to properly service the batteries Batteries give off flammable fumes that can ex plode Electrolyte is an acid and can cause per sonal injury if it contacts the skin or eyes Prevent sparks near the batteries Sparks could cause vapors to explode Do not allow jumper ca ble ends to contact each other or the engine Im proper jumper cable connections can cause an ex plosion Always wear protective glasses when working with batteries 1 Turn the engine start switch key OFF Turn all of the switches OFF 2 Turn the battery disconnect switch OFF Remove the
47. e containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Level 1 Analysis results may indicate the need for a Level 2 Analysis Illustration 100 g01064443 lo o o a A o o H Ps H 4 all o 3 ft ale alll le 2 o FWD Illustration 101 g01063878 The cooling system pressure cap 2 is located under the access door 1 at the top rear of the machine 78 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU7546 03 Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the
48. e on a hard dry level surface e Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles e Make sure that the steering frame lock is in the unlocked position e Fasten the seat belt before you test the brakes The following tests are used to determine whether the braking system is functional These tests are not intended to measure the maximum brake holding effort The required brake holding effort for sustaining a machine at a specific engine rpm varies from one machine to another machine The variations include differences in the engine setting the power train efficiency the brake holding ability etc Service Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake 1 Start the engine Raise the implement slightly Apply the service brake Release the parking brake 2 Move the transmission control to SECOND SPEED FORWARD while the service brakes are applied 3 Gradually increase the engine speed to high idle The machine should not move 4 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Engage the parking brake Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make a
49. eeeeesseeeeeeeenaes 72 Cleaner Bar Tips Replace ceeeeeeeeeees 73 Engine Air Filter Primary Element Clean Replace E E ENA 85 Engine Air Filter Secondary Element Replace 87 Engine Air Precleaner Clean 89 Ether Starting Aid Cylinder Replace 98 Fuel System Prime ec eee eeeeee teens 99 Fuses R place nlad te aiea senin nie iaa 102 Oil Filter Inspect ceeeceeeeceeeeeeeeeeeeteeeteeeees 107 Radiator Core Clean ou ceccccceseeeeeeeesteeeeeeenaes 107 Window Washer Reservoir Fill l a 114 Window Wiper Inspect Replace 0 00 114 Daily Engine Air Filter Service Indicator Inspect 87 Every 10 Service Hours or Daily Backup Alarm Test es eeeeeeeeeeeeeeeeeeeeeeees 67 Cleaner Bar Check Adjust cceeceeeeeeeeeenees 73 Compactor Wheel Chopper Blades Inspect Replace eceececceeceeeeeeeeeeeteeesenteeaees 74 Compactor Wheel Plus Tips Inspect Replace 74 Compactor Wheel Tamping Tips Inspect Replaces ariii a A iai eve dard einen ees 74 Cooling System Coolant Level Check 77 Cutting Edges and End Bits Inspect Replace 80 Engine Oil Level Check sssssseessseseerresessrss 93 Fuel System Primary Filter Water Separator DAU EE AE AE E A TEA 99 Hydraulic System Oil Level Check 106 Seat Belt Inspect 2 0 0 0 eeeeeeeeceeeeeeteeeeees 109 Transmiss
50. em Primary Filter Water Separator Element Replace SMCS Code 1260 510 1263 510 FQ NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts Fuel system should be primed prior to starting the engine HO EN L z pA 2 f 3 E Sool ee d Illustration 147 g00791902 1 The water separator bowl 2 is located on the bottom of the primary fuel filter 1 Open the drain valve 3 on the water separator bowl Allow the water and the fuel to drain into a suitable container 2 Use a strap type wrench to remove the filter from the filter mounting base 3 Remove the water separator bowl from the filter element Clean the water separator bowl and the O ring groove Note The water separator bowl is reusable Do not
51. ersonal injury make sure the Electronic Control Module is not powered and the unit injector solenoids are disconnected NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the unit injector lash is made The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result The operation of Caterpillar engines with improper adjustments of the electronic unit injector can reduce engine efficiency This reduced efficiency could result in excessive fuel usage and or shortened engine component life SEBU7546 03 85 Maintenance Section Engine Air Filter Primary Element Clean Replace Adjust the electronic unit injector at the same interval as the valve lash adjustment Refer to your machine s Service Manual or your Caterpillar dealer for the complete adjustment procedure 101690224 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in o
