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MAINTENANCE INTERVALS - Safety

1. Illustration 205 g01265860 Note If you need to flush the fuel sump use drain valve 2 which is located at the bottom of the fuel tank behind the right tandem housing 102598641 Fuses Replace SMCS Code 1417 510 Fuses Fuses protect the electrical system from damage that is caused by overloaded circuits Replace the fuse if the element is separated Check the circuit if the element is separated in a new fuse Repair the circuit NOTICE Replace the fuses with the same type and size only If itis necessary to replace fuses frequently an electri cal problem may exist Consult your Caterpillar dealer Illustration 206 g01265895 There are two fuse panels The fuse panels are positioned to the left side of the operator on the cab floor Illustration 207 g01113131 Fuse panel 1 Spare 1 15 amp Spare 2 10 amp Implement Control 2 3 15 amp Horn 4 10 amp Backlight 5 10 amp All Wheel Drive AWD Controller 7 15 amp Spare 8 10 amp EJ Monitoring 6 10 amp ia Implement Control 3 9 15 amp 170 Maintenance Section Fuses Replace SEBU7881 16 a amp Ka Spare 10 10 amp
2. Illustration 133 g01071359 3 Remove bolts 2 from cap 1 Remove cap 1 4 Remove one shim from either side of the inserts in order to reduce clearance Note If you need to remove two shims then remove one shim from each side of the inserts 5 Install the cap Install the bolts and tighten the bolts 6 Check the socket for movement If you observe movement in the socket repeat Step 3 through Step 5 Note If no shims remain install new inserts Install two shims on each side of the inserts Add additional shims as needed 102527187 Blade Lift Cylinder Socket Lubricate SMCS Code 5102 086 5103 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the blade lift cylinder sockets Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe all the fittings before you apply lubricant through the fittings Illustration 134 g01071490 There are two blade lift cylinder sockets Each blade lift cylinder socket has one fitting Apply the appropriate lubricant through fitting 1 in order to lubricate the blade lift cylinder sockets 102837232 Brake Accumulator Check SMCS Code 4263 535 Cold ambient temperatures could result in the loss of secondary braking capability due to inadequate hydraulic accumulator nitrogen pre char
3. Illustration 255 g01271804 Typical example The wheel has been removed for ease of viewing SEBU7881 16 195 Maintenance Section Wheel Bearing Oil Level Front Check The front wheel bearings are located on the inner side of each front wheel Check fill plug 1 is located on the housings of each front wheel bearing 1 Clean the surface around the check fill plug 2 Remove the check fill plug 3 Use a 1U 7683 Suction Gun in order to remove the oil from the housing for the wheel bearing 4 Add oil to the housing for the wheel bearing until the oil level is at the bottom of the opening for the check fill plug Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill a Install the check fill plug o Repeat Step 1 through Step 5 for the other wheel bearing 103399644 Wheel Bearing Oil Level Front Check If Equipped SMCS Code 4205 535 FLV 4208 535 FLV 4234 535 FLV 7551 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Z 0 0 O 0 Illustration 256 g01299786 Typical example The wheel has been removed for ease of viewing 1 Clean the surface around check fill plug 1 2 Remove the check fill plug 3 Maintain the oil level to the bottom of the
4. Illustration 131 g01303273 C9 Engine 1 Release the tension on belt 1 Insert a 12 7 mm 0 50 inch ratchet into the square hole in belt tensioner 2 and pry the belt tensioner in a counterclockwise direction 2 Remove the belt Note Removal of the alternator guard is not necessary to remove the belt 3 Install the new belt around the pulleys 4 Inspect the free arm stop of the belt tensioner The free arm stop must be aligned with the green zone which is on the decal of the belt tensioner 5 Check the belt tension after 30 minutes of operation Note The break in period for the belt is considered to be 30 minutes 104000948 Blade Cushion Accumulator Check SMCS Code 5077 535 BG g01296656 Illustration 132 Typical Example Shown Blade cushion accumulators 1 are located on the left side of the front frame Consult your Cat dealer for the correct checking procedure the correct filling procedures and the recommended pressure 102527178 Blade Lift Cylinder Socket Check Adjust Replace SMCS Code 5102 025 5102 510 5102 535 5103 025 5103 510 5103 535 1 Rotate the blade Position the blade at an angle of 90 degrees to the frame Lower the blade to the ground 2 Operate the blade lift cylinders Observe the socket If the socket moves without blade movement adjustment is necessary 132 Maintenance Section Blade Lift Cylinder Socket Lubricate SEBU7881 16
5. Note If the circle shoes are moved outward it may be necessary to slowly inch the machine in a forward direction in order to place a light load between the wear strips for the front circle shoes and the blade circle 11 After adjustments have been made to any circle shoe check the circle shoes for proper clearance If you cannot attain the correct clearance measurement due to worn front shoe wear strips replace the worn shoe wear strips Then repeat Step 10 12 Tighten the shoe mounting fasteners and locknuts for the front circle shoes Note The adjusting bolts must be tight against the circle shoes before you tighten the mounting fasteners and the locknuts 13 Set all of the circle shoes front side and rear to contact the blade circle There will be no clearance between the circle shoes and the blade circle 14 When the pinion clearance is set and the front circle shoes are in contact with the blade circle measure distance Z between each wear strip and the blade circle The clearance should be a maximum of 0 8 mm 0 03 inch 15 Tighten all shoe mounting fasteners 8 to a torque of 530 70 N m 390 50 Ib ft 16 Tighten locknuts 12 to a torque of 200 30 Nm 150 22 Ib ft Note After all the adjustments have been performed the blade circle must rotate freely without binding 140 Maintenance Section Circle Drive Oil Change SEBU7881 16 17 Lubricate the circle pinion and the circle
6. 4 Clean the inside of the air filter housing with a damp cloth 5 Install a clean primary air filter element Install the cover for the air filter housing Ensure that the discharge valve that is attached to the cover is located on the bottom when installing the cover Note If the cover is not positioned correctly or no filter element has been installed the wire fasteners will not fully lock Note Under no circumstance should the inner support tube that is permanently fixed to the air filter housing be removed The support tube is essential for proper operation of the air filter Note Refer to Cleaning Primary Air Filter Elements 6 Close the access door If the alert indicator activates after starting the engine or the exhaust smoke is still black after installation of a clean primary filter element install a new primary filter element If the alert indicator remains activated replace the secondary element Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices available at participating 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
7. Articulation Bearings Lubricate 0 00 128 Axle Oscillation Bearings Lubricate 128 Belt INSP Ct oo ccecee cece eeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 129 Blade Lift Cylinder Socket Lubricate 132 Cab Air Filter Clean Replace eee 135 Centershift Cylinder Socket Lubricate 136 Centershift Lock Bar Clean Lubricate 137 Drawbar Ball and Socket Lubricate 152 Fuel Tank Water and Sediment Drain 168 Hydraulic System Oil Level Check sassen 175 Kingpin Bearings Lubricate 0 0 ee 177 Ripper Cylinder Bearings Lubricate 182 Scarifier Lift Link Socket Lubricate 00 00 184 Secondary Steering Test 0 cceeeeeeeeeenees 186 Steering Cylinder Ends and Tie Rods Lubricate snesena a 187 Tandem Drive Oil Level Check sees 189 Tire Inflation Check aasessiesseerreesssrrrnseerssnsns 189 Wheel Lean Bar Bearings Lubricate 196 Wheel Lean Bearings Lubricate 0 0 196 Wheel Lean Cylinder Bearings Lubricate 197 Work Tool Lift Lubricate 2 00 0 eeeeeeeeeeees 198 Initial 250 Service Hours or at first oil change Engine Valve Lash Check sesiis 162 SEBU7881 16 127 Maintenance Section Maintenance Interval Schedule Every 250 Service Hours Cooling System Coolant Sample Level 1 Opla nen noar ear eie 146 Initial 500 Service
8. Lighter 11 10 amp Radio 12 15 amp Communication Radio 13 20 amp Product Link 14 10 amp Dome Lamp 15 10 amp Implement Control 16 15 amp Steering 17 10 amp Secondary Condenser Fan 18 15 amp Air Filter 19 15 amp Primary Condenser Fan 20 15 amp 22 Qe oO Sonal 23 eS ee 33 24 ie 34 oo 25 i a 35 oe oE 26 aS SS 36 27 ee ose D T 37 2 Le aS 38 J DS CSc e 20 keea L 29 30 a 40 g01114786 Illustration 208 Fuse panel 2 Front Windshield Wiper and Rear Windshield Wiper 21 15 amp Side Windshield Wiper 22 15 amp Turn Signals 23 10 Amp Primary Blade Work Lights 24 15 amp a Work Area Vision System WAVS 25 10 amp Heating and Air Conditioning System 26 15 amp Beacon 27 10 amp Defrost Fan 28 10 amp Secondary Blade Work Lights 29 10 amp amp SEBU7881 16 171 Maintenance Section Gear Group All Wheel Drive Oil Change Rear Work Lights 30 15 amp Heated Mirror 31 10 amp Autolube System 32 10 amp AUTO Right Door Wiper 33 15 amp Backup Alarm 34 10 amp Cab Floodlights 35 15 amp Centershift and Blade Cushion 36 10 amp Sensor Power 37 10 amp Seat 38 15 amp Differential Lock 39 10 amp Left Door Wiper 40 15 amp DO O
9. z MG AA SF Illustration 221 g01263264 3 Clean the area around filters 3 This must be done before the filters can be removed 4 Remove the filters with a strap type wrench See Operation and Maintenance Manual Oil Filter Inspect Discard the used filters properly 5 Clean the filter bases Check for any pieces of the seal from the old filters Remove any pieces of the seal from the old filters 6 Apply a thin coat of clean hydraulic oil to the seal of the new filters 7 Install the new filters by hand until the seals of the new filters contact the bases Note the position of the index marks on the filters in relation to a fixed point on the filter mounting bases Note There are rotation index marks on the filters that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filters use the rotation index marks as a guide 8 Tighten the filters according to the instructions that are printed on the filters Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filters Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filters to the amount that is required for final installation Make sure that the installation tool does not damage the filters SEBU7881 16 179 Maintenance Section Oil Filter Hydraulic Tank Return Replace 9 Maintain the hydraulic oil level a
10. 143 Maintenance Section Cooling System Coolant ELC Change Illustration 156 g01394578 Refrigerant condenser 1 is located in front of the radiator at the rear of the machine 1 Remove the two bolts on the access cover on the left rear of the machine 2 Open the rear access cover on the left rear of the machine 3 Inspect the condenser for debris If necessary clean the condenser 4 Use clean water in order to wash off all dust and dirt from the condenser 5 Close the access cover 6 Install the bolts on the access cover 104111789 Cooling System Coolant ELC Change SMCS Code 1350 044 NL 1350 544 NL 1395 044 NL Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to re lieve pressure only when engine is stopped and al low sufficient time for the cooling system to cool Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Do not change the coolant until you read and under stand the material in the Cooling System Specifica tions section NOTICE Mixing ELC with other products reduc
11. HO DOWG 102773201 Gear Group All Wheel Drive Oil Change If Equipped SMCS Code 4351 044 OC 4355 044 OC S N B9G1 Up S N D9G1 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 If the all wheel drive oil is not being monitored by the Caterpillar S O S Services program or an equivalent oil sampling program change the all wheel drive oil at every 2000 service hour interval Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Operate the machine until the oil is warm Park the machine on a level surface with the front wheel straight ahead Lower all attachments to the ground Apply a slight downward pressure to the attachments Center the articulation of the machine and install the frame lock pin The frame lock pin must move freely in the frame Move the front wheels to vertical and install the wheel lean bolt Engage the parking brake Stop the engine
12. i it A Y 4 FIA 5 Ed WAL Illustration 214 g01163333 SEBU7881 16 175 Maintenance Section Hydraulic System Oil Change 9 Loosen hose clamp 3 on each side of breather 4 and remove breather 4 10 Wash the breather in clean nonflammable solvent 11 Install the clean breather and reattach the hose Tighten the hose clamps 12 Fill the hydraulic system oil tank Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill Note Confirm that the oil type that is added is the same oil type that is shown in Messenger Confirm that the oil type is noted on the hydraulic system oil film 13 Inspect the filler cap gasket If the filler cap gasket is damaged replace the filler cap gasket 14 Install the hydraulic oil filler cap 15 Start the engine Run the engine for a few minutes Illustration 215 g01293902 16 Maintain the oil level above the MIN mark on sight gauge 5 If necessary add oil through the filler tube Note The oil must be free from bubbles If there are bubbles in the oil then air is entering the hydraulic system Inspect the suction hoses and inspect the clamps 17 Stop the engine 18 If necessary tighten any loose clamps and tighten any loose connections Replace a
13. TAN pE Q B8ESSG008 ATLA t oop P ap Illustration 126 g01263278 The fittings for the articulation bearings are located on the front left side of the rear frame Apply the appropriate lubricant through fitting 1 for the upper articulation bearing Apply the appropriate lubricant through fitting 2 for the lower articulation bearing 104000941 Axle Oscillation Bearings Lubricate SMCS Code 3268 4313 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the axle oscillation bearings Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe the fitting before you apply lubricant through the fitting SEBU7881 16 129 Maintenance Section Backup Alarm Test Illustration 127 g01073624 Typical Example Shown The fitting for the axle oscillation bearings is located in the middle of the front axle Apply the appropriate lubricant through the fitting in order to lubricate the axle oscillation bearings 103627273 Backup Alarm Test SMCS Code 7406 081 The backup alarm is on the rear of the machine In order to test the alarm for proper functioning turn the engine start switch to the ON position Apply the service brake Disengage the parking brake Move the transmission control switch to a REVERSE position The backup alarm should start t
