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MAINTENANCE INTERVALS - Safety

1. Illustration 264 g01189335 2 Inspect the radiator core for dust or debris 3 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator fins However the use of compressed air is preferred 4 Close the right side access cover SEBU8021 10 171 Maintenance Section Receiver Dryer Refrigerant Replace 102723802 Receiver Dryer Refrigerant Replace SMCS Code 7322 510 7322 710 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system NOTICE If th
2. 1 Open the right side access door 2 Loosen the drain valve on the bottom of the water separator Allow the water and the sediment to drain into a suitable container 3 Tighten the drain valve 4 Close the right side access door 102379771 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR Illustration 242 g01188331 1 Remove the fuel cap 1 and the fuel fill screen 2 Illustration 243 g00104238 2 Inspect the cap Replace the cap if the cap is damaged Illustration 244 g00104239 3 Wash the fuel fill screen in a clean nonflammable solvent and dry the fuel fill screen 4 Install the fuel fill screen 5 Puta light coating of fuel oil on the cap gasket 6 Install the fuel cap SEBU8021 10 163 Maintenance Section Fuel Tank Water and Sediment Drain 102386891 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 Illustration 245 g01191079 Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 1 Open the drain valve that is located under the fuel tank Allow the water and the sediment to drain into a suitable container Note Discard the drained fluids according to local regulations 2 Close the drain valve 102429405 Fuses Replace SMCS Code 1417 510 1 a gt 8 4
3. How To Take A Good Oil Sample for more information about obtaining a sample of the final drive oil 102166043 Fuel System Prime SMCS Code 1250 548 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates SEBU8021 10 161 Maintenance Section Fuel System Primary Filter Water Separator Element Replace LL Illustration 239 g01098216 1 Operate the fuel priming pump plunger in order to fill the new filter element with fuel Continue to pump until a resistance is felt This resistance will indicate that the filter element is full of fuel 2 Start the engine If the engine will not start further priming is necessary If the engine starts but the engine continues to misfire further priming is necessary If the engine starts but the engine continues to emit smoke further priming is necessary 3 If the engine starts but the engine runs rough continue to run the engine at low idle Continue to run the engine at low
4. Note To check the belt tension apply 98 N 22 Ib of force midway between the pulleys Correctly adjusted belts will deflect 8 to 11 mm 5 16 to 7 16 inch 3 If the deflection is not correct loosen nut 7 Turn adjusting bolt 8 in order to adjust the belt tension 4 Adjust the belt tension 5 When the adjustment is correct tighten bolt 7 to a torque of 28 7 N m 21 5 Ib ft and tighten bolts 8 to a torque of 28 7 N m 21 5 lb ft 6 Check the deflection again 7 Close the engine access door Note If a new belt is installed check the belt adjustment again after 30 minutes of engine operation at the rated speed 102304927 Blade Linkage Lubricate SMCS Code 6060 086 Lower all the work tools and the blade to the ground Wipe all grease fittings before lubricating Illustration 178 g00823677 1 Apply lubricant to grease fitting 2 at the head end of the blade cylinder Apply lubricant to grease fitting 1 at the rod end of the blade cylinder 2 Apply lubricant to grease fittings 3 and 4 for the blade linkage Angle Blade If Equipped Illustration 179 g01154347 1 Apply lubricant to grease fitting 2 at the head end of the blade cylinder Apply lubricant to grease fitting 1 at the rod end of the blade cylinder 140 Maintenance Section Boom and Stick Linkage Lubricate SEBU8021 10 2 Apply lubricant to grease fittings 3
5. Proper repair of frames and structures requires specific knowledge of the following subjects e Materials that have been used to manufacture the frame members e Frame member construction e Repair techniques that are recommended by the manufacturer Consult your Caterpillar dealer if repairs are necessary Your Caterpillar dealer is qualified to carry out repairs on your behalf All repairs should be carried out by a Caterpillar dealer If you carry out your own repairs contact your Caterpillar dealer for advice about proper repair techniques Particular attention should be given to all welded structures The following items should be thoroughly inspected for cracks and for defects e Boom e Stick e Blade e Lifting points e Upper frame e Lower frame NOTICE The areas highlighted are of particular importance but other areas must not be neglected The entire struc ture must be carefully examined SEBU8021 10 141 Maintenance Section Boom Stick and Frame Inspect Boom Check all welded joints and check the mounting points for the cylinder Lifting Points Illustration 181 g01425291 Check all welded joints and check the mounting points for the cylinder go1425213 Illustration 184 Stick g00309343 Illustration 185 Illustration 182 Seem Check the approved lifting points carefully Check 7 the weld
6. SEBU8021 10 137 Maintenance Section Air Conditioner Cab Heater Filter Recirculation Inspect Replace 102788833 Air Conditioner Cab Heater Filter Recirculation Inspect Replace SMCS Code 1054 040 A C 1054 510 A C NOTICE An air recirculation filter element plugged with dust will result in decreased performance and service life to the air conditioner or cab heater To prevent decreased performance clean the filter el ement as required oF ey 2 Illustration 175 g01213860 The filter element is located on the lower right side of the cab 1 In order to remove the filter element slide the filter element outward 2 Inspect the filter element If the filter element is dirty clean the filter element with a mild solution of soap and warm water Note Do not use organic solvents in order to clean the filter element 3 The filter element may also be cleaned with a maximum of 200 kPa 30 psi pressure air Note Refer to Operation and Maintenance Manual General Hazard Information before using pressure air to clean the filter element 4 After you clean the filter element inspect the filter element If the filter element is damaged or badly contaminated use a new filter element 5 Make sure that the filter element is dry Install the filter element into the filter housing Make sure that the filter element is seated in the bottom of the fil
7. e A maximum water temperature of 50 C 120 F e Hold the nozzle perpendicular to the product identification film at a minimum distance of 305 mm 12 inch e Do not direct a stream of water at a sharp angle to the edge of the product identification film 103149045 Final Drive Oil Change SMCS Code 4050 044 FLV Illustration 233 g00740859 Type 1 1 Oil drain plug 2 Oil level plug 3 Oil filler plug Illustration 234 g01619618 Type 2 1 Oil drain plug 2 Oil level plug 3 Oil filler plug Note Your machine may be equipped with a Type 1 final drive or your machine may be equipped with a Type 2 final drive SEBU8021 10 159 Maintenance Section Final Drive Oil Level Check 1 Position one final drive so that oil drain plug 1 is at the bottom Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage 2 Remove oil drain plug 1 level plug 2 and filler plug 3 Allow the oil to drain into a suitable container 3 Clean the plugs and inspect the plugs Replace a worn plug or a damaged plug 4 Apply pipe sealant to oil drain plug 1 level plug 2 and filler plug 3 5 Install drain plug 1 6 Add oil through the opening of filler plug 3 7 Fill the final drive to the bottom of the opening for level plug 2 Refer to Operation and Maintenance Manual Lubricant Viscosit
