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Operation And Maintenance Manual Excerpt - Safety

1. GA g01025459 Illustration 135 The plugs for the drive chain cases as the plugs are viewed from the underside of the machine 1 Remove the drain plug for the left drive chain case and the right drive chain case Allow the oil to drain into a suitable container 2 Apply 169 5464 Quick Cure Primer and 5P 3413 Pipe Sealant to the threads on the drain plugs Install the drain plugs SEBU8019 05 147 Maintenance Section Drive Chain Case Oil Check HEN fA N 2n 102422873 Drive Chain Case Oil Check SMCS Code 3261 535 Illustration 136 g01210036 3 Remove the filler plug for the right side drive chain case Fill the drive chain case with oil to the bottom of the threads on the fill port Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities 4 Apply 169 5464 Quick Cure Primer and 5P 3413 Pipe Sealant to the threads on the filler plug Install the filler plug 5 Repeat the process for the left side drive chain case Illustration 137 g01210036 1 Remove the filler plug for the right side drive chain case The oil level should be at the bottom of the threads on the fill port If necessary refer to Operation and Maintenance Manual Drive Chain Case Oil Change for the proper procedure to add
2. p l IH sit A 4 Illustration 111 5 Air inlet screen 3 Access the screen from the left side of the machine Hold the nozzle approximately 6 mm 0 25 inch away from the screen A If water is used to clean the screen ensure that the screen is dry before the engine is started If necessary use compressed air to dry the screen 102939506 Air Cleaner Dust Valve Clean Inspect SMCS Code 1051 571 VL Service the air filter elements when the alert indicator for air filter restriction lights Refer to Operation and Maintenance Manual Alert Indicators for information about the indicator 1 Open the engine access door 2 The air filter housing is located on the right side of the engine compartment 134 Maintenance Section Air Conditioner Condenser Clean SEBU8019 05 Illustration 112 g01280861 3 Check the dust valve after every ten service hours or at the end of each day Actuate the valve by squeezing the lips of the valve in order to remove any accumulated debris 102916544 Air Conditioner Condenser Clean If Equipped SMCS Code 1805 070 Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 246C 256C 262C 277C
3. 140 132 Maintenance Section Aftercooler Core Inspect Clean SEBU8019 05 102555053 Aftercooler Core Inspect Clean SMCS Code 1064 571 1064 571 Z3 S N RED1 Up Inspect Note Adjust the frequency of inspection according to the effects of the operating environment Clean the aftercooler core when you clean the radiator core The aftercooler is located behind the cab and in front of the engine Illustration 109 g01279112 1 Stop the engine 2 Clean the grill before you access the aftercooler core 3 Remove the pin 2 that holds the grill 1 and lift the grill Note If parts of the aftercooler system may appear to be damaged or if parts of the aftercooler system are repaired a leak test is highly recommended Consult your Caterpillar dealer for the most current information about the aftercooler Inspect the fins and tubes of the aftercooler for damage Some fins and tubes may be worn from abrasive material that has passed through the aftercooler cores Bent fins may be opened with a comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary Clean For air to air aftercoolers use the same methods that are used for cleaning radiators Personal injury can result from air pressure Personal injury can result without following prop er procedur
4. Cooling System Coolant ELC Change SMCS Code 1395 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Mixing ELC with other products will reduce the effec tiveness of the coolant This could result in damage to cooling system compo nents If Caterpillar products are not available and com mercial products must be used make sure they have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants and Caterpillar Extender Note The machine was shipped from the factory with Extended Life Coolant ELC in the cooling system For information about the addition of Extender to your cooling system see the Operation and Maintenance Manual Cooling System Coolant ELC Extender Add or consult your Caterpillar dealer Drain the coolant whenever the coolant is dirty or whenever the coolant is foaming The radiator cap is located under the radiator guard on the top of the engine compartment Allow the machine to cool before you change the coolant 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Raise the radiator guard Refer to Operation and Maintenance Manual Radiator Tilting Note The radiator cap is located on the right side of the radiator SEBU8019 05 141 Maintenance Section
5. Replace SEBU8019 05 320000000 D 4 O 9 Left Joystick 10 Cold Start 11 Rear Work Lights 12 Backup Alarm and Brake Lights 13 HVAC Blower Fan 14 Spare 15 Headlights 16 Hydraulic Solenoid 17 Fuel Shutoff and Secondary Engine Shutoff 18 Hydraulic Quick Coupler 19 Hydraulic Solenoid 20 Spare Solenoids 21 Auxiliary Electrical Control AUX6 C1 2H OQOO eE OO 22 Auxiliary Electrical Control AUX5 C2 23 Secondary Auxiliary Electrical Control C 24 Secondary Auxiliary Electrical Control C y 25 Auxiliary Electrical Control AUX7 26 Stop Lamp 27 Backup Alarm 28 Fuel Shutoff 29 Self Level and Ride Control 30 Glow Plugs SEBU8019 05 161 Maintenance Section Fuses Replace Main Fuse oN y le KA 4 ayy 2 W Illustration 165 g01279310 21 Battery 22 Main fuse The main fuse 22 is located behind the battery 21 on the left side of the machine under the cab This is a 105 amp fuse You must disconnect the negative battery cable before you replace this fuse Fuse panel behind cab There is an additional fuse panel behind the cab on the right side of the machine Illustration 166 g01279419 23 First Pair 24 Second Pair 25 Third Pair This panel has 6 fuse
6. refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system NOTICE If the refrigerant system has been open to the outside air without being plugged for more than 30 minutes the receiver dryer must be replaced Moisture will en ter an open refrigerant system and cause corrosion which will lead to component failure Refer to Service Manual SENR5664 Air Conditioning and Heating R 134a For All Caterpillar Machines for the proper procedure to change the receiver dryer assembly and for the procedure to reclaim the refrigerant gas Note The receiver dryer must also be replaced when the air conditioning system is evacuated 102418592 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect SMCS Code 7323 040 7325 040 Illustration 183 g01280181 1 Inspect the ROPS for loose bolts Tighten the bolts 1 to the following torque 125 20 N m 92 15 Ib ft Check the hinge on the cab 2 Check the ROPS and the FOPS for damaged bolts or missing bolts Replace any damaged bolts
7. 287C 279C and 289C The air conditioner condenser is located behind the engine on the frame Open the engine access door Inspect the air conditioner condenser for the following conditions e Damaged fins e Buildup of debris e Plugged areas Remove any debris Clean the condenser with low pressure air or low pressure water The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi 272C 297C and 299C The air conditioner condenser is attached to the side of the fan housing for the aftercooler 1 Remove the 3 bolts that retain the condenser to the fan housing for the aftercooler 2 Lift the core and remove the core from the retaining lip 3 Clean the condenser core in the opposite direction of the air flow 4 Reinstall the core in reverse order 102580453 Backup Alarm Test SMCS Code 7406 081 To prevent injury make sure that no people are working on the machine or near the machine To prevent injury keep the machine under control at all times 1 Get into the operator s seat Fasten the seat belt and pull the armrests downward 2 Start the engine 3 Disengage the parking brake 4 Move the joystick control to the REVERSE position The backup alarm should sound immediately The backup alarm should continue to sound until the joystick control is returned to the NEUTRAL position or to the FORWARD position SEBU8019 05 135 Maintenance Section Battery or Batt
8. Doors and Covers Illustration 152 g01277108 1 Oil level add mark 2 Full mark 3 Maintain the oil level between the ADD 1 mark and the FULL 2 mark on the dipstick 4 If oil is necessary tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting 5 Remove the oil filler cap 1 and add oil 6 Clean the oil filler cap and install the oil filler cap 7 Tilt the radiator downward 8 Close the engine access door 102743337 Engine Oil and Filter Change SMCS Code 1308 510 1348 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The normal oil change interval for the machine is Every 500 Service Hours or every year when the following conditions are met e Use an engine oil in the Operation and Maintenance Manual Lubricant Viscosities e Caterpillar filters are used e The altitude does not exceed 2300 m 7545 ft e Sulfur content in the fue