14. 1 Install the top retaining plate and install the bottom retaining plate 1 _ Repeat Steps 2 through 10 for the opposite side of the moldboard Note Keeping the wear strips adjusted to specifications regularly will prolong life of components 178 Maintenance Section Oil Filter All Wheel Drive Replace SEBU7881 16 102782451 Oil Filter All Wheel Drive Replace If Equipped SMCS Code 5068 510 YW S N B9G1 Up S N D9G1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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 s a g01263224 Illustration 220 1 Clean the area around hydraulic oil filler cap 1 of any dirt or debris This must be done before the hydraulic oil filler cap can be removed 2 Slowly remove the hydraulic oil filler cap in order to relieve the tank pressure Me T
15. Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the wheel lean cylinder bearings Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe the fittings before you apply lubricant through the fittings Illustration 260 g01271952 The wheel has been removed for ease of viewing The right front wheel has two fittings on the wheel lean cylinder Apply the appropriate lubricant through the fittings in order to lubricate the wheel lean cylinder bearings 102639345 Window Washer Reservoir Fill SMCS Code 7306 544 KE NOTICE Use Caterpillar nonfreezing window washer solvent or a commercially available windshield washer fluid in order to prevent freezing of the windshield washer system The windshield washer reservoir is positioned in the seat support to the left of the operator s seat The level of windshield washer fluid can be viewed through the reservoir T Illustration 261 g01323517 1 Clean the filler cap and the surrounding area 2 Remove the filler cap for the windshield washer reservoir 3 Fill the window washer reservoir with window washer solvent through the filler cap opening 4 Install the filler cap Note The window washer nozzles can be adjusted so that the window washer solvent will be sprayed in the desired direction i
16. air filter housing Also make sure that air filters are installed properly so that the air filters function properly Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points Note Replace the engine air filter secondary element when you service the engine air filter primary element for the third time Replace the secondary element if the exhaust smoke remains black and a clean primary element has been installed Also replace the secondary element if the element has been in service for 1 year 1 Open the access door for the air filter housing Remove the air cleaner cover and the primary element Illustration 180 g02282454 2 Remove the secondary element 1 Pull the secondary from the inner support tube 3 using the outer grip 2 of the element Note Under no circumstance should the inner support tube that is permanently fixed to the air filter housing be removed The support tube is essential for proper operation of the air filter 3 Cover the air inlet opening Clean the inside of the air cleaner housing 4 Uncover the air inlet opening Install a new secondary element 5 Install the primary element and the air cleaner cover 6 Close the access door 101632265 Engine Crankcase Breather Replace SMCS Code 1317 510 Only replace the engine crankcase breather when you rebuild the engine 103674500 Engine Oil Level Check SMC
17. angle of 90 degrees to the frame 2 Lower the blade to the ground 3 Apply the service brake as you slowly inch the machine in a forward direction This will hold a light load between shoe wear strips 10 for the front circle shoes and blade circle 6 4 Engage the parking brake Stop the engine 5 Measure clearance Y that is between the bottom flange of the circle pinion and the inner machined surface of the blade circle If the clearance is not within 49 5 to 52 5 mm 1 95 to 2 07 inch then adjust the clearance Illustration 149 g01141357 6 In order to inspect the shoe wear strips remove shoe mounting fasteners 8 Note Remove each circle shoe 9 one at a time 7 Inspect the shoe wear strips one at a time Measure the thickness of the shoe wear strips on both contact sides Replace the shoe wear strips if there is uneven wear The shoe wear strips should be in complete contact at all points with the blade circle If any wear strip is not in complete contact with the blade circle replace the wear strip 8 Install shoe mounting fasteners 8 Tighten all shoe mounting fasteners 9 Loosen the shoe mounting fasteners by one quarter turn Loosen locknuts 12 Note Adjust the front circle shoes one at a time Adjust the clearance equally for each front circle shoe 10 Turn adjusting bolts 13 inward or turn adjusting bolts 13 outward in order to attain 49 5 to 52 5 mm 1 95 to 2 07 inch
18. coils 5 Install the top cover 6 Install the seat base 7 Install the seat Note If you are operating the machine under harsh conditions or with the cab door open it may be necessary to clean the coils more often 104001035 Fuel System Fill SMCS Code 1250 544 Personal injury or death may result from failure to adhere to the following procedures Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Dispose of all fluids according to local regulations and mandates 164 Maintenance Section Fuel System Prime SEBU7881 16 Reference Refer to Operation and Maintenance Manual Capacities Refill for the fuel tank capacity of your machine A BjO Illustration 195 g01331302 Typical Example Shown 1 Clean filler cap 1 and the surrounding area 2 Remove the filler cap 3 Fill fuel tank 2 with fuel 4 Install the filler cap Note Prime the fue
19. complete valve lash adjustment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life Ensure that the engine is stopped before you measure the valve lash To obtain an accurate measurement allow the valves to cool before you perform this maintenance Remove the cover in order to access the rear of the engine Check the valve lash For the correct adjustment procedure refer to Systems Operation Testing and Adjusting Engine Valve Lash Inspect Adjust 100128925 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to prevent being burned by hot oil spray Inspect the engine valve rotators after the valve clearances have been set 1 Start the engine and run the engine at low idle 2 Watch the top surface of each valve rotator When the intake valve or the exhaust valve closes the engine valve rotator should turn slightly If an intake valve or an exhaust valve fails
20. content above 0 5 refer to Special Publication SEBU6250 Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines 5 In order to verify an oil change interval of 500 hours refer to Program A below 6 Use Program B below to determine an appropriate interval SEBU7881 16 159 Maintenance Section Engine Oil and Filter Change Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Program A Verification for an Oil Change Interval of 500 Hours This program consists of three oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type in Table 20 Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each interval is adjusted an additional 50 hours Periodic oil sampling and analysis is done d
21. cooling system change the coolant before the recommended interval It is important to replace the thermostat in order to avoid any unexpected failure of the thermostat Removing the thermostat is a good preventive maintenance practice that reduces the chances of unscheduled downtime Failure to replace the thermostat on a regularly scheduled basis could cause severe engine damage Note If you are only replacing the thermostat drain the coolant from the cooling system so that the level of the coolant is below the thermostat housing Always operate Caterpillar engines with a thermostat because these engines have a shunt design cooling system Note Thermostats can be reused if the thermostats meet certain test specifications The tested thermostats must not be damaged and the tested thermostats must not have an excessive buildup of deposits 1 Stop the engine and allow the engine to cool Illustration 157 g01292893 2 Open cover 1 3 Clean the area around the cooling system pressure cap of any dirt or debris This must be done before the cooling system pressure cap can be removed 4 Slowly remove the cooling system pressure cap in order to relieve pressure Illustration 158 g01950973 5 Open the drain valve 2 The drain valve is located at the right rear of the machine Allow the coolant to drain into a suitable container 6 Flush the cooling system with clean water until the draining water
22. dirt or debris This must be done before the hydraulic oil filler cap can be removed 2 Slowly remove the hydraulic oil filler cap in order to relieve the tank pressure 3 Clean the area around filter housing 3 This must be done before the filter can be removed 4 Use a strap type wrench to remove the filter housing 3 5 Remove the filter element Dispose of the used filter element properly 6 Clean the filter mounting base 7 Check the condition of the seal If the seal is damaged replace the seal with a new seal 8 Insert a new filter element and install the filter housing 9 Maintain the hydraulic oil level above the MIN mark in sight gauge 2 10 Inspect the filler cap gasket If the filler cap gasket is damaged replace the filler cap gasket 11 Install the hydraulic oil filler cap 180 Maintenance Section Oil Filter Implement Controls Replace SEBU7881 16 102534401 Oil Filter Implement Controls Replace SMCS Code 5068 510 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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 NENG25
23. dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The primary air filter element can be used up to six times if the element is properly cleaned and the element is properly inspected When the primary air filter element is cleaned check for rips or tears in the filter material The primary air filter element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings NOTICE Do not clean the air filter elements by bumping or tap ping This could damage the seals Do not use ele ments with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air filter elements before cleaning Inspect the air filter elements for damage to the seal the gaskets and the outer cover Discard any damaged air filter elements There are two common methods that are used to clean primary air filter elements e Pressurized air e Vacuum cleaning SEBU7881 16 155 Maintenance Section Engine Air Filter Primary Element Clean Replace Pressurized Air Pressurized air can be used to clea
24. filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter mounting 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 8 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide for tightening the filter For non Caterpillar filters use the instructions that are provided with the filter SEBU7881 16 181 Maintenance Section Oil Filter Inspect 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 9 Maintain the hydraulic oil level above the MIN mark in sight gauge 2 10 Inspect the filler cap gasket If the filler cap gasket is damaged replace the filler cap gasket 11 Install the hydraulic oil filler cap 102106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 225 g00100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element ca
25. for the seat belt extension 103827304 Secondary Steering Test SMCS Code 4300 081 SST If the secondary steering activates during opera tion immediately park the machine ina safe loca tion Inspect the machine and correct the condi tion which made the use of the secondary steer ing necessary Do not continue to operate the machine using the secondary steering Personal injury or death can occur if steering is lost completely during operation The test for the secondary steering verifies the supplemental steering pump and the secondary steering valves Note Before the test for the secondary steering is performed the machine must meet the following conditions The engine must be operating The parking brake must be engaged The transmission control switch must be in NEUTRAL The area around the front wheels must be clear of obstacles and of personnel 1 Ensure that the battery disconnect switch is in the ON position Illustration 236 g01257946 2 Push the top of switch 1 and hold This is the TEST position 3 While switch 1 is held in the TEST position provide the following steering inputs with the left hand joystick e Steer left e Steer center e Steer right Verify that the movement of the front wheel aligns with each steering input Note If the steer wheels do not move according to the joystick command contact your local Cat
26. inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 211 g01360715 The all wheel drive oil fill drain plug 1 is located on the front wheel of the machine Refer to Special Publication SEBU6250 S O S Services Oil Analysis for information that pertains to obtaining a sample of the hydraulic oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the hydraulic oil 103837953 Hydraulic System Oil Change SMCS Code 5050 044 5056 044 5095 044 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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 Too
27. lack of oil e Fluid leakage is detected during inspection SEBU7881 16 151 Maintenance Section Cutting Edges and End Bits Inspect Replace e The housing is damaged Refer to Disassembly and Assembly Vibration Damper and Pulley Remove and Install for the procedure to remove the damper and for the procedure to install the damper The vibration damper can be used again if none of the above conditions are found or if the vibration damper is not damaged Note Contact your Caterpillar dealer for further information 103653685 Cutting Edges and End Bits Inspect Replace Includes Overlays SMCS Code 6801 040 6801 510 6804 040 6804 510 Personal injury or death can result from the blade falling Block the blade before changing blade tips Illustration 169 g01071858 End bits 1 and or cutting edges 2 may be damaged The end bits and or the cutting edges may be worn excessively Replace the end bits and or the cutting edges as needed 1 Place blocks under the blade Lower the blade onto the blocks Do not block up the blade too high Just use enough blocks so that the end bits and the cutting edges can be removed 2 Remove the end bits and or the cutting edges 3 Install new end bits and or new cutting edges 4 Raise the blade and remove the blocks 102730438 Display and Camera Clean If Equipped with Work Area Vision System SMCS Code 7347 070 7348 070 In order to
28. machine To adjust the camera loosen bolts 1 and move the camera for your desired view 102103440 Centershift Cylinder Socket Check Adjust Replace SMCS Code 5223 023 5223 025 5223 535 1 Rotate the blade Place the blade at an angle of 90 degrees to the frame Lower the blade to the ground 2 Operate the centershift cylinder Observe the socket If the socket moves without movement of the drawbar adjustment is necessary Illustration 141 g01071500 3 Remove bolts 1 from cap 2 Remove cap 2 4 Remove one shim from either side of the inserts in order to reduce clearance Note If you need to remove two shims then remove one shim from each side of the inserts 5 Install the cap and bolts and tighten the bolts 6 Check the socket for movement If you observe movement in the socket repeat Step 3 through Step 5 Note If no shims remain install new inserts Install two shims on each side of the socket Add additional shims as needed 102527356 Centershift Cylinder Socket Lubricate SMCS Code 5223 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the centershift cylinder socket Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe all the fittings before you apply lubricant through the fittings SEBU7881 16 137 Maintenance S