8. Sa va 20 ES nw 2 30A 3 15A 19 ae 5A 20A 6 ze 1s 18 10A E 156A 7 5A 10A 8 17 lt 10A 5 10A 9 46 _ L__a_ A A 5A 15A _ ea i 15 30A 3 10A C So 7 15A gt Bs 10A 12 C 14 13 Illustration 246 g01213878 The fuse panel is located inside the access cover below the operator s seat Open the access cover for fuse access Fuses Fuses protect the electrical system from damage that is caused by overloaded circuits Change a fuse if the element separates If the element of a new fuse separates check the circuit and or repair the circuit NOTICE Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result NOTICE If it is necessary to replace fuses frequently an elec trical problem may exist Contact your Caterpillar dealer To replace a fuse use a puller that is stored in the fuse panel The following spare fuses are contained in the fuse panel 164 Maintenance Section Hydraulic System Oil Change SEBU8021 10 e 5 Amperes e 10 Amperes e 15 Amperes e 20 Amperes e 30 Amperes The following list identifies the circuits that are protected by each fuse The amperage for each fuse is included with each circuit 2 3 1 N 2 5 30A 19 N oani 5A 6 a a Se 18 7 EE 8 17 9 16 10 12 14 13 g01191716 Illustration 247 1 Engine St
9. and 4 for the blade linkage Apply lubricant to grease fittings 5 for the center pin of the angle blade 3 Apply lubricant to grease fitting 6 at the head end of the cylinder of the angle blade Apply lubricant to grease fitting 7 at the rod end of the cylinder of the angle blade 102386747 Boom and Stick Linkage Lubricate SMCS Code 6501 086 6502 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the boom and stick linkage Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on grease Position the machine into the service position Wipe all fittings before you apply lubricant g01190209 Illustration 180 Apply lubricant to the grease fittings i02860835 Boom Stick and Frame Inspect SMCS Code 6501 6502 6506 All earthmoving equipment is prone to a high degree of wear Regular inspections for structural damage are necessary The interval between these inspections depends on the factors that follow e The age of the machine e The severity of the application e The loads that have been carried on the machine e The amount of routine servicing that has been carried out If the machine has been involved in any kind of accident the machine must be inspected thoroughly Inspect the machine regardless of the date of the last inspection The machine must be clean before the machine is inspected
10. Fluids Recommendations or consult your Caterpillar dealer 102379557 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 1054 510 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 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 if 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 e
11. Machines that are used in severe conditions are not included in the maintenance interval of 4000 service hours or 2 years Machines that are used in severe conditions must use the interval in the Maintenance Interval Schedule Cat HYDO Advanced 10 Oil Change Interval The standard Cat HYDO Advanced 10 oil change interval is every 3000 service hours or 18 months SEBU8021 10 165 Maintenance Section Hydraulic System Oil Change A maintenance interval of 6000 service hours or 3 years for changing the hydraulic oil is available The extended interval requires S O S monitoring of the hydraulic oil The interval for S O S monitoring is every 500 hours The maintenance interval for the hydraulic oil filter is not changed Machines with hammers are not included in the maintenance interval of 6000 service hours or 3 years Machines with hammers must use the intervals that are listed in the Maintenance Interval Schedule Machines that are used in severe conditions are not included in the maintenance interval of 6000 service hours or 3 years Machines that are used in severe conditions must use the interval in the Maintenance Interval Schedule Procedure to Change the Hydraulic Oil Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 1 Park the machine on level ground Illustratio
12. and Maintenance Manual SEBU6250 Caterpillar Coolant Recommendations or consult your Caterpillar dealer 102379547 Cooling System Coolant Level Check SMCS Code 1350 040 1350 535 FLV 1395 535 FLV Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure 1 Open the right side access door POL QAR LOW QALY Illustration 212 g00824033 2 Maintain the coolant level between FULL mark A on the coolant reservoir and LOW mark B on the coolant reservoir Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage 3 If additional coolant is necessary remove the filler cap for the coolant reservoir and add the appropriate coolant mixture Install the filler cap MI W nil W y TANI T bere Illustration 213 g01188129 4 If the coolant reservoir is empty remove the cooling system pressure cap slowly in order to relieve pressure Add coolant to the radiator Illustration 214 g00102170 5 Inspect the condition of the cap gasket If necessary replace the cap 6 Install the cooling system pressure cap 7 Close the right side access door 102425978 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1395 008 1395 554 7542 Note It
13. idle until the engine runs smoothly Fuel System Primary Filter Water Separator Element Replace SMCS Code 1263 510 FQ Illustration 240 1 Open the right side access door 2 Open the drain on the water separator bowl 3 Allow the water and fuel to drain into a suitable container 3 Support the fuel filter water separator element and rotate the locking ring 1 counterclockwise Remove the primary filter water separator 4 Remove the water separator bowl 2 from the bottom of the fuel filter water separator Note The water separator bowl is reusable Do not discard the water separator bowl 5 Inspect the O ring seal of the water separator bowl for damage Replace the O ring seal if necessary 6 Lubricate the O ring seal with clean diesel fuel or lubricate the O ring seal with clean motor oil Place the seal in the water separator bowl 7 Spin the water separator bowl onto the new element by hand until the fuel filter water separator is snug Do not use tools to tighten the fuel filter water separator element to the bowl 8 Clean the filter mounting base 9 Install the new element Rotate the locking ring clockwise in order to fasten the filter to the mounting base 10 Close the right side access door 162 Maintenance Section Fuel System Water Separator Drain SEBU8021 10 102379338 Fuel System Water Separator Drain SMCS Code 1263 SBN Illustration 241 g01188000
14. lubricant through fittings for the bucket 3 and 4 Note Service the above fittings after you operate the bucket under water 102869831 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket tips or side cutters SEBU8021 10 143 Maintenance Section Bucket Tips Inspect Replace Bucket Tips g00101352 Illustration 189 1 Usable 2 Replace this bucket tip 3 Overworn Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip Illustration 190 g01429324 1 Block the bucket 2 Remove mounting bolts 6 and nuts 5 Remove bucket tip 4 3 Clean the mounting surfaces 4 Install the new bucket tip onto the adapter 102798352 Bucket Tips Inspect Replace J200 Tips SMCS Code 6805 040 6805 510 Block the bucket before changing the bucket teeth To prevent possible injury to the eyes wear a pro tective face shield when striking the pin The pin when struck can fly out and cause injury to nearby personnel Bucket Tips g00101352 Illustration 191 1 Usable 2 Replace this bucket tip 3 Overworn Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip 1 Remove the pin from the bucket tip The pin can be removed by one of the following methods e Use a hammer a
15. oil level The oil should be near the bottom of the opening of level plug 2 160 Maintenance Section Final Drive Oil Sample Obtain SEBU8021 10 4 Add oil through the opening of filler plug 3 if necessary Note Overfilling the final drive will cause the seals on the travel motor to allow hydraulic oil or water to enter the final drive This may contaminate the final drive 5 Clean oil level plug 2 and filler plug 3 6 Apply pipe sealant to oil level plug 2 and filler plug 3 7 Install oil level plug 2 8 Install oil filler plug 3 9 Repeat the procedure for the other final drive 104656910 Final Drive Oil Sample Obtain SMCS Code 4011 008 4050 008 4050 SM 7542 008 Illustration 237 g00740859 Type 1 1 Oil drain plug 2 Oil level plug 3 Oil filler plug Illustration 238 g01619618 Type 2 1 Oil drain plug 2 Oil level plug 3 Oil filler plug Note Your machine may be equipped with a Type 1 final drive or your machine may be equipped with a Type 2 final drive Remove oil level plug 2 for the final drive Obtain a sample of the final drive oil by pulling a sample through the opening for oil level plug 2 Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining a sample of the final drive oil Refer to Special Publication PEGJ0047
