Operation and Maintenance Manual Excerpt - Safety
Contents
1. Illustration 116 g01018412 3024 engine s m ZA amp ERE Illustration 117 g01018146 3044 engine 3 Loosen the hose clamp 1 and remove the hose from the thermostat housing assembly 2 4 Remove the two bolts 3 from the thermostat housing assembly Remove the thermostat housing assembly 5 Remove the seal and the thermostat from the thermostat housing assembly 6 Install a new thermostat and a new seal Install the thermostat housing assembly on the engine cylinder head 7 Install the hose Tighten the hose clamp 8 Refill the cooling system See Operation and Maintenance Manual Capacities Refill Refer to Special Publication SEBU6250 Caterpillar Machine Fluid Recommendations for coolant information 9 Close the engine access door SEBU7731 08 121 Maintenance Section Drive Chain Case Oil Change 101990833 Drive Chain Case Oil Change SMCS Code 3261 543 OC 3261 544 OC Ga Okai Illustration 118 901025459 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 Appl2. Illustration 155 900956818 Note This film is located near the hydraulic filler cap on machines that are filled with synthetic oil Operate the machine for a few minutes in order to warm the hydraulic system oil Personal injury or death can result without releas ing all of the hydraulic pressure Release all the pressure from the hydraulic sys tem before any lines are disconnected The machine should be on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine Keep the armrest lowered Turn the engine start switch key to the ON position Push the parking brake switch Move all of the hydraulic control levers 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 DLL i WORE EU EER SIR ENEBEBBERBERBER Rn Illustration 156 900926534 1 Remove the hydraulic tank filler cap Illustration 157 g01021146 2 Remove the access panel in the belly guard underneath the machine Illustration 158 901030411 3 Remove the plug from the end of the drain hose Pull the drain hose through the access panel in the belly guard Open the drain val
3. 121 Every 500 Service Hours or 6 Months Fuel System Primary Filter Water Separator Element Replace suus 132 Hydraulic System Oil Filter Replace 136 Every 500 Service Hours or 1 Year Engine Oil and Filter Change 129 Every 1000 Service Hours Engine Valve Lash Check sssssse 131 Every 1000 Service Hours or 6 Months Drive Chain Case Oil Change 121 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 140 Every 2000 Service Hours Refrigerant Dryer Replace sssss 139 Every 2000 Service Hours or 1 Year Fuel Injection Timing Check 131 Hydraulic System Oil Change 134 Every 3000 Service Hours or 2 Years Cooling System Water Temperature Regulator Repl Ce 52 acier tide dor de REEF ER OBERE e 120 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace sss 141 Every 5000 Service Hours Engine Crankcase Breather Closed Circuit Replace ndr bie adenine 125 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 118 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 116 SEBU7731 08 111 Maintenance Section Backup
4. 7 N m 110 5 Ib ft Airboss and Solid Tires Pneumatic Tires 101982402 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 144 Maintenance Section Window Wiper Inspect Replace SEBU7731 08 Illustration 176 g01027404 The reservoir for the window washer solvent is located inside the cab on the left side Fill the reservoir with window washer solvent 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 101981264 Windows Clean SMCS Code 7310 070 Use commercially available window cleaning solutions in order to clean the windows The side windows of the cab can be removed for cleaning Refer to the following procedure in order to remove the side windows Illustration 177 901026875 1 Release the latch 2 in order to remove the window 1 Pull downward on the window in order to remove the window Pull outward on the window in order to remove the window 2 Release the latch 4 in order to remove the window 3 Pivot the channel for the window
5. 510 1348 044 S N LBA1 Up S N SCL1 Up S N HEN1 6749 S N PAT1 Up S N PDT1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The normal oil change interval for the machine is Every 500 Service Hours or every year when the following conditions are met e Caterpillar oil API Specification Cl 4 CH 4 or CG 4 multigrade oil is used e Caterpillar filters are used The altitude does not exceed 2300 m 7545 ft e Sulfur content in the fuel is between 0 05 and 0 50 An oil change interval of Every 250 Service Hours or every six months is required when the following conditions occur e Caterpillar oil API Specification Cl 4 CH 4 or CG 4 multigrade oil is not used 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 00 130 Maintenance S
