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MAINTENANCE INTERVALS - Safety

1. Table 33 Approximate Refill Capacities 226B3 Compartment or US Imperial System Liters Gallons Gallons Engine Crankcase 10 2 6 2 2 Fuel Tank 58 15 4 12 8 Cooling System 10 5 2 8 2 3 Each Drive Chain Box 6 1 6 1 3 Table 34 Approximate Refill Capacities 242B3 Compartment or US Imperial System Gallons Gallons Engine Crankcase 9 2 6 2 2 Fuel Tank 58 15 4 12 8 Cooling System 12 5 2 8 2 3 Each Drive Chain 8 24 18 Box Table 35 Approximate Refill Capacities 236B3 Compartment US Imperial or System Liters Gallons Gallons Engine Crankcase 9 2 4 2 0 Fuel Tank 90 0 23 8 19 8 Cooling System 12 5 3 3 2 7 Each Drive Chain 75 20 16 Box Table 36 Approximate Refill Capacities 252B3 Compartment or US Imperial System Gallons Gallons Engine Crankcase 9 2 4 2 0 Fuel Tank 90 0 23 8 19 8 Cooling System 12 5 3 3 2 7 Each Drive Chain 8 24 18 Box Table 37 Approximate Refill Capacities 247B3 Compartment Liters US Imperial or System Gallons Gallons Engine Crankcase 10 2 6 2 2 Fuel Tank 62 16 4 13 6 Cooling System 10 2 6 2 2 Each Final Drive 1 0 0 26 0 22 Table 38 Approximate Refill Capacities 257B3 Compartment US Imperial or System Gallons Gallons Engine Crankcase 9 2 4 2 0 Cooling System 12 5 3 3 2 8 E
2. Ad lt LA Illustration 169 901210045 C3 4 3 Loosen the hose clamp 1 and remove the hose from the thermostat housing assembly 2 4 Remove the two bolts 3 from the thermostat housing assembly Remove the thermostat housing assembly 5 Remove the seal and the thermostat from the thermostat housing assembly 6 Install a new thermostat and a new seal Install the thermostat housing assembly on the engine cylinder head 7T Install the hose Tighten the hose clamp 166 Maintenance Section Drive Chain Case Oil Change SEBU8495 03 8 Refill the cooling system Refer to Operation and Maintenance Manual Capacities Refill Refer to Operation and Maintenance Manual Cooling System Coolant ELC Change for information about refilling the cooling system Refer to Special Publication SEBU6250 Caterpillar Machine Fluid Recommendations for coolant information 9 Close the engine access door 101990833 Drive Chain Case Oil Change SMCS Code 3261 543 OC 3261 544 OC S N MWD1 Up S N A9H1 Up S N TNK1 Up SIN JXM1 Up S N SRS1 Up UD n Illustration 170 g01025459 The plugs for the drive chain cases as the plugs are viewed from the underside of the
3. Illustration 125 900930196 2 Remove the pin that holds the lift arm brace in the stored position 3 Lower the lift arm brace to rest on the cylinder housing 4 Mount the machine Secure the seat belt and lower the armrest Start the engine 5 Raise the lift arms until the brace falls onto the cylinder rod Slowly lower the lift arms until the brace stops movement It WOLL LEIL ODAAT Illustration 126 g00952492 6 Stop the engine Exit the machine Secure the retaining pin through the brace below the cylinder rod Disengage the Lift Arm Brace Radial Lift AI OUI LULA DEERE g00952586 Illustration 127 1 Remove the retaining pin from the brace and install the pin 2 in the holding block 2 Detach and swing the pivot lever 1 clockwise onto the retaining pin 3 Mount the machine Secure the seat belt and lower the armrest Start the engine SEBU8495 03 131 Maintenance Section Maintenance Access NENNNI BODIE g00952609 Illustration 128 4 Slowly raise the loader lift arms until the lever engages the retaining pin 5 Slowly lower the lift arms to the ground Stop the engine Exit the machine 6 Raise and secure the brace to the lift arm with the reta
4. VZ SS Ne Illustration 142 g02142341 Apply lubricant to all grease fittings 1 Front pivot 2 Rear pivot Repeat the process for the opposite side of the machine 102580453 Backup Alarm Test SMCS Code 7406 081 To prevent injury make sure that no people are working on the machine or near the machine To prevent injury keep the machine under control at all times 1 Get into the operator s seat Fasten the seat belt and pull the armrests downward 2 Start the engine 3 Disengage the parking brake 4 Move the joystick control to the REVERSE position The backup alarm should sound immediately The backup alarm should continue to sound until the joystick control is returned to the NEUTRAL position or to the FORWARD position 104395699 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1401 561 1402 040 1402 510 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 Disconnect the negative battery cable from the starter Note Do not allow the disconnected battery cable to contact the frame of the machine 3 Disconnect the negative battery cable at the battery 4 Perform the necessary repairs Replace the cable or the battery as needed 5 Connect the negative battery cable at the battery 6 Connect the battery cable to the starter of the machine 7 Install the engine start switch key Repeat the process f
5. 151 Axle Bearings Lubricate 152 Backup Alarm 152 Bogie and Idler Inspect Replace 157 Cooling System Level Check 164 Engine Compartment Inspect Clean 172 Engine Oil Level Check 173 Equipment Lowering Control Valve Check 178 Fuel System Primary Filter Water Separator Draill zoo inne DIPSA 181 Hydraulic System Oil Level Check 191 Lift Arm and Cylinder Linkage Lubricate 192 Quick Coupler Clean Inspect 193 Seat Belt Inspect 196 Sprocket Inspect 197 Sprocket Retaining Nuts Check 200 Tilt Cylinder Bearings and Bucket Linkage Bearings Lubricate 201 Tire Inflation 201 Track Rubber Inspect Adjust 202 Track Inspect Adjust 206 Track Roller and Idler Inspect Replace 207 Wheel Nuts Tighten 208 Work Tool Lubricate 209 Work Tool Mounting Bracket Inspect 211 Initial 250 Service
6. 172 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 195 Every 1000 Service Hours or 1 Year Sprocket Bearings Lubricate 200 Sprocket Sleeve Inspect 201 Every 2000 Service Hours Refrigerant Dryer Replace 195 Every 2000 Service Hours or 1 Year Fuel Injection Timing Check 180 Hydraulic System Oil Change 188 Every Year Cooling System Coolant Sample Level 2 Obtain ee a ee ee 163 Every 3000 Service Hours or 2 Years Cooling System Water Temperature Regulator Replaces wesc on ihe RR a hU t 165 Every 3 Years Seat Belt Replace 196 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 162 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 160 SEBU8495 03 151 Maintenance Section Air Cleaner Dust Valve Clean Inspect 103318742 Air Cleaner Dust Valve Clean Inspect SMCS Code 1051 571 VL Service the air filter elements when the alert indicator for air filter restriction lights Refer to Operation and Maintenance Manual Alert Indicators for information about the indicator 1 Open the engine access door 2 The air filter housing is located in the engine compartmen
7. Note The crankcase drain is located on the right side of the oil pan SEBU8495 03 177 Maintenance Section Engine Oil and Filter Change Illustration 197 g01264593 3 Remove the access panel that is located below the drain plug Remove the drain plug and allow the oil to drain into a suitable container Install the drain plug Illustration 198 g02143271 4 Remove the filter element with a 187 2718 Filter Wrench Refer to Operation and Maintenance Manual Oil Filter Inspect in order to inspect the used filter for debris 5 Apply a thin film of clean engine oil to the sealing surface of the new filter element 6 Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the
8. g00954946 Illustration 122 Illustration 123 g00952728 The cab support lever is in the ENGAGED position 8 Make sure that the cab support lever is in the ENGAGED position Tilting the Cab Downward Note More than one person may be needed to tilt the cab 1 Ensure that all persons are not under the cab Remove all of the tools and unsecured items that are underneath the cab Illustration 124 900952719 The cab support lever is shown in the DISENGAGED position 2 Tilt the cab upward Move the cab support lever to the DISENGAGED position 3 Tilt the cab downward and install the bolts for the ROPS Torque the bolts to 125 20 92 15 Ib ft 4 Remove the supports from the rear of the machine 130 Maintenance Section Maintenance Access SEBU8495 03 101961564 Loader Lift Arm Brace Operation SMCS Code 6119 011 AB 6119 012 AB S N MWD1 Up S N A9H1 Up S N TNK1 Up S N TSL1 Up S N JXM1 Up Loader lift arm brace must be in place when work ing under raised lift arms Failure to follow the instructions or heed the warn ings could result in injury or death Engage the Lift Arm Brace Radial Lift 1 Empty the work tool Remove the work tool Park the machine on level ground Lower lift arms to the ground Stop the engine and exit the machine See Y WILLIS LOUIE AUIS TERRE
9. 4 Close the engine access door 103879812 Cab Tilting SMCS Code 7301 506 7301 509 Do not go beneath cab unless cab is empty and support lever is engaged Failure to follow the instructions or heed the warn ings could result in injury or death Do not tilt the cab using an open door The door must be closed and latched when lifting the cab The door may become dislodged from its hinges and may cause serious personal injury or death Tilting the Cab Upward 1 Park the machine on level ground Note Empty the water tank if equipped before you tilt the cab N Lower the loader arms fully If you tilt the cab upward with the loader lift arms in the RAISED position you must engage the brace for the loader lift arms See Operation and Maintenance Manual Loader Lift Arm Brace Operation for the process for engaging the brace for the loader lift arms C Turn the engine start switch key to the OFF position AR Place supports under the rear of the machine in order to support the machine while the cab is tilted SEBU8495 03 129 Maintenance Section Maintenance Access Illustration 121 g01025254 5 Remove the two front bolts for the ROPS 6 Close the cab door and ensure that the door is latched 7 Tilt the cab upward Stand on the ground when you tilt the cab Note More than one person may be needed to tilt the cab
10. Add or consult your Caterpillar dealer Drain the coolant whenever the coolant is dirty or whenever the coolant is foaming The radiator cap is located under the radiator guard on the top of the engine compartment Allow the machine to cool before you change the coolant 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Raise the radiator guard Refer to Operation and Maintenance Manual Radiator Tilting zd D g00956151 Illustration 157 Typical Example 3 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap SEBU8495 03 161 Maintenance Section Cooling System Coolant ELC Change Note The radiator cap is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The radiator cap is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine 2535 X iD Ter Ullis 27 70 so EZ H zx L Ties ji DATE pou P SN AS Illustration 158 Drain Valve for the C2 2 engine ll Illustration 159 g01018862 Drain Valve for the C3 4 engine 4 Remove the drain plug or open the drain valve if equipped and allow the co
11. Obtain SMCS Code 5050 008 7542 008 Open the rear access door Refer to Operation and Maintenance Manual Access Doors and Covers for information about the rear door Raise the radiator Refer to Operation and Maintenance Manual Radiator Tilting for information about the radiator Illustration 228 901280271 The sampling port for the hydraulic oil is located on the fan motor 101957078 Lift Arm and Cylinder Linkage Lubricate SMCS Code 5102 086 BD 6107 086 BD cU Illustration 229 Radial Lift Illustration 230 g01017361 Extended Reach Apply lubricant to the grease fittings 1 for the lift arm linkage Apply lubricant to the grease fittings 2 for the lift cylinder bearings Repeat the process for the opposite side of the machine 101963869 Lower Machine Frame Clean SMCS Code 7050 070 1 Tilt the cab upward Refer to Operation and Maintenance Manual Cab Tilting SEBU8495 03 193 Maintenance Section Oil Filter Inspect Illustration 231 901020241 2 Remove the access panel in the frame that is located underneath the machine 3 Remove any debris or dirt from the inside of the frame 4 Reinstall the access panel and tilt the cab downward 102106227 Oil Filter Inspect SMCS Code 1308 507 3067
12. Remove the retaining pin from the radiator guard Tilt the radiator guard upward 3 In order to tilt the radiator guard downward pull down on the radiator guard and install the retaining pin 134 Maintenance Section Lubricant Viscosities and Refill Capacities SEBU8495 03 Lubricant Viscosities and Refill Capacities 104777228 Lubricant Viscosities SMCS Code 7581 Selecting the Viscosity Ambient temperature is the temperature of the air in the immediate vicinity of the machine The temperature may differ due to the machine application from the generic ambient temperature for a geographic region When selecting the proper oil viscosity for use review both the regional ambient temperature and the potential ambient temperature for a given machine application Generally use the higher temperature as the criterion for the selection of the oil viscosity Generally use the highest oil viscosity that is allowed for the ambient temperature when you start the machine Refer to the Lubricant Viscosities for Ambient Temperatures tables for guidance In cold weather applications the preferred method is to use properly sized machine compartment heaters and a higher viscosity grade oil Thermostatically controlled heaters that circulate the oil are preferred The proper oil viscosity grade is determined by the minimum ambient temperature the air in the immediate vicinity of the machine The ambient temperature is the
13. Remove the secondary filter element 6 Cover the air inlet opening 7 Clean the inside of the air cleaner housing with a damp cloth if necessary Do not use compressed air to clean the housing 8 Uncover the air inlet opening 9 Install a new secondary element 10 Install the primary element 11 Install the cover for the filter housing 172 Maintenance Section Engine Compartment Inspect Clean SEBU8495 03 Illustration 186 g01433098 12 Rotate the cover clockwise and latch the cover 13 Close the engine access door 103886451 Engine Compartment Inspect Clean SMCS Code 1000 040 CPA 1000 070 CPA Inspect the engine compartment for dirt buildup or debris Remove any dirt or debris from the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 187 g01264593 2 Remove any debris or dirt from the engine compartment If equipped remove the access panel in order to clean out the engine compartment Note Use care when you clean the engine compartment Damage to the machine may occur 3 Close the engine access door Air Conditioning Condenser The air conditioning condenser is located at the back of the engine compartment Cleaning the air conditioning condenser will maintain optimum performance of the air co
14. every 500 service hours or every year Engine oil filter Change the engine oil after every 500 service hours or every year 9 T d Fuel System Water Separator Drain the water separator after every 10 service hours or at the end of each day Fuel System Filter Water Separator Element Replace the filter after every 500 service hours or every 3 months Fuel System Filter Replace the filter after every 500 service hours or every 6 months on C2 2 engines Grease zerk Lubricate the designated locations after every 10 service hours or at the end of each day Hydraulic oil filter Change the filter after every 500 service hours or every 3 months e Dg Hydraulic oil level check Check the hydraulic oil level at the sight gauge after every 10 service hours or at the end of each day Hydraulic oil Change the hydraulic oil after every 2000 service hours or every year 103636245 Welding on Machines and Engines with Electronic Controls SMCS Code 1000 7000 Do not weld on any protective structure If it is necessary to repair a protective structure contact your Caterpillar dealer Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings When possible remove the component that must be welded from the machine or the engine and then weld the component If you must weld near
15. service points 164 Maintenance Section Cooling System Level Check SEBU8495 03 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 Obtain the sample of the coolant from the radiator When the system is cool slowly remove the radiator cap Note The radiator cap is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The radiator cap is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine Note Do not take the sample from the Coolant Overflow Reservoir Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 103880033 Cooling System Level Check SMCS Code 1350 040 HX 1350 535 FLV 1382 070 1382 510 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loo