9. access door 102772835 Engine Compartment Inspect Clean SMCS Code 1000 040 CPA 1000 070 CPA Inspect the engine compartment for dirt buildup or debris Remove any dirt or debris from the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 150 g01264593 2 Remove any debris or dirt from the engine compartment If necessary remove the access panel in order to clean out the engine compartment Note Use care when you clean the engine compartment Damage to the machine may occur 3 Close the engine access door Air Conditioning Condenser The air conditioning condenser is located at the back of the engine compartment Cleaning the air conditioning condenser will maintain optimum performance of the air conditioning system Use low pressure water in order to clean the condenser 102417992 Engine Oil Level Check SMCS Code 1348 535 FLV NOTICE Do not overfill the crankcase Engine damage can re sult 1 Stop the engine and allow the oil to drain back into the oil pan SEBU8019 05 153 Maintenance Section Engine Oil and Filter Change g01209758 Illustration 151 1 Oil Filler Cap 2 Dipstick 2 Open the engine access door Refer to Operation and Maintenance Manual Access
10. and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary 5 Inspect the fins and tubes of the radiator core for damage Some fins and tubes may be worn from abrasive material that has passed through the radiator core Bent fins may be opened with a comb NOTICE Do not clean a rotating fan with high pressure water Fan blade failure can result 6 Remove any dirt or debris from the fan the fan hub the oil cooler the radiator guard and the fan guard Note Dirt or debris on the cooling fan can cause an imbalance 7 Tilt the radiator guard downward 8 Close the engine access door 170 Maintenance Section Refrigerant Dryer Replace SEBU8019 05 101968724 Refrigerant Dryer Replace If Equipped SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling
11. at least one time per year You can clean the primary filter up to three times 1 Open the engine access door 2 The air filter housing is located on the right side of the engine compartment Illustration 145 g00101864 3 Unlatch the air cleaner housing cover 1 Rotate the cover counterclockwise and remove the cover 4 Remove the primary filter element 2 5 Clean the inside of the air cleaner housing with a damp cloth Do not use compressed air to clean the housing 6 Install a new primary filter element into the filter housing 7 Install the cover for the filter housing SEBU8019 05 151 Maintenance Section Engine Air Filter Secondary Element Replace Illustration 146 g01276795 8 Rotate the cover clockwise and latch the cover Note Make sure that the cover is properly positioned The arrows on the air filter cover should point upward when the cover is in the locked position 9 Close the engine access door 10 Start the engine The alert indicator for air filter restriction should turn off If the alert indicator continues to light replace the secondary air filter Refer to Operation and Maintenance Manual Engine Air Filter Secondary Element Replace Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary filter element Nev er attempt to reuse the secondary filter element by cleaning the element When the p
12. bolts 2 to 15 3 N m 11 2 Ib ft g01209498 Illustration 117 3 Tighten the bolts 1 to 12 3 N m 9 2 Ib ft Note Start all the bolts 1 in the holes before you start tightening the bolts This helps align all the holes 4 Close the engine access door 102549571 Blade Frame Adjust SMCS Code 6060 025 BG Height Adjustment Illustration 118 g01161532 1 Height Adjustment for the Frame 2 Adjusting Bolts 3 Frame The height of the frame may be adjusted in order to compensate for the wear on the cutting edge The front portion of the frame needs to be lowered as the cutting edge wears Remove the bolts 2 and lower the frame 3 Install the bolts This will keep the blade level with the ground and this will prevent the blade from digging into the ground Note In order to properly adjust the blade the work tool coupler needs to be vertical The position of the pivot point of the blade is perpendicular to the ground Follow this procedure in order to ensure that the cutting edge will remain flat on the ground during operation 138 Maintenance Section Bucket Cutting Edges Inspect Replace SEBU8019 05 Trunnion Joint Note The trunnion is a dry joint Adding grease to the trunnion simply attracts abrasive particles The tightness of the joint should be monitored Shims should be removed when the joint becom
13. coolant directly to the radiator Remove the radiator cap 2 slowly in order to relieve system pressure Note The radiator cap is located on the right side of the radiator Inspect the cooling system hoses for any leaks cracks or signs of deterioration Replace any damaged hoses 4 Inspect the radiator cap and the gasket Replace the cap if the cap or the gasket is damaged Install the radiator cap 5 Tilt the radiator guard downward Illustration 132 g01018341 6 The coolant overflow reservoir is located on the rear door Maintain the coolant level in the coolant overflow reservoir between the MIN and MAX lines 7 Close the engine access door 103880044 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system Failure to replace the engine s thermostat on a regularly scheduled basis could cause severe engine damage The thermostat should be replaced after the cooling system has been cleaned Replace the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing Caterpillar engines incorporate a shunt design cooling system It is mandatory to always operate the engine with a thermostat 1 Open the engine access door Refer to Op
14. coolant is located on the left side of the radiator on machines that are equipped with the 3044 engine 7 Check the coolant level in the sight gauge on the radiator Maintain the coolant level to the top of the sight gauge with the radiator in the LOWERED position 8 Add the extender directly to the radiator Do not use the coolant overflow reservoir as a filler for the extender 9 Tilt the radiator guard downward 10 Close the engine access door For additional information on the addition of extender see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 102664591 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis i _if x 1 Bard E in 2 O 9 g g o G a J g01210063 Illustration 129 Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of
15. or missing bolts with original equipment parts only 2 Operate the machine on a rough surface Replace the ROPS mounting supports if the ROPS emits a noise Replace the ROPS mounting supports if the ROPS rattles Refer to Operation and Maintenance Manual Cab Tilting for a description of the mounting support Do not straighten the ROPS or the FOPS Do not repair the ROPS or the FOPS by welding reinforcement plates to the ROPS or the FOPS Consult your Caterpillar dealer for repair of any cracks in the ROPS or the FOPS Inspect the Flying Object Guard if equipped for damage Consult your Caterpillar dealer for repair of any cracks in the Flying Object Guard SEBU8019 05 171 Maintenance Section Seat Belt Inspect 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 184 g00932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult
16. procedure in order to remove the side windows Illustration 188 g01209231 1 Release the latch Slide the front window rearward between the circular marks 1 in the top of the window frame Push the window upward in the track Pull outward on the bottom of the window in order to remove the window 2 Release the latch Slide the rear window forward between the circular marks 1 in the top of the window frame Push the window upward in the track Pull outward on the bottom of the window in order to remove the window 3 Pull straight up on the bottom window in order to remove the window from the track Pull inward in order to remove the window 4 Reverse the process in order to install the windows Install the lower window first Then install the rear window in the outer track Install the front window in the inner track next Polycarbonate Front Door and Polycarbonate Top Window Note Do not wipe the window dry Do not use paper towels This may scratch the finish of the polycarbonate windows over time For cleaning your polycarbonate top window or polycarbonate front door use a soft cloth a sponge or a chamois Use any of the following cleaners e soap and water e isopropyl alcohol e kerosene e denatured alcohol e commercially available window cleaning solutions Apply the cleaning solution liberally Wipe the surface SEBU8019 05 175 Maintenance Section Work Tool Lubricate 102729220 Work T
17. requirements must be followed Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended to 3000 hours S O S services may extend the oil change even longer Consult your Cat dealer for details When Required Aftercooler Core Inspect Clean 0 06 132 Aftercooler Intake Screen Clean 0000 133 Air Conditioner Condenser Clean 0 134 Battery or Battery Cable Inspect Replace 135 Blade Frame Adjust cccceeseeeeeeesteeeeeeennaes 137 Bucket Cutting Edges Inspect Replace 138 Bucket Tips Inspect Replace ccceee 138 Cab Air Filter Clean Replace 0 0c0 139 Cab Interior Clean cc ccecccccceceeeeeeeeeeeeeneeeeees 139 Engine Air Filter Primary Element Clean Replace a a a nee ELN 149 Engine Air Filter Secondary Element Replace 151 Fuel System Priming Pump Operate 157 Fuel Tank Cap Clean ccceeeeeeecceceeeeeeeeteees 157 Fuel Tank Water and Sediment Drain 158 Fuses Replace 00 cccccceceeeeeeeeeeeececceceeeeeeeeeeees 158 Lower Machine Frame Clean cnc 167 Oil Filter Inspect eee cece eee eeeeeetteeeeeeeeeeeees 168 Radiator Core Clean neccen 169 Window Washer Reservoir Fill a a