29. machine has two fittings on each side Apply the appropriate lubricant through the fittings in order to lubricate the scarifier lift link socket 102589744 Scarifier Teeth Inspect Replace SMCS Code 6807 040 6807 510 Personal injury or death can result from the scar ifier falling Block the scarifier before changing the teeth Flying objects can cause injury or death Make sure the area is clear of people when remov ing installing scarifier teeth To avoid injury to your eyes wear protective glasses when removing installing scarifier teeth If the scarifier teeth are damaged or worn excessively then change the scarifier teeth Illustration 232 g01296557 1 Block up the scarifier Do not block up the scarifier too high Block up the scarifier to a height that allows you to remove the teeth 2 Remove the scarifier tooth from the shank 3 Clean the shank 4 Install the new scarifier tooth over the shank 5 Drive the scarifier tooth onto the shank 6 Repeat Step 2 through Step 5 in order to replace additional scarifier teeth 7 Raise the scarifier and remove blocking SEBU7881 16 185 Maintenance Section Scarifier Teeth Inspect Replace 102588690 Scarifier Teeth Inspect Replace If Equipped SMCS Code 6807 040 6807 510 Personal injury or death can result from the scar ifier falling Block the scarifier before changing the teeth Flying objects can cause injur
30. maintain sufficient vision keep the Work Area Vision System WAVS camera lens and the display clean Display EES SOG SHOSST Illustration 170 g01223034 WAVS display Use a soft damp cloth in order to clean the display The display has a soft plastic surface that can be easily damaged by an abrasive material The display is not sealed Do not immerse the display with liquid Camera Illustration 171 g01223051 The WAVS camera is located on the rear of the machine on the engine enclosure 152 Maintenance Section Drawbar Ball and Socket Lubricate SEBU7881 16 Use a damp cloth or water spray in order to clean the camera lens The camera is a sealed unit The camera is not affected by high pressure spray The camera is equipped with an internal heater to help counteract the effects of condensation snow or ice Note For more information on WAVS refer to Operation and Maintenance Manual SEBU8157 Work Area Vision System 102585421 Drawbar Ball and Socket Lubricate SMCS Code 6170 086 6171 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the drawbar ball and socket Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe the fitting before you apply lubricant through the fitting g01294398 Illustration 172 Apply the appropriate lubricant t
31. open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis gt g01294622 Illustration 162 C7 Engine y a a Ni uP le e l oe N js ofa tn i Pan AT eN TY IN 7am mM ST PA MYS Illustration 163 g01302535 C9 Engine Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points 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 coolant analysis you must establish a consistent trend of data In order to establish a
32. or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 186 Maintenance Section Seat Belt Replace SEBU7881 16 102429594 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 elie RTE 4 g01152685 Illustration 235 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure
33. pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant Complete the information on the label for the sampling bottle before you begin to take the samples Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 148 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU7881 16 104057749 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1395 554 Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove f
34. 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 Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points Illustration 201 g01294267 C7 Engine Y E O S 1 i O s jire E gees Illustration 202 g01301612 C9 Engine The fuel system water separator is located inside the engine compartment on the left side of the machine 1 Open drain 1 and allow the water and sediment to drain into a suitable container 2 Close the drain 3 Close the access door 168 Maintenance Section Fuel Tank Cap and Strainer Clean SEBU7881 16 104001041 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR 1273 070 Z2 g01331323 Illustration 203 Typical Example Shown 1 Clean fuel tank cap 1 and the surrounding area 2 Remove the fuel tank cap and disassemble the fuel tank cap 3 Inspect the seal on the fuel tank cap for damage If the seal is damaged replace the seal Lubr
35. 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 Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points u Illustration 183 g01295216 C7 Engine 158 Maintenance Section Engine Oil and Filter Change SEBU7881 16 Illustration 184 g01302692 C9 Engine The sampling valve for the engine oil is located on the right side of the engine compartment Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Services Oil Analysis for information that pertains to obtaining a sample of the engine oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil 103674509 Engine Oil and Filter Change SMCS Code 1302 044 OC 1308 510 1318 510 1326 535 OC 1348 044 Select
36. teeth Refer to Operation and Maintenance Manual Circle Drive Pinion Teeth Lubricate for the proper procedure 102517027 Circle Drive Oil Change SMCS Code 5207 510 OC Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 150 g01070293 Bottom view of the blade circle Illustration 151 g01070350 Top view of the blade circle Note Clean the area around the drain plug and clean the area around the check fill plug before you remove the plugs 1 Remove drain plug 1 Remove check fill plug 2 Allow the oil to drain into a suitable container 2 Clean the drain plug and install the drain plug 3 Fill the circle drive housing with oil Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Oper
37. the filter mounting base Note the position of the index marks on the filter in relation to a fixed point on the filter mounting 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 166 Maintenance Section Fuel System Secondary Filter Replace SEBU7881 16 9 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide for tightening the filter For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 10 Prime the fuel system See Operation and Maintenance Manual Fuel System Prime for the proper procedure Note The secondary fuel filter should also be changed at this time See Operation and Maintenance Manual Fuel System Secondary Filter Replace for further instructions 11 Start the engine and check for leaks 12 Close the access door 103674540 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Turn the disconnect switch OFF when draining and or removi
38. the seal of the new filter 5 Install the new filter by hand 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 SEBU7881 16 167 Maintenance Section Fuel System Water Separator Drain 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 6 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 7 Prime the fuel system See Operation and Maintenance Manual Fuel System Prime for the proper procedure 8 Close the access door 103674542 Fuel System Water Separator Drain SMCS Code 1263 543 Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Turn the disconnect switch OFF when draining and or removing any fuel system components NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the
39. top surface of the drawbar 10 Remove the two rear bolts separately Immediately after removing one of the bolts install the corresponding retainer plate Install all of the retainer plates and bolts Note The shims must not be on the top surface of the drawbar before the retainer plates are installed The shims must be within the inside of the pocket 11 Remove the two pusher bolts from the drawbar Reinstall the pusher bolts with the spacers 10 Illustration 146 g01141311 12 Measure clearance X between the top of blade circle 6 and the bottom of drawbar wear strips 5 Maintain a maximum clearance of 0 5 mm 0 02 inch Note Make sure that shoe wear strips 10 are completely seated in circle shoes 9 Shoe mounting fasteners 8 must be tight Note After all the adjustments have been performed the blade circle must rotate freely without binding 13 Lubricate the blade circle and the drawbar Refer to Operation and Maintenance Manual Circle Top Lubricate for the proper procedure Circle Pinion and Circle Teeth Illustration 147 g01141365 SEBU7881 16 139 Maintenance Section Circle Clearances Check Adjust 12 Illustration 148 g01141043 Note The engagement of circle pinion 11 and the circle teeth is affected by the adjustment of circle shoes 9 1 Rotate the blade Place the blade at an
40. 00 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 Park the machine on a level surface with front wheels straight ahead Lower all attachments to the ground Apply a slight downward pressure to the attachments Center the articulation of the machine and install the frame lock pin The frame lock pin must move freely in the frame Move the front wheels to vertical and install the wheel lean locking bolt Engage the parking brake Stop the engine 2 a g01263224 Illustration 223 1 Clean the area around hydraulic oil filler cap 1 of any dirt or debris This must be done before the hydraulic oil filler cap can be removed 2 Slowly remove the hydraulic oil filler cap in order to relieve the tank pressure g01267876 Illustration 224 3 Clean the area around filter 3 This must be done before the filter can be removed 4 Remove the filter with a strap type wrench See Operation and Maintenance Manual Oil Filter Inspect Discard the used filter properly 5 Clean the filter base Check for any pieces of the seal from the old filter Remove any pieces of the seal from the old filter 6 Apply a thin coat of clean hydraulic oil to the seal of the new filter 7 Install the new filter by hand until the seal of the new
41. 04001049 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 g01293778 Illustration 262 Typical Example Shown Inspect front window wiper blade 1 Inspect left window wiper blade 2 If equipped inspect the right window wiper blade and the rear window wiper blade If any of the wiper blades are streaking any of the windows or the rear window replace the wiper blade 198 Maintenance Section Windows Clean SEBU7881 16 104093669 Windows Clean SMCS Code 7310 070 7340 070 When cleaning the windows use the recommend ed procedure in this manual Serious injury or death could result from falling if the appropriate procedure and equipment is not used Illustration 263 g01293786 Typical Example Shown Clean the front left side and right side windows of the cab while you are standing on the ground or ona stable work platform Use the appropriate equipment in order to reach the windows If you are standing on the ground use a squeegee with an extension handle Clean the rear window from the top of the left tandem housing Access this area by using the step that is located at the rear of the tandem housing Be sure to use the area of the walkway that is covered with a slip resistant walkway Use the provided handholds on the engine enclosure to maintain a secure position If necessary use a squeegee with an extension handle to reach across the rear window Use
42. Hours or at first oil change Battery or Battery Cable Inspect Replace 129 Electronic Unit Injector Inspect Adjust 153 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtains esac a A nies Sin a ere 148 Every 500 Service Hours or 3 Months Braking System Test ceeceseeeeeeesteeteeeenaaes 134 Engine Oil Sample Obtain ee 157 Engine Oil and Filter Change n se 158 Engine Shutdown Switch Check seese 161 Fuel System Prime cccccecceeeeeeeeeeeeteeteeeenaes 164 Fuel System Primary Filter Water Separator Element Replace eccecceeeeeeeeeeeeeeseees 165 Fuel System Secondary Filter Replace 166 Fuel Tank Cap and Strainer Clean 168 Gear Group All Wheel Drive Oil Level Check 172 Gear Group All Wheel Drive Oil Sample or EE EE E had facie lads E 173 Hydraulic System Oil Sample Obtain 176 Oil Filter Hydraulic Tank Return Replace 179 Oil Filter Implement Controls Replace 180 Tandem Breather Clean Replace 0 187 Tandem Drive Oil Sample Obtain 189 Transmission and Differential Oil Filter and Screens Replace Clean cccceeeeeeeeeecceeceeeeeeeeeeeteeseees 191 Transmission and Differential Oil Sample OD IN aii ie e e as eee ea tt 194 Wheel Bear
43. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A OB SEBU7881 16 ATERPILLAR Gaoter 2010 Operation and Maintenance Manual 140M Motor Grader 126 Maintenance Section Maintenance Interval Schedule SEBU7881 16 104110550 Maintenance Interval Schedule SMCS Code 1000 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance All adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging are included Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals Note 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 service
44. Oil Change SMCS Code 3080 510 3258 510 OC Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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 Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points Clean the area around the differential drain plug and the area around the transmission drain plug Refer to Illustration 244 for the location of drain plugs Clean the area around the oil level gauge fill cap Refer to Illustration 245 for the location of the oil level gauge fill cap Operate the engine until the transmission oil and the differential oil are warm Park the machine on a level surface and engage the parking brake Lower the blade and apply slight down pressure to the blade Stop the engine Note Drain the transmission case and drain the differential case while the oil is warm This allows waste particles
45. RAR AR AB AA AR i Illustration 252 g01294168 C7 Engine re O 7 SCE asses Illustration 253 g01301196 C9 Engine 1 Open the front left access door 2 Clean the area around oil level gauge fill cap 1 3 Start the engine and run the engine at low idle Remove the oil level gauge fill cap 4 With the oil at an operating temperature of 90 C 194 F maintain the oil level between the marks on oil level gauge fill cap 1 If necessary add oil 5 Stop the engine 6 Close the access door 194 Maintenance Section Transmission and Differential Oil Sample Obtain SEBU7881 16 102540233 Transmission and Differential Oil Sample Obtain SMCS Code 3006 008 3030 008 3080 008 3258 008 7542 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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 fluid
46. S Code 1000 535 FLV 1302 535 FLV 1326 535 FLV 1326 535 OC 1348 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin SEBU7881 16 157 Maintenance Section Engine Oil Sample Obtain NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points Clean the area around the oil level gauge and clean the area around the oil filler cap before you remove the oil level gauge and before you remove the oil filler cap 1 Open the front left access door Z JA p AY Illustration 181 g01294504 C7 Engine 7 TEA KOEN e 00 Sy S E Illustration 182 g01302725 C9 Engine 2 Before starting the engine check oil level gauge 2 Maintain the oil level between the marks on the oil level gauge 3 If necessary remove oil filler cap 1 in order to add oil 4 Clean the oil filler cap and install the oil filler cap 5 Close the access door Engine Oil Sample Obtain SMCS Code 1348 008 1348 554 SM 7542 008 7542 554 OC SM Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be