16. 10 Ib 5 Loosen the mounting bolt 2 Loosen the adjusting locknut 3 6 Move the alternator until the correct tension is reached 7 Tighten the adjusting locknut Tighten the mounting bolt 8 Recheck the belt deflection If the amount of deflection is incorrect repeat step 4 to step 7 9 Install the guard for the V belt 10 Close the engine access door 154 Maintenance Section Belts Inspect Adjust Replace SEBU8495 03 102715751 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 S N A9H1 Up S N B7H1 Up S N TNK1 Up S N SRS1 Up S N YYZ1 Up If a new belt is installed check the belt adjustment after 30 minutes of operation A belt is considered to be used after 30 minutes of operation Belts 1 Stop the engine in order to inspect the belt 2 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers g01209498 Illustration 145 3 Remove the four bolts 1 on the top of the guard Loosen the two bolts 2 on the bottom of the guard 4 Slide the guard upward from bottom bolts Remove the guard for the V belt Illustration 146 g01209499 5 Inspect the condition of the belt 3 and the adjustment of the belt The belt should deflect 10 mm 0 39 inch under a straight pull of 44 N 10 Ib This measurement sho
17. 507 5068 507 Inspect a Used Filter for Debris Illustration 232 900100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 102634143 Quick Coupler Clean Inspect SMCS Code 6129 040 6129 070 Personal injury or death can result from improp erly checking for a leak Always use a board or cardboard when checking for a leak Escaping air or fluid under pre
18. Brace Operation SMCS Code 6119 011 AB 6119 012 AB S N B7H1 Up S N SRS1 Up S N YYZ1 Up Loader lift arm brace must be in place when work ing under raised lift arms Failure to follow the instructions or heed the warn ings could result in injury or death Engage the Lift Arm Brace 1 Empty the work tool Remove the work tool Park the machine on level ground Raise the lift arms to maximum height then lower the lift arms 76 2 mm 3 0 inch 2 Remain in the seat with the seat belt fastened until the brace is installed Illustration 131 902151078 3 A second person must remove the brace from the storage position by removing the retaining pins Illustration 132 902151079 4 The second person should then install the brace over the rod of one of the lift cylinders 5 Lower the loader arms slowly until the brace is held tightly between the rod and the cylinder 6 Secure the two retaining pins through the brace below the rod Disengage the Lift Arm Brace 1 Mount the machine Fasten the seat belt Lower the armrest and remain in the seat until the brace is removed 2 Slowly raise the lift arms until the brace is free 3 second person must remove the retaining pins and the brace from the rod 4 Slowly lower the lift arms to the ground 5 The second person should return th
19. Maintenance Support SEBU8495 03 Maintenance Support 104564699 Service Interval Chart SMCS Code 7000 Refer to the following service interval charts and service intervals for additional maintenance information SEBU8495 03 143 Maintenance Section Maintenance Support 216B3 226B3 and 236B3 WE PN X d uae ar y X SY z L8 500 Bq a 4 k p PEN L bN L C F 4 H20 4 F 4 of or of 2 r kF 4 Illustration 136 g01386832 144 SEBU8495 03 Maintenance Section Maintenance Support 242B3 and 252B3 2 500 4 1000 4 326 5683 FH L r 4 Ere o on Or 2 p 2 Illustration 137 902125913 SEBU8495 03 145 Maintenance Section Maintenance Support 247B3 8 PR Lol 224 ar JB 8 oF OF o 19 16f 9f Illustration 138 g02125914 146 SEBU8495 03 Maintenance Section Maintenance Support 257B3 and 259B3 ki 10000 m a 6000 lt 326 5685 B BF l5 B S OF 8r Of _ Ja Illustration 139 g02125919 Service Intervals Coolant additive Add the extender to the extended life coolant after every 6000 ser
20. Section Cooling System Coolant ELC Change SEBU8495 03 6 Install the filter cover on the machine 7 Remove the brace for the loader lift arms and return the brace to the stored position Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation Recirculation Filter Illustration 156 g01024691 1 Remove the cover in order to access the air filter element 2 Remove the air filter element and clean the element with soap and water Replace the element if the element is damaged 3 Install the element and replace the cover 103879985 Cooling System Coolant ELC Change SMCS Code 1395 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Mixing ELC with other products will reduce the effec tiveness of the coolant This could result in damage to cooling system compo nents If Caterpillar products are not available and com mercial products must be used make sure they have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants and Caterpillar Extender Note The machine was shipped from the factory with Extended Life Coolant ELC in the cooling system For information about the addition of Extender to your cooling system see the Operation and Maintenance Manual Cooling System Coolant ELC Extender
21. air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Note When the primary filter elements are cleaned always begin with the inside in order to force dirt particles toward the outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary filter element 5 nspect the cleaned dry primary air filter element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air filter element Rotate the primary air filter element Inspect the primary air filter element for tears and or holes Inspect the primary air filter element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air filter element to a new primary air filter element that has the same part number 170 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU8495 03 Note Do not use a primary air filter element that has any tears and or holes in the filter material Do not use a primary air filter element with damaged pleats gaskets or seals Discard damaged primary air filter elements 6 Clean the inside of the air cleaner housing with a damp cloth Do not use compressed air to clean the housing 7 Install the primary filter element
22. filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter g01209758 Illustration 199 1 Oil Filler Cap 2 Dipstick 8 Remove the oil filler cap 1 Fill the crankcase with new oil Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities for information about the oil Clean the oil filler plug and install the oil filler plug 9 Start the engine and allow the oil to warm Check for leaks 178 Maintenance Section Engine Valve Lash Check SEBU8495 03 Illustration 200 g01277108 1 Oil level add mark 2 Full mark 10 Stop the engine and allow the oil to drain back into the oil pan Fill the crankcase to the FULL mark 2 on the dipstick Do not exceed the FULL mark on the dipstick Add oil or drain oil if it is necessary 11 Tilt the radiator downward 12 Close the engine access door 13 Install the access panel 101020861 Engine Valve Lash Check SMCS Code 1105 025 Refer to the Service Manual for the complete adjustment procedure for the engine valve lash A qualified mechanic should adjust the engine valve lash and the fuel injector timing because special tools and training are required 103
23. 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 oils with a minimum zinc content of 900 ppm If Caterpillar oils cannot be used use heavy duty oils with the following classification Caterpillar ECF 1 API CG 4 API CF and TO 4 These oils must have a minimum zinc additive of 0 09 percent 900 ppm Note Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems SEBU8495 03 189 Maintenance Section Hydraulic System Oil Change Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours Caterpillar s standard SOS Fluids Analysis or an equivalent oil sampling program should be used The current guidelines for cleanliness of the oil should be observed Refer to Measured Data If an oil sampling program is not available the standard 2000 oil change interval should be used Measured Data The following information should be monitored through sampling of the oil e Significant changes in wear metals should be monitored These metals include iron copper chromium lead aluminum and tin e Significant changes in the following additives should be monitored zinc calcium magnesium and phosphorus e Contaminan
24. front idler 6 Tension the track Refer to Operation and Maintenance Manual Track Inspect Adjust for the procedure 103898486 Track Inspect Adjust CTL SMCS Code 4170 025 4170 040 S N YYZ1 Up Periodic adjustment of the track tension is necessary in order to avoid damage to the tracks Maintaining the tracks at the proper tension will maximize the service life of the undercarriage components The undercarriage components include the final drive sprocket idlers rollers and the track NOTICE Do not overtighten the tracks Tracks that are too tight can cause premature failure of the tracks Tracks that are too tight can cause power loss and bearing fail ures Tracks that are too loose increase the possibility of the track derailing or the drive lugs mis feeding on the drive sprocket In aggressive operating conditions oc casional mis feeding is normal If consistent mis feed ing is observed ensure that the track tension is set to the recommended specification If the track tension is set to the recommended specification and mis feed ing is still observed then your application may require a tighter track tension Increase the track tension until consistent mis feeding is no longer observed The intervals for track tension vary depending on the following conditions the machine application the op erator the soil conditions the climate and the condi tion of the undercarriage components Operators are
25. if the window wiper blade is worn or damaged If the window wiper blade streaks the window replace the window wiper blade 103881935 Work Tool Guard and Reflector Inspect Replace SMCS Code 6700 Ensure that all safety reflectors are clean Ensure that all safety reflectors are not damaged When you clean the safety reflectors use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the safety reflectors Solvents gasoline or harsh chemicals could loosen the adhesive that secures the safety reflectors Loose adhesive will allow the safety reflectors to fall Replace any safety reflector or replace any guards that are damaged or missing If a safety reflector is attached to a part that is replaced install a safety reflector on the replacement part Any Caterpillar dealer can provide new safety reflectors SEBU8495 03 209 Maintenance Section Windows Clean 103880915 Windows Clean SMCS Code 7310 070 Use commercially available window cleaning solutions in order to clean the windows The side windows of the cab can be removed for cleaning Refer to the following procedure in order to remove the side windows Illustration 257 901026875 1 Release the latch 2 in order to remove the window 1 Pull downward on the window in order to remove the window Pull outward on the window in order to remove the window 2 Release the latch 4 in order to remove the wind
26. inch the chain tension does not need further inspection If the total free play exceeds 15 mm 0 6 inch you should continue with the inspection 168 Maintenance Section Drive Chain Tension Check Adjust SEBU8495 03 Illustration 175 g01025547 5 Remove the eight wheel nuts 3 Use an appropriate nylon lifting strap and a hoist in order to remove the tire and rim 1 The approximate weight of the standard tire and rim is 51 kg 113 Ib 6 Remove bolts and the cover 2 for the drive chain case Note Remove the sealant from the cover and from the machine 901025571 Illustration 176 7 Loosen the eight bolts 5 for the axle housing Place 159 3337 Chain Tension Adjuster 7 between the axle housings 6 Illustration 177 g00867842 8 Rotate the axle in order to ensure that the chain 8 is taut below the sprockets Place a straight edge across the top of the sprockets Measure the total amount of movement in the chain B Set the chain tension so that there is a total of 15 mm 0 6 inch movement in the chain This is equal to 7 5 mm 0 3 inch of movement above the straight edge and 7 5 mm 0 3 inch of movement below the straight edge Illustration 178 g00554036 9 Tighten the bolts for the axle housing in the order that is shown above to 160 15 N m 118 11 Ib ft Turn the nuts an additional 60 5 in the same star pattern 10 Remove the chain te
27. the drain hose Pull the drain hose through the access panel in the belly guard Open the drain valve and drain the oil into a suitable container 4 Close the drain valve and pull the drain hose back into the machine Install the drain plug into the drain hose 5 Change the hydraulic system filter Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Change 6 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 7 Maintain the hydraulic oil level approximately in the middle of the sight gauge Check the oil level with the loader arms in the fully lowered position Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction hoses and hose clamps 8 Install the hydraulic tank filler cap 103880895 Hydraulic System Oil Filter Replace SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpill
28. 1 Battery or Battery Cable Inspect Replace 152 Blade Frame Adjust 156 Bucket Cutting Edges Inspect Replace 159 Bucket Tips Inspect Replace 159 Cab Air Filter Clean Replace 159 Engine Air Filter Primary Element Clean R place de AREE E gs 169 Engine Air Filter Secondary Element Replace 171 Fuel System Priming Pump Operate 183 Fuel Tank Cap Clean 184 Fuel Tank Water and Sediment Drain 184 Fuses Replace 185 Headlights Adjust 187 Lower Machine Frame Clean 192 Oil Filter Inspect ssssssesseeeeee 193 Radiator Core Clean 194 Sprocket Inspect 197 Track Rubber Remove Replace 204 Track Rubber Remove Replace 205 Window Washer Reservoir Fill 208 Window Wiper Inspect Replace 208 Work Tool Guard and Reflector Inspect Replace eet ee ete aaa 208 Windows Clean 209 Every 10 Service Hours or Daily Air Cleaner Dust Valve Clean Inspect
29. 2868096 Fuel System Filter In Line Replace SMCS Code 1261 510 S N MWD1 Up S N TSL1 Up S N JXM1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Replace the fuel filter before the scheduled interval if any of the following occur e The filter screen is more than half obstructed e Engine performance is poor 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers g01428665 Illustration 206 2 Loosen hose clamps 3 Remove the fuel filter and discard the fuel filter 4 Replace the fuel filter Ensure that the arrow on the filter points upward 5 Tighten hose clamps 6 Start the engine 7 Check for leaks 8 Close the engine access door Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection mai
30. 5 Rotate the locking ring 2 counterclockwise Remove the bowl assembly 6 Clean the mounting base for the fuel filter water separator 7 Clean the bowl assembly for the fuel water separator 8 Install the bowl assembly onto the new fuel water separator and rotate the locking ring clockwise 9 Install the new fuel filter water separator onto the mounting base Rotate the locking ring clockwise in order to fasten the fuel filter water separator to the mounting base 10 Prime the fuel system in order to fill the fuel filter water separator with fuel Refer to Operation and Maintenance Manual Fuel System Priming Pump Operate 11 Close the engine access door 103880392 Fuel System Priming Pump Operate SMCS Code 1258 548 C2 2 Engine The fuel priming pump is located on top of the fuel filter water separator Illustration 211 901019689 1 Open engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Push down on the top of the fuel priming pump plunger and release the fuel priming pump plunger in order to operate the fuel priming pump Operate the fuel priming pump plunger in order to fill the new filter element with fuel Continue to pump until increased resistance is felt This resistance will indicate that the filter element is full of fuel 3 Attempt to start the engine If the engine starts and the engine runs rough or the engine misfires o
31. 880157 Equipment Lowering Control Valve Check SMCS Code 5147 MA Personal injury or death can result from a work tool falling Keep personnel away from the front of the ma chine when lowering the work tool Before lowering any equipment clear the area around the equipment of all personnel 1 Lower arms to the fully lowered position Turn the keyswitch to the OFF position Illustration 201 g02141938 2 Push reward on the handle in order to fully actuate the valve 3 Pull forward on the handle in order to return the handle to the original position Ensure that the handle is fully seated SEBU8495 03 179 Maintenance Section Final Drive Oil Change 103880188 Final Drive Oil Change SMCS Code 4011 044 OC 4050 044 4050 044 OC 4050 044 FLV 4050 535 FLV 4050 4070 044 7527 S N B7H1 Up S N TSL1 Up S N YYZ1 Up Illustration 202 901291697 Multi Terrain Loader 901451295 Illustration 203 Compact Track Loader 1 Oil fill drain plug 2 Oil check plug 1 Position one final drive so that the oil fill drain plug 1 is at the bottom Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage 2 Use an 8 mm 5 16 inch allen wrench Remove the oil plugs 1 and 2 Allow the oil to drain into a suitable container 3 Check the drained oil for metal c
32. Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance All adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging are included Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals Note The aftertreatment system can be expected to function properly for the useful life of the engine emissions durability period as defined by regulation All prescribed maintenance requirements must be followed Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended to 3000 hours S O S services may extend the oil change even longer Consult your Cat dealer for details When Required Air Conditioner Condenser Clean 15
33. Filter Water Separator Element Replace SMCS Code 1260 510 FQ 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note This unit has a dual purpose The element Serves as a water separator and a fuel filter 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers oz Illustration 209 g01017292 C2 2 SEBU8495 03 183 Maintenance Section Fuel System Priming Pump Operate Illustration 210 g01017293 C3 4 2 Open the drain on the fuel filter water separator 3 Allow the water and fuel to drain into a suitable container 3 Close the drain valve by hand Do not tighten the drain valve with a tool Damage to the valve or to the seals may occur 4 Support the fuel filter water separator and rotate the locking ring 1 counterclockwise Remove the fuel filter water separator
34. Hours Final Drive Oil Change 179 Every 250 Service Hours Final Drive Oil Level Check 180 Every 250 Service Hours or Monthly Belts Inspect Adjust Replace 153 Belts Inspect Adjust Replace 154 Every 500 Service Hours Cooling System Coolant Sample Level 1 ODtallz errr 162 Final Drive Oil Change 179 Hydraulic System Oil Sample Obtain 192 Every 500 Service Hours or 3 Months Drive Chain Case Oil Check 167 Drive Chain Tension Check Agjust 167 150 Maintenance Section Maintenance Interval Schedule SEBU8495 03 Every 500 Service Hours or 6 Months Fuel System Filter In Line Replace 181 Fuel System Primary Filter Water Separator Element Replace 182 Hydraulic System Oil Filter Replace 190 Every 500 Service Hours or 1 Year Engine Oil and Filter Change 174 Engine Oil and Filter Change 176 Every 1000 Service Hours Engine Valve Lash 178 Every 1000 Service Hours or 6 Months Drive Chain Case Oil Change 166 Engine Crankcase Breather Clean
35. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR Pape L Operation and Maintenance Manual 216B3 226B3 236B3 242B3 and 252B3 Skid Steer Loaders 247B3 and 25 B3 Multi Terrain Loader and 259B3 Compact Track Loader JXM1 Up 216B3 MWD1 Up 226B3 A9H1 Up 236B3 SAFETY CAT COM 128 Maintenance Section Maintenance Access SEBU8495 03 Maintenance Section Maintenance Access 101961574 Access Doors and Covers SMCS Code 7273 572 7273 573 Engine Access Door Note A pinch point exists between the top of the engine access door and the radiator guard Keep hands away from this area when you close the engine access door The engine access door is located on the back of the machine ANNANN MANNANNA AMANAN DERBENERRBERERRBEN ERERBERENERERN INAMAANA Illustration 119 901019131 1 Pull the release lever 1 order to open the engine access door 2 Illustration 120 g01019162 2 Move the retaining pin from the stored position 3 and put the retaining pin in the locked position 4 This will prevent the engine access door from closing inadvertently 3 In order to close the engine access door put the retaining pin in the stored position
36. Min Max Min Max Final Drive for Multiterrain Loaders and Cat Synthetic GO SAE 75W 140 30 45 22 113 Compact Track Loaders Special Lubricants Grease In order to use a non Cat grease the supplier must certify that the lubricant is compatible with Cat grease Each pin joint should be flushed with the new grease Ensure that all old grease is removed Failure to meet this requirement may lead to failure of a pin joint Table 30 Recommended Grease C oF Compartment or System GreaseType NLGI Grade Min Max Min Max Cat Advanced 3Moly NLGI Grade 2 20 40 4 104 NLGI Grade 2 30 50 22 122 Cat Ultra 5Moly NLGI Grade 1 35 40 31 104 External Lubrication Points NLGI Grade 0 40 35 40 95 Cat Arctic Platinum NLGI Grade 0 50 20 58 68 Cat Desert Gold NLGI Grade 2 20 60 4 140 General Bearing Lubrication t Multipurpose NLGI Grade 2 30 40 22 104 Diesel Fuel Recommendations Diesel fuel must meet Cat Specification for Distillate Fuel and the latest versions of ASTM D975 or EN 590 in order to ensure optimum engine performance Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for the latest fuel information and for Cat fuel specification This manual may be found on the Web at Safety Cat com The preferred fuels are distillate fuels These fuels are commonly called diesel fuel furnace oil gas oil or kerosene These fuels must meet the Caterpillar Specificat
37. Note Level 1 results may indicate a need for Level 2 Analysis SEBU8495 03 163 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SAE D 900956151 Illustration 163 Typical Example Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of the service points 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 Obtain the sample of the coolant from the radiator When the system is cool slowly remove the radiator cap Note The radiator cap is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The radiator cap is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine Note Do not take the sample from the Coolant Overflow Reservoir 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 Keep the unu
38. O HYDO Advanced ISO M 30 45 22 113 Multi Grade Cat MTO Hydraulic System Cat DEO ULS SAE10W 30 20 40 4 104 Cat DEO Cat DEO ULS Cat DEO SAE15W 40 15 50 5 122 Cat TDTO TMS Multi Grade 15 50 5 122 Cat DEO ULS Cold Weather SAEOW 40 40 40 40 104 Cat TDTO Cold Weather SAE OW 20 40 40 40 104 1 20 C 4 F to 50 C 122 F if equipped with the High Ambient Cooling Attachment Drive Train Components Refer to the Lubricant Information section in the latest revision of the Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for detailed information This manual may be found on the Web at Safety Cat com When you are operating the machine in temperatures below 20 C 4 F refer to Special Publication SEBU5898 Cold Weather Recommendations This publication is available from your Cat dealer Table 28 Drive Chain Case Oil Type and C F SOMPE sl Oil Viscosities _ Requirements Min Max Min Max Cat DEO UES Cold SAE 0W 40 40 40 40 104 Weather Cat DEO ULS Drive Chain Case Cat DEO SAE 10W 30 18 40 0 104 Cat DEO ULS X Cat DEO SAE 15W 40 9 5 50 15 122 138 Maintenance Section Lubricant Viscosities and Refill Capacities SEBU8495 03 Table 29 Multi terrain and Compact track Loaders C oF Compartment or System Qil We and R Oil Viscosities equirements
39. UX6 C1 22 Auxiliary Electrical Control AUX5 C2 23 Secondary Auxiliary Electrical Control C4 24 Secondary Auxiliary Electrical Control C y 25 Auxiliary Electrical Control AUX7 26 Stop Lamp 27 Secondary Auxiliary Electrical Control 28 Fuel Shutoff 29 Hydraulic Flow Control 30 Glow Plugs SEBU8495 03 187 Maintenance Section Headlights Adjust Main Fuse o T uA a Cc L3 9 jj U Illustration 217 902142334 The main fuse 31 is located on the left side of the machine in the rear next to the engine This is a 105 amp fuse You must disconnect the negative battery cable before you replace this fuse Fuse panel behind cab There is an additional fuse panel behind the cab on the left side of the machine S Illustration 218 g02142313 This panel has six fuses In order to change these fuses push up on the locking tab on the fuse cover Pull the cover away from the back of the cab 32 Ignition switch 20 A 33 ECM 20 A 34 Horn 20 A 35 Main power relay 1 60 A 36 Miscellaneous cab acces
40. ach Final Drive 1 0 0 26 0 22 Fuel Tank 84 22 2 18 5 Table 39 Approximate Refill Capacities 259B3 Compartment Liters US Imperial or System Gallons Gallons Engine Crankcase 9 2 4 2 0 Cooling System 12 5 3 3 2 8 Each Final Drive 1 0 0 26 0 22 Fuel Tank 89 23 5 19 6 Table 40 Track Roller Frame Approximate Refill Capacities 259B3 Compartment or System Milliliters Track Roller 240 12 ml Idler Single Flange 349 15 ml Idler Dual Flange 354 15 ml SEBU8495 03 141 Maintenance Section Lubricant Viscosities and Refill Capacities 104311449 S O S Information SMCS Code 1000 7000 7542 008 S O S Services is a highly recommended process for Cat customers to use in order to minimize owning and operating cost Customers provide oil samples coolant samples and other machine information The dealer uses the data in order to provide the customer with recommendations for management of the equipment In addition S O S Services can help determine the cause of an existing product problem Refer to Special Publication SEBU6250 Caterpillar Machine Fluid Recommendations for detailed information concerning S O S Services Refer to the Operation and Maintenance Manual Maintenance Interval Schedule for a specific sampling location and a service hour maintenance interval Consult your Cat dealer for complete information and assistance in establishing an S O S program for your equipment 142 Maintenance Section
41. addition of the coolant additive 5 Add 0 17 L 0 18 qt of cooling system additive 6 Inspect the radiator cap and the gasket If the cap or the gasket is damaged replace the cap Install the radiator cap gt D g00956179 Illustration 162 Typical Example Note The sight gauge for the coolant level is located on the right side of the engine compartment on machines that are equipped with the C2 2 engine The sight gauge for the coolant level is located on the left side of the engine compartment on machines that are equipped with the C3 4 engine 7 Check the coolant level in the sight gauge on the radiator Maintain the coolant level to the top of the sight gauge with the radiator in the LOWERED position 8 Tilt the radiator guard downward 9 Close the engine access door For additional information on the addition of extender see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 103880003 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers
42. age to the rubber on the bogies and idlers is acceptable Minor damage includes nicks cuts small pieces that are missing and small grooves This minor damage is normal and acceptable Minor damage will not adversely affect machine performance The bogies and the idlers should be replaced when the damage to the rubber wheels adversely affects machine performance Replace the bogies and the idlers when the rubber is worn beyond the minimum specifications that are listed below Table 43 Bogie Wheels and Idler Wheels Wear Limits Minimum Width Minimum Thickness 254 mm 10 inch 48 mm 1 9 inch 3 mm 0 12 inch 358 mm 14 inch 48 mm 1 9 inch 3 mm 0 12 inch 158 Maintenance Section Bogie and Idler Inspect Replace SEBU8495 03 Loosen the Track WZ 1S i j E 0 0 i A i 1 901393193 Illustration 152 Use an appropriate floor jack in order to lift the machine off the ground Use appropriate jack stands 1 in order to block up the machine Raise the machine until tracks are approximately 50 mm 2 0 inches A off the ground Loosen the track in order to work on the bogies and idlers Refer to Operation and Maintenance Manual Track Inspect Adjust for the procedure Note The track may be removed in the illustrations for clarity Idler wheels Illustration 153 g01393325 2 Outer idler
43. an electronic control on the machine or the engine temporarily remove the electronic control in order to prevent heat related damage The following steps should be followed in order to weld on a machine or an engine with electronic controls 1 Turn off the engine Place the engine start switch in the OFF position 2 If equipped turn the battery disconnect switch to the OFF position If there is no battery disconnect Switch remove the negative battery cable at the battery NOTICE Do NOT use electrical components ECM or sensors or electronic component grounding points for ground ing the welder 3 Clamp the ground cable from the welder to the component that will be welded Place the clamp as close as possible to the weld Make sure that the electrical path from the ground cable to the component does not go through any bearing Use this procedure in order to reduce the possibility of damage to the following components e Bearings of the drive train e Hydraulic components 148 Maintenance Section Maintenance Support SEBU8495 03 Electrical components e Other components of the machine 4 Protect any wiring harnesses and components from the debris and the spatter which is created from welding 5 Use standard welding procedures in order to weld the materials together SEBU8495 03 149 Maintenance Section Maintenance Interval Schedule 104776468 Maintenance Interval Schedule SMCS Code 7000
44. ar products Dispose of all fluids according to local regulations and mandates The hydraulic oil filter is located in the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers SEBU8495 03 191 Maintenance Section Hydraulic System Oil Level Check Illustration 224 g00926534 2 Remove the hydraulic tank filler cap Illustration 225 g01017252 3 Remove the filter with a strap type wrench Note Place a suitable nonconductive container under the hydraulic oil filter Use this container in order to catch any oil that may spill from the filter or the filter element mounting base 4 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 5 Apply a light coat of oil to the gasket of the new filter element gasket 6 Install a new filter hand tight until the seal of the filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filt
45. ator guard downward 8 Close the engine access door 101968724 Refrigerant Dryer Replace If Equipped 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 cartto 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 Refer to Service Manual SENR5664 Air Conditioning and Heating R 134a For All Cat
46. ccording to local regulations and mandates Illustration 220 900956818 Note This film is located near the hydraulic filler cap on machines that are filled with arctic oil Operate the machine for a few minutes in order to warm the hydraulic system oil Personal injury or death can result without releas ing all of the hydraulic pressure Release all the pressure from the hydraulic sys tem before any lines are disconnected The machine should be on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine Keep the armrest lowered Turn the engine start switch key to the ON position Push the parking brake switch Move all of the joystick controls while you press several times on each side of the auxiliary hydraulic control if equipped in order to relieve hydraulic pressure Move the engine start switch key to the OFF position 190 Maintenance Section Hydraulic System Oil Filter Replace SEBU8495 03 Illustration 221 900926534 1 Remove the hydraulic tank filler E xj a a LES 901021146 Illustration 222 2 Remove the access panel in the belly guard underneath the machine Illustration 223 g01030411 3 Remove the plug from the end of
47. ck in order to maximize the slack between the front idler and the drive sprocket 7 Keep the track supported with a hoist Lift the track over the flange of the front idler so that the inner track guides clear flanges 8 Lift the track over the sprocket with a suitable lifting device The inner guides need to clear the sprocket teeth 9 Lift the track over the rear idler The inner track guides need to clear the rear idler Installing the Track Note The approximate weight of the track is 247 kg 545 Ib 1 Use a suitable lifting device Slide the track onto the rear idler so that the inner track guides straddle the rear idler If your machine is equipped with an idler with dual flanges the inner track guides must seat between the flanges 2 Pull the track forward in order to ensure that the track guides are fully seated on the rear idler 3 Lift the track over the final drive sprocket so that the inner track guides straddle the sprocket teeth The sprocket teeth should seat in the openings in the middle of the track 206 Maintenance Section Track Inspect Adjust SEBU8495 03 4 Pull all of the slack forward This will provide the maximum amount of slack to aid with installation across the front idlers Note It is helpful to support the bottom of the track in order to maximize the slack This will help with installation 5 Position the track so that the inner track guides seat between the flanges on the