6. Alarm Test 101017495 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 armrest downward 2 Start the engine 3 Disengage the parking brake 4 Move the speed direction control lever to the REVERSE position The backup alarm if equipped should sound immediately The backup alarm should continue to sound until the speed direction control lever is returned to the HOLD position or to the FORWARD position 100993589 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations A battery supplier e An authorized battery collection facility e Recycling facility 101719520 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1401 561 1402 040 1402 510 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 Disconnect the negative battery cable from the starter Note Do not allow the disconnected battery cable to contact the frame of the machine 3 Disconnect the negative battery cable at the battery 4 Perform the necessary repairs Replace the cable or the battery as needed 5 Connect the negative battery cable at the ba
7. damage is suspected consult your Caterpillar dealer before you use the work tool
8. downward Pull the window outward in order to remove the window 3 Slide the window 5 forward Pull the window outward in order to remove the window 102728710 Work Tool Lubricate SMCS Code 6700 086 Multipurpose Bucket 900534457 Illustration 178 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 SEBUT7731 08 145 Maintenance Section Work Tool Lubricate Apply lubricant to the grease fitting 3 for the head Industrial Grapple Tools end of the multipurpose bucket cylinder Repeat for the other side of the bucket There are six grease fittings Utility Grapple Tools Illustration 181 900645995 Apply lubricant to the four grease fittings for the fork cylinders Illustration 179 900647980 Apply lubricant to the four grease fittings for the grapples g00646004 Illustration 182 Apply lubricant to the four grease fittings for the two forks There are eight grease fittings Illustration 180 900647988 Apply lubricant to the two fittings for the grapple cylinder There are six grease fittings 146 Maintenance Section Work Tool Lubricate SEBU7731 08 Grapple Rake Illustration 183 g01368386 Apply lubricant to the four grease fittings for the grapple cylinders Apply lubricant to the four grea
9. 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 QUU VLEEEEDOD ENEBEBBEBERBER Illustration 159 900926534 2 Remove the hydraulic tank filler cap Illustration 160 901017252 The hydraulic filter is located on the left side of the engine compartment 3 Remove the filter with a strap type wrench Note Place a suitable nonconductive container under the hydraulic oil filter Use this container in order to catch any oil that may spill from the filter or the filter element mounting base 4 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 5 Apply a light coat of oil to the gasket of the new filter element gasket 6 Install a new filter hand tight until the seal of the filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the fi
10. 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 125 900554036 SEBU7731 08 123 Maintenance Section Engine Air Filter Primary Element Clean Replace 9 Tighten the bolts for the axle housing in the order that is shown above to 50 x 15 N m 37 x 11 Ib ft Torque all nuts again to 50 15 N m 37 11 Ib ft and turn an additional 90 5 in the same order 10 Remove the chain tension adjuster 11 Install the bolts and the cover for the drive chain case Note Use 8T 9022 Silicone Gasket in order to seal the cover to the machine 12 Use an appropriate nylon lifting strap and a hoist in order to position the tire and rim to the axle The weight of the tire and rim is 51 kg 113 Ib Refer to Operation and Maintenance Manual Wheel Nuts Tighten for the procedure to tighten the wheel nuts 13 Lower the front of the machine to the ground Repeat the procedure on the opposite side of the machine if it is necessary 14 Repeat the adjustment procedure on the rear drive chains if it is necessary 101961088 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOT
11. water separator with fuel Refer to Operation and Maintenance Manual Fuel System Priming Pump Operate 11 Close the engine access door SEBU7731 08 133 Maintenance Section Fuel System Priming Pump Operate 102509334 Fuel System Priming Pump Operate SMCS Code 1258 548 3024 Engine The fuel priming pump is located on top of the fuel filter water separator Illustration 151 901019689 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Push down on the top of the fuel priming pump plunger and release the fuel priming pump plunger in order to operate the fuel priming pump Operate the fuel priming pump plunger in order to fill the new filter element with fuel Continue to pump until increased resistance is felt This resistance will indicate that the filter element is full of fuel 3 Attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate the engine at low idle until the engine runs smoothly If the engine fails to start or if the engine continues to misfire or smoke repeat the priming procedure 4 Close the engine access door 3044 Engine Machines that are equipped with the 3044 engine are equipped with a fuel transfer pump that is electric 1 Momentarily turn the engine start switch to the START position and then return the engine start Switch to the ON position Note Do not star
12. 12 Tire Segment Replace Removal SMCS Code 4203 510 SEG Illustration 174 1 Remove any dirt buildup from the segment 1 Remove any dirt buildup from the stud threads 2 2 Remove the locknuts 3 and washers 4 There are four locknuts and washers per segment 3 Remove the segment from the rim Installation 1 Clean the inner surface of the rim Clean the outer surface of the rim 2 Align the studs in the segment with the holes in the rim Install the segment the washers and the locknuts Illustration 175 900756806 3 Tighten the locknuts 1 2 3 and 4 in order Refer to the table below for the correct torque Table 40 The Recommended Torques for the Locknuts All Sizes Except 19 5L 24 19 5L 24 amp 17 5 25 amp 17 5 25 15 1 Nm 11 amp 1 Ib ft 35 1 Nm 26 1 Ib ft 101203574 Wheel Nuts Tighten SMCS Code 4210 527 Check the torque on new wheels or reinstalled wheels after every one service hour until the specified torque is maintained After the specified torque is maintained check the torque on the nuts after every ten service hours or every day Check the nuts on all four wheels Use a star pattern when you are tightening the nuts The torque specifications are given in the following table Table 41 Tightening Torque for Wheels 163 7 N m 120 5 Ib ft 149
13. ADA Illustration 163 Radial Lift Illustration 164 g01017361 Extended Reach Apply lubricant to the grease fittings 1 for the lift arm linkage Apply lubricant to the grease fittings 2 for the lift cylinder bearings Repeat the process for the opposite side of the machine 101963869 Lower Machine Frame Clean SMCS Code 7050 070 1 Tilt the cab upward Refer to Operation and Maintenance Manual Cab Tilting 138 Maintenance Section Oil Filter Inspect SEBU7731 08 Illustration 165 g01020241 2 Remove the access panel in the frame that is located underneath the machine 3 Remove any debris or dirt from the inside of the frame 4 Reinstall the access panel and tilt the cab downward 102106227 Oil Filter Inspect SMCS Code 1308 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 166 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 Nonf
14. Fan and the Solenoid for the Compressor 116 Maintenance Section Cooling System Coolant ELC Change SEBU7731 08 18 Fuel Shutoff solenoid e 19 Interlock ECM e 20 Beacon e 21 Gauges e 22 The fan for the air conditioner condenser e 23 Ignition Switch 24 Miscellaneous Power e 25 Horn e 27 Auxiliary Hydraulic C e 28 Auxiliary Hydraulic C e 29 Auxiliary Tools e 30 Auxiliary Electrical Control C1 e 33 Spare e 34 Auxiliary Electrical Control C2 e Relays e 1 Finger Trigger for the Work Tool e 26 Auxiliary Hydraulic C Solenoid e 31 Auxiliary Electric Control C1 e 32 Auxiliary Hydraulic C Solenoid e 35 ECM signal for the Auxiliary Hydraulic C and the Auxiliary Hydraulic C e 36 Auxiliary Electric Control C2 Diodes e 37 C e 38 C Illustration 106 g01019607 Circuit Breaker The main circuit breaker is located in the engine compartment on the left side Press the switch and release the switch in order to reset the circuit breaker 101961213 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 tivenes
15. ICE 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 recommendations if you at tempt to clean the filter element Never tap or strike the filter element in order to remove dust Never wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 206 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 tearing or voiding the pleats Service the air filter elements when the alert indicator for air filter restriction lights Refer to Operation and Maintenance Manual Alert Indicators 1 Open the engine access door Illustration 126 900891467 2 The air filter housing is located on the left side of the engine compartment on machines that are equipped with the 3024 engine The air filter housing is located on the right side of the engine compartment on machines that are equipped with the 3044 engine Illustration 127 900101864 3 Unlatch the air cleaner housing cover 1 Rotate th
16. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR S 200 ILL Operation and Maintenance Manual 216B 226B 232B 236B 242B 246B 248B 252B 262B and 268B Skid Steer Loaders RLL1 6799 216B Machine MJH1 10574 226B Machine SCH1 2474 232B Machine BXM1 4224 242B Machine SCL1 Up 248B Machine PAT1 Up 246B Machine PDT1 Up 252B Machine SCP1 4599 262B Machine LBA1 Up 268B Machine 110 Maintenance Section Maintenance Interval Schedule SEBU7731 08 102743799 Maintenance Interval Schedule SMCS Code 7000 S N LBA1 Up S N SCL1 Up S N HEN1 6749 S N SCP1 4599 S N PAT1 Up S N PDT1 Up When Required Battery Recycle sese 111 Battery or Battery Cable Inspect Replace 111 Blade Frame Adjust sseeeeses 112 Bucket Cutting Edges Inspect Replace 113 Bucket Tips Inspect Replace 113 Cab Air Filter Clean Replace 114 Circuit Breakers and Fuses Reset Replace 114 Engine Air Filter Primary Element Clean Replace iiit ies diis 123 Engine Air Filter Secondary Element Replace 124 Fuel System Priming Pump Operate 133 Fuel Tank Cap Clean ssssssss 133 Fuel Tank Water and Sediment Drain 134 Lower Machine Frame Cl
17. The radiator cap is located on the right side of the radiator on machines that are equipped with the 3044 engine 3 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap 4 If necessary drain enough coolant from the radiator in order to allow the addition of the coolant additive 5 Add 0 17 L 0 18 qt of cooling system additive 6 Inspect the radiator cap and the gasket If the cap or the gasket is damaged replace the cap Install the radiator cap JEL gt D g00956179 Illustration 112 Note The sight gauge for the coolant level is located on the right side of the radiator on machines that are equipped with the 3024 engine The sight gauge for the 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 SEBU7731 08 119 Maintenance Section Cooling System Level Check 8 Tilt the radiator guard downward 9 Close the engine access door For additional information on the addition of extender see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 101959244 Cooling System Level Check SMCS Code 1350 040 HX 1350 535 FLV 1382 070 1382 510 Pressurized system Hot coolant can cau
18. aged 3 Install the element and replace the cover 102429415 Circuit Breakers and Fuses Reset Replace SMCS Code 1417 510 1420 529 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 SEBU7731 08 115 Maintenance Section Circuit Breakers and Fuses Reset Replace Vi elc EXE A e ae P Illustration 104 g01019673 The fuse panel is located behind the cover underneath the seat Remove the cover in order to access the fuse panel 27 28 29 30 31 Illustration 105 Fuses and Relays e Fuses e 2 Finger Trigger for the Work Tool e 3 Front Work Lights e 4 Rear Work Lights e 5 Left Tail Lamp e 6 Right Tail Lamp e 7 Spare e 8 Backup Alarm 9 Cold Start g01213939 10 Radio 11 Spare 12 Spare 13 12 volt power socket 14 Hydraulic Quick Coupler 15 Wiper 16 Auxiliary Hydraulic ECM 17 HVAC Blower
19. ash 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 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 102645127 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 mand
20. ates The fuel system water separator is located in the left side of the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers aa Illustration 147 g01023095 Illustration 148 901023096 132 Maintenance Section SEBU7731 08 Fuel System Primary Filter Water Separator Element Replace 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 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 102645133 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 purpo
21. block 102811482 Engine Oil and Filter Change SMCS Code 1308 510 1348 044 S N MJH1 10574 S N SCH1 2474 S N RLL1 6799 S N BXM1 4224 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 250 Service Hours or every year when the following conditions are met e Caterpillar oil API Specification Cl 4 CH 4 or CG 4 multigrade oil is used e Caterpillar filters are used e The altitude does not exceed 2300 m 7545 ft 128 Maintenance Section Engine Oil and Filter Change SEBU7731 08 e Sulfur content in the fuel is between 0 05 and 0 50 An oil change interval of Every 200 Service Hours or every six months is required when the following conditions occur e Caterpillar oil API Specification Cl 4 CH 4 or CG 4 multigrade oil is not used e The altitude exceeds 2300 m 7545 ft e Sulfur content in the fuel is between 0 50 and 1 0096 An oil change int