16. 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 Replacing the Air Filter Element The air filter element should be replaced immediately if the element is damaged 1 Open the right side access door S Jz FAA HA O aee O Thi A i Illustration 219 g01188133 2 Unclamp the access cover and remove the access cover to the air cleaner 154 Maintenance Section Engine Air Filter Secondary Element Replace SEBU8021 10 Illustration 220 g01188134 3 Remove the primary filter element from the air cleaner housing 4 Inspect the filter element If the pleats the gaskets or the seals are damaged discard the filter element Replace damaged filter elements with new filter elements 5 Wipe dust from the interior of the air cleaner housing Remove the cover from the air inlet port Leave the secondary filter element in place while you clean the air cleaner housing 6 Put the clean air filter element into the air cleaner housing and push the air filter element into position 7 Install the access cover 8 Close the right side access door 102015686 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 NOTICE Always replace t
17. the OFF position Turn all of the switches to the OFF position Remove the key 2 Disconnect the negative battery cable at the battery 3 Disconnect the positive battery cable at the battery 4 Disconnect the battery cables from the machine if new cables are needed 5 Make necessary repairs or replace the battery 6 Connect the battery cables to the machine if the battery cables were removed 7 Connect the positive battery cable of the battery 8 Connect the negative battery cable of the battery 9 Install the key into the engine start switch 102385778 Belt Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 1397 025 1397 040 1397 510 NOTICE The V belt must be tensioned correctly Failure to ten sion the belt properly could cause damage to the belt and or to the air conditioner compressor For maximum engine performance and maximum utilization of your engine inspect the belts for wear and for cracking Check the belt tension Adjust the belt tension in order to minimize belt slippage Belt slippage will decrease the belt life Belt slippage will also cause poor performance of the alternator and of any driven equipment If new belts are installed recheck the belt adjustment after 30 minutes of operation If two belts or more are required for an application replace the belts in belt sets If only one belt of a pair is replaced the new belt will carry more load This is due to the fa
18. 0 S O S Oil Analysis for information that pertains to obtaining a sample of the hydraulic oil Refer to Special Publication PEGJ0047 How To Take A Good Oil Sample for more information about obtaining a sample of the hydraulic oil 102106227 Oil Filter Inspect SMCS Code 1308 507 5068 507 Inspect a Used Filter for Debris Illustration 259 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 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 lubr
19. 0824766 8 Apply a thin coat of clean engine oil to the gasket of the new filter 9 Install the new oil filter by hand When the gasket contacts the filter base tighten the filter for an additional three quarters of a turn 10 Remove the oil filler cap 2 SEBU8021 10 157 Maintenance Section Engine Valve Lash Check 11 Fill the crankcase with new oil Refer to Operation and Maintenance Manual Capacities Refill and Operation and Maintenance Manual Lubricant Viscosities 12 Clean the oil filler cap and install the oil filler cap 13 Start the engine and operate the engine at low idle for several minutes While the engine is running check the filter base for oil leaks 14 Stop the engine Wait for thirty minutes in order to allow the oil to drain back into the crankcase 15 Remove the dipstick and wipe off the oil 16 Reinsert the dipstick 17 Remove the dipstick and check the oil level on the dipstick Illustration 230 g00824779 18 Maintain the oil within area A on the dipstick 19 Close the engine access door 102865346 Engine Valve Lash Check SMCS Code 1102 082 1102 535 1102 1105 025 1105 535 1121 535 1209 082 1209 535 1209 7527 Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow addit
20. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR aries LL Operation and Maintenance Manual 303 5C CR 303C CR 304C CR and 305C CR Mini Hydraulic Excavators HWJ1 Up 305C CR DMY1 Up 303 5C CR SAFETY CAT COM SEBU8021 10 135 Maintenance Section Maintenance Interval Schedule i04909771 Maintenance Interval Schedule SMCS Code 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced 10 hydraulic oil is used the hydraulic oil change interval is extended to 3000 hours S O S services may extend the oil chan
21. after the thermostat and the coolant level stabilizes 13 Stop the engine w y Li iS I Ir oL oj Illustration 211 g01187910 14 Check the coolant level of the coolant reservoir Maintain the coolant level between the FULL mark and the LOW mark 15 If additional coolant is necessary remove the reservoir cap and add the appropriate coolant solution 16 Install the reservoir cap 17 Close the right side access door Note Drained fluids should always be disposed of according to local regulations 101278063 Cooling System Coolant Extender ELC Add SMCS Code 1352 1353 1395 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loose the cap slowly to relieve the pressure When a Caterpillar Extended Life Coolant is used an extender must be added to the cooling system See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval The amount of extender is determined by the cooling system capacity 150 Maintenance Section Cooling System Coolant Level Check SEBU8021 10 Table 48 RECOMMENDED AMOUNT OF EXTENDER BY COOLING SYSTEM CAPACITY Recommended Amount of Extender 2 L 0 19 qt Cooling System Capacity 4 to 8 L 1 1 to 2 1 US gal For additional information on the addition of extender see Operation
22. alize the pressure 5 Check the amount of sag Adjust the track as needed 6 Replace the cover plate for the track adjustment valve 7 Repeat the same procedure for the other track Loosening the Track Illustration 275 g00825999 1 Remove the cover plate for the track adjustment valve SEBU8021 10 175 Maintenance Section Track Adjustment Inspect Illustration 276 g00825994 2 Loosen fitting 1 carefully until the track begins to loosen One turn should be the maximum 3 Tighten fitting 1 to 34 N m 25 Ib ft when the desired track tension is reached 4 Operate the track back and forth in order to equalize pressure 5 Check the amount of sag in the track Adjust the track as needed 6 Replace the cover plate for the track adjustment valve 7 Repeat the same procedure for the other track 102385623 Track Adjustment Inspect SMCS Code 4170 040 Note Keeping the track properly adjusted will increase the service life of the track components and the drive components Check the rubber tracks for the following conditions e Steel cords that are cut Core irons that are fractured Rubber flaking off to the point of showing steel cords or core irons e Loss of traction or grousers are worn down to approximately 5 mm 0 2 inch in height If any of the above conditions or a combination of the abo
23. arked and affixed to the seat belt retractor and buckle Note Date of installation labels should be permanently marked by punch retractable belt or stamp non retractable belt If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 102880113 Swing Frame and Cylinder Bearings Lubricate SMCS Code 5105 086 BD 6506 086 BD 6507 086 BD 1 Lower all work tools to the ground 2 Wipe all grease fittings before you lubricate the grease fittings Illustration 267 g01190032 3 Apply lubricant to the grease fittings for the swing frame Illustration 268 g01191058 4 Apply lubricant to the grease fitting for the rod end of the swing cylinder SEBU8021 10 173 Maintenance Section Swing Gear and Bearing Lubricate Illustration 269 g01433588 303C CR and 303 5C CR Illustration 270 g01249957 304C CR and 305C CR 5 Apply lubricant to the grease fitting for the head end of the swing cylinder 102496857 Swing Gear and Bearing Lubricate SMCS Code 7063 086 Illustration 271 g01248601 303C CR and 303 5C CR 1 Swing bearing 2 Swing gear Illustration 272 g01249948 304C CR and 305C CR 1 Swing bearing 2 Swing gear The grease fittings for the swing gear and for the swing bearing are located on the right s