52. ess should be monitored by particle count analysis Contamination levels should not exceed normal levels by more than two ISO codes Action should be taken in order to determine the cause of the contamination The system should be returned to the original levels of contamination e There should not be significant changes in sodium silicon copper and potassium e The allowable level of oxidation is 40 percent 0 12 Abs units e The kinematic viscosity at 100 C 212 F should not exceed 2 cSt Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Operate the machine for a few minutes in order to warm the hydraulic oil Park the machine on level ground Lower the blade to the ground and apply slight downward pressure Engage the parking brake and stop the engine 1 Illustra
53. fer to Service Manual SENR5664 Air Conditioning and Heating System with R 134a Refrigerant for All Caterpillar Machines for the proper procedure to change the receiver dryer assembly and for the procedure to reclaim the refrigerant gas SEBU7546 03 109 Maintenance Section Rollover Protective Structure ROPS Inspect 101528092 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 Ld s R Illustration 164 g00793150 Inspect the ROPS for bolts that are loose or damaged Use original equipment parts only to replace bolts that are damaged or missing Tighten the four cab mounting bolts to a torque of 850 100 N m 629 74 lb ft Note Apply oil to all bolt threads before installation Failure to apply oil can result in improper bolt torque Do not repair the ROPS by welding reinforcement plates to the ROPS Consult your Caterpillar dealer for repair of cracks in any welds in any castings or in any metal section of the ROPS 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
54. ht side of the machine Circuit breakers are also located in the operator s compartment Main Circuit 1 80 Amperes S Alternator 2 80 Amperes l Ignition Key 3 10 Amperes Engine Control 4 15 Amperes Running Lights 5 15 Amperes Seat Air Compressor 6 15 amp Fan Motor 7 15 amp 8 O SEBU7546 03 73 Maintenance Section Cleaner Bar Check Adjust 102580074 Cleaner Bar Check Adjust SMCS Code 7160 025 7160 535 S N BKL1 Up 102580075 Cleaner Bar Tips Replace SMCS Code 7160 510 TIP S N BKL1 Up Illustration 92 g00771661 1 Measure the clearance between the ends of the scraper tips and the wheel drum The correct clearance is between 12 mm 0 5 inch to 25 mm 1 0 inch 2 If the clearance is greater than 25 mm 1 0 inch loosen the two nuts 1 and slide the scraper arm 2 back to the proper clearance 3 Tighten the nuts to a torque of 370 50 N m 270 35 Ib ft After a few hours of operation tighten the nuts again Illustration 93 g00771661 1 Remove two nuts 1 two bolts and the scraper arm 2 from the cleaner bar 2 Drive the pin out of the tip from the retainer side of the tip Remove the tip from the retainer 3 Clean the adapter the pin and the retainer 4 Install the retainer in the groove in the side of the adapter 5 Install a new tip over the retainer Install the pin 6 Install the scraper a
55. ion Oil Level Check 00 0 0 eee 113 Windows Clean 00 eeeeeeeeeteeeeeeeetteeeeeeettaeeeeeenaees 115 Every 50 Service Hours or Weekly Cab Air Filter Clean Replace ceee 71 Fuel Tank Water and Sediment Drain 102 Tire Inflation Check asseeeeseerrsrerrrerreen 110 Every 100 Service Hours or 2 Weeks Axle Oscillation Bearings Lubricate 0 00 67 Bulldozer Stabilizer Lubricate 0 0 eee 71 Lift Cylinder Upper Bearings Lubricate 107 Steering Cylinder Bearings Lubricate 110 Every 250 Service Hours or Monthly Battery Glean ees acna a 68 Belt Inspect Adjust Replace ceeee 69 Brake Accumulator Check cccseeeeteeteees 70 Braking System Test 0 70 Differential and Final Drive Oil Level Check 82 Differential and Final Drive Oil Sample Obtain 83 Drive Shaft Spline Center Lubricate 84 Engine Air Filter Service Indicator Inspect REplace c ecceceecceceeeeeeeeeeeeeeneesaeees 88 Engine Oil High Speed and Oil Filter Change 90 Engine Oil and Filter Change 94 Fan Drive Bearing Lubricate eeeeeeeeeees 98 Every 500 Service Hours Hydraulic System Oil Sample Obtain 106 Transmission Oil Sample Obtain 0 114 Every 500 Service Hours or 3 Months Cooling System Coolant Sample Level 1 Obtainh