22. e Drain the water and the sediment from the fuel tank when the tank is almost empty 1 Slowly remove the fuel tank cap in order to relieve the tank pressure C 3C C C3 Illustration 153 901023153 2 The fuel tank drain plug is located underneath the machine at the left rear corner Loosen the plug 3 Allow the water and the sediment to drain into a suitable container 4 Install the fuel tank drain plug Note Apply 5P 3413 Pipe Sealant to the threads on the drain plug 5 Install the fuel tank cap 101957445 Hydraulic Oil Sample Obtain SMCS Code 5050 008 7542 008 Illustration 154 g01026057 The sampling port for the hydraulic oil is located on the fan motor 101962605 Hydraulic System Oil Change SMCS Code 5095 044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates SEBU7731 08 135 Maintenance Section Hydraulic System Oil Change
23. e breather hoses Ensure that the connections are tight 102022498 Engine Crankcase Breather Clean SMCS Code 1317 070 S N MJH1 10574 S N SCH1 2474 S N RLL1 6799 SIN BXM1 4224 Note Ensure that the area around the vent hole on the breather cover is clean and that the vent hole is not restricted Ensure that the components of the breather assembly are seated in the correct positions Otherwise engine damage could result 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 i Illustration 132 g01018945 126 Maintenance Section Engine Oil Level Check SEBU7731 08 Illustration 133 g01044243 3 The breather is located on top of the valve cover on the 3024 engine Remove the screws 1 Remove the breather cover 2 4 Remove the diaphragm assembly 4 Remove the spring 3 The diaphragm assembly consists of the diaphragm and the locating ring 5 Clean the cavity for the breather 5 6 Remove the gauze that is located below the cavity for the breather 7 Clean the following items with a clean diesel fuel e Breather e Breather cover e Diaphragm assembly e Location ring assembly e Spring e Gauze 8 Allow the parts to dry Pressure air may be used to dry the parts 9 Install the gauze and install the components of the breathe
24. e cover and remove the cover 4 Remove the primary filter element 2 5 Install a clean filter element into the filter housing and install the cover for the filter housing 6 Close the engine access door 124 Maintenance Section Engine Air Filter Secondary Element Replace SEBU7731 08 7 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 102020796 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary air filter element Never attempt to reuse it by cleaning The secondary air fil ter element should be replaced at the time the primary element is serviced for the third time The secondary filter element should also be replaced if the alert indi cator for air filter restriction lights 1 Open the engine access door XH 2 The air filter housing is located on the left side of the engine compartment on machines that are equipped with the 3024 engine The air filter housing is located on the right side of the engine compartment on machines that are equipped with the 3044 engine Illustration 128 900891467 Illustration 129 900101864 3 Unlatch the air cleaner hous
25. e tires is not recommended Note There are four drive chains on the skid steer loader that must be checked and adjusted 122 Maintenance Section Drive Chain Tension Check Adjust SEBU7731 08 1 Park the machine on level ground and stable ground 2 Chock the rear tires 3 Use an appropriate floor jack to lift the front of the machine so that the front tires are off of the ground Block up the front of the machine with two 1U 9758 Jack Stands TIEFE HELLE 901025514 Illustration 121 4 Rotate the wheel forward and backward Measure the total free play A Note If the total free play does not exceed 15 mm 0 6 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 901025547 Illustration 122 5 Remove the eight wheel nuts 3 Use an appropriate nylon lifting strap and a hoist in order to remove the tire and rim 1 The weight of the standard tire and rim is 51 kg 113 Ib 6 Remove bolts and the cover 2 for the drive chain case Note Remove the sealant from the cover and from the machine Illustration 123 901025571 7 Loosen the eight bolts 5 for the axle housing Place 159 3337 Chain Tension Adjuster 7 between the axle housings 6 Illustration 124 900867842 8 Rotate the axle in order to ensure that the chain 8 is taut below