18. the service points Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure Obtain the sample of the coolant from the radiator When the system is cool slowly remove the radiator cap 2 Note Do not take the sample from the Coolant Overflow Reservoir Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Keep the unused sampling bottles stored in plastic bags e Keep the lids on empty sampling bottles until you are ready to collect the sample 144 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU8019 05 Complete the information on the label for the sampling bottle before you begin to take the samples e Use a designated pump to collect the sample in order to avoid contamination Obtain coolant samples directly from the coolant tank You should not obtain the samples from any other location e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid cont
19. the angle cylinder Illustration 196 g00648037 Apply lubricant to the grease fitting on the horizontal pivot point of the blade Illustration 197 g00648038 Apply lubricant to the grease fitting on the vertical pivot point of the blade Repeat for opposite side of the blade Illustration 198 g00677570 This is a bottom view of the angle blade Apply lubricant to the grease fitting on the pivot point of the cylinder There are five grease fittings SEBU8019 05 177 Maintenance Section Work Tool Mounting Bracket Inspect Dozer Blade Illustration 199 g01073259 Apply lubricant to the grease fitting on both ends of the right hand angle cylinder 1 Repeat for opposite side of the blade Apply lubricant to the grease fitting on the pivot points on each end of the tilt cylinder 2 There are six grease fittings 101809997 Work Tool Mounting Bracket Inspect SMCS Code 6700 040 BK Illustration 200 g00925058 Inspect upper angled plate 1 and ensure that the plate is not bent or otherwise damaged Inspect holes 2 for wear and for damage Inspect lower angled plate 3 and ensure that the plate is not bent or otherwise damaged If any wear is suspected or any damage is suspected consult your Caterpillar dealer before you use the work tool
20. with plastic g01271190 Illustration 180 1 Access panel 2 Retaining bolts 3 The access panel 1 is located in the frame underneath the machine 4 Remove the four retaining bolts 2 5 Slide the panel forward or slide the panel rearward Pull the panel downward and remove the access panel from the machine 168 Maintenance Section Oil Filter Inspect SEBU8019 05 6 Remove any debris or dirt from the inside of the frame 7 Reinstall the access panel 8 Remove the cover from the ventilation ducts 9 Tilt the cab downward 102106227 Oil Filter Inspect SMCS Code 1308 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 181 g00100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small 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
21. 11 Close the engine access door i02418180 Fuel System Priming Pump Operate SMCS Code 1258 548 This machine is equipped with a fuel transfer pump that is electric Two examples that may cause the fuel system to lose prime are listed here e The machine runs completely out of fuel e The Fuel System Filter Water Separator Element is replaced Follow the steps below in order to prime the fuel system 1 Ensure that the engine start switch is in the OFF position Turn the engine start switch to the ON position Note Do not start the engine This operation only starts the fuel pump 2 Locate the Primary Fuel Filter This is located in the left side of the engine compartment 3 Examine the clear bowl The bowl must be completely full of fuel If the bowl is not full of fuel repeat Steps 1 and 2 4 Attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate the engine at low idle until the engine runs smoothly Note If the engine fails to start or if the engine continues to misfire or smoke stop the engine and repeat the procedure If the problem persists after repeating the procedure consult your Caterpillar dealer i01819309 Fuel Tank Cap Clean SMCS Code 1273 070 Z2 1 Remove the fuel cap 158 Maintenance Section Fuel Tank Water and Sediment Drain SEBU8019 05 Illustration 160 g00104238 2 Inspect the cap Replace the cap if
22. 7 510 1417 7528 Fuses Fuses Fuses protect the electrical system from damage that is caused by overloaded circuits Replace the fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary NOTICE Replace the fuses with the same type and size only Otherwise electrical damage can result If it is necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer SEBU8019 05 159 Maintenance Section Fuses Replace _ SS Illustration 162 g01287527 The fuse panel is located behind the seat on the right side Illustration 163 g01210555 Remove the cover in order to access the fuse panel Sy x m 1 21 F 3 O xp 2 22 is Oe a Q xj 5 23 lt A fa 6 y a7 24 O eo 8 e K w 9 26 m O mO 11 28 30 Illustration 164 g01262480 The following is a list of the fuses in the panel 1 Spare Q 2 Wiper F t 3 Front Work Lights and Beacon 4 Right Joystick 5 12 volt power socket 6 Radio 7 Solenoid for the Compressor 8 Air Conditioner BOOS amp 160 Maintenance Section Fuses
23. Cooling System Coolant ELC Change i _ _if x 1 SSe E g 2 O 9 g g E G F g01210063 Illustration 124 1 Sight gauge 2 Radiator cap 3 Slowly loosen the radiator cap 2 in order to relieve system pressure Remove the radiator cap o o0 T X o o0 f i 7 e 7 w o Qo fe N 0 OF OF f BZ g01279512 Illustration 125 Coolant drain 4 Locate the drain hose for the coolant system The drain hose is attached to the drain valve that is shown in illustration 125 Illustration 126 g01264593 5 Remove the access panel under the rear of the machine Pull the drain hose through the access hole 6 Open the drain and allow the coolant to drain into a suitable container 7 Close the drain 8 Push the hose back into the engine compartment Replace the access panel 9 Replace the thermostat See Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the process for replacing the thermostat 10 Add the coolant solution directly to the radiator Do not use the coolant overflow reservoir as a filler for the coolant Refer to Operation and Maintenance
24. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR Goober 26 LUI Operation and Maintenance Manual 246C 256C 262C and 272C Skid Steer Loaders JAY1 Up 246C RED1 Up 272C SAFETY CAT COM 130 Maintenance Section Maintenance Interval Schedule SEBU8019 05 104112615 Maintenance Interval Schedule SMCS Code 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance All adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging are included Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals Note The aftertreatment system can be expected to function properly for the useful life of the engine emissions durability period as defined by regulation All prescribed maintenance
25. Manual Capacities Refill Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Note Premix the coolant solution before filling the cooling system The coolant solution should contain 50 percent coolant and 50 percent distilled water Note Add the coolant solution at a maximum rate of five liters per minute This will reduce the chance of trapping air inside the engine block A large amount of trapped air can cause localized heating to occur upon start up Localized heating may result in engine damage which may lead to failure of the engine 142 Maintenance Section Cooling System Coolant Extender ELC Add SEBU8019 05 11 Start the engine Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes If necessary add coolant Note The sight gauge for the coolant level is located on the left side of the radiator 12 Check the coolant level in the sight gauge on the radiator Maintain the coolant level to the top of the sight gauge with the radiator in the LOWERED position 13 Stop the engine Inspect the radiator cap and the gasket Replace the cap if the cap or the gasket is damaged Install the radiator cap 14 Pull the radiator guard downward 15 Close the engine access door 102417747 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Pressurized system Hot coolant can cause seri ous burn To o
26. The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction hoses and hose clamps 8 Install the hydraulic tank filler cap 102743340 Hydraulic System Oil Filter Replace SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The hydraulic oil filter is located in the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Remove the hydraulic tank filler cap Illustration 171 g01209326 The hydraulic filter is located on the rear door 3 Remove the filter with a strap type wrench Note Place a suitable nonconductive container under the hydraulic oil filter Use this container in order to catch any oil that may spill from the filter or the filter element mounting base 4 Clean the filter element mounting base Remo