56. l filler tube The Landfill Compactor filler tube is located behind the operator s cab Reference For more information refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 13 Clean the filler cap and install the filler cap 14 Remove transmission breather 1 from the top of the transmission Wash the transmission breather in a clean nonflammable solvent Allow the transmission breather to dry Then install the transmission breather 15 Start the engine and run the engine at low idle Apply the service brake Slowly operate the transmission controls in order to circulate the oil 16 Move the transmission control to the NEUTRAL position Engage the parking brake and stop the engine Inspect the transmission for leaks 17 Check the transmission oil level Reference For more information refer to Operation and Maintenance Manual Transmission Oil Level Check 101528362 Transmission Oil Filter Replace SMCS Code 3067 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and
57. lace any tamping tips that are worn to the wear cavity Cooling System Coolant ELC Change SMCS Code 1350 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure SEBU7546 03 75 Maintenance Section Cooling System Coolant ELC Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life Reference For information about adding Extender to your cooling system
58. line near the hydraulic oil tank 1 3 Use the hydraulic oil sampling valve 2 in order to obtain a sample of the hydraulic oil Reference For more information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis and Special Publication PEHP6001 How To Take A Good Oil Sample SEBU7546 03 107 Maintenance Section Lift Cylinder Upper Bearings Lubricate 101526478 Lift Cylinder Upper Bearings Lubricate SMCS Code 5102 086 BD S N BGF1 Up S N BMR1 Up Illustration 160 g00792956 Wipe all fittings before lubrication There is one fitting on each side of the lift cylinder Lubricate both fittings 102106227 Oil Filter Inspect SMCS Code 1308 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 161 g00100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure 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 amo
59. llustration 138 g00753767 API Trademark Commercial oils that are licensed by the American Petroleum Institute API bear this trademark Commercial oils that do not bear this trademark are not licensed and these oils are not recommended Oils that are not listed in Table 10 and in Table 11 are not recommended Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environment or extremely dusty conditions may require a reduction in engine oil change intervals from the recommendations in Table 10 and in Table 11 Also refer to Manual SEBU5898 Cold Weather Recommendations Poor maintenance of air filters or of fuel filters requires reduced oil change intervals See your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments SEBU7546 03 95 Maintenance Section Engine Oil and Filter Change Table 10 814F Wheel Tractor Engine Oil Change Interval Operating Conditions Severe Normal High Fuel Altitude Multigrade Load Sulfur above Oil Type Factor from 1830 m above 0 3 to 6000 ft 40L 11 0 5 US gal per hr of fuel Cat DEO Preferred 500 hr 500 hr 500 hr 250 hr API CH 4 11 0 minimum 500 hr 500 hr 500 hr 250 hr TBN Preferred API CH 4 TBN 500 hr 500 hr 250 hr 250 hr below 11 0 API CG 4 500 hr 250 hr
60. lso if the exhaust smoke remains black and a clean primary element has been installed replace the secondary element 1 Remove the primary element Reference Refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace for the correct procedure Z Illustration 127 g00864077 2 Remove the secondary element Illustration 128 g00864079 3 Cover the air inlet opening Clean the inside of the air cleaner housing 4 Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged 5 Uncover the air inlet opening Install a new secondary element 6 Install a clean primary element and the cover for the air cleaner housing 7 Close the access door 8 Repeat the procedure for the other air cleaner 102086463 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 1 g01063447 Illustration 129 The location of air filter service indicator 1 from the rear view of the engine 88 Maintenance Section Engine Air Filter Service Indicator Inspect Replace SEBU7546 03 Illustration 130 g00103777 Typical Service Indicator The air filter service indicator 1 is located on the left side of the machine beneath the engine air precleaner Observe the service indicator 1 The air cleaner element should be cleaned or replaced