24. btaining a sample of the engine oil Refer to Special Publication PEGJ0047 How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil 102379585 Engine Oil and Filter Change SMCS Code 1318 510 Note If the sulfur content in the fuel is greater than 1 5 by weight use an oil that has a TBN of 30 and reduce the oil change interval by one half Drain the crankcase while the oil is warm g d Illustration 226 g00824782 1 Open the crankcase access cover that is under the rear of the machine Remove the bolts that secure the access cover Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage Illustration 227 g01188174 2 Remove the crankcase drain plug Allow the oil to drain into a suitable container Note Discard any drained fluids according to local regulations 3 Clean the drain plug and install the drain plug 4 Install the crankcase access cover 5 Open the access door a Sal I Illustration 228 g01188175 6 Remove the oil filter 1 with a filter wrench Discard the used oil filter properly 7 Clean the filter housing base Make sure that all of the former filter gasket is removed Note Always discard used filters according to local regulations JID j Illustration 229 g0
25. ct that the older belts are stretched The additional load on the new belt could cause the new belt to break Water Pump Belt Fan Drive Belt and Alternator Belt Illustration 176 g01190206 1 Adjusting bolt 2 Water pump pulley 3 Alternator pulley 4 Alternator mounting bolt 5 Belt 6 Crankshaft pulley 1 Open the engine access door 2 Apply approximately 98 N 22 Ib of force midway between the pulleys 3 Measure the deflection of the belt The belt should deflect 8 to 11 mm 5 16 to 7 16 inch SEBU8021 10 139 Maintenance Section Blade Linkage Lubricate 4 If the deflection is not correct loosen alternator mounting bolt 4 and adjusting bolt 1 Move the alternator forward and backward in order to adjust belt 5 to the specified tension 5 When the adjustment is correct tighten adjusting bolt 1 and mounting bolt 4 securely 6 Check the deflection of the belt again 7 Close the engine access door Note If a new belt is installed check the belt adjustment again after 30 minutes of engine operation at the rated engine speed Air Conditioner Belt If Equipped NOTICE The V belt must be tensioned correctly Failure to ten sion the belt properly could cause damage to the belt and or to the air conditioner compressor 1 Open the engine access door Illustration 177 g01190210 7 Nut 8 Adjustment bolt 2 Check the belt tension
26. e 140 Boom Stick and Frame Inspect 2 05 140 Engine Oil and Filter Change s es 156 Final Drive Oil Sample Obtain 0 160 Fuel System Primary Filter Water Separator Element Replace cecceceeeeeeeeeteeeeees 161 Fuel Tank Cap and Strainer Clean 5 162 Hydraulic System Oil Filter Return Replace 166 Hydraulic System Oil Sample Obtain 168 Every 1000 Service Hours Battery COA enr A T 137 Battery Hold Down Tighten ceeeeeeeeeeees 137 Engine Valve Lash Check seses 157 136 Maintenance Section Maintenance Interval Schedule SEBU8021 10 Final Drive Oil Change eeeeeeeeeeeeeeeeeeeeees 158 Every 2000 Service Hours or 1 Year Hydraulic System Oil Change e 164 Receiver Dryer Refrigerant Replace 171 Every Year Cooling System Coolant Sample Level 2 OD AUN E E E tidal ane 152 Engine Air Filter Secondary Element Replace 154 Every 3000 Service Hours or 18 Months Hydraulic System Oil Change ee 164 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cceccssescsesssseseseeeees 172 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 149 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 148
27. e machine 1 Open the right side access cover SEBU8021 10 167 Maintenance Section Hydraulic System Oil Level Check 2 3 Clean the area thoroughly in order to prevent dirt from entering the hydraulic oil tank Slowly loosen the hydraulic oil filler cap in order to relieve the pressure in the hydraulic oil tank 0 09 gt Illustration 255 g01189656 Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 4 5 Remove bolt 1 washer 2 and right cover 3 Remove spring 5 valve 6 and element 7 from the case Inspect O ring 4 Replace the O ring if the O ring is worn or damaged Reverse steps 4 and 5 in order to install the new element Tighten the hydraulic oil filler cap Close the right side access cover 102384736 Hydraulic System Oil Level Check SMCS Code 5050 535 Note Check the hydraulic system oil level with the machine on a level surface Illustration 256 1 g00825529 Extend the stick and the bucket fully Lower the boom so that the bucket is rested on the ground Lower the blade to the ground Ace atl Hf ots IA am G N LE ee ustration 257 g01189326 2 The sight gauge is loca
28. e 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 System with R 134a Refrigerant for All Caterpillar Machines for the proper procedure to change the receiver dryer assembly and for the procedure to reclaim the refrigerant gas 104423622 Seat Belt Inspect SMCS Code 7327 040 Always inspect the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 265 g02620101 Typical example Inspect buckle 1 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect seat belt 2 for webbing that is worn or frayed Replace the seat belt if the webbing is worn or frayed Inspect all seat belt mounting hardware for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension Contact your Cat dealer for the replacement of the seat belt and the mounting hardware Note The seat belt should be replaced within 3 y
29. e same side of the retainer drive the pin through the bucket tip the retainer assembly and the adapter e Use a Pin Master Follow Step 5 a through Step 5 e for the procedure Illustration 195 g01209166 8 Pin a Insert pin 8 through the bucket tip SEBU8021 10 145 Maintenance Section Bucket Tips Inspect Replace Illustration 196 g01209140 4 Back of Pin Master 9 Pin holder 10 Pin setter b Place the Pin Master over the bucket tips so that the pin will fit into the counterbore of the pin holder 9 c Strike the Pin Master with a hammer at the back of the tool 4 in order to insert the pin d Slide pin holder 9 away from the pin and rotate the tool slightly in order to align pin setter 10 with the pin Illustration 197 g01209159 Final assembly of pin into bucket tip e Strike the end of the tool until the pin is fully inserted Side Cutters Illustration 198 g01092808 Bucket With Side Cutters A Side cutters 1 Remove the mounting bolts and the side cutters 2 Clean the mounting surface of the side plate on the bucket and of the side cutter Remove any burrs or protrusions on the mating surfaces Illustration 199 g01092810 A Side cutter Note Some side cutters may be rotated for additional wear 3 Install the side cutter Note Certain b
30. ears of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts 172 Maintenance Section Seat Belt Replace SEBU8021 10 104421974 Seat Belt Replace SMCS Code 7327 510 The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts ef 0 4 Illustration 266 g01152685 Typical Example 1 Date of installation retractor 2 Date of installation buckle 3 Year of manufacture tag fully extended Web 4 Year of manufacture underside buckle Consult your Cat dealer for the replacement of the seat belt and the mounting hardware Determine age of new seat belt before installing on seat A manufacture label is on belt webbing and imprinted on belt buckle Do not exceed install by date on label Complete seat belt system should be installed with new mounting hardware Date of installation labels should be m