27. able level of oxidation is 40 percent 0 12 Abs units e The kinematic viscosity of 100 C 212 F oil should not exceed a change of more than 2 cSt from new oil Procedure for Changing the Hydraulic Oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 168 g00956818 Note This film is located near the hydraulic filler cap on machines that are filled with arctic oil Operate the machine for a few minutes in order to warm the hydraulic system oil Personal injury or death can result without releas ing all of the hydraulic pressure Release all the pressure from the hydraulic sys tem before any lines are disconnected The machine should be on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine Keep the armrests lowered Turn the engine start switch key to the ON position Push the parking brake switch Move all of the hydraulic control
28. amination e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102664598 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers i _if x 1 Bard E in 2 O 9 g g E G FF g01210063 Illustration 130 Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of the service points Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure Obtain the sample of the coolant from the radiator When the system is cool slowly remove the radiator cap 2 Note Do not take the sample from the Coolant Overflow Reservoir Obtain the sample of t
29. bricate SMCS Code 5104 086 BD 6107 086 BD Wipe all of the grease fittings before you apply lubricant 172 Maintenance Section Tire Inflation Check SEBU8019 05 P Illustration 186 g00955895 Note Lubricate the fittings with the loader lift arms in the fully lowered position Apply lubricant to the grease fittings 1 for the upper bearings for the tilt cylinders Apply lubricant to the grease fittings 2 for the lower bearings for the tilt cylinders Apply lubricant to the grease fittings 3 for the coupler engagement pins Apply lubricant to the grease fitting 4 for the pivot pin of the quick coupler assembly There are a total of 8 grease fittings 102596114 Tire Inflation Check SMCS Code 4203 535 Al Table 32 Tire size and recommended inflation pressure cold for Caterpillar Skid Steer Loader C Series Models Size Ply Rating Pressure Caterpillar Premium 12x16 5 10 310 kPa 45 psi 3 10 bar Conventional Caterpillar Low Side Wall 305 546 10 310 kPa 45 psi 3 10 bar Caterpillar Extreme Duty 12x16 5 14 345 kPa 50 psi 3 45 bar Caterpillar Premium 33x15 5x16 5 12 240 kPa 35 psi 2 41 bar Conventional Floatation Galaxy Beefy Baby 12x16 5 10 310 kPa 45 psi 3 10 bar SEBU8019 05 173 Maintenance Section Wheel Nuts Tighten The ab
30. e When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes NOTICE When you are using compressed air or high pressure water to clean the radiator fins ensure that the air or water is directed parallel to the fins If the compressed air or high pressure water is not directed parallel to the radiator fins the radiator fins could be bent or dam aged Pressurized air is the preferred method for removing loose debris Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes The air nozzle should point in the opposite direction of the flow of the fan This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Use a degreaser and steam for removal of oil and grease Wash the core with detergent and hot water Thoroughly rinse the core with clean water After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Note Adjust the frequency of cleaning acco
31. e and rim 1 The weight of the standard tire and rim is 51 kg 113 Ib 5 Remove bolts and the cover 2 for the drive chain case Note Remove the sealant from the cover and from the machine Illustration 140 g01210016 6 Loosen the eight bolts 5 for the axle housing Place the chain tension adjuster 7 between the axle housings 6 Illustration 141 g01210018 7 Rotate the axle in order to ensure that the chain 8 is taut below the sprockets Place a straight edge across the top of the sprockets Measure the total amount of movement in the chain B Set the chain tension so that there is a total of 15 mm 0 6 inch movement in the chain This is equal to 7 5 mm 0 3 inch of movement above the straight edge and 7 5 mm 0 3 inch of movement below the straight edge Illustration 142 g00554036 SEBU8019 05 149 Maintenance Section Engine Air Filter Primary Element Clean Replace 8 Torque the nuts for the axle housing in the order that is shown above to 160 15 N m 118 11 Ib ft and turn an additional 60 5 in the same order 9 Remove the chain tension adjuster 10 Install the bolts and the cover for the drive chain case Note Use 8T 9022 Silicone Gasket in order to seal the cover to the machine 11 Use an appropriate nylon lifting strap and a hoist in order to position the tire and rim to the axle The weight of the tire and rim is 51 kg 113 Ib Refer to Operatio
32. e cover 2 Remove the air filter element from the duct and clean the filter element with low pressure air maximum 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the side of the filter opposite of the air flow Replace the element if the element is damaged or if the element seal is damaged Replace the element if the air conditioner performance is low Note Do not use water for cleaning the filter 3 Install the element Replace the cover and tighten the thumb screws 102616708 Cab Interior Clean SMCS Code 7301 070 The floor mat is removable The floor mat has sides in order to help retain the material 140 Maintenance Section Cooling System Coolant ELC Change SEBU8019 05 Illustration 122 g01312450 Floor mat in the cab The floor mat does not protect the foot pedal and the pedal linkage Debris may accumulate around the foot pedal The foot pedal must be kept clear of excessive dirt and debris in order to ensure proper activation of the pedal Debris must be cleaned from the area around the pedal This can be done after you remove the floor mat g01312452 Illustration 123 The drain on the left side of the machine You can wash the floor of the cab with water There is a drain in the front left corner of the floor of the cab i02807909
33. e maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual 6000 hour oil drain intervals are possible when using S 0 S Services oil analysis When you switch to Cat HYDO Advanced 10 cross contamination with the previous oil should be kept to less than 10 Consult your Cat dealer for details about the benefits from the improved performance designed into Cat HYDO Advanced 10 Oil Filters Caterpillar oil filters are recommended The interval for changing the oil filter should be 500 hours Oil The 6000 hour interval for changing the oil is specific to HYDO Advance 10 The 4000 hour interval for changing the oil is for the following oil types e Caterpillar Hydraulic Oil HYDO e Caterpillar Transmission and Drive Train Oil TDTO e Caterpillar TDTO TMS e Caterpillar Diesel Engine Oil e Caterpillar Biodegradable Hydraulic Oils HEES e Caterpillar Multipurpose Tractor Oil MTO e Heavy duty diesel engine oils with a minimum zinc content of 900 ppm If Caterpillar oils cannot be used use heavy duty oils with the following classification Caterpillar ECF 1 API CG 4 API CF and TO 4 These oils must have a minimum zinc additive of 0 09 percent 900 ppm Note Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems Monitoring the Condition of the Oil The oil should be monitored during intervals of 500 hours Caterpilla
34. e primary filter element can be used up to three times if the element is properly cleaned and if the element is properly inspected When the primary filter element is cleaned check for rips or tears in the filter material The primary filter element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings 1 Open the engine access door 2 The air filter housing is located on the right side of the engine compartment Illustration 143 g00101864 3 Unlatch the air cleaner housing cover 1 Rotate the cover counterclockwise and remove the cover 4 Remove the primary filter element 2 5 If itis appropriate clean the primary filter element Use air pressure to clean the primary filter elements Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Note When the primary filter elements are cleaned always begin with the inside in order to force dirt particles toward the outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary filter element 150 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU8019 05 6 Inspect the cleaned dry primary air filter element Use a 60 watt blue light in a dark room or ina simila
35. elt adjustment after 30 minutes of operation A belt is considered to be used after 30 minutes of operation Belts 1 Stop the engine in order to inspect the belt 2 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers g01209498 Illustration 113 3 Remove the four bolts 1 on the top of the guard Loosen the two bolts 2 on the bottom of the guard 4 Slide the guard upward from bottom bolts Remove the guard for the V belt 136 Maintenance Section Belts Inspect Adjust Replace SEBU8019 05 1 Inspect the condition of the belt and the adjustment of the belt The belt should deflect 10 mm 0 39 inch under a straight pull of 44 N 10 Ib This measurement should be taken between the air conditioner compressor pulley and the crankshaft pulley Illustration 114 g01209499 5 Inspect the condition of the belt 3 and the adjustment of the belt The belt should deflect 10 mm 0 39 inch under a straight pull of 44 N 10 Ib This measurement should be taken between the alternator pulley and the crankshaft pulley Note A 144 0235 Borroughs Belt Tension Gauge may be used to measure belt tension This measurement should be taken between the alternator pulley and the crankshaft pulley Refer to the following table for belt tension Table 31 Belt Tens