61. ng is located on the stabilizer Apply lubricant to this fitting 101521741 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Illustration 88 g00790441 Open the access door that is located on both sides of the cab Remove the two air filters 72 Maintenance Section Circuit Breakers Reset SEBU7546 03 Illustration 89 g00790464 Remove the air filter that is located on the inside of the cab Clean the filter elements with pressure air or wash the filter elements in warm water with a nonsudsing household detergent If water and detergent are used to clean the filter elements rinse the filter elements in clean water and allow the filter elements to air dry thoroughly Note If either filter element is damaged install a new filter element Install the filter elements Install the filter covers and close the access doors 101708323 Circuit Breakers Reset SMCS Code 1420 529 Illustration 90 g00790613 N Di Illustration 91 g00879293 Circuit Breaker Reset Depress the button in order to reset the circuit breakers If the circuit is functioning properly the button will remain depressed If the button will not remain depressed check the appropriate electrical circuit Circuit breakers are located in the engine compartment on the rig
62. ny necessary repairs before the machine is returned to operation SEBU7546 03 71 Maintenance Section Bulldozer Stabilizer Lubricate Parking Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move reduce the engine speed immediately and apply the service brake pedal This test is performed when the parking brake is engaged If the machine begins to move compare the engine rpm to the engine rpm of a prior test This will indicate the amount of system deterioration 1 Start the engine Raise the implement slightly Engage the parking brake 2 Move the transmission control to SECOND SPEED REVERSE Make sure that the autoshift control is in the OFF position The parking brake indicator light should come on 3 Gradually increase the engine speed to high idle The machine should not move 4 Reduce the engine speed to low idle Move the transmission direction control to the NEUTRAL position Lower the implement to the ground Stop the engine If the machine moved during the test consult your Caterpillar dealer for a brake inspection Make any necessary repairs before the machine is returned to operation 101521227 Bulldozer Stabilizer Lubricate SMCS Code 6071 086 BD S N BGF1 Up y FWD Illustration 87 g00790037 Wipe all fittings before you apply lubricant One fitti
63. o a suitable container Clean the drain plug and install the drain plug 4 Change the transmission oil filter Reference For the correct procedure refer to Operation and Maintenance Manual Transmission Oil Filter Replace 5 Remove bolts 2 and cover 3 from the front left side of the transmission case 6 Remove magnetic screen tube assembly 6 and screen 7 from the housing Remove three magnets from the magnetic screen tube assembly 7 Wash the magnetic screen tube assembly and the screen in a clean nonflammable solvent NOTICE Do not drop or rap the magnets against any hard ob jects Replace any damaged magnets 8 Use a cloth a stiff bristle brush or pressure air to clean the magnets 9 Clean cover 3 and inspect seal 4 Replace the seal if the seal is damaged 10 Install three magnets on magnetic screen tube assembly Insert the suction screen and the magnetic screen tube assembly in the housing 11 Install cover 3 and four bolts 2 112 Maintenance Section Transmission Oil Filter Replace SEBU7546 03 Illustration 170 g00793947 wa Oro Illustration 171 g00793970 Landfill Compactor 12 Remove transmission oil filler cap on the left side of the machine Fill the transmission with oil through the transmission oi
64. on the right side of the engine near the engine oil filter 94 Maintenance Section Engine Oil and Filter Change SEBU7546 03 2 Remove engine oil dipstick 2 and wipe the dipstick with a clean cloth Then insert the dipstick and remove the dipstick again This will ensure a more accurate measurement of the engine oil level 3 While the engine is stopped check the ENGINE STOPPED side of engine oil dipstick 2 Maintain the oil level between the marks on the dipstick 4 If necessary remove oil filler plug 1 and add oil through the oil filler tube 5 Clean the oil filler plug and install the oil filler plug 6 Close the engine access door 102094193 Engine Oil and Filter Change SMCS Code 1318 510 Selection of the Oil Change Interval NOTICE This machine is equipped with an engine that meets EPA Tier 2 Euro Stage Il or MOC Step 2 emission regulations A 500 hour engine oil change interval is available provided that operating conditions and rec ommended multigrade oil types are met When these requirements are not met shorten the oil change interval to 250 hours or use an S O S oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine Caterpillar oil filters are recommended Recommended multigrade oil types are listed in Table 10 and in Table 11 I