47. The all wheel drive system has an oil fill drain plug and an oil check plug on each front wheel The all wheel drive oil must be changed on both wheels 172 Maintenance Section Gear Group All Wheel Drive Oil Level Check SEBU7881 16 Illustration 209 g01360462 Note Position the wheel so the oil fill drain plug 2 is at the six o clock position 1 Clean the area around the all wheel drive oil check plug 1 and the all wheel drive oil fill drain plug 2 2 Slowly remove the all wheel drive oil check plug in order to relieve the pressure 3 Open the fill drain plug 2 Drain the oil into a suitable container 4 Replace the fill drain plug and tighten the fill drain plug Clean the area around the fill drain plug 5 Position the wheel so the oil check plug is at the nine o clock position 6 Open the check plug 1 7 Fill the all wheel drive oil gearbox through the fill drain plug to a level even with the check plug 8 Replace the check plug and tighten the check plug 9 Repeat these steps on the other wheel 102773212 Gear Group All Wheel Drive Oil Level Check If Equipped SMCS Code 4351 535 FLV 4355 535 FLV S N B9G1 Up S N D9G1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Operate the machine until the oil is warm Park the machine on a level surface with front wheels straight ahead Lower all attac
48. When the water separator is full of fuel attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate at low idle until the engine is running smoothly If the engine cannot be started or if the engine continues to misfire or smoke repeat Step 1 SEBU7881 16 165 Maintenance Section Fuel System Primary Filter Water Separator Element Replace 103674523 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1263 510 FQ Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Turn the disconnect switch OFF when draining and or removing any fuel system components NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill the fuel filters with fuel before installing the fuel filters The fuel will not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts Ref
49. ach front wheel has two kingpins Each kingpin has two fittings Apply the appropriate lubricant through the fittings in order to lubricate the kingpin bearings 102704846 Moldboard Wear Strip Inspect Adjust Replace SMCS Code 6174 025 6174 040 6174 510 1 Rotate the blade Position the blade at an angle of 90 degrees to the frame Lower the blade to 10 mm 0 40 inch above the ground Engage the parking brake Stop the engine Illustration 219 g01298017 2 Visually inspect the wear strips through the cutout feature that is provided on top retaining plate 2 and bottom retaining plate 3 If the wear strips are worn close to the moldboard replace the wear strips 3 Remove top retaining plate 2 and bottom retaining plate 3 4 Loosen the locknuts on set screws 1 5 Start the engine Sideshift the blade through the entire limit of travel Measure the clearance between the wear strips and the blade at four equally spaced points This will allow you to determine the location of the minimum clearance 6 Sideshift the blade to the location of the minimum clearance 7 Stop the engine 8 Tighten the set screws in order to obtain 0 13 to 0 89 mm 0 005 inch to 0 035 inch clearance between the moldboard rail and the wear strips at the location of minimum clearance 9 Tighten the locknuts on the set screws Refer to Specifications SENR3130 Torque Specifications for the recommended torque
50. aken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates When a Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system See Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval The amount of extender is determined by the cooling system capacity 1 Stop the engine and allow the engine to cool g01292893 Illustration 159 2 Open cover 1 3 Clean the area around the cooling system pressure cap of any dirt or debris Cleaning the area around the pressure cap must be done before the cooling system pressure cap can be removed 4 Remove the cooling system pressure cap slowly in order to relieve the pressure 5 Drain some coolant from the radiator into a suitable container Draining some coolant will allow space for additional cooling system coolant extender 6 In order to add cooling system coolant extender refer to Special Publication SEBU6250 Extended Life Coolant ELC Ref
51. anual Engine Oil Level Check for more information 13 Stop the engine Close all access doors 102210900 Engine Overheating SMCS Code 1000 1350 1353 If your machine experiences an engine overheating problem perform the following maintenance procedures in the order that is listed 1 Operation and Maintenance Manual Cooling System Coolant Level Check 2 Operation and Maintenance Manual Radiator Clean 3 Operation and Maintenance Manual Belt Inspect 4 Operation and Maintenance Manual Belt Replace 5 Operation and Maintenance Manual Cooling System Pressure Cap Clean Replace 6 Operation and Maintenance Manual Radiator Core Clean 7 Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace If the engine overheating problem is not corrected consult your Caterpillar dealer 102488454 Engine Power Loss SMCS Code 1000 1051 1250 If your machine experiences an engine power loss perform the following maintenance procedures in the order that is listed 1 Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace 2 Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 3 Operation and Maintenance Manual Fuel Tank Water and Sediment Drain 4 Operation and Maintenance Manual Fuel Tank Cap and Strainer Clean 5 Operation and Main
52. at ECF 1 11 0 minimum 500 hr 500 hr 500 hr 250 hr TBN Preferred Cat ECF 1 250 TBN 500 hr 500 hr h 250 hr r6 below 11 0 250 API CG 4 500 hr 250 hr hr 250 hr 1 The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines 2 Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments 3 High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption of your machine exceeds 24 L 6 4 US gal per hour follow the High Load Factor recommendations in Table 20 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change 4 For sulfur
53. ation and Maintenance Manual Capacities Refill 4 Clean the check fill plug and install the check fill plug 5 Start the engine Operate the machine for a few minutes Check the circle drive housing for leaks 6 Stop the engine Remove the check fill plug and check the oil level Maintain the oil level to the bottom of the filler opening If necessary add oil 7 Install the check fill plug 102100323 Circle Drive Oil Level Check SMCS Code 5207 535 OC If a leak develops or you suspect a leak check the oil level Wipe the surfaces around the opening for the check fill plug before you check the oil and before you add oil SEBU7881 16 141 Maintenance Section Circle Drive Pinion Teeth Lubricate The check fill plug is located on top of the circle drive housing at the front of the circle ay Illustration 152 g01070369 1 Remove check fill plug 1 2 Maintain the oil level to the bottom of the opening for the check fill plug 3 Install check fill plug 1 102527479 Circle Drive Pinion Teeth Lubricate SMCS Code 5207 086 PI Contact with a moving attachment may cause in jury or death Avoid contact with a moving attachment when lu bricating or maintaining the attachment Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the circle drive pinion teeth Refer to Special Publication SEBU6250 Caterpillar Ma
54. bove the MIN mark in sight gauge 2 10 Inspect the filler cap gasket If the filler cap gasket is damaged replace the filler cap gasket 11 Install the hydraulic oil filler cap 103036729 Oil Filter Hydraulic Tank Return Replace SMCS Code 5068 510 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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 Park the machine on a level surface with front wheels straight ahead Lower all attachments to the ground Apply a slight downward pressure to the attachments Center the articulation of the machine and install the frame lock pin The frame lock pin must move freely in the frame Move the front wheels to vertical and install the wheel lean locking bolt Engage the parking brake Stop the engine g01267806 Illustration 222 1 Clean the area around hydraulic oil filler cap 1 of any
55. ccess covers 101671005 Radiator Core Clean SMCS Code 1353 070 1353 070 KO You can use compressed air high pressure water or steam to remove dust and other debris from the radiator core However the use of compressed air is preferred 182 Maintenance Section Receiver Dryer Refrigerant Replace SEBU7881 16 See Special Publication SEBD0518 Know Your Cooling System for the complete procedure for cleaning the radiator core i02667695 Receiver Dryer Refrigerant Replace SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the
56. chine Fluids Recommendations for more information on molybdenum grease The circle drive pinion teeth are located under the circle drive housing Illustration 153 g01071611 1 Clean the dirt and the old lubricant from circle drive pinion teeth 1 and from blade circle 2 2 Apply the appropriate lubricant to circle drive pinion teeth 1 and blade circle 2 102103680 Circle Top Lubricate SMCS Code 6154 086 TP 1 Park the machine on a level surface and engage the parking brake 2 Stop the engine Lower the blade and any attachments to the ground Ov 4 Illustration 154 g01071683 3 Apply a dry film lubricant to the 5 mm 0 2 inch gap between the circle and the drawbar yoke Apply the dry film lubricant around the entire circle See Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Dry Film Lubricant for further information 142 Maintenance Section Circuit Breakers Reset SEBU7881 16 102519424 Circuit Breakers Reset SMCS Code 1417 529 1420 529 Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points Circuit Breaker Resets Push the buttons inward in order to reset the circuit breakers If the system is working properly the buttons will remain depressed If the buttons do not stay depressed check the appropriate elect
57. commercially available window cleaning solutions to clean the windows 102589851 Work Tool Lift Lubricate SMCS Code 6700 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the work tool lift Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe the fittings before you apply lubricant through the fittings Illustration 264 g01296618 The machine has eleven fittings Apply the appropriate lubricant through the fittings in order to lubricate the work tool lift
58. e to operate with a water temperature regulator could result in either an over heating or an overcooling condition NOTICE If the water temperature regulator is installed incor rectly it will cause the engine to overheat 4 Install a new water temperature regulator and a new gasket Install the water temperature regulator housing 5 Install the water temperature regulator housing and the hose Tighten the hose clamp 6 Add the cooling system coolant Refer to Operation and Maintenance Manual Cooling System Coolant Level Check for further information 103674481 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Damage to the vibration damper or failure of the vibration damper will increase torsional vibrations These vibrations will result in damage to the crankshaft and to the other engine components A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range o 6 o D 1 o K Q 0 g01162930 Illustration 167 C7 Engine Illustration 168 g01303381 C9 Engine Caterpillar recommends replacing vibration damper 1 for any of the following reasons e The engine has had a failure because of a broken crankshaft e The S O S analysis detected a worn crankshaft front bearing e The S O S analysis detected a large amount of gear train wear that is not caused by a
59. ection Centershift Lock Bar Clean Lubricate AA a I 5 s 4 7 i an a J 7y Ad i TTE PS JY AZ ms A Ol Illustration 142 g01071609 There are two centershift cylinder sockets Each centershift cylinder socket has one fitting Apply the appropriate lubricant through the fittings in order to lubricate the centershift cylinder sockets 102327869 Centershift Lock Bar Clean Lubricate SMCS Code 5221 070 5221 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the centershift lock bar Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Illustration 143 g00811486 Centershift lock bar 1 is located under the front frame and above the circle Clean the dirt the lubricant and the rust from the holes in the centershift lock bar Apply the appropriate lubricant to the holes in the centershift lock bar 102327897 Circle Clearances Check Adjust SMCS Code 6152 025 6152 535 6153 025 6153 535 6154 025 6154 535 6155 025 6155 535 Note In order to improve the accuracy for all adjustments remove debris and abrasive material from the entire blade circle Blade Circle and Drawbar 1 Rotate the blade Place the blade at an angle of 90 degrees to the frame A WARNING Personal injury or death ca
60. em Oil Sample Obtain SEBU7881 16 a g01263224 Illustration 216 1 Operate the machine until the oil is warm 2 Park the machine on a level surface with the front wheels straight ahead 3 Lower all attachments to the ground Apply a slight downward pressure to the attachments 4 Center the articulation of the machine and install the frame lock pin The frame lock pin must move freely in the frame 5 Move the front wheels to vertical and install the wheel lean locking bolt 6 Engage the parking brake Stop the engine 7 Maintain the oil level above the MIN mark on sight gauge 2 8 If necessary add oil Clean the area around hydraulic oil filler cap 1 of any dirt or debris This must be done before the hydraulic oil filler cap can be removed Note Confirm that the oil type added is the same oil type shown in Messenger and on the hydraulic system oil film 9 Slowly remove the hydraulic oil filler cap in order to relieve the tank pressure 10 Add oil through the filler tube 11 Clean the hydraulic oil filler cap and install the hydraulic oil filler cap 102533919 Hydraulic System Oil Sample Obtain SMCS Code 4129 008 5050 008 5056 008 5095 008 5095 SM S N B9D1 Up S N B9M1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluid
61. ent Do not use a filter element with damaged pleats or a damaged seal If the filter element is damaged replace the filter element 6 Install the filter element 7 Close access cover 3 8 Turn thumb screw 4 clockwise in order to install the thumb screw 103653715 Camera Adjust If Equipped SMCS Code 7348 025 Failure to use an appropriate external ladder or an appropriate platform for direct access to the rear view camera could result in slipping and falling which could result in personal injury or death Be sure to use an appropriate external ladder or an appropriate platform for direct access to the rear view camera 136 Maintenance Section Centershift Cylinder Socket Check Adjust Replace SEBU7881 16 Unexpected machine movement can cause injury or death In order to avoid possible machine move ment move the hydraulic lockout control to the LOCKED position and attach a Special Instruc tion SEHS7332 Do Not Operate or similar warning tag to the hydraulic lockout control When maintenance or servicing of the rear view camera is required follow these steps 1 Park the machine on a level surface 2 Turn the engine start switch to the OFF position and remove the engine start switch key 3 Turn the battery disconnect switch to theOFF position Adjust the Area of Visibility Illustration 140 g01960631 Aim the camera downward in order to show a portion of the rear of the