48. ct tension is reached Note A hole 8 in the bracket has been provided in order to aid with the adjustment of the tension 4 Tighten the adjusting locknut Tighten the mounting bolt 5 Recheck the belt deflection If the amount of deflection is incorrect repeat step 2 to step 4 Finish 1 Apply thread lock compound to the threads on bolts 1 10 11 Illustration 148 g01364054 2 Install the guard for the V belt 9 Ensure that the guard is inserted between the mounting bracket 10 and the spreader plate 11 before you tighten the bolts 2 Tighten the bolts 2 to 15 3 11 2 Ib ft 901209498 Illustration 149 3 Tighten the bolts 1 to 12 3 9 x 2 Ib ft Note Start all the bolts 1 in the holes before you start tightening the bolts This helps align all the holes 4 Close the engine access door 156 Maintenance Section Blade Frame Adjust SEBU8495 03 102549571 Blade Frame Adjust SMCS Code 6060 025 BG Height Adjustment Illustration 150 901161532 1 Height Adjustment for the Frame 2 Adjusting Bolts 3 Frame The height of the frame may be adjusted in order to compensate for the wear on the cutting edge The front portion of the frame needs to be lowered as the cutting edge wears Remove the bolts 2 and lower the frame 3 Install the bolts This will keep the bla
49. de level with the ground and this will prevent the blade from digging into the ground Note In order to properly adjust the blade the work tool coupler needs to be vertical The position of the pivot point of the blade is perpendicular to the ground Follow this procedure in order to ensure that the cutting edge will remain flat on the ground during operation Trunnion Joint Note The trunnion is a dry joint Adding grease to the trunnion simply attracts abrasive particles The tightness of the joint should be monitored Shims should be removed when the joint becomes too loose This may be indicated by excessive movement in the blade 2 t e ay A 9 B 3 1 A 2 4 Illustration 151 901173519 A Trunnion Joint B Bolts C Shims e Remove the four retaining bolts B and the cap e Remove the necessary shims e Replace the cap and bolts The tightening sequence is shown in illustration 151 Torque the bolts to 530 70 N m 391 52 Ib ft Note Some noise is typical and the noise does not indicate a problem SEBU8495 03 157 Maintenance Section Bogie and Idler Inspect Replace 103318544 Bogie and ldler Inspect Replace SMCS Code 4159 040 4159 510 4192 040 4192 510 S N B7H1 Up S N TSL1 Up Inspect Clean the undercarriage before inspecting the bogies and the idlers Inspect the bogies and idlers for damage and wear Note Minor dam
50. diator guard downward SEBU8495 03 165 Maintenance Section Cooling System Water Temperature Regulator Replace Illustration 167 901018341 7 The coolant reservoir is located on either the left side of the engine compartment or on the engine access door Maintain the coolant level in the coolant reservoir between the MIN and MAX lines 8 Close the engine access door 103880044 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system Failure to replace the engine s thermostat on a regularly scheduled basis could cause severe engine damage The thermostat should be replaced after the cooling system has been cleaned Replace the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing Caterpillar engines incorporate a shunt design cooling system It is mandatory to always operate the engine with a thermostat 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Drain the coolant from the machine See Operation and Maintenance Manual Cooling System Coolant ELC Change for the procedure to drain the cooling system Illustration 168 g01018412 C2 2
51. e a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter Illustration 195 901018561 8 Remove the oil filler cap 2 Fill the crankcase with new oil See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Clean the oil filler plug and install the oil filler plug 9 Start the engine and allow the oil to warm Check for leaks 176 Maintenance Section Engine Oil and Filter Change SEBU8495 03 Illustration 196 g02126167 10 Stop the engine and allow the oil to drain back into the oil pan Fill the crankcase to the FULL mark 4 on the oil level gauge 1 Do not exceed the FULL mark on the dipstick Add oil or drain oil if it is necessary 11 Tilt the radiator downward 12 Close the engine access door 103900344 Engine Oil and Filter Change SMCS Code 1308 510 1348 044 S N A9H1 Up SIN B7H1 Up S N TNK1 Up S N SRS1 Up S N YYZ1 Up 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 Specia
52. e brace to the storage location Attach the brace with the retaining pins 101961858 Radiator Tilting SMCS Code 1353 506 1353 509 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers SEBU8495 03 133 Maintenance Section Maintenance Access Illustration 133 g01019329 2 The release lever for the radiator latch is located on the left side or the right side of the radiator Pull the release lever for the radiator latch Tilt the radiator upward Illustration 134 901028581 3 The strut lock is located on the right side or the left side of the engine compartment Make sure that the strut lock is in the LOCKED position 4 In order to tilt the radiator downward push the strut lock to the left 5 Tilt the radiator downward Make sure that the radiator is in the LOCKED position 6 Close the engine access door Tilting the Radiator Guard 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers ETT Til M e z 901019340 Illustration 135 2
53. e ground Use appropriate jack stands 1 in order to block up the machine Raise the machine until tracks are approximately 50 mm 2 0 inch A off the ground 5 Detension the track Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust Illustration 249 g01393194 6 Remove the front idler wheel Refer to Operation and Maintenance Manual Bogie and Idler Inspect Replace for the procedure to remove the idler wheels 7 If necessary lubricate the remaining front idler wheel and the inside of the track in order to ease the removal of the track 8 Grasp the track on top of the front idler Pull the track forward and pull the track away from the frame Slide the drive lugs past the inside front idler wheels 9 Lift the track off the drive sprocket and pull the track away from the rear idler wheels Installing the Track 1 Slide the track onto the drive sprocket 2 Position the rear of the track so that the drive lugs are aligned between the rear idler wheels 3 Pull all of the slack forward and make sure that the drive lugs are properly meshed with the drive sprocket This will provide the maximum amount of slack to aid with installation across the front idler 4 Lubricate the idler wheels and the inside of the track in order to ease the installation of the track 5 Pull the track over the front idler wheel SEBU8495 03 205 Maintenance Section Track Rubber Rem
54. e the diaphragm assembly 4 Remove the spring 3 The diaphragm assembly consists of the diaphragm and the locating ring 5 Clean the cavity for the breather 5 Illustration 190 g02126142 6 Remove the gauze that is located below the cavity M for the breather 7 Clean the following items with a clean diesel fuel Breather 174 Maintenance Section Engine Oil and Filter Change SEBU8495 03 901209758 Illustration 191 C3 4 1 Oil Filler Cap 2 Oil Level Gauge 2 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 192 g02126152 3 Add 4 Full mark 3 Maintain the level of the oil between the ADD 3 mark and the FULL 4 mark on the oil level gauge 2 4 If oil is necessary tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting 5 Remove the oil filler cap 1 and add oil 6 Clean the oil filler cap and install the oil filler cap 7 Tilt the radiator downward 8 Close the engine access door 103880121 Engine Oil and Filter Change SMCS Code 1308 510 1348 044 S N MWD1 Up S N TSL1 Up SIN JXM1 Up 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 conta
55. ed These products are applicable to diesel and biodiesel fuels Consult your Cat dealer for availability Biodiesel Biodiesel is a fuel that can be made from various renewable resources that include vegetable oils animal fat and waste cooking oil Soybean oil and rapeseed oil are the primary vegetable oil sources In order to use any of these oils or fats as fuel the oils or fats are chemically processed esterified The water and contaminants are removed U S distillate diesel fuel specification ASTM D975 09a includes up to B5 5 percent biodiesel Currently any diesel fuel in the U S may contain up to B5 biodiesel fuel European distillate diesel fuel specification EN 590 includes up to B5 5 percent and in some regions up to B7 7 percent biodiesel Any diesel fuel in Europe may contain up to B5 or in some regions up to B7 biodiesel fuel When biodiesel fuel is used certain guidelines must be followed Biodiesel fuel can influence the engine oil aftertreatment devices non metallic fuel system components and others Biodiesel fuel has limited storage life and has limited oxidation stability Follow the guidelines and requirements for engines that are seasonally operated and for standby power generation engines In order to reduce the risks associated with the use of biodiesel the final biodiesel blend and the biodiesel fuel used must meet specific blending requirements All the guidelines and requirements a
56. equipped with the C3 4 engine 10 Stop the engine Inspect the radiator cap and the gasket Replace the cap if the cap or the gasket is damaged Install the radiator cap 11 Pull the radiator guard downward 12 Close the engine access door 162 Maintenance Section Cooling System Coolant Extender ELC Add SEBU8495 03 103879996 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 When a Caterpillar Extended Life Coolant is used an extender must be added to the cooling system periodically 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting SAE D 900956151 Illustration 161 Typical Example Note The radiator cap is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The radiator cap is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine 3 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap 4 If necessary drain enough coolant from the radiator in order to allow the
57. er Use the index marks as a guide Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 8 Maintain the hydraulic oil level to the middle of the sight gauge Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check Do not overfill the hydraulic tank 9 Inspect the gasket on the hydraulic tank filler cap for damage Replace the hydraulic tank filler cap if necessary Install the hydraulic tank filler cap 10 Close the engine access door 101957050 Hydraulic System Oil Level Check SMCS Code 5095 535 FLV Illustration 226 g00956818 Note This film is located near the hydraulic filler cap on machines that are filled with synthetic oil ANNI A 13 120 WIRE ag ULL LL Illustration 227 g00926177 1 Park the machine on level ground 192 Maintenance Section Hydraulic System Oil Sample Obtain SEBU8495 03 2 Lower the work tool to the ground Turn off the engine 3 Wait for about five minutes before checking the level of the hydraulic oil 4 Maintain the oil level to the middle of the sight gauge Do not overfill the hydraulic tank 102920120 Hydraulic System Oil Sample
58. erpillar Machines for the proper procedure to change the receiver dryer assembly and for the procedure to reclaim the refrigerant gas Note The receiver dryer must also be replaced when the air conditioning system is evacuated 102798931 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect SMCS Code 7323 040 7325 040 T Illustration 234 g01022156 1 Front ROPS retaining bolt one bolt per side 196 Maintenance Section Seat Belt Inspect SEBU8495 03 2 3 OIL AANA MAANA OOS aaa VOODOO at IIL UOO OL Illustration 235 g00925477 2 Rear ROPS retaining bolt one bolt per side 3 Retaining bolts for the FOPS 2 Note There is a total of four retaining bolts for the ROPS There is a total of eight retaining bolts for the FOPS 2 1 Inspect the ROPS and the FOPS for loose bolts Tighten the bolts 1 to the following torque 125 10 N m 92 7 Ib ft Tighten the bolts 2 to the following torque 55 5 N m 41 4 lb ft Tighten the bolts 3 to the following torque 240 40 N m 177 x 30 Ib ft ROPS and the FOPS for damaged bolts or missing bolts Replace any damaged bolts or missing bolts with original equipment parts only 2 Operate the mach
59. he filler plug for the right side drive chain case The oil level should be at the bottom of the threads on the fill port If necessary refer to Operation and Maintenance Manual Drive Chain Case Oil Change for the proper procedure to add oil 2 Apply 169 5464 Quick Cure Primer and 5P 3413 Pipe Sealant to the threads on the filler plug Install the filler plug 3 Repeat the process for the left side drive chain case 103886391 Drive Chain Tension Check Adjust SMCS Code 3261 025 3261 535 S N MWD1 Up S N A9H1 Up S N TNK1 Up S N JXM1 Up S N SRS1 Up Note Steel tracks that go over the tires should only be used with pneumatic tires When you use steel tracks that go over tires or any drive train device except tires the interval for checking the drive chains should be reduced to every 100 Service Hours The use of rubber tracks that go over the tires is not recommended Note There are four drive chains on the skid steer loader that must be checked and adjusted 1 Park the machine on level ground and stable ground 2 Chock the rear tires 3 Use an appropriate floor jack to lift the front of the machine so that the front tires are off of the ground Block up the front of the machine with two 1U 9758 Jack Stands HHH UP 901025514 Illustration 174 4 Rotate the wheel forward and backward Measure the total free play A Note If the total free play does not exceed 15 mm 0 6
60. hips or for particles If there are any chips or particles consult your Caterpillar dealer Note Dispose of drained fluids according to local regulations 4 Clean the plugs and inspect the plugs Replace a worn plug or a damaged plug 5 Position the final drive so that the oil fill drain plug 1 is at the top 6 Add oil through the opening of the oil fill drain plug 1 that is now at the top 7 Fill the final drive to the bottom of the opening for the oil check plug 2 Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 8 Install the two oil plugs Tighten the oil plugs to a torque of 27 1 N m 20 0 7 Ib ft 9 Perform Step 1 to Step 8 on the other final drive 10 Completely remove any oil that has spilled 11 Start the engine and allow the final drives to operate through several cycles 12 Stop the engine 13 Check the oil level 14 Maintain the oil level to the bottom of the opening for the fill drain plug 2 180 Maintenance Section Final Drive Oil Level Check SEBU8495 03 103880192 Final Drive Oil Level Check SMCS Code 4011 535 FLV 4050 535 FLV 4050 4070 535 FLV 7524 7527 S N B7H1 Up S N TSL1 Up S N YYZ1 Up Illustration 204 901457026 Multi Terrain Loader Illustration 205 g01457009 Compact Track Loader 1 Oil fill drain plug 2 Oil check plug 1 Po
61. ine Fluids Recommendations for detailed information This manual may be found on the Web at Safety Cat com The following are the preferred oils for use in most Cat machine hydraulic systems Cat HYDO Advanced 10 SAE 10W Cat HYDO Advanced 30 SAE Cat BIO HYDO Advanced Cat HYDO Advanced fluids have a 50 increase in the standard oil drain interval for machine hydraulic systems 3000 hours versus 2000 hours over second and third choice oils when you follow the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual for your particular machine 6000 hour oil drain intervals are possible when using S 0 S Services oil analysis Consult your Cat dealer for details When switching to Cat HYDO Advanced fluids cross contamination with the previous oil should be kept to less than 1096 Second choice oils are listed below Cat MTO Cat DEO e Cat DEO ULS e Cat TDTO e Cat TDTO Cold Weather e Cat TDTO TMS SEBU8495 03 137 Maintenance Section Lubricant Viscosities and Refill Capacities e Cat DEO ULS Cold Weather Table 27 Hydraulic System oF Compartment or System eu bi and Oil Viscosities equirements Min Max Min Max Cat HYDO Advanced 100 Cat TDTO SAE 10W 20 40 4 104 Cat HYDO Advanced 30 Cat TDTO SAE 30 0 50 32 122 Cat BI
62. ine on a rough surface Replace the ROPS mounting supports if the ROPS emits a noise Replace the ROPS mounting supports if the ROPS rattles Do not straighten the ROPS or the FOPS Do not repair the ROPS or the FOPS by welding reinforcement plates to the ROPS or the FOPS Consult your Caterpillar dealer for repair of any cracks in the ROPS or the FOPS Inspect the Flying Object Guard if equipped for damage Consult your Caterpillar dealer for repair of any cracks in the Flying Object Guard 104423622 Seat Belt Inspect SMCS Code 7327 040 Always inspect the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 236 902620101 Typical example Inspect buckle 1 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect seat belt 2 for webbing that is worn or frayed Replace the seat belt if the webbing is worn or frayed Inspect all seat belt mounting hardware for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension Contact your Cat dealer for the replacement of the seat belt and the mounting hardware Note The seat belt should be replaced