65. ould result Illustration 131 g01063447 The location of the air filter service indicator 1 from the rear view of the engine Engine air filter service indicator 1 is located on the left side of the machine beneath the engine air precleaner 1 Start the engine 2 Run the engine at high idle 3 Stop the engine 4 Open the engine access door on the left side of the machine 5 Inspect the engine air filter service indicator If the yellow piston in the filter service indicator enters the red zone service the air cleaner 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 6 Reset the engine air filter service indicator 7 Close the engine access door SEBU7546 03 89 Maintenance Section Engine Air Precleaner Clean 101522826 Engine Air Precleaner Clean SMCS Code 1055 070 Illustration 132 1 g00791212 Loosen the bolt on clamp 2 Remove hood assembly 1 Loosen hose clamp 4 Remove hose 5 from the hood assembly Loosen clamp 6 Remove body assembly 3 Clean all of the parts with compressed air or wash all of the parts in warm water Allow all of the parts to dry Install body assembly 3 Tighten
66. rder to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components Clean the engine air filter primary element when the clogged air filter indicator is displayed on the Caterpillar controller Clean the engine air filter primary element as soon as convenient a j Bt Illustration 122 g00792297 1 Open the engine hood Access the air cleaner from the left side of the machine Illustration 123 g00845360 2 Loosen the four cover latches and remove the air cleaner cover Note The latches for the air cleaner housing may snap open when you release the latches 86 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU7546 03 Illustration 124 g00101415 3 Remove the primary filter element from the air cleaner housing In order to remove the engine air filter primary element pull the element outward While you pull the element outward rock the element Use Steps 4 through 6 in order to clean the primary element 4 Inspect the primary element If the pleats the gaskets
67. rm two bolts and two nuts on the cleaner bar Slide the scraper arm so that the clearance between the tip and the wheel drum is between 12 mm 0 5 inch to 25 mm 1 0 inch Reference For more information refer to Operation and Maintenance Manual Cleaner Bar Check Adjust 7 Tighten the nuts to a torque of 370 50 N m 270 35 Ib ft After a few hours of operation tighten the nuts again 74 Maintenance Section Compactor Wheel Chopper Blades Inspect Replace SEBU7546 03 102087257 Compactor Wheel Chopper Blades Inspect Replace SMCS Code 4206 040 BG 4206 510 BG S N BMR1 Up Illustration 94 g00772408 Inspect all of the chopper blades frequently Replace any chopper blade before wear on the gusset occurs 102087334 Compactor Wheel Plus Tips Inspect Replace SMCS Code 6806 040 6806 510 S N BMR1 Up Illustration 95 g00880067 Inspect the plus tips Replace the plus tips if necessary Reference Refer to Special Instruction SEHS9442 01 8E1849 Plus Tip Wear Guage Procedure for the correct procedure for the inspection of the plus tips Refer to Special Instruction SEHS9325 02 Plus Tips Wheel Pattern Template for the correct procedure for the replacement of the plus tips 102087314 Compactor Wheel Tamping Tips Inspect Replace SMCS Code 6806 040 6806 510 S N BKL1 Up Illustration 96 g00790724 Inspect all of the tamping tips Rep
68. rogram B below to determine an appropriate interval Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Program A Verification for an Oil Change Interval of 500 Hours 92 Maintenance Section Engine Oil High Speed and Oil Filter Change SEBU7546 03 This program consists of three oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type that is listed in Table 8 and 9 Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each increment is an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interv
69. rs before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts Fuel system should be primed prior to starting the engine oz A oe es I Tp os o o n o _ f S E N H Hoot J Hos yJ O T EN Illustration 149 g00791919 1 Use a strap type wrench to remove the secondary fuel filter The secondary fuel filter is located on the right side of the machine in the engine compartment Dispose of the used filter properly 2 Clean the filter mounting base Remove all of the used seal from the filter mounting base Illustration 150 g00101318 3 Lubricate the seal of the new secondary fuel filter with clean diesel fuel 4 Install the new secondary fuel filter by hand When the seal contacts the filter mounting base tighten the filter by an additional 3 4 turn 5 Prime the fuel filters Reference Refer to Operation and Maintenance Manual Fuel System Prime for the proper procedure