26. ean 137 Oil Filter Inspect sem 138 Tire Segment Replace 143 Window Washer Reservoir Fill 143 Window Wiper Inspect Replace 144 Windows Clean sesseeseeeeee 144 Every 10 Service Hours or Daily Backup Alarm Test ssssssssssss 111 Cooling System Level Check 119 Engine Oil Level Check ssssss 126 Fuel System Primary Filter Water Separator Dralbisiientt etie iet A 131 Hydraulic System Oil Level Check 137 Lift Arm and Cylinder Linkage Lubricate 137 Quick Coupler Inspect sssssssssss 138 Radiator Core Clean eee 139 Seat Belt Inspect sssssssssssssss 140 Tilt Cylinder Bearings and Bucket Linkage Bearings l ubricate gend euet 141 Tire Inflation Check eeens 142 Wheel Nuts Tighten iiec 143 Work Tool Lubricate eeens 144 Work Tool Mounting Bracket Inspect 147 Every 250 Service Hours Engine Oil Sample Obtain 127 Every 250 Service Hours or Monthly Belts Inspect Adjust Replace 111 Every 500 Service Hours Hydraulic Oil Sample Obtain 134 Every 500 Service Hours or 3 Months Drive Chain Tension Check Adjust
27. ection Engine Oil and Filter Change SEBU7731 08 Refer to the results of the S O S oil analysis in order to determine if the oil change interval should be decreased Consult your Caterpillar Dealer for detailed information regarding the optimum oil change interval 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting eh X J AE CL ps Illustration 143 901031090 3044 engine Note The crankcase drain is located on the right side of the oil pan 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 oe 4i AAP id FT Illustration 144 3044 engine 901022355 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 positio
28. er ELC Add SEBU7731 08 JEL gt D g00956179 Illustration 110 Note The sight gauge for the coolant level is located on the right side of the radiator on machines that are equipped with the 3024 engine The sight gauge for the coolant level is located on the left side of the radiator on machines that are equipped with the 3044 engine 9 Maintain the coolant level in the sight gauge 10 Stop the engine Inspect the radiator cap and the gasket Replace the cap if the cap or the gasket is damaged Install the radiator cap 11 Pull the radiator guard downward 12 Close the engine access door 101962081 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure When a Caterpillar Extended Life Coolant is used an extender must be added to the cooling system periodically 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting ELLO SMe D g00956151 Illustration 111 Note The radiator cap is located on the left side of the radiator on machines that are equipped with the 3024 engine
29. errous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 101734746 Quick Coupler Inspect SMCS Code 6129 040 Illustration 167 g00889446 1 Move the quick coupler levers 1 to the disengaged position Ensure that the levers are not bent or broken 2 Check the top edges of the quick coupler assembly 2 for wear or for damage SEBU7731 08 139 Maintenance Section Radiator Core Clean N Illustration 168 900889412 3 Move the quick coupler levers 1 to the engaged position Ensure that the levers move freely without restriction 4 Make sure that the coupler pins 3 extend through the bottom of the quick coupler assembly Check the pins for wear and check the pins for damage 5 Move the quick coupler levers to the disengaged position If any wear is suspected or damage is suspected consult you
30. erval of Every 125 Service Hours is required when the following condition occurs e Sulfur content in the fuel is above 1 00 Refer to the results of the S O S oil analysis in order to determine if the oil change interval should be decreased Consult your Caterpillar Dealer for detailed information regarding the optimum oil change interval 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting Illustration 139 901022394 3024 engine Note The crankcase drain is located on the right side of the oil pan 3 Pull the drain hose for the crankcase through the opening in the rear of the machine and remove the plug in the end of the drain hose Open the crankcase drain valve and drain the oil into a suitable container Close the crankcase drain valve Install the plug in the drain hose Illustration 140 g01022354 3024 engine 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 p
31. for the coupler engagement pins Apply lubricant to the grease fitting 4 for the pivot pin of the quick coupler assembly There are a total of 8 grease fittings 102124717 Tire Inflation Check SMCS Code 4203 535 Al Measure the tire pressure on each tire Consult your Caterpillar dealer for the correct load rating and for the correct operating pressures These correct load ratings and correct operating pressures can also be obtained from your tire dealer 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 Tire Inflation with Nitrogen Caterpillar recommends the use of dry nitrogen gas for tire inflation and for tire pressure adjustments This includes all machines with rubber tires Nitrogen is an inert gas that will not aid combustion inside the tire Proper nitrogen inflation equipment and training in using the equipment are necessary to avoid over inflation A tire blowout or rim failure can re sult from improper or misused e