63. iners 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 The normal oil change interval for the machine is Every 500 Service Hours or every year when the following conditions are met Usean engine oil in the Operation and Maintenance Manual Lubricant Viscosities e Caterpillar filters are used The altitude does not exceed 2300 m 7545 ft e Sulfur content in the fuel is between 0 05 and 0 50 An oil change interval of Every 250 Service Hours or every six months is required when the following conditions occur e Use an engine oil in the Operation and Maintenance Manual Lubricant Viscosities The altitude exceeds 2300 m 7545 ft e Sulfur content in the fuel is between 0 50 and 1 00 An oil change interval of Every 125 Service Hours is required when the following condition occurs e Sulfur content in the fuel is above 1 00 SEBU8495 03 175 Maintenance Section Engine Oil and Filter Change Refer to the results of the S O S oil analysis order to determine if the oil change interval should be decreased Consult your Caterpillar Dealer for detailed information regarding the optimum oil change interval 1 Open
64. ining pin 7 Install the pivot lever into the STORED position Engage the Lift Arm Brace Extended Lift 1 Empty the work tool Remove the work tool Park the machine on level ground Raise the lift arms to maximum height 2 Remain in the seat with the seat belt fastened until the brace is installed IMERNERRN Illustration 129 900930202 3 A second person must remove the brace from the storage position by removing the retaining pins UM Illustration 130 4 900952659 The second person should then install the brace over the rod of one of the lift cylinders Lower the loader arms slowly until the brace is held tightly between the rod and the cylinder Secure the two retaining pins through the brace below the rod Disengage the Lift Arm Brace Extended Lift 1 o N AR Mount the machine Fasten the seat belt Lower the armrest and remain in the seat until the brace is removed Slowly raise the lift arms until the brace is free A second person must remove the retaining pins and the brace from the rod Slowly lower the lift arms to the ground The second person should return the brace to the storage location Attach the brace with the retaining pins 132 Maintenance Section Maintenance Access SEBU8495 03 103917798 Loader Lift Arm
65. into the filter housing 8 Install the cover for the filter housing Illustration 180 g01433098 9 Rotate the cover clockwise and latch the cover 10 Close the engine access door 11 Start the engine The alert indicator for air filter restriction should turn off If the alert indicator continues to light replace the secondary air filter Refer to Operation and Maintenance Manual Engine Air Filter Secondary Element Replace Replace The primary filter element should be replaced at least one time per year You can clean the primary filter up to three times 1 Open the engine access door Illustration 181 900101864 2 Unlatch the air cleaner housing cover 1 Rotate the cover counterclockwise and remove the cover 3 Remove the primary filter element 2 4 Clean the inside of the air cleaner housing with a damp cloth Do not use compressed air to clean the housing 5 Install a new primary filter element into the filter housing 6 Install the cover for the filter housing Illustration 182 g01433098 7 Rotate the cover clockwise and latch the cover 8 Reset the air filter service indicator Refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect 9 Close the engine access door SEBU8495 03 171 Maintenance Section Engine Air Filter Secondary Element Replace 10 Start the engine The alert indicator for air filter restrict
66. ion for Distillate Diesel Fuel for Off Highway Diesel Engines Diesel Fuels that meet the Cat specification will help provide maximum engine service life and performance Misfueling with fuels of high sulfur level can have the following negative effects e Reduce engine efficiency and durability Lower fuel economy Increase overall operating costs Increase the wear Increase the corrosion Increase the deposits Negatively impact engine emissions Shorten the time period between oil drain intervals more frequent oil drain intervals SEBU8495 03 139 Maintenance Section Lubricant Viscosities and Refill Capacities Failures that result from the use of improper fuels are not Caterpillar factory defects Therefore the cost of repairs would not be covered by a Caterpillar warranty Caterpillar does not require the use of ULSD in off road and machine applications that are not Tier 4 Stage IIIB certified engines ULSD is not required in engines that are not equipped with after treatment devices Follow operating instructions and fuel tank inlet labels if available in order to ensure that the correct fuels are used Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more details about fuels and lubricants This manual may be found on the Web at Safety Cat com Fuel Additives Cat Diesel Fuel Conditioner and Cat Fuel System Cleaner are available for use when need
67. ion should turn off If the alert indicator continues to light replace the secondary air filter Refer to Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 102879321 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary filter element Nev er attempt to reuse the secondary filter element by cleaning the element When the primary filter element is cleaned for the third time the secondary filter element should be replaced The secondary filter element should also be replaced if the restricted Air Filter indicator comes on after the installation of a clean primary filter element or if the exhaust smoke is still black The air filter housing is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The air filter housing is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine Illustration 183 000891467 1 Open the engine access door Illustration 184 g00101864 2 Unlatch the air cleaner housing cover 1 Rotate the cover counterclockwise and remove the cover 3 Remove the primary filter element 2 Illustration 185 900038606 4 Clean the inside of the air cleaner housing with a damp cloth Do not use compressed air to clean the housing 5
68. l Grapple Tools Illustration 261 g00645995 Apply lubricant to the four grease fittings for the fork cylinders Illustration 262 g00646004 Apply lubricant to the four grease fittings for the two forks There are eight grease fittings Grapple Rake Illustration 263 g01368386 Apply lubricant to the four grease fittings for the grapple cylinders Apply lubricant to the four grease fittings for the two grapples There are eight grease fittings Angle Blade g00648033 Illustration 264 Apply lubricant to the grease fitting on the rod end of the angle cylinder SEBU8495 03 211 Maintenance Section Work Tool Mounting Bracket Inspect Illustration 265 g00648037 Apply lubricant to the grease fitting on the horizontal pivot point of the blade Illustration 266 g00648038 Apply lubricant to the grease fitting on the vertical pivot point of the blade Repeat for opposite side of the blade Illustration 267 900677570 This is a bottom view of the angle blade Apply lubricant to the grease fitting on the pivot point of the cylinder There are five grease fittings Dozer Blade Illustration 268 g01073259 Apply lubricant to the grease fitting on both ends of the right hand angle cylinder 1 Repeat for opposite side of the blade Apply lubricant to the grease fitting on the pivot poi
69. l 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 The normal oil change interval for the machine is Every 500 Service Hours or every year when the following conditions are met Useanengine oil in the Operation and Maintenance Manual Lubricant Viscosities e Caterpillar filters are used The altitude does not exceed 2300 m 7545 ft e Sulfur content in the fuel is between 0 05 and 0 50 An oil change interval of Every 250 Service Hours or every six months is required when the following conditions occur e Use an engine oil in the Operation and Maintenance Manual Lubricant Viscosities The altitude exceeds 2300 m 7545 ft e Sulfur content in the fuel is between 0 50 and 1 0096 An oil change interval of Every 125 Service Hours is required when the following condition occurs e Sulfur content in the fuel is above 1 00 Refer to the results of the S O S oil analysis in order to determine if the oil change interval should be decreased Consult your Caterpillar Dealer for detailed information regarding the optimum oil change interval 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting
70. machine 1 Remove the drain plug for the left drive chain case and the right drive chain case Allow the oil to drain into a suitable container 2 Apply 169 5464 Quick Cure Primer and 5P 3413 Pipe Sealant to the threads on the drain plugs Install the drain plugs Illustration 171 g01025470 3 Remove the filler plug for the right side drive chain case Fill the drive chain case with oil to the bottom of the threads on the fill port Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities 4 Apply 169 5464 Quick Cure Primer and 5P 3413 Pipe Sealant to the threads on the filler plug Install the filler plug 5 Repeat the process for the left side drive chain case Drive Chain Case Breathers Illustration 172 901031152 The breathers for the drive chain cases are located underneath the cab 1 Refer to Operation and Maintenance Manual Cab Tilting SEBU8495 03 167 Maintenance Section Drive Chain Case Oil Check Remove the breathers and inspect the breathers when the oil in the drive chain cases is changed In order to clean the breathers use solvent and low pressure air If the breather is badly plugged replace the breather 102799544 Drive Chain Case Oil Check SMCS Code 3261 535 S N MWD1 Up S N A9H1 Up S N TNK1 Up S N JXM1 Up S N SRS1 Up Illustration 173 g01025470 1 Remove t
71. meet the various machine compartment performance specification recommendations For the best results do not mix oil brands Note The availability of the various Cat oils will vary by region Note SAE 10W viscosity grade oil used in most Cat machine compartments must have a minimum viscosity of 5 8 cSt at 100 C 212 F ASTM D445 Note The minimum acceptable viscosity for commercial alternative oils in most Cat machine hydraulic and hydrostatic transmission systems is 6 6 cSt at 100 212 F ASTM 0445 Cat GO Gear Oil is available in SAE 80W 90 and SAE 85W 140 viscosity grades Cat SYNTHETIC GO is an SAE 75W 140 viscosity grade oil Cat FDAO Final Drive and Axle Oil exceeds the FD 1 oil performance requirements Cat TDTO TMS Transmission Multi Season Oil is a synthetic blend that exceeds the TO 4M multigrade oil performance requirements Note Cat oils are the preferred oils ALL other oil types and specifications that are listed in the applicable section are acceptable oils When you are operating the machine in temperatures below 20 4 F refer to Special Publication SEBU5898 Cold Weather Recommendations This publication is available from your Cat dealer For cold weather applications where transmission oil SAE OW 20 is recommended Cat Cold Weather TDTO is the first choice oil Second choice oils for cold weather transmission applications are commercial oils of full sy
72. 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 Service the air filter elements when the alert indicator for air filter restriction lights Refer to Operation and Maintenance Manual Alert Indicators The air filter housing is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The air filter housing is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine Clean The primary filter element can be used up to three times if the element is properly cleaned and if the element is properly inspected When the primary filter element is cleaned check for rips or tears in the filter material The primary filter element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings 1 Open the engine access door Illustration 179 g00101864 2 Unlatch the air cleaner housing cover 1 Rotate the cover counterclockwise and remove the cover 3 Remove the primary filter element 2 4 If itis appropriate clean the primary filter element Use air pressure to clean the primary filter elements Pressurized
73. n maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note Drain the water and the sediment from the fuel tank when the tank is almost empty 1 Slowly remove the fuel tank cap in order to relieve the tank pressure CU CD C C3 Illustration 213 901023153 2 The fuel tank drain plug is located underneath the machine at the left rear corner Loosen the plug 3 Allow the water and the sediment to drain into a suitable container 4 Install the fuel tank drain plug Note Apply 5P 3413 Pipe Sealant to the threads on the drain plug 5 Install the fuel tank cap SEBU8495 03 185 Maintenance Section Fuses Replace 103898484 Fuses Replace SMCS Code 1417 510 1417 7528 Fuses Fuses Fuses protect the electrical system from damage that is caused by overloaded circuits Replace the fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary NOTICE Replace the fuses with the same type and size
74. nditioning system Use low pressure water in order to clean the condenser 103880064 Engine Crankcase Breather Clean SMCS Code 1317 070 S N MWD1 Up S N TSL1 Up S N JXM1 Up Note Ensure that the area around the vent hole on the breather cover is clean and that the vent hole is not restricted Ensure that the components of the breather assembly are seated in the correct positions Otherwise engine damage could result SEBU8495 03 173 Maintenance Section Engine Oil Level Check 1 Open the engine access door Refer to Operation Breather cover and Maintenance Manual Access Doors and Covers Diaphragm assembly 2 Tilt the radiator upward Refer to Operation and e Location ring assembly Maintenance Manual Radiator Tilting Spring e Gauze 8 Allow the parts to dry Pressure air may be used to dry the parts 9 Install the gauze and install the components of the breather Install the breather cover 10 Tilt the radiator downward 11 Close the engine access door i Illustration 188 g01018945 103880105 Engine Oil Level Check SMCS Code 1348 535 FLV NOTICE Do not overfill the crankcase Engine damage can re sult 1 Stop the engine and allow the oil to drain back into the oil pan Illustration 189 901044243 3 The breather is located on top of the valve cover Remove the screws 1 Remove the breather cover 2 4 Remov
75. nflation chuck and stand be hind the tread when inflating a tire to prevent per sonal injury NOTICE Set the tire inflation equipment regulator at no more than 140 kPa 20 psi over the recommended tire pressure Use 6V 4040 Inflation Group or an equivalent inflation group to inflate tires with a nitrogen gas cylinder Reference For tire inflation instructions refer to Special Instruction SMHS7867 Nitrogen Tire Inflation Group For nitrogen inflation use the same tire pressures that are used for air inflation Consult your tire dealer for operating pressures 102970641 Track Rubber Inspect Adjust SMCS Code 4197 4198 025 4198 040 SIN B7H1 Up SIN TSL1 Up Periodic adjustment of the track tension is necessary in order to avoid damage to the tracks Maintaining the tracks at the proper tension will maximize the service life of the undercarriage components The undercarriage components include the sleeves of the drive sprocket the rings of the drive sprocket the wheels and the track SEBU8495 03 203 Maintenance Section Track Rubber Inspect Adjust NOTICE Do not overtighten the tracks Tracks that are too tight can cause premature failure of the tracks Tracks that are too tight can cause power loss and bearing fail ures Tracks that are too loose increase the possibility of the track derailing or the drive lugs mis feeding on the drive sprocket In aggressive operating conditio
76. ng 8 Install the sleeves and the rings 9 Install the new locknuts Do not reuse the locknuts Tighten the locknuts to a torque of 70 5 N m 51 6 3 7 Ib ft in a star pattern Turn the nuts an additional 120 degrees 5 degrees in the same star pattern 10 Install the sprocket on the drive motor Tighten the bolts to a torque of 270 40 N m 199 30 Ib ft Track Tighten the track to the proper tension Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust for the procedure Sprocket Inspection for 259B3 Inspect E H A 0 e I ff 7m Pa e Nw C 902789983 Illustration 240 1 Measure the sprocket teeth in three places as shown in illustration 240 2 Calculate the average of the 3 measurements to determine the 50 wear limit 3 If the average of 3 measurements is less than 178 mm 7 inch relocate the sprocket to the opposite side of the machine Follow the steps in the Relocate section If the average of 3 measurements is less than 165 mm 6 5 inch then replace the sprocket Follow the steps in the Replace section Relocate 1 Remove the track on both sides of the machine 2 Remove the sprocket on the left side of the machine Move the sprocket to the right side 3 Remove the sprocket on the right side of the machine Move the sprocket to the left side 4 Install the sprockets Tighten the bolts to the proper torq