36. eration and Maintenance Manual Access Doors and Covers 2 Drain the coolant from the machine See Operation and Maintenance Manual Cooling System Coolant ELC Change for the procedure to drain the cooling system 146 Maintenance Section Drive Chain Case Oil Change SEBU8019 05 Illustration 133 g01018412 C2 2 PA DA j Al ges A VAN Illustration 134 g01210045 C3 4 3 Loosen the hose clamp 1 and remove the hose from the thermostat housing assembly 2 Remove the two bolts 3 from the thermostat housing assembly Remove the thermostat housing assembly Remove the seal and the thermostat from the thermostat housing assembly Install a new thermostat and a new seal Install the thermostat housing assembly on the engine cylinder head Install the hose Tighten the hose clamp 8 Refill the cooling system Refer to Operation and Maintenance Manual Capacities Refill Refer to Operation and Maintenance Manual Cooling System Coolant ELC Change for information about refilling the cooling system Refer to Special Publication SEBU6250 Caterpillar Machine Fluid Recommendations for coolant information 9 Close the engine access door 102417847 Drive Chain Case Oil Change SMCS Code 3261 543 OC 3261 544 OC
37. ery Cable Inspect Replace 103659214 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1401 561 1402 040 1402 510 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 The battery is located on the left side of the machine under the cab Raise the cab Refer to Operation and Maintenance Manual Cab Tilting for information on raising the cab 3 Disconnect the negative battery cable at the battery Note Do not allow the disconnected battery cable to contact the negative battery post 4 Disconnect the negative battery cable from the frame in order to inspect the cable 5 Disconnect the positive battery cable at the battery 6 Perform the necessary repairs Replace the cables or the battery as needed 7 Connect the positive battery cable at the battery 8 Connect the negative battery cable to the frame of the machine 9 Connect the negative battery cable at the battery 10 Lower the cab Refer to Operation and Maintenance Manual Cab Tilting for information on lowering the cab Recycle the Battery 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 102715751 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 If a new belt is installed check the b
38. es too loose This may be indicated by excessive movement in the blade oy Illustration 119 g01173519 A Trunnion Joint B Bolts C Shims e Remove the four retaining bolts B and the cap e Remove the necessary shims e Replace the cap and bolts e The tightening sequence is shown in illustration 119 e Torque the bolts to 530 70 N m 391 52 lb ft Note Some noise is typical and the noise does not indicate a problem 101743875 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket cutting edge is accessible 2 Place blocks under the raised edge of the bucket 3 Remove the bolts Remove the cutting edge and the end bits 4 Clean the contact surfaces 5 Use the opposite side of the cutting edge if this side is not worn 6 Install a new cutting edge if both edges are worn 7 Install the bolts 8 Remove the blocks that are under the bucket 9 After a few hours of operation check the bolts for proper torque 101764331 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the buck
39. et so that the bucket tips are accessible 2 Place blocks under the raised edge of the bucket 3 Remove the mounting bolts Remove the bucket tips SEBU8019 05 139 Maintenance Section Cab Air Filter Clean Replace 4 Clean the mounting surface a Replace the bucket tips o Install the bolts 7 Remove the blocks that are under the bucket 8 After a few hours of operation check the bolts for proper torque 102417532 Cab Air Filter Clean Replace If Equipped SMCS Code 7342 070 7342 510 Fresh Air Filter Note The cover for the cab air filter is located on the left hand side of the machine behind the cab Illustration 120 g01287414 1 Turn the thumb screw until the thumb screw is free from the duct Lift up on the cover and remove the cover 2 Remove the air filter element from the duct and clean the filter element with low pressure air maximum 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the side of the filter opposite of the air flow Replace the element if the element is damaged or if the element seal is damaged Replace the element if the air conditioner performance is low Note Do not use water for cleaning the filter 3 Install the element Replace the cover and tighten the thumb screw Recirculation Filter g01209486 Illustration 121 1 Turn the thumb screws until the thumb screws are free from the duct Remove th
40. he coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer SEBU8019 05 145 Maintenance Section Cooling System Level Check 102417701 Cooling System Level Check SMCS Code 1350 040 HX 1350 535 FLV 1382 070 1382 510 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward ir x 1 cn 2 9 g 8 om E gi g01210063 Illustration 131 1 Sight gauge 2 Radiator cap 3 Check the coolant level in the sight gauge 1 on the radiator Maintain the coolant level to the top of the sight gauge with the radiator in the LOWERED position If you need to add coolant add the
41. ic System Oil Level Check SMCS Code 5095 535 FLV _ _if x g o G Fi g01306294 Illustration 172 Filler for adding hydraulic oil Illustration 173 g01280697 2 Sight gauge on right side of tank 1 Park the machine on level ground 2 Lower the work tool to the ground Turn off the engine 3 Wait for about five minutes before checking the level of the hydraulic oil 4 Use the hydraulic oil filler on the radiator in order to top off the hydraulic oil 5 Maintain the oil level to the middle of the two lines on the sight gauge Do not overfill the hydraulic tank 102920120 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 7542 008 Open the rear access door Refer to Operation and Maintenance Manual Access Doors and Covers for information about the rear door Raise the radiator Refer to Operation and Maintenance Manual Radiator Tilting for information about the radiator 166 Maintenance Section Hydraulic Tank Breather Replace SEBU8019 05 Illustration 174 g01280271 The sampling port for the hydraulic oil is located on the fan motor 102557991 Hydraulic Tank Breather Replace SMCS Code 5050 510 BRE 5056 510 BRE 102418559 Lift Arm and Cyl
42. inder Linkage Lubricate SMCS Code 5102 086 BD 6107 086 BD Illustration 175 g01280304 The breather for the hydraulic tank is located on the top of the hydraulic tank 1 Raise the cab Refer to Operation and Maintenance Manual Cab Tilting for the procedure to raise the cab 2 Remove the breather 3 Install the new breather and tighten to 20 3 N m 15 2 lb ft Illustration 176 g01210414 Radial Lift 1 Lift Arm Pivot 2 Lift Cylinder Rod End 3 Head End Fitting Illustration 177 g01210415 Vertical Lift 1 Lift Arm Pivot 2 Lift Cylinder Rod End 3 Head End Fitting 4 Link Arm SEBU8019 05 167 Maintenance Section Lower Machine Frame Clean Illustration 178 g01210416 The Link Arm is located behind the loader arm 5 Mounting for Link Pin 6 Rear of Link Arm Apply lubricant to all the grease fittings on one side Repeat the process for the opposite side of the machine 102418560 Lower Machine Frame Clean SMCS Code 7050 070 1 Tilt the cab upward Refer to Operation and Maintenance Manual Cab Tilting Illustration 179 g01270620 This film is located in the air duct NOTICE Do not spray water or cleaning fluids into the venti lation ducts Cover the opening in order to prevent foreign material or fluid from entering the ventilation ducts 2 Seal the opening of the ventilation ducts
43. ion Belt Tension Initial Used 534 22 N 120 5 Ib 400 44 N 90 10 Ib 6 Loosen the mounting bolt 4 Loosen the adjusting locknut 5 7 Move the alternator until the correct tension is reached 8 Tighten the adjusting locknut Tighten the mounting bolt 9 Recheck the belt deflection If the amount of deflection is incorrect repeat step 5 to step 8 Air Conditioner if equipped Note If your machine is equipped with an air conditioner use the same procedure and the same measurements for the belt tension Illustration 115 g01279933 2 Loosen the mounting bolt 6 for the air conditioner compressor Loosen the adjusting locknut 7 for the air conditioner compressor 3 Move the air conditioner compressor until the correct tension is reached Note A hole 8 in the bracket has been provided in order to aid with the adjustment of the tension 4 Tighten the adjusting locknut Tighten the mounting bolt 5 Recheck the belt deflection If the amount of deflection is incorrect repeat step 2 to step 4 Finish 1 Apply thread lock compound to the threads on bolts 1 SEBU8019 05 137 Maintenance Section Blade Frame Adjust 10 11 Illustration 116 g01364054 2 Install the guard for the V belt 9 Ensure that the guard is inserted between the mounting bracket 10 and the spreader plate 11 before you tighten the bolts 2 Tighten the