62. er to Operation and Maintenance Manual Access Doors and Covers for the location of the service points g01294251 Illustration 197 C7 Engine Ui ee 1 AK EW i Wid A 3 AEEEP HIE EQ Illustration 198 g01301636 C9 Engine The primary fuel filter is located inside the engine compartment on the left side of the machine 1 In order to drain the primary fuel filter open drain valve 3 on water separator bowl 2 The water separator bowl is under primary fuel filter 1 Catch the fuel in a suitable container 2 Remove primary fuel filter 1 and water separator bowl 2 Clean the filter housing base 3 Remove the water separator bowl from the primary fuel filter Note Check the water separator bowl for damage Reuse the water separator bowl if no damage is present 4 Clean the water separator bowl and clean the groove for the O ring Wash the water separator bowl in a clean nonflammable solvent Use pressure air to dry the water separator bowl 5 Lubricate the O ring with clean diesel fuel or lubricate the O ring with clean motor oil Place the O ring in the groove on the water separator bowl 6 Install the clean water separator bowl onto a new filter by hand 7 Apply clean diesel fuel to the seal of the new filter 8 Install the new filter hand tight until the seal of the filter contacts
63. er to the table for the correct amount of Caterpillar Extended Life Coolant ELC Extender that needs to be added to the cooling system 7 Install the cooling system pressure cap Close the cover 146 Maintenance Section Cooling System Coolant Level Check SEBU7881 16 104111791 Cooling System Coolant Level Check SMCS Code 1350 040 1350 040 HX 1350 535 FLV 1350 535 1353 535 FLV 1354 535 1395 082 1395 535 FLV 1395 535 Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to re lieve pressure only when engine is stopped and al low sufficient time for the cooling system to cool Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points XN g01294047 ustration 160 1 Maintain the coolant level between the FULL mark and the ADD mark on coolant tank 1 g01295120 Illustrat
64. erpillar dealer Note In order to protect the secondary steering pump the secondary steering test will shut off if switch 1 is held in the TEST position for more than 10 seconds If the secondary steering test shuts off alert indicator 2 will not be amber in color SEBU7881 16 187 Maintenance Section Steering Cylinder Ends and Tie Rods Lubricate s O Wy t Sa O gt C D BRBB BBB Ye Blo BABABA Illustration 237 g01257960 4 Alert Indicator 2 will become amber in color during the test If the alert indicator is not illuminated after the test the test was successful and the steering performance was normal Note If the alert indicator is red in color the test has failed The warning level that is issued will provide instructions that must be followed Refer to the troubleshooting section in Specifications Systems Operation Troubleshooting Testing and Adjusting RENR8472 for further information i04001045 Steering Cylinder Ends and Tie Rods Lubricate SMCS Code 4303 086 BD 4318 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the cylinder ends and the tie rods Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe the fittings before you apply lubricant through the fittings 4 f Illustration 238 g01142294 Typical Example Sho
65. es the effective ness of the coolant and shortens coolant life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specifications for pre mixed or concentrate coolants Use only Caterpillar Extender with Caterpillar ELC Failure to follow these recommendations could result in the damage to cool ing systems components If ELC cooling system contamination occurs see the topic Extended Life Coolant ELC in the Special Pub lication SEBU6250 Caterpillar Machine Fluids Rec ommendations 144 Maintenance Section Cooling System Coolant ELC Change SEBU7881 16 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates If the coolant in the machine is changed to Extended Life Coolant from another type of coolant see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Extended Life Coolant ELC Cooling System Maintenance If the coolant is dirty or if you observe any foaming in the
66. fferential Oil Filter and Screens Replace Clean Illustration 248 g01271423 1 Remove drain plug 4 on transmission oil filter housing 3 Allow the oil to drain into a suitable container 2 Loosen oil sampling valve 1 or pressure test port 2 in order to vent the transmission oil filter housing 3 Remove the transmission oil filter housing 4 Remove the used element and discard the used element 5 Clean the transmission oil filter housing with a clean nonflammable solvent 6 Clean the base of the transmission oil filter housing 7 Insert a new filter element into the transmission oil filter housing 8 Replace the filter housing base seal 9 Install the transmission oil filter housing 10 Install drain plug 4 in transmission oil filter housing 3 Illustration 249 g01440673 11 Remove the three bolts of the cover for magnetic screen 6 Slowly remove the cover from the housing 5 for the magnetic screen Allow the oil to drain into a suitable container 12 Remove the magnetic screen tube assembly 13 Separate the magnet and the tube assembly from the screen Wash the screen and the tube assembly in clean nonflammable solvent Allow the screen to dry and allow the tube assembly to dry NOTICE Do not drop or rap magnets on hard objects or dam age can result Replace damaged magnets 14 Clean the magnet with a cloth or clean the magnet with a firm brush All
67. ge The loss of the secondary braking system as well as the main hydraulic pressure will result in little or no braking capability and a potential for injury or death It is recommended to perform a brake accumula tor check anytime the machine has been idle for longer than two hours below 25 C 13 F Refer to Operation and Maintenance Manual before performing any check of the brake accumulator 1 Move the engine start switch to the ON position SEBU7881 16 133 Maintenance Section Brakes Indicators and Gauges Test 5 gwing o i m es NI a a o O gt lt BABB BBB oe l o alee eels A o B oo Illustration 135 g01257893 Note Alert indicator 1 will illuminate if the brake system is not at the normal operating pressure 2 Start the engine and run the engine for one minute in order to increase the accumulator pressure Alert indicator 1 should turn off Stop the engine 3 Apply the service brake pedal and release the service brake pedal in order to decrease the accumulator pressure Apply the service brake pedal and release the service brake pedal for a minimum of five applications until alert indicator 1 illuminates g01296741 Illustration 136 4 If alert indicator 1 illuminates with less than five applications of the service brake pedal measure the nitrogen precharge pressure of accumulators 2 Consult S
68. hments to the ground Apply a slight downward pressure to the attachments Center the articulation of the machine and install the frame lock pin The frame lock pin must move freely in the frame Move the front wheels to vertical and install the wheel lean bolt Engage the parking brake Stop the engine Check the all wheel drive oillevel by opening the oil filler plug The oil filler plug is located on the front wheel of the machine There is an oil filler plug on each front wheel of the machine Illustration 210 g01360462 Note Position the wheel so the oil check plug 1 is at the nine o clock position 1 Clean the area around the all wheel drive oil check plug of any dirt or debris This must be done before the all wheel drive oil check plug can be removed 2 Open the oil check plug 1 SEBU7881 16 173 Maintenance Section Gear Group All Wheel Drive Oil Sample Obtain 3 Maintain the oil level even with the oil check plug 1 4 If necessary add oil through the oil fill drain plug 2 opening 5 Clean the oil check plug and install the oil check plug 102773233 Gear Group All Wheel Drive Oil Sample Obtain If Equipped SMCS Code 4351 008 OC 4355 008 OC S N B9G1 Up S N D9G1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of
69. hrough the fitting in order to lubricate the drawbar ball and socket 102585430 Drawbar Ball and Socket End Play Check Adjust SMCS Code 6170 025 6170 535 6171 025 6171 535 Check Rotate the blade so that the blade is placed at an angle of 90 degrees to the frame Lower the blade to the ground While you maintain a light load between the ball and the socket inch the machine slowly to the rear Stop the machine and shut off the engine a CPPS g iC FN f SNA lt ANP N i Illustration 173 g01294408 Measure the end play that is between ball 2 and cap 3 The end play should be 0 6 0 2 mm 02 01 inch Adjust the end play if necessary Adjust 1 Support the drawbar and support the circle 2 Remove bolts 1 that hold the drawbar to the bolster Move the drawbar backward or move the machine forward 3 Ys MN 7 VS COZZI 7 Illustration 174 g01265363 SEBU7881 16 153 Maintenance Section Electronic Unit Injector Inspect Adjust 3 Remove capscrews 7 from cap 3 that holds the drawbar and adapter 6 together Remove the adapter 4 As required remove shims 4 or install shims 4 in order to attain an end play of 0 6 0 2 mm 02 01 inch 5 Install capscrews 7 in cap 3 and adapter 6 Rotate cap 3 by hand The socket should rotate freely on ball 2 6 Check the torque on bolts 5 that hold bal
70. icate the seal on the fuel tank cap 4 Replace the element on the fuel tank cap 5 Remove the strainer from the filler opening 6 Wash the strainer in clean nonflammable solvent 7 Install the strainer 8 Install the fuel tank cap 103434444 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Turn the disconnect switch OFF when draining and or removing any fuel system components 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 g01265849 Illustration 204 Drain valve 1 is located at the bottom of the fuel tank behind the left tandem housing 1 Remove the fuel tank drain plug Drain the water and sediment into a suitable container 2 Install the fuel tank drain plug SEBU7881 16 169 Maintenance Section Fuses Replace
71. il cools the waste particles will settle to the bottom of the crankcase The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with the new oil Illustration 185 g01265545 1 Open crankcase drain valve 1 Allow the oil to drain into a suitable container 2 Close crankcase drain valve 1 160 Maintenance Section Engine Oil and Filter Change SEBU7881 16 Y 4 iG 2 Illustration 186 g01294218 C7 Engine Nae yy e e l g01302764 Illustration 187 C9 Engine 3 Open the right side access door 4 Clean the area around engine oil filter 2 before you remove the engine oil filter Remove the engine oil filter with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect 5 Clean the base of the engine oil filter housing Make sure that all of the old filter gasket is removed 6 Apply a thin film of engine oil to the gasket of the new filter 7 Install the new filter by hand 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 awa
72. iller cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes Note Ensure that the engine is warmed up to operating temperature and running in order to obtain the sample NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates 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 Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points Obtain the sample of the coolant as c
73. ing Oil Level Front Check 195 Wheel Bearing Oil Sample Front Obtain 195 Every 1000 Service Hours or 6 Months Blade Cushion Accumulator Check a e 131 Rollover Protective Structure ROPS Inspect 183 Transmission and Differential Oil Change 190 Every 1000 Service Hours or 1 Year Oil Filter All Wheel Drive Replace 178 Every 2000 Service Hours or 1 Year Engine Valve Lash Check eessen 162 Hydraulic System Oil Change e eee 173 Hydraulic System Oil Change n 175 Every 2000 Service Hours or 2 Years Battery or Battery Cable Inspect Replace 129 Circle Drive Oil Change n se 140 Condenser Refrigerant Clean cee 142 Cooling System Pressure Cap Clean Replace 148 Crankshaft Vibration Damper Inspect 150 Electronic Unit Injector Inspect Adjust 153 Engine Valve Rotators Inspect 0 eeeee 162 Evaporator Coil and Heater Coil Clean 163 Gear Group All Wheel Drive Oil Change 171 Radiator Core Clean oo eeeeeeeeeeeeeeeeeeeeeneeees 181 Tandem Drive Oil Change n se 188 Wheel Bearing Oil Front Change 20 194 Every Year Cooling System Coolant Sample Level 2 ODI anii aaoi eaaa a ag aaa GaaS 148 Engine Air Filter Primary Element Clean Replace eu r aae enna i aN 153 Every 3 Years After Date of Installation or Every 5 Years After Da
74. ion 161 2 If necessary add the appropriate coolant mixture 3 Open cover 2 4 Clean the area around the filler cap of any dirt or debris Cleaning the area around the cap must be done before the filler cap can be removed 5 Remove the filler cap slowly in order to relieve pressure 6 Add coolant through the filler tube 7 Install the filler cap Close the cover 103674440 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1395 554 Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC This includes the following types of coolants e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat Diesel Engine Antifreeze Coolant DEAC e Commercial heavy duty antifreeze coolant SEBU7881 16 147 Maintenance Section Cooling System Coolant Sample Level 1 Obtain 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
75. ion of the Oil Change Interval NOTICE A 500 hour engine oil change interval is available pro vided that the operating conditions and recommend ed multigrade oil types are met When these require ments are not met shorten the oil change interval to 250 hours or use an S O S Services oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine Caterpillar oil filters are recommended Recommended multigrade oil types are listed in Table 20 Do not use single grade oils Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals from the recommendations in Table 20 Also refer to Special Publication SEBU5898 Cold Weather Recommendations Poor maintenance of air filters or of fuel filters requires reduced oil change intervals See your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments Table 20 Engine Oil Change Interval Operating Conditions Severe Multi d 7 Fuel Altitude oi Type A High Sulfur above Normal Load from 1830 m Factor 9 3 6000 ft to 0 5 4 Cat DEO soohr 500 hr 500hr 250 hr Preferred C
76. is transparent 7 Close the drain valve 8 Add the Extended Life Coolant Refer to Operation and Maintenance Manual Capacities Refill Note Make sure that the cooling system pressure cap is removed for Steps 9 through 10 9 Start the engine and run the engine until the thermostat opens and the coolant level stabilizes SEBU7881 16 145 Maintenance Section Cooling System Coolant Extender ELC Add 10 Maintain the coolant level between the FULL mark and the ADD mark on the coolant tank 11 Install the cooling system pressure cap Close cover 1 12 Check the radiator for any external leaks Check for air bubbles in the radiator 13 Stop the engine 104111790 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1352 535 1352 544 1352 544 NL 1395 081 Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to re lieve pressure only when engine is stopped and al low sufficient time for the cooling system to cool Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes NOTICE Care must be t