77. ng edge if both edges are worn 7 Install the bolts 8 Remove the blocks that are under the bucket 9 After a few hours of operation check the bolts for proper torque 101764331 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket tips are accessible 2 Place blocks under the raised edge of the bucket 3 Remove the mounting bolts Remove the bucket tips 4 Clean the mounting surface 5 Replace the bucket tips 6 Install the bolts 7 Remove the blocks that are under the bucket 8 After a few hours of operation check the bolts for proper torque 101962545 Cab Air Filter Clean Replace If Equipped SMCS Code 7342 070 7342 510 Fresh Air Filter 1 Raise the loader lift arms Install the brace for the loader lift arm Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation Illustration 155 901019732 2 Remove the filter cover 3 Remove the seal from the cover and inspect the seal If the seal is damaged replace the seal 4 Remove the air filter element from the cover and clean the filter element with low pressure air Replace the element if the element is damaged 5 Install the seal onto the filter cover and install the filter element 160 Maintenance
78. ns oc casional mis feeding is normal If consistent mis feed ing is observed ensure that the track tension is set to the recommended specification If the track tension is set to the recommended specification and mis feed ing is still observed then your application may require a tighter track tension Increase the track tension until consistent mis feeding is no longer observed The intervals for track tension vary depending on the following conditions the machine application the op erator the soil conditions the climate and the condi tion of the undercarriage components Operators are responsible for basic visual inspections of the track tension on a daily basis Track Adjustment Illustration 245 g01393224 1 Place approximately 45 kg 100 Ib between the drive sprocket and the idlers Place a straight edge across the drive sprocket and idlers Measure the track sag between the bottom of the straight edge and the top of the track The track sag should be set at 12 mm 0 5 inch If the track needs adjustment proceed with the following steps Illustration 246 901393226 2 Loosen the jam nut 1 3 Turn the adjuster 2 in order to raise or lower the drive sprocket 4 Inspect the hoses Ensure that the hoses are not kinked If the hoses are kinked loosen the clamp and move the hoses so that the hoses are not kinked Note In order to detension the track for removal fully lower the drive
79. nsion adjuster 11 Install the bolts and the cover for the drive chain case Note Use 8T 9022 Silicone Gasket in order to seal the cover to the machine 12 Use an appropriate nylon lifting strap and a hoist in order to position the tire and rim to the axle The approximate weight of the tire and rim is 51 kg 113 Ib Refer to Operation and Maintenance Manual Wheel Nuts Tighten for the procedure to tighten the wheel nuts SEBU8495 03 169 Maintenance Section Engine Air Filter Primary Element Clean Replace 13 Lower the front of the machine to the ground Repeat the procedure on the opposite side of the machine if it is necessary 14 Repeat the adjustment procedure on the rear drive chains if it is necessary 103880059 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Never service the air cleaner when the engine is run ning to avoid engine damage NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure
80. ntenance 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 The fuel system water separator is located in the left side of the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 182 Maintenance Section SEBU8495 03 Fuel System Primary Filter Water Separator Element Replace ji AC NK BS SVR f Illustration 207 g02126392 C22 Illustration 208 902126394 C3 4 The Fuel Filter Water Separator is located on the left side of the engine compartment 2 Insert drain hose 1 into a suitable container Loosen drain valve 2 on the bottom of the water separator 3 Tighten drain valve 2 by hand Do not tighten the drain valve with a tool Damage to the valve or to the seals may occur 4 Close the engine access door 5 Dispose of the water and sediment according to local regulations 103880390 Fuel System Primary
81. nthetic basestock that do not have viscosity index improvers and do meet the performance requirements of the Cat TO 4 specification Typical lubricant viscosity grades are SAE OW 20 SAE OW 30 and SAE 5W 30 Commercial oils that contain a Cat TO 4 additive package and a lubricant viscosity grade of SAE OW 20 SAE OW 30 or SAE 5W 30 are a last choice The footnotes are a key part of the tables Read ALL footnotes that pertain to the machine compartment in question Lubricant Viscosities for Ambient Temperatures General Lubricants Cat FDAO SYN Cat FDAO or commercial FD 1 are the preferred oil types to maximize gear and bearing life Do not use Cat FDAO Cat FDAO SYN or CatFD 1 in compartments containing clutches and or brakes Cat TDTO Cat TDTO TMS or commercial TO 4 oil types must be used in any compartment containing friction material unless specified otherwise by Cat For the Final Drives in severe usage or in continuous operations WARM UP is required Exercise the final drives for several minutes with the engine at a partial throttle in order to warm up the oil prior to production operation Engine Crankcase Refer to the General Information for Lubricants article for important lubricant information Supplemental heat is recommended for cold soaked starts below the minimum ambient temperature The parasitic load and other factors will determine if supplemental heat is required for cold soaked starts that are ab
82. nts on each end of the tilt cylinder 2 There are six grease fittings i01809997 Work Tool Mounting Bracket Inspect SMCS Code 6700 040 BK Illustration 269 900925058 212 Maintenance Section Work Tool Mounting Bracket Inspect SEBU8495 03 Inspect upper angled plate 1 and ensure that the plate is not bent or otherwise damaged Inspect holes 2 for wear and for damage Inspect lower angled plate 3 and ensure that the plate is not bent or otherwise damaged If any wear is suspected or any damage is suspected consult your Caterpillar dealer before you use the work tool
83. oil is in the system that is not integral to the service brakes the clutches the final drives or the differentials The standard change interval is 2000 hours The oil should be monitored during intervals of 500 hours The extended 4000 hour interval can be used if the following criteria are met HYDO Advanced 10 Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic and hydrostatic transmission systems when ambient temperature is between 20 C 4 F and 40 C 104 F Cat HYDO Advanced 10 has an SAE viscosity grade of 10W Cat HYDO Advanced 10 has a 50 increase in the standard oil drain interval up to 3000 hours for machine hydraulic systems over second and third choice oils when you follow the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual 6000 hour oil drain intervals are possible when using S 0 S Services oil analysis When you switch to Cat HYDO Advanced 10 cross contamination with the previous oil should be kept to less than 1096 Consult your Cat dealer for details about the benefits from the improved performance designed into Cat HYDO Advanced 10 Cil Filters Caterpillar oil filters are recommended The interval for changing the oil filter should be 500 hours Cil The 6000 hour interval for changing the oil is specific to HYDO Advance 10 The 4000 hour interval for changing the oil is for the
84. olant to drain into a suitable container 5 Install the drain plug or close the drain valve if equipped 6 Replace the thermostat See Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the process for replacing the thermostat 7 Add the coolant solution Refer to Operation and Maintenance Manual Capacities Refill Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Note Premix the coolant solution before filling the cooling system The coolant solution should contain 50 percent coolant and 50 percent distilled water Note Add the coolant solution at a maximum rate of five liters per minute This will reduce the chance of trapping air inside the engine block A large amount of trapped air can cause localized heating to occur upon start up Localized heating may result in engine damage which may lead to failure of the engine 8 Start the engine Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes gt amp 900956179 Illustration 160 Typical Example 9 Maintain the coolant level in the sight gauge Note The sight gauge is located on the right side of the engine compartment on machines that are equipped with the C2 2 engine The sight gauge is located on the left side of the engine compartment on machines that are
85. only Otherwise electrical damage can result If itis necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer Illustration 214 902142168 The fuse panel is located behind the seat on the right side Remove the cover in order to access the fuse panel Illustration 215 g02142844 26 I 11 11 12 due 27 i 13 Mes 28 sal 11 15 iT 16 29 M I 17 11 18 30 Lie 19 qi 20 Illustration 216 902142845 The following is a list of the fuses in the panel 1 Gauge eN 2 Wiper 3 Rear Work Lights and Beacon 186 Maintenance Section Fuses Replace SEBU8495 03 4 Right Joystick and Parking Brake Solenoid 5 12 volt power socket 6 Spare 7 Spare 8 Air Conditioner Condenser Fans 9 Spare 10 Spare 11 Front Work Lights 12 Stop Lamp and Back Up Alarm 13 HVAC Blower Fan 14 Beacon 15 Headlights 16 Work Tool Auxiliary Electrical Control Pin H 17 Fuel Pump O amp amp O 0 amp 00meo i ui 9 18 Hydraulic Quick Coupler and Self Level 19 Work Tool Auxiliary Electrical Control Left Hand C1 C2 and right Hand Trigger Pins B C amp D 20 Spare Solenoids D amp D D 21 Auxiliary Electrical Control A
86. or excessive end play Contact your Caterpillar dealer if either leaks or excessive end play is found 101203574 Wheel Nuts Tighten SMCS Code 4210 527 S N MWD1 Up S N A9H1 Up S N TNK1 Up S N JXM1 Up S N SRS1 Up Check the torque on new wheels or reinstalled wheels after every one service hour until the specified torque is maintained After the specified torque is maintained check the torque on the nuts after every ten service hours or every day Check the nuts on all four wheels Use a star pattern when you are tightening the nuts The torque specifications are given in the following table Table 44 Tightening Torque for Wheels Airboss and Solid Tires 163 7 N m 120 5 Ib ft Pneumatic Tires 149 7 110 x 5 Ib ft 103880912 Window Washer Reservoir Fill If Equipped SMCS Code 7306 544 KE NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solvent or equivalent System damage can result from freezing Illustration 256 g01027404 The reservoir for the window washer solvent is located inside the cab on the left side Fill the reservoir with window washer solvent Note Window washer solvent with isopropyl alcohol is recommended 102810705 Window Wiper Inspect Replace If Equipped SMCS Code 7305 040 7305 510 Inspect the condition of the front window wiper blade Replace the window wiper blade
87. or the positive battery cable SEBU8495 03 153 Maintenance Section Belts Inspect Adjust Replace Battery Recycle Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier An authorized battery collection facility e Recycling facility 101957641 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 S N MWD1 Up S N TSL1 Up S N JXM1 Up If a new belt is installed check the belt adjustment after 30 minutes of operation A belt is considered to be used after 30 minutes of operation 1 Stop the engine in order to inspect the belt 2 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 143 g01017605 3 Remove the guard for the V belt Illustration 144 901017632 4 Inspect the condition of the belt 1 and the adjustment of the belt The belt should deflect 10 mm 0 39 inch under a straight pull of 44 N 10 Ib This measurement should be taken between the alternator pulley and the crankshaft pulley Note A 144 0235 Borroughs Belt Tension Gauge may be used to measure belt tension This measurement should be taken between the alternator pulley and the crankshaft pulley Refer to the following table for belt tension Table 41 Belt Tension Belt Tension Initial Used 534 22 N 120 5 Ib 400 44 N 90
88. our Cat dealer if additional information is needed Note Oil viscosity grade selection is also machine compartment specific Some machine models and or machine compartments do not allow the use of all available viscosity grades For guidance on selecting oil viscosity refer to the Lubricant Viscosities for Ambient Temperatures tables Note Generally use the highest oil viscosity that is available to meet the requirement for the temperature at start up NOTICE Proper oil viscosity AND oil type specification are required to maximize machine compartment perfor mance and life Do NOT use only oil viscosity or only oil type to determine the machine compartment oil se lection Using only the oil viscosity or only the oil type to determine a machine compartment oil selection can lead to reduced performance and compartment failure Refer to the Lubricant Viscosities for Ambient Temperatures tables and to ALL of the associated footnotes NOTICE Not following the recommendations found in the Lu bricant Viscosities for Ambient Temperatures tables and associated footnotes can lead to reduced perfor mance and compartment failure NOTICE In colder ambient conditions a machine warm up pro cedure and or supplemental machine fluid compart ment heat may be required Machine specific warm up procedures can typically be found in the Operation and Maintenance Manual for the machine In addi tion generic machine warm up proced
89. ove Replace 6 Install the front idler wheel Refer to Operation and Maintenance Manual Bogie and Idler Inspect Replace for the procedure to install the idler wheel 7 Tension the track Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust 103880903 Track Rubber Remove Replace CTL SMCS Code 4197 4198 011 4198 510 SIN YYZ1 Up Removing the Track 1 Position the machine on firm level ground 2 Remove any work tool that is attached to the quick coupler 3 Raise the loader arms and install the brace for the loader lift arm Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation A M D XS S Illustration 250 902142365 4 Use an appropriate floor jack in order to lift the machine off the ground Use appropriate jack stands in order to block up the machine Raise the machine until tracks are approximately 50 mm 2 0 inch A off the ground 5 Detension the track Refer to Operation and Maintenance Manual Track Inspect Adjust g02142368 Illustration 251 1 Final Drive Sprocket 2 Front idler wheel Note The approximate weight of the track is 247 kg 545 Ib 6 Use a suitable lifting device Lift the track at middle position between the front idler and the final drive sprocket until the front idler collapses fully Note It is helpful to support the bottom of the tra
90. ove the minimum temperature that is stated Cold soaked starts occur when the engine has not been operated for time The oil becomes more viscous due to cooler ambient temperatures 136 Maintenance Section Lubricant Viscosities and Refill Capacities SEBU8495 03 For oil recommendations for Tier 4 EPA certified engines EU stage IIIB and IV type approved engines and Japan Step IV approved engines refer to the Engine Oil section in this Special Publication Refer to the Lubricant Information section in this Special Publication for a list of all Cat engine oils Cat DEO ULS SYN and Cat DEO SYN are SAE 5W 40 viscosity grade oils Cat Cold Weather DEO ULS is an SAE OW 30 viscosity grade oil Cat ECF refers to Engine Crankcase Fluid specifications Refer to the Maintenance section in this Special Publication Lubricant Information for details Commercial alternative diesel engine oils must meet one or more of these Cat ECF specifications Table 26 Engine Crankcase Oil Type and Performance Hi C F C tment or System Cil Viscosities 4 Requirements Min Max Min Max Cat DEO ULS Cold Weather SAE 0W 40 40 40 40 104 Cat DEO ULS E Engine Crankcase Cat DEO POE OM 0 18 40 0 104 Cat DEO ULS T Cat DEO SAE 15W 40 9 5 50 15 122 Hydraulic System Refer to the Lubricant Information section in the latest revision of the Special Publication SEBU6250 Caterpillar Mach