31. ed in order to clean the product identification films Ensure that all the product identification films are not damaged or missing Clean the product identification films or replace the films Hand Washing Use a wet solution with no abrasive material that contains no solvents and no alcohol Use a wet solution with a pH value between 3 and 11 Use a soft brush a rag or a sponge in order to clean the product identification films Avoid wearing down the surface of the product identification films with unnecessary scrubbing Ensure that the surface of the product identification films is flushed with clean water and allow the product identification films to air dry Power Washing Power washing or washing with pressure may be used in order to clean product identification films However aggressive washing can damage the product identification films Excessive pressure during power washing can damage the product identification films by forcing water underneath the product identification films Water lessens the adhesion of the product identification film to the product allowing the product identification film to lift or curl These problems are magnified by wind These problems are critical for the perforated film on windows To avoid lifting of the edge or other damage to the product identification films follow these important steps e Use a spray nozzle with a wide spray pattern e A maximum pressure of 83 bar 1200 psi
32. ge to a longer interval Consult your Caterpillar dealer for details When Required Air Conditioner Cab Heater Filter Recirculation Inspect Replace cececccceeceeeeeeeeeteettteteeeeees 137 Battery Recycle oo eeeeeeeeeneeneeeeeeenteeeeeeenaaes 137 Battery or Battery Cable Inspect Replace 138 Bucket Tips Inspect Replace ccceee 142 Bucket Tips Inspect Replace ccceeee 143 Bucket Tips Inspect Replace ccceeeee 146 Condenser Refrigerant Clean s es 148 Engine Air Filter Primary Element Clean Replace uiringen einai neal 152 Engine Air Filter Secondary Element Replace 154 Film Product Identification Clean 157 Fuel System Prime cceececeeeeeeeeeeeeeeeeeeenaaes 160 Fuel System Water Separator Drain 162 Fuses Replace 00 cccccccceeeeeeeeeeeeeeeceeeeeeeeeeteees 163 Oil Filter Inspect iniae aiina anaana iae 168 Radiator Core Clean cceceeeeeeeccecceeeeeeeeeees 170 Track Adjustment Adjust 0 eect eeeteeeeeee 174 Window Washer Reservoir Fill 00006 177 Window Wiper Inspect Replace 0006 177 Windows Clean cccecceeeeeeeeeeeeseeseeaeeees 177 Every 10 Service Hours Cooling System Coolant Level Check 150 Engine Air Filter Service Indicator Inspect 154 Engine Oil Level Check 155 Hydraulic System O
33. ght side access door 2 Start the engine 3 Run the engine at high idle 4 If the piston in the engine air filter service indicator enters the red zone service the air cleaner 5 Stop the engine Note See the Operation and Maintenance Manual Engine Air Filter Element Clean Replace 6 Close the right side access door 102379576 Engine Oil Level Check SMCS Code 1000 535 NOTICE Do not overfill the crankcase Engine damage can re sult 1 Open the engine access door and lock the door open ei Illustration 223 g01188158 2 Remove the dipstick 1 Wipe the oil off the dipstick and reinsert the dipstick Illustration 224 g00824454 3 Remove the dipstick and check the dipstick Maintain the oil level in area A on the dipstick 4 If necessary remove the oil filler cap 2 and add oil Allow the oil to drain into the crankcase before you check the oil level 5 Clean the oil filler cap and install the oil filler cap 6 Close the engine access door Engine Oil Sample Obtain SMCS Code 1000 008 1000 1348 008 1348 554 SM 7542 008 7542 554 OC SM iC amp faan Illustration 225 g01188166 Obtain the oil sample of the engine oil through the opening for the dipstick 156 Maintenance Section Engine Oil and Filter Change SEBU8021 10 Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to o
34. he secondary filter element Never attempt to reuse the element by cleaning The secondary filter element should be replaced at the time the primary element is serviced for the third time NOTICE The filter should be kept in service for no longer than one year NOTICE Always leave the secondary filter element in place while you clean the air cleaner housing 1 Open the engine access door 2 Remove the air cleaner housing cover 3 Remove the primary filter element Refer to Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace Illustration 221 g00470240 4 Remove the secondary filter element Pull out in order to remove the element 5 Cover the air inlet opening Clean the inside of the air cleaner housing 6 Install a new secondary filter element Push the element firmly in order to properly seat the element Write the date on the element 7 Install the primary filter element and the air cleaner housing cover 8 Close the engine access door 102379569 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 DJ NOTICE Service the air cleaner only with the engine stopped Engine damage could result if the air cleaner is ser viced while the engine is running SEBU8021 10 155 Maintenance Section Engine Oil Level Check Ze JS Illustration 222 g01188149 1 Open the ri
35. icating system and the particles could cause damage SEBU8021 10 169 Maintenance Section Quick Coupler Clean 104673589 Quick Coupler Clean SMCS Code 6129 070 Illustration 260 g01155173 Typical example 1 Remove pin 1 2 Remove safety pin 2 from the quick coupler The pin may be located on the right side or located on the rear of the quick coupler 3 Clean safety pin 2 4 Clean out bore 3 on either side of the coupler 5 Remove any trash or buildup from the quick coupler 6 Apply grease to safety pin 2 Refer to Special Publication SEBU6250 Caterpillar Machine Fluid Recommendations for more information about the selection of grease 7 Insert safety pin 2 into bore 3 on the right side 8 Insert pin 1 into safety pin 2 on the left side of the quick coupler 102973110 Quick Coupler Lubricate If Equipped SMCS Code 6129 086 1 Lower all work tools to the ground 2 Wipe off the fittings before you lubricate the fitting Illustration 261 g01167510 Typical example 3 Apply grease to the fittings of the quick coupler Illustration 262 g01167518 Typical example 4 Apply grease to the external surface of the pin in the lock assembly Note The lock assembly may be located on the side of the coupler or located on the rear of the coupler 5 Check the overall condition of the quick cou
36. ide of the machine 1 Lower all work tools to the ground 2 Open the right side access door 3 Wipe all grease fittings before you lubricate the grease fittings 4 Apply lubricant through fitting 1 until the old lubricant is pushed out from the seal surface 5 Apply lubricant through fitting 2 174 Maintenance Section Track Adjustment Adjust SEBU8021 10 6 Rotate the upper structure for 90 7 Repeat Step 5 and Step 6 until the upper structure has rotated 360 8 Close the right side access door 101592596 Track Adjustment Adjust SMCS Code 4170 025 Personal injury or death can result from grease under pressure Grease coming out of the relief valve under pres sure can penetrate the body causing injury or death Do not watch the relief valve to see if grease is es caping Watch the track or track adjustment cylin der to see if the track is being loosened Loosen the relief valve one turn only If track does not loosen close the relief valve and contact your Caterpillar dealer Tightening the Tracks Illustration 273 g00825999 1 Remove the cover plate for the track adjustment valve Illustration 274 g00825994 2 Wipe fitting 1 before you add grease 3 Add grease through fitting 1 until the correct tension is reached 4 Operate the track back and forth in order to equ
37. ies and Operation and Maintenance Manual Capacities Refill 8 Install level plug 2 and filler plug 3 9 Perform Step 1 to Step 8 on the other final drive Do not combine the oil for the final drives in the same container The oil from the final drives must be kept separate for the check that is performed in Step 15 10 Completely remove any oil that has spilled 11 Start the engine and allow the final drives to operate through several cycles 12 Stop the engine 13 Check the oil level 14 Maintain the oil level to the bottom of the opening for level plug 2 15 Check the drained oil for metal chips or for particles If there are any chips or particles consult your Caterpillar dealer Note Dispose of drained fluids according to local regulations i04656869 Final Drive Oil Level Check SMCS Code 4050 535 FLV Illustration 235 g00740859 Type 1 1 Oil drain plug 2 Oil level plug 3 Oil filler plug g01619618 Illustration 236 Type 2 1 Oil drain plug 2 Oil level plug 3 Oil filler plug Note Your machine may be equipped with a Type 1 final drive or your machine may be equipped with a Type 2 final drive 1 Position one final drive so that oil drain plug 1 is at the bottom Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 2 Remove oil level plug 2 3 Check the