77. l 2 in place The correct torque is 500 65 N m 370 50 Ib ft 7 Assemble the drawbar to the bolster Tighten bolts 1 to a torque of 950 50 N m 701 37 lb ft 101649392 Electronic Unit Injector Inspect Adjust SMCS Code 1251 025 1251 040 1290 025 1290 040 Be sure the engine cannot be started while this maintenance is being performed To prevent pos sible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting the unit injectors The electronic unit injectors use high voltage Dis connect the unit injector enable circuit connector in order to prevent personal injury Do not come in contact with the injector terminals while the en gine is running NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life The initial adjustment to the unit injector is recommended at the initial 500 hour interval The unit injector adjustment should then be made at every 2000 hour interval The operation of Caterpillar engines with improper adjustments of the electronic unit injecto
78. l Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note The normal hydraulic oil change interval is at every 2000 Service Hours or 1 Year By performing S O S oil analysis the hydraulic oil change interval may be extended to 4000 Service Hours or 2 Years S O S oil analysis must be performed at every 500 Service Hours or 3 Months in order to extend the hydraulic oil change interval The results from the S O S oil analysis will determine if the hydraulic oil change interval may be extended If S O S oil analysis is not available the hydraulic oil change interval must remain at every 2000 Service Hours or 1 Year Refer to the Operation and Maintenance Manual S O S Information 174 Maintenance Section Hydraulic System Oil Change SEBU7881 16 Note Cat HYDO Advanced 10 has 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 following 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 O S Services oil analysis Contact your Cat dealer for details Operate the machine until the oil is warm Park the machine on a level surface with the fron
79. l system Refer to Operation and Maintenance Manual Fuel System Prime for more information Machines that are Equipped with a Fast Fill Fuel Arrangement NOTICE Use only a Caterpillar approved fast fill system to fuel machines Over pressurization may cause tank defor mation and fuel spillage Contact your Cat dealer for fast fill system availability Illustration 196 g01289047 1 Park the machine on a level surface 2 Remove dust cover 3 Note The maximum fuel flow rate for the fast fill fuel arrangement is 375 L min 100 US gpm 3 Fill the fuel tank through the fast fill fuel adapter Note Prime the fuel system Refer to Operation and Maintenance Manual Fuel System Prime for more information 102096133 Fuel System Prime SMCS Code 1250 548 1258 548 NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component 1 Turn the engine start switch to the ON position Leave the engine start switch in the ON position for two minutes 2 Verify that the water separator is full of fuel 3 If the water separator is not full of fuel turn the engine start switch OFF and then turn the engine start switch ON This will cycle the fuel priming pump again 4
80. ll the oil check plug 10 Start the engine Operate the machine for a few minutes Check the tandem drive housing for leaks 11 Stop the engine Remove the oil check plug 12 Check the oil level Maintain the oil level to the bottom of the opening for the oil check plug Add oil if necessary 13 Install the oil check plug 14 Repeat Step 1 through Step 13 for the other side of the machine SEBU7881 16 189 Maintenance Section Tandem Drive Oil Level Check 102593951 Tandem Drive Oil Level Check SMCS Code 4071 535 ye Illustration 241 g01298219 1 Clean the surface area around the oil check plug 2 Remove the oil check plug 3 Maintain the oil level to the bottom of the opening for the oil check plug If additional oil is necessary perform the following Steps a Remove a plate from the walkway that is located on top of the tandem drive housing This must be done in order to access one of the covers on the top of the tandem drive housing b Clean the area around one of the covers of any dirt or debris This must be done before the cover is removed c Remove a cover from the top of the tandem drive housing Fill the tandem drive housing with new oil Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill d Clean the cover and install the cover on the top of the tandem dri
81. lose as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis Reference For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 104111792 Cooling System Pressure Cap Clean Replace SMCS Code 1382 070 1382 510 Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to re lieve pressure only when engine is stopped and al low sufficient time for the cooling system to cool Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes g01292893 Illustration 164 SEBU7881 16 149 Maintenance Section Cooling System Water Temperature Regulator Replace The cooling system pressure cap is located on top of the engine compartment 1 Open cover 1 2 Clean the area a
82. n 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 102792849 Radiator Clean SMCS Code 1353 070 1805 070 1810 070 Illustration 226 g01394578 1 Remove the two bolts on the access cover on the left rear of the machine Remove the two bolts on the access cover on the right rear of the machine 2 Open the access cover on the left rear of the machine Open the access cover on the right rear of the machine 3 Remove any dirt from the area around the radiator Remove any debris from the area around the radiator 4 Close the access covers 5 Install the bolts on the a
83. n primary air filter elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 177 g00281692 Note When the primary air filter elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air filter element Dirt could be forced further into the pleats Vacuum Cleaning Vacuum cleaning is another method for cleaning primary air filter elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Inspecting the Primary Air Filter Elements Illustration 178 g00281693 Inspect the clean 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
84. n result from blade falling 2 Lift the blade 10 mm 0 39 inch off the ground 3 Engage the parking brake Stop the engine ah 7 Illustration 144 g01141116 4 Remove plate retainer bolts 1 and remove retainer plates 2 138 Maintenance Section Circle Clearances Check Adjust SEBU7881 16 Illustration 145 g01150053 5 Reinstall two bolts in the drawbar without the retainer plates Remove the two pusher bolts near the circle drive Reinstall the pusher bolts into drawbar 7 without the spacers Refer to Illustration 145 for the correct locations This ensures that blade circle 6 is properly seated on the circle shoes 6 Remove shims 3 spacer plates 4 and drawbar wear strips 5 7 Inspect the wear strips Inspect the drawbar Measure the thickness of the drawbar wear strips Replace the wear strips if there is uneven wear The wear strips should be in complete contact at all points with the blade circle If any wear strip is not in complete contact with the blade circle replace the wear strip 8 If the wear strips can be reused switch wear strip A with wear strip C Switch wear strip D with wear strip F This will help keep the wear on the wear strips even 9 Reinstall the wear strips spacer plates and the shims Install shims until the shims are flush with the
85. ng any fuel system components NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points A IF EFN SKI 15 Illustration 199 g01294261 C7 Engine Cras 1 Q eS ORON Doc Illustration 200 g01301628 C9 Engine The secondary fuel filter is located inside the engine compartment on the left side of the machine 1 Remove secondary fuel filter 1 2 Drain the fuel from the secondary fuel filter into a suitable container 3 Clean the mounting base for the secondary fuel filter Make sure that you remove all of the old seal 4 Apply clean diesel fuel to
86. ns to move during test reduce the engine speed immediately and engage the parking brake NOTICE If the machine begins to move reduce the engine speed immediately and engage the parking brake NOTICE If the machine moved while testing the service brake consult your Caterpillar dealer Have the dealer inspect and if necessary repair the service brakes before returning the machine to oper ation Make sure that the area around the machine is clear of personnel and clear of obstacles Test the service brake on a dry level surface Fasten your seat belt before you test the brakes Use the following test in order to determine whether the service brake is functional This test is not intended to measure the maximum holding ability of the service brake 1 Start the engine Raise the blade slightly Depress the transmission modulator control inching pedal Apply the service brake control 2 Select the FIFTH SPEED FORWARD position on the transmission Set the throttle hold mode switch to the MANUAL position Push the top of the throttle set accel switch in order to set the engine speed to high idle 3 Gradually release the transmission modulator control inching pedal The machine should not move The engine should stall 4 Reduce the engine speed to low idle Engage the parking brake control Lower the blade to the ground Stop the engine Note The friction material for the brake may require replacement The new f
87. ny damaged hoses 103827244 Hydraulic System Oil Change Alternate Viscosity SMCS Code 5050 044 5056 044 5095 044 The steering circuit temperature monitoring sys tem if equipped will alert you when reduced steering performance is detected due to cold temperatures Failure to respond to this warn ing could result in injury or death Ensure that the hydraulic oil type installed in the machine is matched to the hydraulic oil type setting in Messenger If an alternate hydraulic oil viscosity is desired contact your local Caterpillar dealer for this service so that a proper hydraulic system flush is completed and the proper oil type is configured in Messenger Hydraulic System Oil Level Check SMCS Code 5050 535 FLV 5056 535 F LV 5095 535 FLV 7479 535 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Operate the machine until the oil is warm Park the machine on a level surface with front wheels straight ahead Lower all attachments to the ground Apply a slight downward pressure to the attachments Center the articulation of the machine and install the frame lock pin The frame lock pin must move freely in the frame Move the front wheels to vertical and install the wheel lean bolt Engage the parking brake Stop the engine The hydraulic tank sight gauge is positioned on the left side of the machine 176 Maintenance Section Hydraulic Syst
88. o a level below the housing assembly for the water temperature regulator NOTICE Failure to replace the engine s water temperature reg ulator on a regularly scheduled basis could cause se vere engine damage Note When replacing the water temperature regulator drain the cooling system coolant to a level that is below the housing assembly for the water temperature regulator No n Illustration 165 g01162907 C7 Engine FF yi A a9 O N j l 1 Y oe 8 8 a t H i gt 2 ojo A g01303365 Illustration 166 C9 Engine 1 Loosen hose clamp 1 and remove the hose from the water temperature regulator housing 2 Remove bolts 2 from the water temperature regulator housing and remove the water temperature regulator housing 3 Remove the gasket and remove the water temperature regulator from the water temperature regulator housing 150 Maintenance Section Crankshaft Vibration Damper Inspect SEBU7881 16 NOTICE The water temperature regulators may be reused if the water temperature regulators are within test specifica tions are not damaged and do not have excessive buildup of deposits NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a water temperature regulator Depending on load failur
89. o sound immediately The alarm alerts the personnel behind the machine that the machine is backing up The backup alarm will continue to sound until the transmission control switch is moved to the NEUTRAL position or to any FORWARD position 100993589 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility i01770781 Battery or Battery Cable Inspect Replace SMCS Code 1401 510 1402 510 1 Turn the engine start switch key to the OFF position Turn all the switches to the OFF position 2 Turn the key for the battery disconnect switch to the OFF position Remove the key 3 Disconnect the negative battery cable at the battery disconnect switch The battery disconnect switch is connected to the machine frame Note Do not allow the disconnected battery cable to contact the battery disconnect switch or the machine 4 Disconnect the negative battery cable from the battery 5 Disconnect the positive battery cable from the battery 6 Inspect the battery terminals for corrosion Inspect the battery cables for wear or damage 7 If necessary make repairs If necessary replace the battery cable or the battery 8 Connect the positive battery cable at the battery 9 Connect the negative battery cable at the battery 10 Connec
90. opening for the check fill plug If necessary add oil 4 Install the check fill plug 5 Repeat Step 1 through Step 4 for the other wheel bearing Wheel Bearing Oil Sample Front Obtain If Equipped SMCS Code 4205 008 4234 008 7542 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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 196 Maintenance Section Wheel Lean Bar Bearings Lubricate SEBU7881 16 Illustration 257 g01271804 Typical example The wheel has been removed for ease of viewing The wheel bearing sample plug 1 is located on the inner side of each front wheel of the machine Refer to Special Publication SEBU6250 S O S Services Oil Analysis for information that pertains to obtaining a sample of the oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample fo
91. ow the magnet to dry 15 Install the magnet and the tube assembly into the screen 16 Install the screen 17 Inspect the cover seals If the cover seals are damaged replace the cover seals 18 Install the covers and tighten the bolts 19 Repeat steps 11 through 18 for the transmission suction screen 7 20 Start the engine 21 With the parking brake engaged run the engine at low idle in order to circulate the transmission oil 22 Inspect all of the transmission components for leaks I mg r me AM ARIA ARAVA IMO h Illustration 250 g01441716 C7 Engine SEBU7881 16 193 Maintenance Section Transmission and Differential Oil Level Check Illustration 251 g01441722 C9 Engine 23 Clean the area around oil level gauge fill cap 8 24 With the engine at low idle maintain the oil level between the marks on the oil level gauge If necessary add oil through oil level gauge fill cap 25 Stop the engine 103674581 Transmission and Differential Oil Level Check SMCS Code 3030 535 FLV 3080 535 FLV 3258 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points AR