91. ow 3 Pivot the channel for the window downward Pull the window outward in order to remove the window 3 Slide the window 5 forward Pull the window outward in order to remove the window Polycarbonate Front Door Note Do not wipe the window dry Do not use paper towels This may scratch the finish of the polycarbonate windows over time For cleaning your polycarbonate top window use a soft cloth a sponge or a chamois Use any of the following cleaners e soap and water e isopropyl alcohol kerosene e denatured alcohol commercially available window cleaning solutions Apply the cleaning solution liberally Wipe the surface 102728710 Work Tool Lubricate SMCS Code 6700 086 Multipurpose Bucket Illustration 258 g00534457 Apply lubricant to the grease fitting 1 for the pivot pin of the apron Apply lubricant to the grease fitting 2 for the rod end of the multipurpose bucket cylinder Apply lubricant to the grease fitting 3 for the head end of the multipurpose bucket cylinder Repeat for the other side of the bucket There are six grease fittings Utility Grapple Tools Illustration 259 g00647980 Apply lubricant to the four grease fittings for the grapples 210 Maintenance Section Work Tool Lubricate SEBU8495 03 Illustration 260 g00647988 Apply lubricant to the two fittings for the grapple cylinder There are six grease fittings Industria
92. p S N TSL1 Up Illustration 242 g00953040 Check the torque on the nuts for new sprockets or for sprockets that have been reinstalled after every ten service hours until the specified torque is maintained Check the nuts on both sprockets Use a star pattern when you tighten the nuts Tighten the nuts for the 247 and 257 to the following torque 175 30 N m 129 x 22 Ib ft Tighten the nuts for the 267 277 and 287 to the following torque 270 40 N m 199 x 30 Ib ft SEBU8495 03 201 Maintenance Section Sprocket Sleeve Inspect 102790866 Sprocket Sleeve Inspect SMCS Code 4164 040 ZV S N B7H1 Up S N TSL1 Up Note Operating the machine in conditions that are muddy or sandy will cause accelerated wear on the sprocket and other undercarriage components It is important to clean the undercarriage of the machine daily in order to maximize component life Sleeves that do not meet the minimum thickness or sleeves that do not turn freely may cause unnecessary wear on the drive lugs on the rubber track Illustration 243 g01394383 Check the outer sleeves in order to ensure that the sleeves rotate freely If the sleeves do not rotate freely refer to Operation and Maintenance Manual Sprocket Inspect for information about the inspection of the sprocket assembly Tilt Cylinder Bearings and Bucket Linkage Bearings Lubricate SMCS Code 5104 086 BD 6107 086 BD Wipe all of the g
93. per or misused equipment Before inflating tire install on the machine or put tire in restraining device NOTICE Set the tire inflation equipment regulator at no more than 140 kPa 20 psi over the recommended tire pressure Tire Inflation with Nitrogen Caterpillar recommends the use of dry nitrogen gas for tire inflation and for tire pressure adjustments This includes all machines with rubber tires Nitrogen is an inert gas that will not aid combustion inside the tire Proper nitrogen inflation equipment and training in using the equipment are necessary to avoid over inflation A tire blowout or rim failure can re sult from improper or misused equipment and per sonal injury or death can occur A tire blowout and or rim failure can occur if the in flation equipment is not used correctly due to the fact that a fully charged nitrogen cylinder s pres sure is approximately 15000 kPa 2200 psi There are other benefits to using nitrogen in addition to reducing the risk of an explosion The use of nitrogen for tire inflation lessens the slow oxidation of the rubber Use of nitrogen also slows gradual tire deterioration This is especially important for tires that are expected to have a long service life of at least four years Nitrogen reduces the corrosion of rim components Nitrogen also reduces problems that result from disassembly A tire blowout or a rim failure can cause personal injury Use a self attaching i
94. perate the engine at low idle until the engine runs smoothly If the engine fails to start or if the engine continues to misfire or smoke repeat the priming procedure 4 Close the engine access door C3 4 Engine Machines that are equipped with the C3 4 engine are equipped with a fuel transfer pump that is electric 1 Momentarily turn the engine start switch to the START position and then return the engine start switch to the ON position Note Do not start the engine This operation only starts the fuel pump 184 Maintenance Section Fuel Tank Cap Clean SEBU8495 03 2 Leave the engine start switch in the ON position for thirty seconds 3 Attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate the engine at low idle until the engine runs smoothly If the engine fails to start or if the engine continues to misfire or smoke repeat the priming procedure 101819309 Fuel Tank Cap Clean SMCS Code 1273 070 Z2 1 Remove the fuel cap Illustration 212 900104238 2 Inspect the cap Replace the cap if the cap is damaged 3 Wash the fuel cap in a clean nonflammable solvent and dry the fuel cap 4 Put a light coating of fuel on the cap gasket 5 Install the fuel cap 101971189 Fuel Tank Water Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspectio
95. r sleeve 7 Inner sleeve The sprocket is equipped with two types of sleeves e Inner Sleeves 6 Outer sleeves 5 SEBU8495 03 199 Maintenance Section Sprocket Inspect The outer sleeves are free to rotate on the inner sleeves The sleeves are held in position by the sprocket mounting ring Note There are many parts in the sprocket assembly Remove the sprocket completely from the machine in order to work on the sprocket Use a clean flat surface in order to disassemble the sprocket and assemble the sprocket 1 Remove the 12 locknuts and washers that hold the sprocket mounting ring in place 2 Remove the ring 3 Remove the outer sleeves and the inner sleeves 4 Measure thickness A for the outer sleeves If the thickness of the outer sleeves measures less than 3 mm 0 12 inch replace the sleeves Sleeves that do not meet the minimum thickness or sleeves that do not turn freely may cause unnecessary wear on the drive lugs on the rubber track 5 When you replace the outer sleeves rotate the inner sleeves for 180 If the inner sleeves have already been rotated replace the inner sleeves 6 Repeat steps 2 through 5 for each set of sleeves 7 The sprocket mounting rings of the drive sprocket will wear from the rotation of the outer sleeves Measure the thickness of the inner rings and outer rings If the thickness of the inner ring or outer ring measures less than 4 75 mm 0 19 inch replace the ri
96. re provided in the latest revision of Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations This manual may be found on the Web at Safety Cat com Coolant Information The information provided in this Coolant Recommendation section should be used with the Lubricants Information provided in the latest revision of Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations This manual may be found on the Web at Safety Cat com The following two types of coolants may be used in Cat diesel engines Preferred Cat ELC Extended Life Coolant Acceptable Cat DEAC Diesel Engine Antifreeze Coolant NOTICE Never use water alone as a coolant Water alone is corrosive at engine operating temperatures In addi tion water alone does not provide adequate protec tion against boiling or freezing i04040409 Capacities Refill SMCS Code 7560 Table 31 Approximate Refill Capacities Common for AII B3 Series Compartment or US Imperial System Liters Gallons Gallons Hydraulic Tank 35 0 9 3 7 7 Table 32 Approximate Refill Capacities 216B3 Compartment or US Imperial System Liters Gallons Gallons Engine Crankcase 10 2 6 2 2 Fuel Tank 58 15 4 12 8 Cooling System 9 2 4 2 0 Each Drive Chain Box 6 1 6 1 3 140 Maintenance Section Lubricant Viscosities and Refill Capacities SEBU8495 03
97. rease fittings before you apply lubricant Illustration 244 g00955895 Note Lubricate the fittings with the loader lift arms in the fully lowered position Apply lubricant to the grease fittings 1 for the upper bearings for the tilt cylinders Apply lubricant to the grease fittings 2 for the lower bearings for the tilt cylinders Apply lubricant to the grease fittings 3 for the coupler engagement pins Apply lubricant to the grease fitting 4 for the pivot pin of the quick coupler assembly There are a total of 8 grease fittings 102124717 Tire Inflation Check SMCS Code 4203 535 Al S N MWD1 Up S N 9 1 S N TNK1 Up S N JXM1 Up S N SRS1 Up Measure the tire pressure on each tire Consult your Caterpillar dealer for the correct load rating and for the correct operating pressures These correct load ratings and correct operating pressures can also be obtained from your tire dealer 202 Maintenance Section Track Rubber Inspect Adjust SEBU8495 03 Inflate the tires if necessary Tire Inflation with Air Use a self attaching inflation chuck and stand be hind the tread when inflating a tire Proper inflation equipment and training in using the equipment are necessary to avoid overinfla tion A tire blowout or rim failure can result from impro
98. responsible for basic visual inspections of the track tension on a daily basis Inspect D ed bod bod SY Illustration 252 g02142344 Support the machine so that the track is a minimum of 51 mm 2 inches above the ground Illustration 253 g02142348 Measure the track sag at the third roller from the front Measure the distance from the bottom surface of the flange on the roller to the inside top surface of the track The minimum track sag should be 15 mm 0 59 inch The maximum track sag should be 25 mm 0 98 inch SEBU8495 03 207 Maintenance Section Track Roller and Idler Inspect Replace Track Adjustment 9 Illustration 254 g02142349 1 In order to adjust the track remove the access panel on the side of the undercarriage g02142351 Illustration 255 2 Pressurized grease in a cylinder is used in order to provide tension on the track Use a grease gun in order to apply grease to the grease fitting on the cylinder This will tighten the track 3 Recheck the track tension 4 Replace the access panel when the 15 mm 0 59 inch sag is achieved Detension the track Personal injury or death can result from grease under pressure Grease coming out of the relief valve under pres sure can penetrate the body causing injury or death Do not watch the relief valve to see if grea
99. rized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Use a degreaser and steam for removal of oil and grease Wash the core with detergent and hot water Thoroughly rinse the core with clean water 3 Clean the radiator core from the top toward the fan Note If parts of the cooling system appear to be damaged or if parts of the cooling system are repaired a leak test is highly recommended Consult your Caterpillar dealer for the most current information about the cooling system 4 After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary 5 Inspect the fins and tubes of the radiator core for damage Some fins and tubes may be worn from abrasive material that has passed through the radiator core Bent fins may be opened with a comb SEBU8495 03 195 Maintenance Section Refrigerant Dryer Replace NOTICE Do not clean a rotating fan with high pressure water Fan blade failure can result 6 Remove any dirt or debris from the fan the fan hub the oil cooler the radiator guard and the fan guard Note Dirt or debris on the cooling fan can cause an imbalance 7 Tilt the radi
100. s 8 Inspect the steel material of the quick coupler for cracks Note Perform all repairs before placing the quick coupler back into operation i03886849 Radiator Core Clean SMCS Code 1353 070 KO The radiator is located at the rear of the machine above the engine compartment 1 Stop the engine Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes NOTICE When you are using compressed air or high pressure water to clean the radiator fins ensure that the air or water is directed parallel to the fins If the compressed air or high pressure water is not directed parallel to the radiator fins the radiator fins could be bent or dam aged Note Pressurized air is the preferred method for removing loose debris Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes The air nozzle should point in the opposite direction of the flow of the fan This will remove debris that is between the tubes Pressu
101. se is es caping Watch the track or track adjustment cylin der to see if the track is being loosened Loosen the relief valve one turn only If track does not loosen close the relief valve and contact your Caterpillar dealer Note Many operations for maintenance of the undercarriage require the track to be loosened 1 In order to detension the track remove the access panel on the side of the undercarriage 2 Loosen the grease fitting with a suitable device Loosen the grease fitting carefully until the track begins to loosen Note Catch the grease in a suitable container Dispose of the grease in accordance with all applicable regulations Note One turn should be the maximum 3 Tighten the grease fitting to a torque of 74 14 N m 55 10 Ib ft when the desired track tension is reached 4 Replace the access panel 103880910 Track Roller and Idler Inspect Replace SMCS Code 4159 040 4159 510 4180 040 4180 510 S N YYZ1 Up Inspect Clean the undercarriage before inspecting the idlers and the rollers Inspect the idlers and the rollers for damage and wear 208 Maintenance Section Wheel Nuts Tighten SEBU8495 03 The idlers and the rollers should be replaced when the damage to the wheels adversely affects machine performance Note The idlers and the rollers contain oil The idlers and the rollers are sealed for life Periodically inspect the idlers and the rollers for leaks or f
102. sed sampling bottles stored in plastic bags Keep the lids on empty sampling bottles until you are ready to collect the sample Complete the information on the label for the sampling bottle before you begin to take the samples Use a designated pump to collect the sample in order to avoid contamination Obtain coolant samples directly from the coolant tank You should not obtain the samples from any other location Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination 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 103880006 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers SAE t Illustration 164 g00956151 Typical Example Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of the
103. sen cap slowly to relieve the pressure 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting gt D Illustration 165 g00956179 Note The sight gauge for the coolant level is located on the right side of the engine compartment on machines that are equipped with the C2 2 engine The sight gauge for the coolant level is located on the left side of the engine compartment on machines that are equipped with the C3 4 engine 3 Maintain the coolant to the top of the sight gauge with the radiator in the LOWERED position oe D g00956151 Illustration 166 Note The radiator cap is located on the left side of the engine compartment on machines that are equipped with the C2 2 engine The radiator cap is located on the right side of the engine compartment on machines that are equipped with the C3 4 engine 4 If you need to add coolant to the radiator remove the radiator cap slowly in order to relieve system pressure Note Inspect the cooling system hoses for any leaks cracks or signs of deterioration Replace any damaged hoses 5 Inspect the radiator cap and the gasket Replace the cap if the cap or the gasket is damaged Install the radiator cap 6 Tilt the ra
104. should be marked and affixed to the seat belt retractor and buckle Note Date of installation labels should be permanently marked by punch retractable belt or stamp non retractable belt If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 104776649 Sprocket Inspect SMCS Code 4164 040 S N B7H1 Up S N TSL1 Up S N YYZ1 Up Note Operating the machine in conditions that are muddy or sandy will cause accelerated wear on the sprocket and other undercarriage components Clean the undercarriage of the machine daily in order to maximize component life Sprocket Inspection for 247B3 and 257B3 Note Sleeves that do not meet the minimum thickness or sleeves that do not turn freely may cause unnecessary wear on the drive lugs on the rubber track 198 SEBU8495 03 Maintenance Section Sprocket Inspect Remove the Sprocket Illustration 238 g01394413 1 Drive motor 2 Bolts and washers 3 Sprocket assembly Note In order to service the sprocket the tracks must Sleeves and Rings be loosened Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust for the procedure 1 Remove the 12 bolts and the 12 washers that hold the sprocket assembly to the drive motor 2 Slide the sprocket assembly off the drive motor Illustration 239 g01394415 4 Sprocket mounting ring 5 Washers and Locknuts 6 Oute