44. l is between 0 05 and 0 50 An oil change interval of Every 250 Service Hours or every six months is required when the following conditions occur e Use an engine oil in the Operation and Maintenance Manual Lubricant Viscosities e The altitude exceeds 2300 m 7545 ft e Sulfur content in the fuel is between 0 50 and 1 00 An oil change interval of Every 125 Service Hours is required when the following condition occurs e Sulfur content in the fuel is above 1 00 Refer to the results of the S O S oil analysis in order to determine if the oil change interval should be decreased Consult your Caterpillar Dealer for detailed information regarding the optimum oil change interval 154 Maintenance Section Engine Oil and Filter Change SEBU8019 05 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting Note The crankcase drain is located on the right side of the oil pan Illustration 153 g01264593 3 Remove the access panel that is located below the drain plug Remove the drain plug and allow the oil to drain into a suitable container Install the drain plug and install the access panel Ill
45. lid Tires 163 7 N m 120 5 Ib ft 149 7 N m 110 5 Ib ft Pneumatic Tires 102418610 Window Washer Reservoir Fill If Equipped SMCS Code 7306 544 KE NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solvent or equivalent System damage can result from freezing Illustration 187 g01209248 The reservoir for the window washer solvent is located inside the cab by the left footrest Fill the reservoir with window washer solvent Window washer solvent with isopropyl alcohol is recommended 174 Maintenance Section Window Wiper Inspect Replace SEBU8019 05 102810705 Window Wiper Inspect Replace If Equipped SMCS Code 7305 040 7305 510 Inspect the condition of the front window wiper blade Replace the window wiper blade if the window wiper blade is worn or damaged If the window wiper blade streaks the window replace the window wiper blade 102418633 Windows Clean SMCS Code 7310 070 Rear Window and Glass Front Door Use commercially available window cleaning solutions in order to clean the windows Apply the cleaning solution liberally Wipe the surface Dry the surface in order to prevent spots Side Windows Use commercially available window cleaning solutions in order to clean the windows The side windows of the cab can be removed for cleaning Refer to the following
46. n 173 Window Wiper Inspect Replace 0 00 174 Windows Clean ou ee ee cccecccceeeces cesses aeeeeeneeeees 174 Every 10 Service Hours or Daily Air Cleaner Dust Valve Clean Inspect 133 Backup Alarm Test 2 ecceeceeeeeeeeeeeeeeeees 134 Cooling System Level Check n se 145 Engine Compartment Inspect Clean 152 Engine Oil Level Check ccceeeeeeeereeeeneeeees 152 Equipment Lowering Control Valve Check 155 Fuel System Primary Filter Water Separator Drai ii eeraa tee aiden eee La donde eet 156 Hydraulic System Oil Level Check 165 Lift Arm and Cylinder Linkage Lubricate 166 Quick Coupler Clean Inspect eee 168 Seat Belt Inspect occ ee eeeeeeeeeceeeeeeeeees 171 Tilt Cylinder Bearings and Bucket Linkage Bearings LUDIC cresket anan eea E fiaansecsts aaeg 171 Tire Inflation Check asseeeseesseerressssrrrssrrrrsesns 172 Wheel Nuts Tighten i e 173 Work Tool Lubricate 0 0 0 cceeeeeeeereeeeeeeeeeeeeeee 175 Work Tool Mounting Bracket Inspect 177 Every 250 Service Hours or Monthly Belts Inspect Adjust Replace eee 135 Every 500 Service Hours Cooling System Coolant Sample Level 1 OD aI e een titeees ae eeeeeri ADA 143 Hydraulic System Oil Sample Obtain 165 Every 500 Service Hours or 3 Months Drive Chain Case Oil Check 147 D
47. n and Maintenance Manual Wheel Nuts Tighten for the procedure to tighten the wheel nuts 12 Repeat the procedure on the opposite side of the machine if it is necessary 13 Lower the machine to the ground 102417909 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Never service the air cleaner when the engine is run ning to avoid engine damage NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components Service the air filter elements when the alert indicator for air filter restriction lights Refer to Operation and Maintenance Manual Alert Indicators for information about the indicator Clean Th
48. oil 2 Apply 169 5464 Quick Cure Primer and 5P 3413 Pipe Sealant to the threads on the filler plug Install the filler plug 3 Repeat the process for the left side drive chain case 102710828 Drive Chain Tension Check Adjust SMCS Code 3261 025 3261 535 Note Steel tracks that go over the tires should only be used with pneumatic tires When you use steel tracks that go over tires or any drive train device except tires the interval for checking the drive chains should be reduced to every 100 Service Hours The use of rubber tracks that go over the tires is not recommended Note There are four drive chains on the skid steer loader that must be checked and adjusted 148 Maintenance Section Drive Chain Tension Check Adjust SEBU8019 05 1 Park the machine on level ground and stable ground 2 Use appropriate floor jacks in order to lift the machine off the ground Illustration 138 g01360620 3 Rotate the front wheel forward and backward Measure the total free play A Repeat the process for the rear wheel Note If the total free play A does not exceed 15 mm 0 6 inch the chain tension does not need further inspection If the total free play exceeds 15 mm 0 6 inch you should continue with the inspection A Illustration 139 g01360622 4 Remove the wheel nuts 3 Use an appropriate nylon lifting strap and a hoist in order to remove the tir
49. oil Clean the oil filler plug and install the oil filler plug SEBU8019 05 155 Maintenance Section Engine Valve Lash Check 9 Start the engine and allow the oil to warm Check for leaks Illustration 156 g01277108 1 Oil level add mark 2 Full mark 10 Stop the engine and allow the oil to drain back into the oil pan Fill the crankcase to the FULL mark 2 on the dipstick Do not exceed the FULL mark on the dipstick Add oil or drain oil if it is necessary 11 Tilt the radiator downward 12 Close the engine access door 101020861 Engine Valve Lash Check SMCS Code 1105 025 Refer to the Service Manual for the complete adjustment procedure for the engine valve lash A qualified mechanic should adjust the engine valve lash and the fuel injector timing because special tools and training are required 102808037 Equipment Lowering Control Valve Check SMCS Code 5147 MA Personal injury or death can result from a work tool falling Keep personnel away from the front of the ma chine when lowering the work tool Before lowering any equipment clear the area around the equipment of all personnel 1 Lower arms to the fully lowered position Turn the keyswitch to the OFF position 2 Slide the seat forward Slide the left hand armrest forward Illustration 157 g01400888 3 Pull up on the red handle in order to fully actuate the valve 4 Push the
50. ompartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers ne ee oo A 3 2 1 Illustration 158 g01264527 The Fuel Filter Water Separator is located on the left side of the engine compartment 2 Insert the drain hose 3 into a suitable container Loosen the drain valve on the bottom of the water separator 3 Tighten the drain valve by hand Do not tighten the drain valve with a tool Damage to the valve or to the seals may occur 4 Close the engine access door 5 Dispose of the water and sediment according to local regulations 102520124 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note This unit has a dual purpose The element serves as a water separator and a fuel fil
51. ool Lubricate SMCS Code 6700 086 Multipurpose Bucket Illustration 189 g01280216 Apply lubricant to the grease fitting 1 for the pivot pin of the apron Apply lubricant to the grease fitting 2 for the rod end of the multipurpose bucket cylinder Apply lubricant to the grease fitting 3 for the head end of the multipurpose bucket cylinder Repeat for the other side of the bucket There are six grease fittings Utility Grapple Bucket and Utility Grapple Fork Illustration 190 g00647980 Apply lubricant to the four grease fittings for the grapples Illustration 191 g00647988 Apply lubricant to the two fittings for the grapple cylinder There are six grease fittings Industrial Grapple Bucket and Industrial Grapple Fork Illustration 192 g00645995 Apply lubricant to the four grease fittings for the fork cylinders Illustration 193 g00646004 176 Maintenance Section Work Tool Lubricate SEBU8019 05 Apply lubricant to the four grease fittings for the two forks There are eight grease fittings Grapple Rake Illustration 194 g01368386 Apply lubricant to the four grease fittings for the grapple cylinders Apply lubricant to the four grease fittings for the two grapples There are eight grease fittings Angle Blade g00648033 Illustration 195 Apply lubricant to the grease fitting on the rod end of
52. order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 102634143 Quick Coupler Clean Inspect SMCS Code 6129 040 6129 070 Personal injury or death can result from improp erly checking for a leak Always use a board or cardboard when checking for a leak Escaping air or fluid under pressure even a pin hole size leak can penetrate body tis sue causing serious injury and possible death If fluid is injected into your skin it must be treated immediately by a doctor familiar with this type of injury Note Do not weld on the quick coupler without consulting your Caterpillar dealer 1 Clean the quick coupler prior to inspection in order to properly inspect the quick coupler FZ Illustration 182 g01322438 This is the back side of the quick coupler The lift arm and the tilt cylinder are removed for clarity 2 Tilt the quick coupler all the way forward in order to clean the debris away from the pins 3 Move the quick coupler levers Ensure that the levers are not bent or broken 4 Make sure that the coupler pins extend through the b