38. il Level Check nasses 167 Seat Belt Inspect eeeeeeeeeseecteeeeeeeeees 171 Travel Alarm Test l eerren 176 Undercarriage Check 0 eeeceeeeceeeeteeeeeeeneeees 176 Every 50 Service Hours Blade Linkage Lubricate ccceeeeeeeeeees 139 Bucket Linkage Lubricate 0 142 Fuel Tank Water and Sediment Drain 163 Quick Coupler Clean ceceeseeeeeseeceeeeeeeeeees 169 Quick Coupler Lubricate cseeeeereees 169 Quick Coupler Lubricate ccceeeeeee 170 Swing Frame and Cylinder Bearings Lubricate 172 Track Adjustment Inspect eeeeeeeeeeees 175 Initial 100 Service Hours Engine Oil and Filter Change 156 Every 100 Service Hours Swing Gear and Bearing Lubricate 173 Initial 250 Service Hours Engine Valve Lash Check seeen 157 Final Drive Oil Change eesse 158 Hydraulic System Oil Filter Return Replace 166 Every 250 Service Hours Belt Inspect Adjust Replace eeeee 138 Cooling System Coolant Sample Level 1 ODIAIN ort teenies aha eee eee 150 Engine Oil Sample Obtain assises 155 Final Drive Oil Level Check eeeeeeeeeees 159 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Opti ni ceil e A eee eee 152 Every 500 Service Hours Boom and Stick Linkage Lubricat
39. ing 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 217 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 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 218 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air filter elements in volatile corrosion inhibitor VCI paper Place the
40. ional time for the engine to cool before mea suring adjusting valve lash clearance NOTICE Only qualified service personnel should perform this maintenance Refer to the Systems Operation Testing and Adjusting Manual Valve Lash and Valve Bridge Adjustment article or consult your Caterpillar dealer for the complete valve lash adjustment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life For the serial number BXT1 up and DMY1 up refer to Service Manual RENR9640 Mitsubishi Diesel Engines S3Q S3Q2 T in order to perform the complete procedure for the valve lash adjustment For the serial number FPK1 up and HWJ1 up refer to Service Manual RENR9620 Mitsubishi Diesel Engines S4Q S4Q2 in order to perform the complete procedure for the valve lash adjustment i03997106 Film Product Identification Clean SMCS Code 7405 070 7557 070 a b a a g02174985 Illustration 231 158 Maintenance Section Final Drive Oil Change SEBU8021 10 Illustration 232 g02175297 Typical example of the Product Identification Films Cleaning of the Films Make sure that all of the product identification films are legible Make sure that the recommended procedures are us
41. is not necessary to obtain a Coolant Sample Level 1 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 SEBU8021 10 151 Maintenance Section Cooling System Coolant Sample Level 1 Obtain 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 solution 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 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 an
42. lements 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 Pressurized Air Pressurized air can be used to clean 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 216 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 SEBU8021 10 153 Maintenance Section Engine Air Filter Primary Element Clean Replace 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 clean
43. n There is not an omega mark on the steel tracks You do not need to align the steel tracks The proper amount of sag for steel tracks is 25 to 35 mm 1 0 to 1 4 inch If the correct adjustment cannot be achieved consult your Caterpillar dealer 102378200 Travel Alarm Test If Equipped SMCS Code 7429 081 The travel alarm will sound when the machine is moved forward or backward You must move the machine in order to test the travel alarm 1 Start the engine Move the hydraulic lockout control to the LOWERED position 2 Raise the work tool Make sure that there is adequate overhead clearance ii H Illustration 280 g01187193 3 Use the travel levers to move the machine forward The travel alarm should sound 4 Release the travel levers in order to stop the machine 5 Use the travel levers to move the machine backward The travel alarm should sound 6 Release the travel levers in order to stop the machine Lower the work tool to the ground Deactivate the hydraulic controls by placing the hydraulic lockout control in the RAISED position Stop the engine i01722112 Undercarriage Check SMCS Code 4150 535 l Illustration 281 g00885424 1 Check the carrier rollers the track rollers and the idler wheels for possible leakage 2 Check the surface of the track the carrier rollers
44. n 249 g01188740 Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 5 Remove the hydraulic oil drain plug Allow the oil to drain into a suitable container 6 Clean the drain plug and inspect the drain plug Replace the drain plug if the drain plug is damaged or worn Reinstall the plug Illustration 248 g00825578 2 Extend the stick and the bucket fully Lower the boom so that the bucket is rested on the ground Lower the blade to the ground 3 The hydraulic tank is located under the access cover on the right side of the machine Open the access cover for the hydraulic tank Clean the area around the hydraulic oil filler cap in order to prevent dirt from entering the hydraulic tank 4 Relieve the internal pressure from the hydraulic tank by loosening the hydraulic oil filler cap After the pressure is relieved remove the hydraulic oil filler cap Illustration 250 g01188745 7 Remove bolt 1 washer 2 and left cover 3 8 Remove spring 4 and screen 5 Note Do not allow spring 4 to fall into the hydraulic tank 166 Maintenance Section Hydraulic System Oil Filter Return Replace SEBU8021 10 Illustration 251 g00825626 9 Clean screen 5 and inspect screen 5 Replace the screen if the screen is damaged or badly contaminated 10 Inspect O ring seal 6 Replace the O ring seal if i
45. nd a punch from the retainer side of the bucket to drive out the pin e Use a Pin Master Follow Step 1 a through Step 1 c for the procedure 144 Maintenance Section Bucket Tips Inspect Replace SEBU8021 10 a pes R a a A L b Illustration 192 a Place the Pin Master on the bucket tip 7 MA g00590670 4 Back of Pin Master 5 Extractor b Align extractor 5 with the pin c Strike the Pin Master at the back of the tool 4 and remove the pin Note Discard the old pin and the retainer assembly When you change tips use a new pin and a new retainer assembly Refer to the appropriate parts manual for your machine Illustration 193 g01194448 6 Retainer assembly 7 Adapter 2 Clean the adapter and the pin 3 Fit retainer assembly 6 into the counterbore that is in the side of adapter 7 Make sure that the face of the retainer assembly with the marking OUTSIDE is visible Illustration 194 g00101359 4 Install the new bucket tip onto the adapter Note The bucket tips can be rotated by 180 degrees in order to allow the tip to wear evenly You may also move the tips from the outside teeth to the inside teeth Check the tips often If wear is present on the tips rotate the tips The outside teeth generate the most wear 5 Drive the pin through the bucket tip The pin can be installed by using one of the following methods e From th
46. olts may require thread compound 4 Hand tighten the bolts 146 Maintenance Section Bucket Tips Inspect Replace SEBU8021 10 A C E D g01092812 Illustration 200 Section B B From Illustration 199 A Side cutter C Shear ledge on a side cutter D Side plate on a bucket E 0 0 mm 0 0 inch 5 Make sure that there is not a gap between the side plate on the bucket and the shear ledge on the side cutter 6 Torque the mounting bolts to the correct specification Bucket Tips Inspect Replace Vertical Retention System for a Round Hole Tip SMCS Code 6805 040 6805 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket tips or side cutters Bucket Tips Illustration 201 g00101352 1 Usable 2 Replace this bucket tip 3 Overworn Check the bucket tips for wear If the bucket tip has a hole replace the bucket tip Illustration 202 g00823856 1 Block the bucket Illustration 203 g00823857 2 Remove the pin from the bucket tip Use a hammer and a punch in order to drive the pin from the bucket tip SEBU8021 10 147 Maintenance Section Bucket Tips Inspect Replace mo a ea 2 a S Le 5 Illustration 204 g01198006 4 Tip 5 Adapter 6 Pin 3 Clean the adapter and the pin When you replace tip 4 also replace pin 6 Illustration 205 g00823892 4 In