70. s 500 hours if the operating conditions and recommended oil types that are listed in this table are met Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines 2 Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments 3 High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption of your 815F Soil Compactor or 816F Landfill Compactor exceeds 47 L 12 US gal per hour follow the High Load Factor recommendations in Table 9 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change 4 For sulfur content above 0 5 refer to Operation and Maintenance Manual SEBU6250 Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines 5 In order to verify an oil change interval of 500 hours refer to Program A below 6 Use P
71. supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Park the machine on a hard level surface Lower the bucket to the ground with a slight downward pressure Engage the parking brake and stop the engine SEBU7546 03 113 Maintenance Section Transmission Oil Level Check S mi 2s gt Illustration 172 g00793312 2 The transmission oil filter is located on the left side of the machine near the articulation joint Use a strap type wrench to remove the transmission oil filter Dispose of the used oil filter properly 3 Clean the filter mounting base Remove all of the used filter gasket from the filter mounting base Illustration 173 g00101318 4 Apply a thin coat of clean transmission oil to the gasket of the new filter element Install the new filter element by hand When the gasket contacts the filter mounting base tighten the transmission oil filter by an additional 3 4 turn 5 Start the engine Slowly operate the transmission controls in order to circulate the transmission oil 6 Move the transmission control to the NEUTRAL position Inspect the transmission oil filter for leaks 7 Check the transmission oil level Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for th
72. sure cap until the water temperature regulator opens and the coolant level stabilizes 76 Maintenance Section Cooling System Coolant Extender ELC Add SEBU7546 03 7 Maintain the coolant level in the sight gauge 3 on the upper right side of the radiator tank Open the left rear access door in order to access the sight gauge 8 Install the cooling system pressure cap Close the engine hood 101708325 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life Use only Caterpillar products or commercial products tha
73. t have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants Use only Extender with Cat ELC Failure to follow these recommendations can result in shortened cooling system component life Reference For information about adding Extender to your cooling system refer to Operation and Maintenance Manual Cooling System Coolant Extender ELC Add or consult your Caterpillar dealer If an Extended Life Coolant was previously used flush the cooling system with clean water No other cleaning agents are required Use the following procedure to change the Extended Life Coolant Illustration 98 g00792796 The cooling system pressure cap 2 is located under the access door 1 at the top rear of the machine 1 Slowly loosen the cooling system pressure cap in order to relieve system pressure Remove the cooling system pressure cap 2 Place the drain hose 4 into a suitable container Open the drain valve 5 on the bottom of the radiator Allow the coolant to drain into a suitable container Note The Landfill Compactor is equipped with bottom guards The radiator guard needs to be lowered in order to access the drain valve 3 Flush the cooling system with clean water until the draining water is clean Close the drain valve 4 Replace the water temperature regulator Reference Refer to Operation and Maintenance Manual Cooling System Water Temperat
74. tal Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines 5 In order to verify an oil change interval of 500 hours refer to Program A below 6 Use Program B below to determine an appropriate interval Table 11 815F Soil Compactor 816F Landfill Compactor Engine Oil Change Interval Operating Conditions Severe Normale High Fuel Altitude Multigrade Load Sulfur above Oil Type Factor from 1830 m above 0 3 to 6000 ft 47L 12 0 5 US gal per hr of fuel Cat DEO soo hr 500hr 500 hr 250 hr Preferred API CH 4 11 0 minimum 500 hr 500 hr 500 hr 250 hr TBN Preferred API CH 4 TBN 500 hr 500 hr 250hr 250 hr below 11 0 API CG 4 500 hr 250 hr 250 hr 250 hr API CF 4 250 hr 250 hr 250 hr 250 hr 1 The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines 2 Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not incl