53. ottom of the quick coupler assembly Check the pins for wear and check the pins for damage SEBU8019 05 169 Maintenance Section Radiator Core Clean 5 Check the top edges of the quick coupler assembly for wear or for damage Check the face of the quick coupler assembly for wear or for damage 6 Inspect the components inside the quick coupler for the following problems loose bolts oil leaks broken parts missing parts and cracked components 7 Inspect the hydraulic lines and the hydraulic fittings for damage or for wear Repair any worn components or replace any worn components Repair any leaking components 8 Inspect the steel material of the quick coupler for cracks Note Perform all repairs before placing the quick coupler back into operation 102575087 Radiator Core Clean SMCS Code 1353 070 KO The radiator is located at the rear of the machine above the engine compartment Note Adjust the frequency of cleaning according to the effects of the operating environment On models 272C and 297C clean the aftercooler core when you clean the radiator core 1 Stop the engine Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting Personal injury can result from air pressure Personal injury can result without following prop er procedure When using p
54. ove recommended tire inflation pressure is based on a standard machine with the following conditions e 75 kg operator e Typical operating conditions e Full fluid levels e The machine weight and the weight of the work tool must not exceed the weight limit on the ROPS certification Note Consult your Caterpillar dealer if your machine is experiencing excessive tire slippage Slippage may be the result of tire wear Inflate the tires if necessary Tire Inflation with Air Use a self attaching inflation chuck and stand be hind the tread when inflating a tire Proper inflation equipment and training in using the equipment are necessary to avoid overinfla tion A tire blowout or rim failure can result from improper or misused equipment Before inflating tire install on the machine or put tire in restraining device NOTICE Set the tire inflation equipment regulator at no more than 140 kPa 20 psi over the recommended tire pressure 102558956 Wheel Nuts Tighten SMCS Code 4210 527 When wheels are installed check the torque after every one service hour until the specified torque is maintained After the specified torque is maintained check the torque on the nuts after every ten service hours or every day Check the nuts on all four wheels Use a star pattern when you are tightening the nuts The torque specifications are given in the following table Table 33 Tightening Torque for Wheels So
55. pen cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure When a Caterpillar Extended Life Coolant is used an extender must be added to the cooling system periodically 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting i _if x 1 Bard E in 2 O 9 g g E G FF g01210063 Illustration 127 1 Sight gauge 2 Radiator cap Note The radiator cap is located on the right side of the radiator 3 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap oxy wy Y E e 0 0 5 _ oA pe o KOR A Illustration 128 g01279512 Coolant drain 4 If necessary drain enough coolant from the radiator in order to allow the addition of the coolant additive 5 Add 0 17 L 0 18 qt of cooling system additive SEBU8019 05 143 Maintenance Section Cooling System Coolant Sample Level 1 Obtain 6 Inspect the radiator cap and the gasket If the cap or the gasket is damaged replace the cap Install the radiator cap Note The sight gauge for the
56. r facility Place the blue light in the primary air filter element Rotate the primary air filter element Inspect the primary air filter element for tears and or holes Inspect the primary air filter element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air filter element to a new primary air filter element that has the same part number Note Do not use a primary air filter element that has any tears and or holes in the filter material Do not use a primary air filter element with damaged pleats gaskets or seals Discard damaged primary air filter elements 7 Clean the inside of the air cleaner housing with a damp cloth Do not use compressed air to clean the housing 8 Install the primary filter element into the filter housing 9 Install the cover for the filter housing Illustration 144 g01276795 10 Rotate the cover clockwise and latch the cover Note Make sure that the cover is properly positioned The arrows on the air filter cover should point upward when the cover is in the locked position 11 Close the engine access door 12 Start the engine The alert indicator for air filter restriction should turn off If the alert indicator continues to light replace the secondary air filter Refer to Operation and Maintenance Manual Engine Air Filter Secondary Element Replace Replace The primary filter element should be replaced
57. r s standard SOS Fluids Analysis or an equivalent oil sampling program should be used The current guidelines for cleanliness of the oil should be observed Refer to Measured Data If an oil sampling program is not available the standard 2000 oil change interval should be used Measured Data The following information should be monitored through sampling of the oil e Significant changes in wear metals should be monitored These metals include iron copper chromium lead aluminum and tin Significant changes in the following additives should be monitored zinc calcium magnesium and phosphorus e Contaminants should not be present These contaminants include fuel and antifreeze Water content should be 5 percent or less e The silicon level should not exceed 15 parts per million for new oil The particle counts should be monitored e The recommended level of cleanliness for Caterpillar machines that are operated in the field is ISO 18 15 or cleaner The cleanliness should be monitored by particle count analysis The levels of contamination should not exceed the normal by more than two ISO codes Action should be taken in order to determine the cause of the contamination The system should be returned to the original levels of contamination e There should not be significant changes in sodium silicon copper and potassium SEBU8019 05 163 Maintenance Section Hydraulic System Oil Change e The allow
58. rding to the effects of the operating environment If there is an extreme amount of debris you may need to remove the air conditioning condenser or the cover plate from the fan housing for the aftercooler Close the grill and replace the retaining pin SEBU8019 05 133 Maintenance Section Aftercooler Intake Screen Clean 102559029 Aftercooler Intake Screen Clean SMCS Code 1063 070 Z3 S N RED1 Up Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Note Adjust the frequency of cleaning according to the effects of the operating environment Note Pressurized air is the preferred method for removing loose debris Pressurized water may also be used for cleaning Use pressurized water in order to soften mud Clean the screen from both sides The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi 1 Turn off the engine Illustration 110 g01281019 1 Cylinder for the lift arm 2 Air inlet screen 3 Hydraulic tank 4 Electrical connectors N Access the screen from the right side of the machine Hold the nozzle approximately 6 mm 0 25 inch away from the screen Ensure that the spray nozzle is past the electrical connections
59. red handle to the original position Ensure that the handle is fully seated 100916186 Fuel Injection Timing Check SMCS Code 1251 531 Note The correct fuel timing specification is found on the Engine Information Plate Fuel timing specifications may vary for different engine applications and or for different power ratings A qualified mechanic should adjust the fuel injection timing because special tools and training are required Refer to the Service Manual for the complete adjustment procedure for the fuel injection timing Refer to your Caterpillar dealer for the complete adjustment procedure for the fuel injection timing 156 Maintenance Section Fuel System Primary Filter Water Separator Drain SEBU8019 05 102520136 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection 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 The fuel system water separator is located in the left side of the engine c
60. ressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes NOTICE When you are using compressed air or high pressure water to clean the radiator fins ensure that the air or water is directed parallel to the fins If the compressed air or high pressure water is not directed parallel to the radiator fins the radiator fins could be bent or dam aged Note Pressurized air is the preferred method for removing loose debris Hold the nozzle approximately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes The air nozzle should point in the opposite direction of the flow of the fan This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Use a degreaser and steam for removal of oil and grease Wash the core with detergent and hot water Thoroughly rinse the core with clean water 3 Clean the radiator core from the top toward the fan Note If parts of the cooling system appear to be damaged or if parts of the cooling system are repaired a leak test is highly recommended Consult your Caterpillar dealer for the most current information about the cooling system 4 After cleaning start the engine
61. rimary filter element is cleaned for the third time the secondary filter element should be replaced The secondary filter element should also be replaced if the restricted Air Filter indicator comes on after the installation of a clean primary filter element or if the exhaust smoke is still black 1 Open the engine access door 2 The air filter housing is located on the right side of the engine compartment Illustration 147 g00101864 3 Unlatch the air cleaner housing cover 1 Rotate the cover counterclockwise and remove the cover 4 Remove the primary filter element 2 Illustration 148 g00038606 5 Clean the inside of the air cleaner housing with a damp cloth Do not use compressed air to clean the housing 6 Remove the secondary filter element 7 Cover the air inlet opening 8 Clean the inside of the air cleaner housing with a damp cloth if necessary Do not use compressed air to clean the housing 9 Uncover the air inlet opening 10 Install a new secondary element 11 Install the primary element 12 Install the cover for the filter housing 152 Maintenance Section Engine Compartment Inspect Clean SEBU8019 05 Illustration 149 g01276795 13 Rotate the cover clockwise and latch the cover Note Make sure that the cover is properly positioned The arrows on the air filter cover should point upward when the cover is in the locked position 14 Close the engine
62. rive Chain Tension Check Adjust 147 Every 500 Service Hours or 6 Months Fuel System Primary Filter Water Separator Element Replace ececceeeeeeeeeeeeeeeeees 156 Hydraulic System Oil Filter Replace 164 Every 500 Service Hours or 1 Year Engine Oil and Filter Change s e 153 Hydraulic Tank Breather Replace 5 166 Every 1000 Service Hours Engine Valve Lash Check c ceeseeeeeeeeeeeees 155 Every 1000 Service Hours or 6 Months Drive Chain Case Oil Change cees 146 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 170 SEBU8019 05 131 Maintenance Section Maintenance Interval Schedule Every 2000 Service Hours Refrigerant Dryer Replace n se 170 Every 2000 Service Hours or 1 Year Fuel Injection Timing Check n se 155 Hydraulic System Oil Change ee 162 Every Year Cooling System Coolant Sample Level 2 Obtain shaken E T 144 Every 3000 Service Hours or 2 Years Cooling System Water Temperature Regulator Replace ste Sie tia a tania 145 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccccceceeeeseeeeseseeeeeees 171 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 142 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change
63. s In order to change these fuses push up on the locking tab on the fuse cover Pull the cover away from the back of the cab 26 27 28 E lt BE bes 20A 20A 20A Illustration 167 g01279483 26 Ignition switch 27 ECM 28 Horn 29 Main power relay 1 30 Miscellaneous cab accessories 31 Main power relay 2 0000 162 Maintenance Section Hydraulic System Oil Change SEBU8019 05 103740801 Hydraulic System Oil Change SMCS Code 5095 044 Selection of the Oil Change Interval Your machine may be able to use a 4000 hour interval for the hydraulic oil The hydraulic oil is in the system that is not integral to the service brakes the clutches the final drives or the differentials The standard change interval is 2000 hours The oil should be monitored during intervals of 500 hours The extended 4000 hour interval can be used if the following criteria are met HYDO Advanced 10 Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic and hydrostatic transmission systems when ambient temperature is between 20 C 4 F and 40 C 104 F Cat HYDO Advanced 10 has an SAE viscosity grade of 10W Cat HYDO Advanced 10 has a 50 increase in the standard oil drain interval up to 3000 hours for machine hydraulic systems over second and third choice oils when you follow th
64. s while you press several times on each side of the auxiliary hydraulic control if equipped in order to relieve hydraulic pressure Move the engine start switch key to the OFF position Illustration 169 g01280697 1 Hydraulic oil tank cap 2 Sight Gauge 1 Remove the hydraulic oil tank cap 1 g01333250 Illustration 170 Access panel 164 Maintenance Section Hydraulic System Oil Filter Replace SEBU8019 05 2 Remove the access panel in the belly guard underneath the machine 3 The hose is located on the right side Pull the drain hose through the access hole in the belly guard Remove the plug from the end of the drain hose Drain the oil into a suitable container 4 Install the drain plug into the drain hose Tighten to 22 3 N m 16 2 Ib ft Pull the drain hose back into the machine 5 Change the hydraulic system filter Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Change 6 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill for the type of oil and the proper amount of oil 7 Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check Maintain the hydraulic oil level approximately in the middle of the sight gauge 2 Check the oil level with the loader arms in the fully lowered position Note
65. ter 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers SEBU8019 05 157 Maintenance Section Fuel System Priming Pump Operate ee oo 3 2 l Illustration 159 g01264527 The Fuel Filter Water Separator is located on the left side of the engine compartment 2 Open the drain on the fuel filter water separator 3 Allow the water and fuel to drain into a suitable container 3 Close the drain valve by hand Do not tighten the drain valve with a tool Damage to the valve or to the seals may occur 4 Support the fuel filter water separator and rotate the locking ring 1 counterclockwise Remove the fuel filter water separator 5 Rotate the locking ring 2 counterclockwise Remove the bowl assembly 6 Clean the mounting base for the fuel filter water separator 7 Clean the bowl assembly for the fuel water separator 8 Install the bowl assembly onto the new fuel water separator and rotate the locking ring clockwise 9 Install the new fuel filter water separator onto the mounting base Rotate the locking ring clockwise in order to fasten the fuel filter water separator to the mounting base 10 Prime the fuel system in order to fill the fuel filter water separator with fuel Refer to Operation and Maintenance Manual Fuel System Priming Pump Operate
66. the cap is damaged 3 Wash the fuel cap in a clean nonflammable solvent and dry the fuel cap 4 Put a light coating of fuel on the cap gasket 5 Install the fuel cap 102418544 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S 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 Drain the water and the sediment from the fuel tank when the tank is almost empty 1 Slowly remove the fuel tank cap in order to allow the tank to vent while you drain the tank Illustration 161 g01209601 2 The fuel tank drain plug is located on the bottom of the fuel tank in the engine compartment on the right side of the machine Remove the plug 3 Allow the water and the sediment to drain into a suitable container 4 Install the fuel tank drain plug Note Apply 5P 3413 Pipe Sealant to the threads on the drain plug 5 Install the fuel tank cap 102417559 Fuses Replace SMCS Code 141
67. ustration 154 g01209695 4 Remove the filter element with a 187 2718 Filter Wrench Refer to Operation and Maintenance Manual Oil Filter Inspect in order to inspect the used filter for debris 5 Apply a thin film of clean engine oil to the sealing surface of the new filter element 6 Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter g01209758 Illustration 155 1 Oil Filler Cap 2 Dipstick 8 Remove the oil filler cap 1 Fill the crankcase with new oil Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities for information about the
68. ve any part of the filter element gasket that remains on the filter element mounting base 5 Apply a light coat of oil to the gasket of the new filter element gasket 6 Install a newfilter hand tight until the seal of the filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter SEBU8019 05 165 Maintenance Section Hydraulic System Oil Level Check Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 8 Maintain the hydraulic oil level to the middle of the sight gauge Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check Do not overfill the hydraulic tank 9 Inspect the gasket on the hydraulic tank filler cap for damage Replace the hydraulic tank filler cap if necessary Install the hydraulic tank filler cap 10 Close the engine access door 102418557 Hydraul
69. your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 102429594 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 elie moe 4 g01152685 Illustration 185 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension Tilt Cylinder Bearings and Bucket Linkage Bearings Lu

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