47. op Solenoid 30 Amp 2 Spare 5 Amp 3 Spare 10 Amp 4 Cigar Lighter 15 Amp 5 Heater and Air Conditioner Blower 20 Amp 6 Radio Window Wiper Window Washer and Air Conditioner 15 Amp 7 Beacon and Cab Fan 10 Amp 8 Alternator Fuel Pump Glow Plug and Travel Alarm 10 Amp 9 Work Lights 15 Amp 10 Travel Speed Boom Swing and Auxiliary Controller 10 Amp 11 Engine Speed 15 Amp 12 PAT Controller and Crane Controller 10 Amp 13 Spare 20 Amp 14 Spare 15 Amp 15 Spare 30 Amp 16 Glow Indicator 5 Amp 17 Engine Start Switch 10 Amp 18 Horn and Service Hour Meter 5 Amp 19 Spare 10 Amp 20 Dome Lamp Engine Shutoff Timer Radio Memory and Monitor 5 Amp 103653097 Hydraulic System Oil Change SMCS Code 5056 044 Cat HYDO Oil Change Interval The standard Cat HYDO oil change interval is every 2000 service hours or 1 year A maintenance interval of 4000 service hours or 2 years for changing the hydraulic oil is available The extended interval requires S O S monitoring of the hydraulic oil The interval for S O S monitoring is every 500 hours The maintenance interval for the hydraulic oil filter is not changed Machines with hammers are not included in the maintenance interval 4000 service hours or 2 years Machines with hammers must use the intervals that are listed in the Maintenance Interval Schedule
48. ound defective 1 Open the access cover on the right side of the machine Illustration 209 g01198735 2 Inspect the condenser for debris Clean the condenser if necessary 3 You can use compressed air high pressure water or steam to remove dust and other debris from the condenser However the use of compressed air is preferred 4 Close the access cover on the right side of the machine 102379208 Cooling System Coolant ELC Change SMCS Code 1350 044 NOTICE Do not change the coolant until you read and under stand the cooling system information in Special Pub lication SEBU6250 Caterpillar Machine Fluids Rec ommendations Failure to do so could result in damage to the cooling system components NOTICE Mixing ELC with other products will reduce the effec tiveness of the coolant This could result in damage to 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 This machine was filled at the factory with Caterpillar Extended Life Coolant If the coolant in the machine is changed to Extended Life Coolant from another type of coolant see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 1 Open the
49. pler Look for the following conditions loose bolts worn parts broken parts missing parts and damaged parts Make any necessary repairs 170 Maintenance Section Quick Coupler Lubricate SEBU8021 10 104587970 Quick Coupler Lubricate Hydraulic Pin Grabber Quick Coupler If Equipped SMCS Code 6129 086 1 Ensure that the work tool is in a stable and safe storage position on the ground Refer to Operation and Maintenance Manual Quick Coupler Operation Hydraulic Pin Grabber Quick Coupler for the proper procedure Illustration 263 g02741682 2 Wipe off the fitting before you lubricate the fitting 3 Apply grease to the fitting of the quick coupler 4 Check that all pin retainers are in place and that all bolts and nuts are tight including the hydraulic cylinder mounting bolts 5 Check the hydraulic hoses and fittings for any leaks damage or wear Replace immediately if required 6 Check the full operation of all the moving parts within the quick coupler Repair or replace immediately if required 7 Check that there is no material buildup around the rear locking mechanism cylinder or wedge plate Check that there is no material buildup around the front locking mechanism 8 Check the quick coupler for cracks bent components or wear 102384754 Radiator Core Clean SMCS Code 1353 070 1 Open the right side access cover ED et
50. right side access door SEBU8021 10 149 Maintenance Section Cooling System Coolant Extender ELC Add Illustration 210 g01187906 2 Slowly loosen the cooling system pressure cap 1 in order to relieve cooling system pressure Remove the pressure cap Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 3 Open the drain valve 2 that is under the radiator Allow the coolant to drain into a suitable container 4 Close the drain valve Fill the system with a solution that consists of clean water and of cooling system cleaner 5 Start the engine Run the engine for approximately ten minutes in order to raise the coolant temperature 6 Stop the engine Open the drain valve and allow the cleaning solution to drain into a suitable container 7 Flush the cooling system with water until the draining water is transparent 8 Close the drain valve 9 Add the Extended Life Coolant Refer to the following topics e Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations e Operation and Maintenance Manual Capacities Refill 10 Start the engine Leave the cooling system pressure cap off Run the engine in order to expel any air from the system 11 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe 12 Install the cooling system pressure cap
51. s Check that the plates are not excessively Check all welded joints and check the mounting bent Check that the lifting holes are not deformed points for the cylinder Blade a g01425286 Illustration 183 142 Maintenance Section Bucket Linkage Lubricate SEBU8021 10 Upper Frame Illustration 186 g01425289 Check for damaged panels Specifically look for any damage to the cab or damage to the canopy that might invalidate the certification The cab or the canopy is a safety device that must be maintained in good condition Check for loose hardware or missing hardware Lower Frame Illustration 187 g0 1425287 Check the weld joints in the lower structure Check for loose hardware or missing hardware Check the ring of bolts that secure the swing gear 102386794 Bucket Linkage Lubricate SMCS Code 6513 086 Note Caterpillar recommends the use of 5 molybdenum grease for lubricating the bucket linkage Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information on molybdenum grease Apply lubricant through all fittings after operation under water Wipe all fittings before you apply lubricant Illustration 188 g01190973 Note Completely fill all cavities of the bucket control linkage with grease when you initially install a bucket 1 Apply lubricant through fittings for the linkages 1 and 2 2 Apply
52. stall the new bucket tip onto the adapter Note The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration 5 Drive pin 6 through tip 4 6 After you drive pin 6 make sure that the pin fits snugly into the groove Side Cutters Illustration 206 g01092808 Bucket With Side Cutters A Side cutters 1 Remove the mounting bolts and the side cutters 2 Clean the mounting surface of the side plate on the bucket and of the side cutter Remove any burrs or protrusions on the mating surfaces Illustration 207 g01092810 A Side cutter Note Some side cutters may be rotated for additional wear 3 Install the side cutter Note Certain bolts may require thread compound 4 Hand tighten the bolts 148 Maintenance Section Condenser Refrigerant Clean SEBU8021 10 A C E D g01092812 Illustration 208 Section B B From Illustration 207 A Side cutter C Shear ledge on a side cutter D Side plate on a bucket E 0 0 mm 0 0 inch 5 Make sure that there is not a gap between the side plate on the bucket and the shear ledge on the side cutter 6 Torque the mounting bolts to the correct specification i02399962 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 f