92. r can reduce engine efficiency This reduced efficiency could result in excessive fuel usage and or shortened engine component life 104071569 Engine Air Filter Primary Element Clean Replace SMCS Code 1051 070 PY 1051 510 PY 1054 070 PY 1054 510 PY NOTICE Service the air cleaner only with the engine stopped Engine damage could result Note Use caution when removing and installing an air filter Make sure not to damage the inner tube within the air filter housing Also make sure that air filters are installed properly so that the air filters function properly Service the air cleaner filter element when the Check Engine alert indicator is activated The indicator is located inside the cab The alert indicator will activate when there is an inlet air restriction and the Messenger display will provide a message regarding the specific problem Refer to Operation and Maintenance Manual Monitoring System for further information 1 Open the access door for the air filter housing Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 175 g02281853 154 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU7881 16 3 Ii M a e Ww gt g02281873 Illustration 176 2 Unlock wire fasteners 1 and remove cover 2 3 Remove primary filter element 3 from the air filter housing turning slightly counterclockwise
93. r more information about obtaining a sample of the hydraulic oil 102622524 Wheel Lean Bar Bearings Lubricate SMCS Code 5225 086 BD Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the wheel lean bar bearings Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe the fittings before you apply lubricant through the fittings N N w sy Illustration 258 g01271900 The wheel has been removed for ease of viewing Each front wheel has one fitting Apply the appropriate lubricant through the fittings in order to lubricate the wheel lean bar bearings 102540560 Wheel Lean Bearings Lubricate SMCS Code 5225 086 BD Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the wheel lean bearings Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe the fittings before you apply lubricant through the fittings Illustration 259 g01271922 The wheel has been removed for ease of viewing Each front wheel has two fittings Apply the appropriate lubricant through the fittings in order to lubricate the wheel lean bearings SEBU7881 16 197 Maintenance Section Wheel Lean Cylinder Bearings Lubricate 102540570 Wheel Lean Cylinder Bearings Lubricate SMCS Code 5211 086 BD
94. rator s seat has been removed for ease of viewing oy T Illustration 139 g01323235 The inside cab air filter is located behind the operator s seat The outside cab air filter is located behind access cover 3 Note Clean the cab air filters more often in dusty conditions Inside Filter 1 Turn thumb screws 1 counterclockwise in order to remove the thumb screws 2 Remove filter cover 2 3 Remove the filter element Clean the filter element with pressure air or wash the filter element in warm water and in a nonsudsing household detergent 4 Rinse the filter element in clean water Thoroughly air dry the filter element 5 After you clean the filter element inspect the filter element Do not use a filter element with damaged pleats or a damaged seal If the filter element is damaged replace the filter element 6 Install the filter element 7 Install filter cover 2 8 Turn thumb screws 1 clockwise in order to install the thumb screws Outside Filter 1 Turn thumb screw 4 counterclockwise in order to remove the thumb screw 2 Open access cover 3 3 Remove the filter element Clean the filter element with pressure air or wash the filter element in warm water and in a nonsudsing household detergent 4 Rinse the filter element in clean water Thoroughly air dry the filter element 5 After you clean the filter element inspect the filter elem
95. refrigerant from the air condition ing system Illustration 227 g01268854 In line refrigerant dryer 1 and refrigerant accumulator 2 are located behind the cab on the right side Refer to Service Manual SENR5664 Air Conditioning and Heating with R 134a for All Caterpillar Machines In Line Refrigerant Dryer Remove and Install for the replacement procedure of the in line refrigerant dryer Refer to Service Manual SENR5664 Air Conditioning and Heating with R 134a for All Caterpillar Machines Refrigerant Accumulator Remove and Install for the replacement procedure of the refrigerant dryer 102598720 Ripper Cylinder Bearings Lubricate SMCS Code 5352 086 6325 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the ripper cylinder bearings Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe all the fittings before you apply lubricant through the fittings Illustration 228 g01287430 Fitting 1 is on each side of the trunnion Apply the appropriate lubricant through each fitting in order to lubricate the trunnion Fitting 2 is mounted on the left side rod end of the ripper cylinder Apply the appropriate lubricant through the fitting in order to lubricate the
96. rical circuit Illustration 155 g01260787 The circuit breaker resets are located in the left front compartment of the machine AccuGrade Circuit Breaker 1 The accugrade circuit breaker is 20 amp This circuit breaker is an attachment Transmission Chassis Control Circuit Breaker 2 The transmission chassis control circuit breaker is 15 amp Keyswitch Circuit Breaker 3 The keyswitch circuit breaker is 15 amp HO O OF Engine Control Circuit Breaker 4 The engine control circuit breaker is 20 amp Alternator Circuit Breaker 5 The alternator circuit breaker is 150 amp This circuit breaker is standard 90 Main Circuit Breaker 6 The main circuit breaker feeds power to the fuses in the cab that are turned on with the ignition key The main circuit breaker is 80 amp Load Circuit Breaker 7 The load circuit breaker feeds power to the fuses in the cab that are continuously on The load circuit breaker is 80 amp OSD OG 102792884 Condenser Refrigerant Clean SMCS Code 1805 070 NOTICE If excessively dirty clean condenser with a brush To prevent damage or bending of the fins do not use a stiff brush Repair the fins if found defective Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points SEBU7881 16
97. riction material for the brake may require conditioning for maximum performance Consult your Caterpillar dealer or see Special Instruction SEHS9187 for the procedure for conditioning Parking Brake Holding Ability Test Personal injury can result if the machine moves while testing It the machine begins to move during test reduce the engine speed immediately and engage the ser vice brake control NOTICE If the machine moved while testing the parking brake consult your Caterpillar dealer Have the dealer inspect and if necessary repair the parking brake before returning the machine to opera tion Be sure that the area around the machine is clear of personnel and clear of obstacles Test the parking brake on a hard dry surface Fasten the seat belt before you test the parking brake Use the following test to determine whether the parking brake is functional This test is not intended to measure the maximum holding ability of the parking brake 1 Position the machine on a slope of 20 percent 2 Engage the parking brake control Release the service brake control The wheels should not rotate If the wheels rotate engage the service brake control SEBU7881 16 135 Maintenance Section Cab Air Filter Clean Replace 102638988 Cab Air Filter Clean Replace SMCS Code 7311 070 Fl 7311 510 Fl 7342 070 7342 510 Illustration 138 g01299060 The ope
98. rod end of the ripper cylinder SEBU7881 16 183 Maintenance Section Ripper Tip Inspect Replace 101563909 Ripper Tip Inspect Replace SMCS Code 6808 040 6808 510 Personal injury or death can result from the ripper falling Block the ripper before changing teeth Retainer pin when struck with force can fly out and cause injury to nearby people Make sure the area is clear of people when driving retainer pins To avoid injury to your eyes wear protective glasses when striking a retainer pin Inspect the ripper tips Replace the ripper tips if the tips are damaged or the tips are worn excessively 1 Block up the ripper to a height that is adequate for the removal of the tips Illustration 229 g00110460 2 Drive out the retainer pin from the retainer side of the ripper tip Remove the ripper tip and the retainer 3 Clean the adapter the retainer pin and the retainer Install the retainer in the groove 4 Install the new ripper tip over the retainer 5 Drive the retainer pin through the retainer through the adapter and through the ripper tip from the opposite side of the retainer 6 Repeat Step 2 through Step 5 in order to replace additional ripper tips 7 Raise the ripper Remove the block Lower the ripper to the ground 102538048 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 NOTICE Do not attempt to straighten the ROPS struc
99. round the pressure cap of any dirt or debris Cleaning the area around the cap must be done before the pressure cap can be removed 3 Remove the pressure cap slowly in order to relieve pressure 4 Inspect the cap and the cap seal for damage deposits and foreign material Clean the cap with a clean cloth Replace the cap if the cap is damaged 5 Install the cap Close the cover 104111794 Cooling System Water Temperature Regulator Replace SMCS Code 1355 070 1355 510 1393 010 Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to re lieve pressure only when engine is stopped and al low sufficient time for the cooling system to cool Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes Replace the water temperature regulator on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system The water temperature regulator should be replaced after the cooling system has been cleaned Replace the water temperature regulator while the cooling system is drained or while the coolant is drained t
100. rsrrerrsssrerrsssrees 169 Moldboard Wear Strip Inspect Adjust Replace 177 Oil Filter Inspect eee ceeeceeeeceeeeeeeeeeeeeeeneeeaeees 181 Radiator Clean cccceccccecceeeeeeeeceeeneecaeeeeeeeeees 181 Radiator Core Clean ccceeeeeeeeseeceeeeeeeeeees 181 Receiver Dryer Refrigerant Replace 182 Ripper Tip Inspect Replace eee 183 Scarifier Teeth Inspect Replace 0 06 184 Scarifier Teeth Inspect Replace 185 Window Washer Reservoir Fill 0 000 197 Window Wiper Inspect Replace 6 197 Windows Clean cccccceceeeeeeeeeeeeeseneeeaeees 198 Every 10 Service Hours or Daily Backup Alarm Test ceceeeeeeeeeeeeteeeeeees 129 Brakes Indicators and Gauges Test 133 Circle Drive Pinion Teeth Lubricate 141 Circle Top Lubricate ceseceeeseseeeeeeeeeeees 141 Cooling System Coolant Level Check 146 Engine Oil Level Check ccceeeeeeeereeeeneeeees 156 Fuel System Water Separator Drain 167 Seat Belt Inspect oo eee eeeeeeeeecteeeeeeeeees 185 Transmission and Differential Oil Level Check 193 Initial 100 Service Hours Transmission and Differential Oil Filter and Screens Replace Clean 00 2 ceceeeeeeeeeeeeceeceeeeeeeeeeeteeeeees 191 Every 100 Service Hours or 2 Weeks
101. run the engine at low idle Inspect the transmission and differential components for leaks 8 Engage the transmission modulator control inching pedal Slowly operate the transmission in order to circulate the oil 9 With the engine at low idle maintain the oil level between the marks on the oil level gauge If necessary add oil through oil level gauge fill cap 3 10 Stop the engine 11 Close the access door 103674570 Transmission and Differential Oil Filter and Screens Replace Clean SMCS Code 3030 070 Z3 3030 510 Z3 3067 070 3067 510 3258 070 Fl 3258 070 Z3 3258 5 10 23 3258 510 FI Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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 7 1 Oa Illustration 247 g01271420 Cutaway view 192 Maintenance Section SEBU7881 16 Transmission and Di
102. s according to local regulations and mandates 7 1 a Illustration 254 g01271753 Sampling valve 1 for the transmission and differential oil is located on the transmission filter The transmission filter is located on the right rear of the transmission Refer to Special Publication SEBU6250 S O S Services Oil Analysis for information that pertains to obtaining a sample of the transmission and differential oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the transmission and differential oil 103399645 Wheel Bearing Oil Front Change If Equipped SMCS Code 4205 044 4208 044 4234 044 7551 044 WHL Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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
103. s 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 g01267459 Illustration 217 Hydraulic oil sampling valve 1 is located under the left rear of the machine Refer to Special Publication SEBU6250 S O S Services Oil Analysis for information that pertains to obtaining a sample of the hydraulic oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the hydraulic oil SEBU7881 16 177 Maintenance Section Kingpin Bearings Lubricate 104093709 Kingpin Bearings Lubricate SMCS Code 4314 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the kingpin bearings Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe all the fittings before you apply lubricant through the fittings i Illustration 218 g01267710 The wheel has been removed for ease of viewing E
104. s 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 AN Illustration 240 W g01298140 1 Clean the surface area around oil check plug 1 2 Remove drain plug 2 Remove the oil check plug Allow the oil to drain into a suitable container Note When you change the tandem drive oil use diesel fuel in order to clean the housing of the sludge and flush the housing of the sludge 3 Clean the drain plug and install the drain plug 4 Remove a plate from the walkway that is located on top of the tandem drive housing This must be done in order to access one of the covers on the top of the tandem drive housing 5 Clean the area around one of the covers of any dirt or debris This must be done before the cover is removed 6 Remove a cover from the top of the tandem drive housing Fill the tandem drive housing with new oil Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill 7 Clean the cover and install the cover on the top of the tandem drive housing 8 Install the plate to the walkway 9 Clean the oil check plug and insta
105. s may extend the oil change even longer Consult your Cat dealer for details When Required All Wheel Drive Motor Supply Hose Inspect ReEplace cccccceceeeeeeteeteeseenneeeees 128 Battery Recycle ececceceeceeseececeeeseeeeeeeneeeees 129 Belt Replace ccccccccccceceeeeeeeeeeeeeceeeeeeeeeeeeees 130 Blade Lift Cylinder Socket Check Adjust RREPIACC EEE EE TE cies EN E A 131 Brake Accumulator Check seeseeseeeereeeee 132 Camera Adjust 00 ceceeeecteeeeeeettteeeeeeentteeeeeenaaes 135 Centershift Cylinder Socket Check Adjust Replace nai nie ave ag etl deli a E N 136 Circle Clearances Check Adjust eeeee 137 Circle Drive Oil Level Check 140 Circuit Breakers Reset a e 142 Condenser Refrigerant Clean eeeeee 142 Cutting Edges and End Bits Inspect Replace 151 Display and Camera Clean ceeeeseereeeeeees 151 Drawbar Ball and Socket End Play GHECKIAGJUSE leia ienien duns cdetetsane cee 152 Engine Air Filter Primary Element Clean Replace se ade delat tacit sateen ai 153 Engine Air Filter Secondary Element Replace 156 Engine Crankcase Breather Replace 156 Engine Overheating cccccceeseeeeeeenteeeeeeenaes 161 Engine Power LOSS ccecceeceeseeeeeeeenteeeeeeeaaes 161 Ether Starting Aid Cylinder Replace 162 Fuel System Fill prire rrain a 163 Fuses Replace sssseesseeersseeerr