32. gas Note The receiver dryer must also be replaced when the air conditioning system is evacuated 102798931 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect SMCS Code 7323 040 7325 040 Illustration 169 g01022156 1 Front ROPS retaining bolt one bolt per side 2 3 oo 00 OI LLL SOQUEL IAA a AQAA Saat OOS SAS gaa BENHBBEBBEBNBEBRR NAMANA DEDEDE ata IIA MENNERERER UOO I Illustration 170 g00925477 2 Rear ROPS retaining bolt one bolt per side 3 Retaining bolts for the FOPS 2 Note There is a total of four retaining bolts for the ROPS There is a total of eight retaining bolts for the FOPS 2 1 Inspect the ROPS and the FOPS for loose bolts Tighten the bolts 1 to the following torque 125 10 N m 92 7 Ib ft Tighten the bolts 2 to the following torque 55 5 N m 41 x 4 Ib ft Tighten the bolts 3 to the following torque 240 40 N m 177 x 30 Ib ft ROPS and the FOPS for damaged bolts or missing bolts Replace any damaged bolts or missing bolts with original equipment parts only 2 Operate the 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 Do not straighten the ROPS or the FOPS Do not re
33. he radiator cap in order to relieve system pressure Remove the radiator cap MEE VI EE Ly x Eo ER eer Er WKN Mw Nw A Ie 900954319 Illustration 108 3024 drain valve e ll gm E Illustration 109 901018862 3044 drain valve 4 Remove the drain plug and allow the coolant to drain into a suitable container 5 Install the drain plug 6 Replace the thermostat See Operation and Maintenance Manual Cooling System Water Temperature Regulator Replace for the process for replacing the thermostat 7 Add the coolant solution Refer to Operation and Maintenance Manual Capacities Refill Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Note Premix the coolant solution before filling the cooling system The coolant solution should contain 50 percent coolant and 50 percent distilled water Note Add the coolant solution at a maximum rate of five liters per minute This will reduce the chance of trapping air inside the engine block A large amount of trapped air can cause localized heating to occur upon start up Localized heating may result in engine damage which may lead to failure of the engine 8 Start the engine Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes 118 Maintenance Section Cooling System Coolant Extend
34. 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 acertified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system 140 Maintenance Section SEBU7731 08 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 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
35. ighten the adjusting locknut Tighten the mounting bolt 8 Recheck the belt deflection If the amount of deflection is incorrect repeat step 4 to step 7 9 Install the guard for the V belt 10 Close the engine access door 102549571 Blade Frame Adjust SMCS Code 6060 025 BG Height Adjustment Illustration 100 901161532 1 Height Adjustment for the Frame 2 Adjusting Bolts 3 Frame The height of the frame may be adjusted in order to compensate for the wear on the cutting edge The front portion of the frame needs to be lowered as the cutting edge wears Remove the bolts 2 and lower the frame 3 Install the bolts This will keep the 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 SEBU7731 08 113 Maintenance Section Bucket Cutting Edges Inspect Replace Trunnion Joint Note The trunnion is a dry joint Adding grease to the trunnion simply attracts abrasive particles The tightness of the joint should be monitored Shims should be removed when the joint becomes too loose This may be indicated by excessive movement in the blade PN Illustrat
36. ing cover 1 Rotate the cover and remove the cover 4 Remove the primary filter element 2 Illustration 130 900038606 5 Remove the secondary filter element 6 Cover the air inlet opening Clean the inside of the air cleaner housing 7 Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged 8 Uncover the air inlet opening Install a new secondary element 9 Install the primary element and the air cleaner housing cover 10 Close the engine access door SEBU7731 08 125 Maintenance Section Engine Crankcase Breather Closed Circuit Replace 101961301 Engine Crankcase Breather Closed Circuit Replace SMCS Code 1317 510 S N LBA1 Up S N SCL1 Up S N HEN1 6749 S N SCP1 4599 S N PAT1 Up S N PDT1 Up Illustration 131 901018922 The breather is located on the right side of the 3044 engine NOTICE Ensure that the breather pipe connections are tight Do not overfill the engine cranckcase If there is too much oil in the crankcase oil may enter the breather Oil entering the breather may cause the engine speed to increase rapidly without control 1 Firmly grasp the breather and pull up on the breather in order to remove the breather 2 Remove the breather hoses Clean the hoses with nonflammable solvent 3 Install a new breather Ensure that the breather is properly seated in the base 4 Install th