75. th suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Open the access door that is located on the left side of the machine cJ oe food Illustration 139 g00791382 2 Remove the filter element 1 with a strap type wrench Inspect the filter Reference Refer to Operation and Maintenance Manual Oil Filter Inspect 3 Clean the filter mounting base with a clean cloth Make sure that the used filter gasket has been completely removed SEBU7546 03 97 Maintenance Section Engine Valve Lash Check Illustration 140 g00101318 4 Apply a thin film of clean engine oil to the sealing surface of the new filter element Note There are rotation index marks on each engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten engine oil filters use the rotation index marks as a guide 5 Install the engine oil filter element 1 hand tight until the seal of the engine
76. tion 155 g00792101 The hydraulic tank is located on the right side of the machine Open the access door that is located on the platform on the right side of the cab Slowly remove the hydraulic tank filler cap 1 in order to relieve system pressure 1 Remove hydraulic tank filler cap and the filler strainer Wash the filler cap and the strainer in a clean nonflammable solvent Install the strainer 2 Inspect the gasket on the filler cap for damage Replace the gasket if necessary 3 Remove the drain plug 3 from the bottom of the hydraulic tank Wash the drain plug in a clean nonflammable solvent 4 Your machine is equipped with an ecology drain valve Install a 6B 3156 Pipe Nipple with a hose in order to unseat the internal drain valve Allow the hydraulic oil to drain into a suitable container NOTICE Never start the engine while the hydraulic oil tank is being drained or while the hydraulic oil tank is empty Excessive wear and damage to the hydraulic compo nents can occur 5 Remove the pipe nipple in order to close the drain valve Install the drain plug 6 Replace the hydraulic oil filter Reference Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Replace for the correct procedure SEBU7546 03 105 Maintenance Section Hydraulic System Oil Filter Replace 7 Fill the hydraulic tank with clean oil Make sure that the oil level is at the FULL mark on the sight
77. ude high load factor harsh operating cycles or harsh environments 3 High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption of your 815F Soil Compactor or 816F Landfill Compactor exceeds 47 L 12 US gal per hour follow the High Load Factor recommendations in Table 11 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change 4 For sulfur content above 0 5 refer to Operation and Maintenance Manual SEBU6250 Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines 5 In order to verify an oil change interval of 500 hours refer to Program A below 6 Use Program B below to determine an appropriate interval Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Program A Verification for an Oil Change Interval of 500 Hours 96 Maintenance Section Engine Oil and Filter Change SEBU7546 03 This program consists of three oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six
78. unts 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 i01527940 Radiator Core Clean SMCS Code 1353 070 KO H SSS il li p T l g00793362 Illustration 162 1 Press the button and open the radiator guard 108 Maintenance Section Refrigerant Dryer Replace SEBU7546 03 M J 2 oo oo eo eo oo 2 x_n E Eh a_i le Tel on le o ol zhi ap Illustration 163 g00793380 2 Lift up on the control knobs 1 and 3 Open the oil cooler 4 and condenser 2 3 You can use compressed air high pressure water or steam in order to remove dirt and debris from the radiator fins The use of compressed air is preferred 4 Close the cooler
79. ure Regulator Replace for the correct procedure 5 Add the Extended Life Coolant Reference Refer to Operation and Maintenance Manual Capacities Refill for the refill capacity of the cooling system SEBU7546 03 77 Maintenance Section Cooling System Coolant Level Check 6 Start the engine Run the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes 7 Maintain the coolant level in the sight gauge 3 on the upper right side of the radiator tank Open the left rear access door in order to access the sight gauge 8 Install the cooling system pressure cap Close the engine hood 102086041 Cooling System Coolant Level Check SMCS Code 1350 535 FLV m FA Illustration 99 g01063851 The coolant level sight gauge 1 is located on the left side of the machine Maintain the coolant level within the sight gauge Add coolant if necessary Note If it is necessary to add coolant daily inspect the cooling system for leaks 102088268 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitabl

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