106. t wheel straight ahead Lower all attachments to the ground Apply a slight downward pressure to the attachments Center the articulation of the machine and install the frame lock pin The frame lock pin must move freely in the frame Move the front wheels to vertical and install the wheel lean bolt Engage the parking brake Stop the engine The hydraulic system oil tank is positioned behind the left rear access door on the machine IY 8 al Illustration 212 901299835 1 Open cover 1 2 Clean the area around the hydraulic oil filler cap of any dirt or debris This must be done before the hydraulic oil filler cap can be removed 3 Slowly remove the hydraulic oil filler cap in order to relieve the tank pressure a eo a gt c 2 F O os A 0 P Illustration 213 g01163329 4 Open drain valve 2 Drain the oil into a suitable container 5 Close the drain valve Clean the area around the drain valve 6 Replace the filters for the hydraulic system oil Refer to the following procedures e Operation and Maintenance Manual Oil Filter Hydraulic Tank Return Replace e Operation and Maintenance Manual Oil Filter Implement Controls Replace 7 Remove the filler screen from the filler tube in the hydraulic oil tank Wash the filler screen in clean nonflammable solvent Allow the filler screen to dry 8 Install the filler screen
107. t the battery cable at the battery disconnect switch 11 Install the key for the battery disconnect switch Turn the battery disconnect switch to the ON position 103674422 Belt Inspect SMCS Code 1357 040 1397 040 Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points 1 Stop the engine 2 Open the engine access door on the right side of the machine 130 SEBU7881 16 Maintenance Section Belt Replace 5 Inspect the free arm stop of belt tensioner 2 The free arm stop must be aligned with the green a zone which is on the decal of the belt tensioner If the free arm stop is in either of the red zones RS replace the belt 103674424 Belt Replace R SMCS Code 1357 510 1397 510 Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points Illustration 128 A 5 C7 Engine g01162613 Illustration 130 C7 Engine Illustration 129 g01303273 C9 Engine 3 Inspect the condition of belt 1 Note Removal of the alternator guard is not necessary to inspect the belt 4 Replace the belt if any of the following conditions exist e excessive cracking e excessive wear e excessive damage SEBU7881 16 131 Maintenance Section Blade Cushion Accumulator Check
108. te of Manufacture Seat Belt Replace 20 0 cccssessstsssseseeeeeees 186 Every 3000 Service Hours or 3 Years Cooling System Water Temperature Regulator Replace iein ia a aiaa eia 149 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 145 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 143 128 Maintenance Section All Wheel Drive Motor Supply Hose Inspect Replace SEBU7881 16 102784922 All Wheel Drive Motor Supply Hose Inspect Replace If Equipped SMCS Code 3154 040 YW 3154 510 YW 4351 040 YW 4351 510 YW S N B9G1 Up S N D9G1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Illustration 125 g01263171 Supply hoses for the all wheel drive motors 1 Clean the area around each hose before you begin inspection 2 Inspect each hose for the following conditions e Leaks e Wear e Damage 3 Correct any leaks 4 Replace any worn hoses Replace any damaged hoses 102525595 Articulation Bearings Lubricate SMCS Code 7057 086 BD Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the articulation bearings Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe all the fittings before you apply lubricant through the fittings
109. tenance Manual Fuel System Primary Filter Water Separator Element Replace 6 Operation and Maintenance Manual Fuel System Secondary Filter Replace If the problem with engine power loss is not corrected consult your Caterpillar dealer 102885845 Engine Shutdown Switch Check SMCS Code 7418 535 ZS g01436602 g01436725 Illustration 191 162 Maintenance Section Engine Valve Lash Check SEBU7881 16 The engine shutdown switch 1 is located on the left rear of the machine 1 While the engine is running move the engine shutdown switch 1 to the STOP position The engine will shut down 2 Move the engine shutdown switch 1 to the RUN position 3 Turn the engine start switch 2 to the OFF position 4 Restart the engine 104093750 Engine Valve Lash Check SMCS Code 1105 535 Ensure that the engine cannot be started while this maintenance is being performed To help prevent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance NOTICE Only qualified service personnel should perform this maintenance Refer to the Systems Operation Testing and Adjusting Manual Valve Lash and Valve Bridge Adjustment article or consult your Caterpillar dealer for the
110. that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the case The particles will not be removed by draining the oil and the particles will recirculate in the lubrication system with the new oil Illustration 244 g01271184 Bottom view 1 Remove transmission drain plug 1 and remove differential drain plug 2 Drain the oil into a suitable container 2 Change the filter element and clean the screens Refer to Operation and Maintenance Manual Transmission and Differential Oil Filter and Screens Replace Clean for the proper procedure 3 Clean the drain plugs and install the drain plugs 4 Open the front left access door SEBU7881 16 191 Maintenance Section Transmission and Differential Oil Filter and Screens Replace Clean Illustration 245 g01294176 C7 Engine ave g01301574 Illustration 246 C9 Engine 5 Fill the transmission case and the differential case with oil through oil level gauge fill cap 3 Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill 6 Remove transmission breather 4 and discard the transmission breather Install a new transmission breather 7 Start the engine and
111. the primary air filter element to a new primary air filter element that has the same part number 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 Storing Primary Air Filter Elements If a primary air filter element that passes inspection will not be used the primary air filter element can be stored for future use Illustration 179 g00281694 156 Maintenance Section Engine Air Filter Secondary Element Replace SEBU7881 16 Do not use paint a waterproof cover or plastic as a protective covering for storage An air flow restriction may result To protect against dirt and damage wrap the primary air filter elements in Volatile Corrosion Inhibited VCI paper Place the primary air filter element into a box for storage For identification mark the outside of the box and mark the primary air filter element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 104072229 Engine Air Filter Secondary Element Replace SMCS Code 1051 510 SE 1054 510 SE NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Note Use caution when removing and installing an air filter Make sure not to damage the inner tube within the
112. to rotate consult your Caterpillar Dealer 103674520 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points g01294347 Illustration 192 C7 Engine SEBU7881 16 163 Maintenance Section Evaporator Coil and Heater Coil Clean Illustration 193 g01302662 C9 Engine 1 Open the right side access door 2 Loosen the retaining clamp on ether starting aid cylinder 1 Remove the empty ether starting aid cylinder Properly discard the empty ether starting aid cylinder 3 Remove the used gasket Install the new gasket that is provided with each new ether starting aid cylinder 4 Install the new ether starting aid cylinder Tighten the ether starting aid cylinder hand tight Tighten the retaining clamp on the ether starting aid cylinder securely 5 Close the access door 102591928 Evaporator Coil and Heater Coil Clean SMCS Code 7309 070 7343 070 The evaporator coil and the heater coil are located under the seat in the cab 1 Remove the seat from the seat base 2 Remove the seat base 3 Remove the top cover Illustration 194 g01102120 4 Clean evaporator coil 1 and clean heater coil 2 If necessary replace both
113. ture Do not repair the ROPS by welding reinforcement plates to the structure If there are any cracks in the welds in the castings or in any metal section of the ROPS consult your Cater pillar dealer for repairs g01270477 Illustration 230 1 There are four mounting bolts 1 for the ROPS Two mounting bolts are located on each side of the cab 2 Inspect the ROPS for any loose bolts or any damaged bolts Replace any damaged mounting bolts or any missing mounting bolts with only original equipment parts 3 If necessary tighten the four mounting bolts Refer to Specifications SENR3130 Torque Specifications for the recommended torque 4 When you operate the machine on a rough surface the ROPS may rattle or the ROPS may make a noise If the ROPS rattles or if the ROPS makes a noise replace the ROPS mounting supports 184 Maintenance Section Scarifier Lift Link Socket Lubricate SEBU7881 16 102588674 Scarifier Lift Link Socket Lubricate If Equipped SMCS Code 6162 086 LNK Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the scarifier lift link socket Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Wipe the fittings before you apply lubricant through the fittings Illustration 231 g01073062 The
114. uring each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above Procedure for Changing the Engine Oil and Filter Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage Refer to Operation and Maintenance Manual Access Doors and Covers for the location of the service points Park the machine on a level surface and engage the parking brake Stop the engine Note Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the o
115. ve housing e Install the plate to the walkway 4 Clean the oil check plug and install the oil check plug 102772093 Tandem Drive Oil Sample Obtain SMCS Code 4071 008 ye Illustration 242 g01298219 1 Clean the surface area around the oil check plug 2 Remove the oil check plug in order to obtain an oil sample 3 Clean the oil check plug and install the oil check plug Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Services Oil Analysis for information that pertains to obtaining a sample of the tandem drive oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the tandem drive oil 100149440 Tire Inflation Check SMCS Code 4203 535 Al 4203 535 PX Illustration 243 g00103147 190 Maintenance Section Transmission and Differential Oil Change SEBU7881 16 Measure the air pressure on each tire Consult your tire dealer for the correct load rating and for the correct operating pressures If necessary inflate the tires Refer to the following additional information about tire inflation e Operation and Maintenance Manual Tire Inflation with Nitrogen e Operation and Maintenance Manual Tire Shipping Pressure e Operation and Maintenance Manual Tire Inflation Pressure Adjustment 103674565 Transmission and Differential
116. wn Both steering cylinders have two fittings Both tie rods have one fitting Apply the appropriate lubricant through the fittings in order to lubricate the cylinder ends and the tie rods i02593781 Tandem Breather Clean Replace SMCS Code 4062 070 BRE 4062 510 BRE Illustration 239 g01298118 The tandem breathers are located on the top of each tandem 1 Remove a plate from the walkway that is located on top of the tandem drive housings This must be done in order to access breathers 1 on the top of the tandem drive housings 2 Clean the area around the breathers of any dirt or debris This must be done before the breathers are removed 3 Remove breather 1 from both tandems 4 Wash the breathers in clean nonflammable solvent 188 Maintenance Section Tandem Drive Oil Change SEBU7881 16 5 Use pressure air to dry the breathers 6 Install the breathers in both tandems Note Replace the breathers if the breathers are damaged 7 Install the plate to the walkway 102593825 Tandem Drive Oil Change SMCS Code 4071 510 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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 container
117. y from each other When you tighten the filter use the rotation index marks as a guide 8 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter g01294219 Illustration 188 C7 Engine 7 E a O 3 4 a a BS ly a L jee He ses Illustration 189 g01302771 C9 Engine 9 Clean the area around oil filler cap 3 before you remove the oil filler cap Clean the area around oil level gauge 4 before you remove the oil level gauge Remove the oil filler cap Fill the crankcase with new oil Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill 10 Clean the filler cap and install the filler cap 11 Start the engine and allow the oil to warm Check the engine for leaks SEBU7881 16 161 Maintenance Section Engine Overheating 12 Check the oil level If necessary add oil Refer to Operation and Maintenance M
118. y or death Make sure the area is clear of people when remov ing installing scarifier teeth To avoid injury to your eyes wear protective glasses when removing installing scarifier teeth If the scarifier teeth are damaged or worn excessively then change the scarifier teeth Illustration 233 g01073079 1 Block up the scarifier Do not block up the scarifier too high Block up the scarifier to a height that allows you to remove the teeth 2 Remove the scarifier tooth from the shank 3 Clean the shank 4 Install the new scarifier tooth over the shank 5 Drive the scarifier tooth onto the shank 6 Repeat Step 2 through Step 5 in order to replace additional scarifier teeth 7 Raise the scarifier and remove blocking 102429589 Seat Belt Inspect SMCS Code 7327 040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 234 g00932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn
119. ystems Operation Testing and Adjusting Brake Accumulator Test and Charge for the following information e The correct checking procedure The correct filling procedure e The recommended pressure Your Caterpillar dealer has the appropriate tools for measuring the precharge pressure of the brake accumulators Note Only use dry nitrogen gas to recharge the brake accumulators 102514369 Brakes Indicators and Gauges Test SMCS Code 4251 081 4267 081 4269 081 7000 081 7450 081 7490 081 A 5 Y w NUT 20 O 5 Qun C gt BBBB BRB Bl o KASASSA S O oe Illustration 137 g01257920 Look for broken lenses on the gauges broken indicator lights or broken switches etc Start the engine Run the engine until the gauges have stabilized Look for inoperative gauges Turn on all of the machine lights Check for proper operation Sound the horn Move the machine forward and test the service brakes If the service brakes do not function properly refer to Operation and Maintenance Manual Braking System Test Stop the engine Make any needed repairs before you operate the machine 134 Maintenance Section Braking System Test SEBU7881 16 102662777 Braking System Test SMCS Code 3077 081 4011 081 4250 081 4251 081 4267 081 Service Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begi

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