53. t is necessary 11 Install the screen by reversing step 7 and step 8 Note Make sure that the O ring seal and the spring are properly positioned during installation 12 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Capacities Refill Illustration 252 g00101462 13 Inspect the pressure cap Clean the pressure cap Replace the pressure cap if damage is evident 14 Install the pressure cap 15 Start the engine and run the engine for a few minutes Slowly operate the control levers in order to cause the hydraulic oil to flow through the circuits Illustration 253 g00825578 16 Extend the stick and the bucket fully Lower the boom so that the bucket is rested on the ground Lower the blade to the ground ae e IA i amp Illustration 254 g01188773 17 Maintain the hydraulic oil level between mark A and mark B of the sight gauge 18 Close the right side access door 102385140 Hydraulic System Oil Filter Return Replace SMCS Code 5068 510 RJ NOTICE Hot oil can cause personal injury Remove the hy draulic oil filler cap only when the engine is stopped Allow time for the hydraulic system to cool Remove hydraulic oil filler cap slowly in order to relieve pres sure The hydraulic oil tank is located under the access cover on the right side of th
54. ted on the side of the hydraulic tank 3 Maintain the hydraulic system oil level between top mark A and bottom mark B on the sight gauge 4 If additional hydraulic oil is needed the hydraulic oil filler cap is located on top of the hydraulic tank under the access door on the right side of the machine 168 Maintenance Section Hydraulic System Oil Sample Obtain SEBU8021 10 NOTICE Never remove the hydraulic tank filler cap from the hydraulic tank if the oil is hot Hot oil can cause burns Air can enter the system Air in the system can cause pump damage 5 Remove the hydraulic tank filler cap 1 slowly in order to relieve any pressure Add hydraulic oil if necessary 6 Inspect the gasket on the hydraulic tank filler cap If the gasket is damaged replace the hydraulic tank filler cap N Install the hydraulic tank filler cap 103998619 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 OC 5095 008 5095 SM 7542 008 7542 Fev MTNA fl Pee es EIN l SA 1 IETT AN ial TA Wg N HAN h PAA AE at BG i H H Toy Illustration 258 g01189323 Park the machine on level ground Lower the bucket to the ground with the stick in the vertical position Obtain a sample of the hydraulic oil through the sampling valve The sampling valve for the hydraulic oil is located on the main control valve Refer to Special Publication SEBU625
55. ter Never use a cleaning solvent on poly carbonate windows Cleaning Methods Aircraft Windshield Cleaner Apply the cleaner with a soft cloth Rub the window with moderate pressure until all the dirt is removed Allow the cleaner to dry Wipe off the cleaner with a clean soft cloth Soap and Water Use a clean sponge or a soft cloth Wash the windows with a mild soap or with a mild detergent Also use plenty of lukewarm water Rinse the windows thoroughly Dry the windows with a moist chamois or with a moist cellulose sponge Stubborn Dirt and Grease Wash the windows with a good grade of naphtha or isopropyl alcohol or of Butyl Cellosolve Then wash the windows with soap and with water
56. ter housing before the system is operated 100934864 Battery Clean SMCS Code 1401 070 Clean the battery surface with a clean cloth Keep the terminals clean and keep the terminals coated with petroleum jelly Install the post cover after you coat the terminal post with petroleum jelly i00993589 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 101586700 Battery Hold Down Tighten SMCS Code 7257 Tighten the hold downs for the battery in order to prevent the batteries from moving during machine operation 138 Maintenance Section Battery or Battery Cable Inspect Replace SEBU8021 10 101999587 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1401 561 1401 1402 040 1402 510 Personal injury can result from battery fumes or explosion Batteries give off flammable fumes that can ex plode Electrolyte is an acid and can cause per sonal injury if it contacts the skin or eyes Prevent sparks near the batteries Sparks could cause vapors to explode Do not allow jumper ca ble ends to contact each other or the engine Im proper jumper cable connections can cause an ex plosion Always wear protective glasses when working with batteries 1 Turn the engine start switch key to
57. the track rollers the idler wheels the track shoes and the drive sprockets Look for signs of wear and loose mounting bolts SEBU8021 10 177 Maintenance Section Window Washer Reservoir Fill 3 Listen for any abnormal noises while you are moving slowly in an open area 4 If abnormal wear exists or abnormal noises or leaks are found consult your Caterpillar dealer 101021011 Window Washer Reservoir Fill SMCS Code 7306 544 KE NOTICE When operating in freezing temperatures use Caterpillar or any commercially available nonfreezing window washer solvent The washer fluid bottle is located in the engine compartment 1 Open the engine access door 2 Remove the filler cap 3 Fill the washer fluid bottle with washer fluid through the filler opening 4 Replace the filler cap 5 Close the engine access door 101223970 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 Inspect the wiper blade on the front window Replace the wiper blade if the wiper blade is worn or damaged Replace the wiper blade if the front window is streaked after use i01592019 Windows Clean SMCS Code 7310 070 7340 070 Use commercially available window cleaning solutions in order to clean the windows Note When you are cleaning the window above the front window you should use a soft cloth that is not abrasive This window can be easily scratched Wash polycarbonate windows with a mild soap and wa
58. ve conditions are observed replace the belt Measuring Rubber Track Tension 1 Park the machine on a level surface Illustration 277 g01190135 2 Position the upper frame over the tracks at a 90 angle 3 Lower the bucket to the ground with the stick in a vertical position 4 Chock the track that is not being lifted off the ground 5 Apply boom down pressure until the track that is on the same side as the bucket has cleared the ground 6 Chock the lower frame of the machine in this position 7 Clean the track rollers and the area around the skid plate Illustration 278 g00484245 8 For a machine that is equipped with the rubber tracks locate the omega mark on the inside flat of the track 9 Locate the omega mark under the center track roller 176 Maintenance Section Travel Alarm Test SEBU8021 10 Illustration 279 g00522663 The distance B should be 10 to 15 mm 0 4 to 0 6 inch 10 Measure the sag in the track The sag is measured from the bottom of the roller to the surface on the top of the track A properly adjusted track will have 10 to 15 mm 0 4 to 0 6 inch of sag Measuring Steel Track Tension Note The track tension must be set according to the current operating conditions Keep the track as slack as possible if the soil is heavy Follow the same procedures for measuring rubber track tensio
59. y 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 Obtain the sample of the coolant as close as possible to the recommended sampling interval The recommended sampling interval for Level 1 Coolant Analysis is every 250 service hours In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles e Never collect samples from the drain for a system Illustration 215 g00544510 Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling s
60. ystem components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 The machine needs to be operated in order to circulate the coolant Collect the sample after a normal workday Collect the samples from one to two hours after the engine has been shut off 2 Start the engine momentarily in order to circulate the coolant again 3 Shut off the engine 4 Carefully remove the radiator cap 5 Use a vacuum pump and draw the sample Do not allow dirt or other contaminants to enter the sampling bottle Fill the sampling bottle three fourths from the top Do not fill the bottle completely 6 Place the sampling bottle with the completed label into the mailing tube N Install the radiator cap 152 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU8021 10 102049802 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1395 008 1395 554 7542 Reference Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Submit the sample for Level 2 analysis Reference For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine

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