105. sition one final drive so that the oil fill drain plug 1 is at the top Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 2 Use an 8 mm 5 16 inch allen wrench Remove the oil check plug 2 3 Check the oil level The oil should be near the bottom of the opening for the oil check plug 2 4 Add oil through the opening for the oil fill drain plug 1 if necessary Note Overfilling the final drive will cause the seals on the travel motor to allow hydraulic oil or water to enter the final drive This may contaminate the final drive 5 Clean the oil plugs 6 Install the oil plugs Tighten the oil plugs to a torque of 27 1 N m 20 0 7 Ib ft 7 Repeat the procedure for the other final drive 100916186 Fuel Injection Timing Check SMCS Code 1251 531 Note The correct fuel timing specification is found on the Engine Information Plate Fuel timing specifications may vary for different engine applications and or for different power ratings A qualified mechanic should adjust the fuel injection timing because special tools and training are required Refer to the Service Manual for the complete adjustment procedure for the fuel injection timing Refer to your Caterpillar dealer for the complete adjustment procedure for the fuel injection timing SEBU8495 03 181 Maintenance Section Fuel System Filter In Line Replace i0
106. sories 20 A 37 Main power relay 2 60 A D QD p 102127331 Headlights Adjust SMCS Code 1429 025 Illustration 219 g00714442 Roading Lights Perform the following procedure in order to align the headlights 1 Verify that the tires are inflated properly 2 Position the machine in the following manner when you adjust the headlights a Park the machine in a dark area b Park the machine on level ground 188 Maintenance Section Hydraulic System Oil Change SEBU8495 03 c Face the machine toward a wall with 10 m 32 8 ft between the wall and the face of the headlights 3 Place a second person or 75 kg 165 Ib in the operator s seat 4 Turn on the headlights 5 Cover one headlight 6 Loosen the other headlight clamp 7 Move the headlight so that the headlight is pointing straight anead Measure the height from the ground to the center of the headlight 8 Twist the headlight so that the upper edge of the light that is shown on the wall is two thirds of the height from the ground to the center of the headlight Ensure that the line of the light that is shown on the wall is horizontal 9 Tighten the headlight clamp 10 Repeat the process for the other headlight 103880891 Hydraulic System Oil Change SMCS Code 5095 044 Selection of the Oil Change Interval Your machine may be able to use a 4000 hour interval for the hydraulic oil The hydraulic
107. sprocket ofl Illustration 247 901497493 Note that the rubber track is removed for clarity 1 Hoses at the frame 2 Fittings on final drive Note The hoses should not be under tension The fittings at the drive motor may leak if there is tension on the hoses 5 Tighten the jam nut to the following torque 270 40 N m 199 x 30 Ib ft 204 Maintenance Section Track Rubber Remove Replace SEBU8495 03 6 Recheck the track tension 7 Check the hoses Ensure that there is no tension in the hoses Ensure that the hoses are not kinked Tighten the hose clamps at the frame Note Too much slack in the hoses may allow the hoses to contact other components Not enough slack may strain hose connections at the drive motor 103880897 Track Rubber Remove Replace MTL SMCS Code 4197 4198 011 4198 510 S N B7H1 Up S N TSL1 Up Removing the Track 1 Position the machine on firm level ground 2 Remove any work tool that is attached to the quick coupler 3 Raise the loader arms and install the brace for the loader lift arm Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation 22 0 A E 1S j E 0 2 ES 0 A 1 Illustration 248 901393193 4 Use an appropriate floor jack in order to lift the machine off th
108. ssure even a pin hole size leak can penetrate body tis sue causing serious injury and possible death If fluid is injected into your skin it must be treated immediately by a doctor familiar with this type of injury Note Do not weld on the quick coupler without consulting your Caterpillar dealer 1 Clean the quick coupler prior to inspection in order to properly inspect the quick coupler 194 Maintenance Section Radiator Core Clean SEBU8495 03 Illustration 233 901322438 This is the back side of the quick coupler The lift arm and the tilt cylinder are removed for clarity 2 Tilt the quick coupler all the way forward in order to clean the debris away from the pins 3 Move the quick coupler levers Ensure that the levers are not bent or broken 4 Make sure that the coupler pins extend through the bottom of the quick coupler assembly Check the pins for wear and check the pins for damage 5 Check the top edges of the quick coupler assembly for wear or for damage Check the face of the quick coupler assembly for wear or for damage 6 Inspect the components inside the quick coupler for the following problems loose bolts oil leaks broken parts missing parts and cracked components 7 Inspect the hydraulic lines and the hydraulic fittings for damage or for wear Repair any worn components or replace any worn components Repair any leaking component
109. t Illustration 140 901433144 3 Check the air cleaner dust valve after every ten service hours or at the end of each day Actuate the valve by squeezing the lips of the valve in order to remove any accumulated debris 103879882 Air Conditioner Condenser Clean If Equipped SMCS Code 1805 070 Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes The air conditioner condenser is located behind the engine on the frame Open the engine access door Inspect the air conditioner condenser for the following conditions Damaged fins e Buildup of debris e Plugged areas Remove any debris Clean the condenser with low pressure air or low pressure water The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi 152 Maintenance Section Axle Bearings Lubricate SEBU8495 03 102772986 Axle Bearings Lubricate SMCS Code 3282 086 BD S N B7H1 Up S N TSL1 Up Illustration 141 g01387575 Apply lubricant to the grease fittings for the rear axle bearings and the front axle bearings Repeat the process for the opposite side of the machine 103898482 Axle Bearings Lubricate SMCS Code 3282 086 BD S N YYZ1 Up
110. temperature when the machine is started and while the machine is operated In order to determine the proper oil viscosity grade refer to the Min column in the table This information reflects the coldest ambient temperature condition for starting a cold machine and for operating a cold machine Refer to the Max column in the table in order to select the oil viscosity grade for operating the machine at the highest temperature that is anticipated Unless specified otherwise in the Lubricant Viscosities for Ambient Temperatures tables use the highest oil viscosity that is allowed for the ambient temperature when you start the machine Machines that are operated continuously should use oils that have the higher oil viscosity in the final drives and in the differentials The oils that have the higher oil viscosity will maintain the highest possible oil film thickness Refer to this Special Publication General Information for Lubricants article Lubricant Viscosities tables and any associated footnotes Consult your Cat dealer if additional information is needed Note SAE OW and SAE 5W oils where allowed for use in non hydraulic system compartments are not recommended for use in machines that are operated continuously and or are heavily loaded Refer to the Lubricant Viscosities for Ambient Temperatures tables for guidance The oils that have the higher oil viscosity will maintain the highest possible oil film thickness Consult y
111. the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting Illustration 193 901022394 Note The crankcase drain is located on the right side of the oil pan 3 Pull the drain hose for the crankcase through the opening in the rear of the machine and remove the plug in the end of the drain hose Open the crankcase drain valve and drain the oil into a suitable container Close the crankcase drain valve Install the plug in the drain hose Illustration 194 g01022354 4 Remove the filter element with a 187 2718 Filter Wrench Refer to Operation and Maintenance Manual Oil Filter Inspect in order to inspect the used filter for debris 5 Apply a thin film of clean engine oil to the sealing surface of the new filter element 6 Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide Note You may need to us
112. ts should not be present These contaminants include fuel and antifreeze Water content should be 5 percent or less e The silicon level should not exceed 15 parts per million for new oil The particle counts should be monitored e The recommended level of cleanliness for Caterpillar machines that are operated in the field is ISO 18 15 or cleaner The cleanliness should be monitored by particle count analysis The levels of contamination should not exceed the normal by more than two ISO codes Action should be taken in order to determine the cause of the contamination The system should be returned to the original levels of contamination e There should not be significant changes in sodium silicon copper and potassium e The allowable level of oxidation is 40 percent 0 12 Abs units e The kinematic viscosity of 100 C 212 F oil should not exceed a change of more than 2 cSt from new oil Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids a
113. ue 5 Install the track on both sides of the machine Replace 1 Remove the track on both sides of the machine 200 Maintenance Section Sprocket Bearings Lubricate SEBU8495 03 2 Remove the sprocket on the left side of the machine Install the new sprocket 3 Tighten the bolts to the proper torque 4 Remove the sprocket on the right side of the machine Install the new sprocket 5 Tighten the bolts to the proper torque 6 Install the track on both sides of the machine 101992415 Sprocket Bearings Lubricate SMCS Code 4164 086 BD 7551 086 JK S N B7H1 Up S N TSL1 Up NOTICE The service interval for the lubrication of the sprock et bearings should be reduced to every 500 service hours if the machine is operated in wet and muddy conditions Illustration 241 g01025225 typical example 1 Use a mallet in order to pound the housing plug inward until the plug falls out of the housing If the plug was damaged during removal replace the plug 2 Wipe the old grease out of the housing 3 Pull out the bearing seal Replace the seal if the seal is damaged 4 Pack the bearing with clean grease and push the seal into position Place clean grease on the outside of the seal in order to protect the seal 5 If the old housing plug is reinstalled reverse the housing plug and pound the plug into the housing 102125302 Sprocket Retaining Nuts Check SMCS Code 4164 535 NT S N B7H1 U
114. uld be taken between the alternator pulley and the crankshaft pulley Note A 144 0235 Borroughs Belt Tension Gauge may be used to measure belt tension This measurement should be taken between the alternator pulley and the crankshaft pulley Refer to the following table for belt tension Table 42 Belt Tension Belt Tension Initial Used 534 22 N 120 5 Ib 400 44 N 90 10 Ib 6 Loosen the mounting bolt 4 Loosen the adjusting locknut 5 7T Move the alternator until the correct tension is reached 8 Tighten the adjusting locknut Tighten the mounting bolt 9 Recheck the belt deflection If the amount of deflection is incorrect repeat step 5 to step 8 Air Conditioner if equipped Note If your machine is equipped with an air conditioner use the same procedure and the same measurements for the belt tension SEBU8495 03 155 Maintenance Section Belts Inspect Adjust Replace 1 Inspect the condition of the belt and the adjustment of the belt The belt should deflect 10 mm 0 39 inch under a straight pull of 44 N 10 Ib This measurement should be taken between the air conditioner compressor pulley and the crankshaft pulley Illustration 147 g01279933 2 Loosen the mounting bolt 6 for the air conditioner compressor Loosen the adjusting locknut 7 for the air conditioner compressor 3 Move the air conditioner compressor until the corre
115. ures can be found in this Special Publication Procedures for Ma chines that are Used in Cold Weather Generic topic Some of the Lubricant Viscosities for Ambient Temperatures tables in this Special Publication in clude footnotes that address compartment warm up General Information for Lubricants The information provided in this Lubricant Viscosities for Ambient Temperatures article and Tables should be used with the information provided in the Lubricant Specifications section Maintenance Section of this Special Publication SEBU8495 03 135 Maintenance Section Lubricant Viscosities and Refill Capacities NOTICE Cat does not warrant the quality or performance of non Cat fluids and greases NOTICE Not following the recommendations found in this Spe cial Publication can lead to reduced performance and compartment failure NOTICE Do NOT use only the oil viscosities when determining the recommended oil for an engine compartment The oil type performance requirements MUST also be used Note Some machine models and or machine compartments do NOT allow the use of all available oil viscosity grades Note Only use the oil type and the specification that is recommended for the various machine compartments Note Some machine compartments allow the use of more than one oil type For the best results do not mix oil types Note Different brand oils may use different additive packages to
116. vice hours or every 3 years each day Coolant level radiator Check the Cooling system coolant Change the coolant level in the radiator at the sight ELC Extended Life Coolant after every gauge after every 10 service hours or at 12 000 hours or every 6 years the end of each day Coolant level reservoir Check the coolant level in the coolant reservoir after every 10 service hours or at the end of SEBU8495 03 147 Maintenance Section Maintenance Support Drive Chain Oil Check the drive chain case oil after every 500 service hours Change the oil for the drive chain case after every 1 000 hours or every 6 months Final Drive Oil Check the final drive oil after every 250 service hours Change the final drive oil after the initial 250 service ours Change the oil for the final drive after every 500 hours 2 Engine air filter primary element Clean the primary air filter element or replace the primary air filter element The alert indicator or the air filter indicates when servicing is necessary h Engine air filter secondary element Replace the secondary air filter element with every third change of the primary air filter ment Replace the secondary air filter element if ecessary before service hour requirement 39 Engine oil level check Check the engine oil level after every 10 service hours or at the end of each day Engine oil Change the engine oil after
117. wheel 3 Bolts and washers for the wheels 1 Remove the bolts 3 and the washers for the outer idler wheel 2 2 Remove the outer idler wheel 3 If necessary remove the bolts and the washers for the inner idler wheel and remove the wheel 4 Install the wheels Tighten the bolts to a torque of 50 5 37 3 7 Ib ft Turn the bolts an additional 45 degrees 5 degrees in the same star pattern Bogie wheels Illustration 154 901393304 4 Bogie Wheel 5 Bolts and washers for the wheels 1 Remove the bolts 5 and the washers for the outer bogie wheel 4 SEBU8495 03 159 Maintenance Section Bucket Cutting Edges Inspect Replace 2 Remove the outer bogie wheel 3 If necessary remove the bolts and the washers for the inner bogie wheel and remove the wheel 4 Install the wheels Tighten the bolts to a torque of 150 20 N m 110 15 Ib ft 101743875 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket cutting edge is accessible 2 Place blocks under the raised edge of the bucket 3 Remove the bolts Remove the cutting edge and the end bits 4 Clean the contact surfaces 5 Use the opposite side of the cutting edge if this side is not worn 6 Install a new cutti
118. within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts 104421974 Seat Belt Replace SMCS Code 7327 510 The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts SEBU8495 03 197 Maintenance Section Sprocket Inspect eL U 4 Illustration 237 901152685 Typical Example 1 Date of installation retractor 2 Date of installation buckle 3 Year of manufacture tag fully extended Web 4 Year of manufacture underside buckle Consult your Cat dealer for the replacement of the seat belt and the mounting hardware Determine age of new seat belt before installing on seat A manufacture label is on belt webbing and imprinted on belt buckle Do not exceed install by date on label Complete seat belt system should be installed with new mounting hardware Date of installation labels

MAINTENANCE INTERVALS - Safety

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