37. ion 101 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 101 e Torque the bolts to 530 70 N m 391 52 Ib ft Note Some noise is typical and the noise does not indicate a problem i01743875 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 T Install the bolts 8 Remove the blocks that are under the bucket 9 After a few hours of operation check the bolts for proper torque 101764331 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket tips are accessible 2 Place blocks under the raised edge of the bucket 3 Remove the mo
38. lter Use the index marks as a guide Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 8 Maintain the hydraulic oil level to the middle of the sight gauge Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check Do not overfill the hydraulic tank 9 Inspect the gasket on the hydraulic tank filler cap for damage Replace the hydraulic tank filler cap if necessary Install the hydraulic tank filler cap SEBU7731 08 137 Maintenance Section Hydraulic System Oil Level Check 10 Close the engine access door 101957050 Hydraulic System Oil Level Check SMCS Code 5095 535 FLV Illustration 161 900956818 Note This film is located near the hydraulic filler cap on machines that are filled with synthetic oil i01957078 Lift Arm and Cylinder Linkage Lubricate SMCS Code 5102 086 BD 6107 086 BD Illustration 162 900926177 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 Maintain the oil level to the middle of the sight gauge Do not overfill the hydraulic tank cU AQUI
39. n of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide Note You may need to 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 Illustration 145 901018171 3044 engine 8 Remove the oil filler plug 1 Fill the crankcase with new oil See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Clean the oil filler plug and install the oil filler plug 9 Start the engine and allow the oil to warm Check for leaks SEBU7731 08 131 Maintenance Section Engine Valve Lash Check CANAAAAA 0 Illustration 146 900849728 10 Stop the engine and allow the oil to drain back into the oil pan Fill the crankcase to the FULL mark on the dipstick 1 Do not exceed the FULL mark on the dipstick Add oil or drain oil if it is necessary 11 Tilt the radiator downward 12 Close the engine access door 101020861 Engine Valve L
40. oint on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide Note You may need to 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 SEBU7731 08 129 Maintenance Section Engine Oil and Filter Change Illustration 141 901018561 3024 engine 8 Remove the oil filler plug 1 Fill the crankcase with new oil See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Clean the oil filler plug and install the oil filler plug 9 Start the engine and allow the oil to warm Check for leaks e CANAAAAA 0 Illustration 142 900849728 10 Stop the engine and allow the oil to drain back into the oil pan Fill the crankcase to the FULL mark on the dipstick 1 Do not exceed the FULL mark on the dipstick Add oil or drain oil if it is necessary 11 Tilt the radiator downward 12 Close the engine access door 102742743 Engine Oil and Filter Change SMCS Code 1308
41. pair 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 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 SEBU7731 08 141 Maintenance Section Seat Belt Replace Illustration 171 900932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt b
42. quipment and per sonal injury or death can occur A tire blowout and or rim failure can occur if the in flation equipment is not used correctly due to the fact that a fully charged nitrogen cylinder s pres sure is approximately 15000 kPa 2200 psi There are other benefits to using nitrogen in addition to reducing the risk of an explosion The use of nitrogen for tire inflation lessens the slow oxidation of the rubber Use of nitrogen also slows gradual tire deterioration This is especially important for tires that are expected to have a long service life of at least four years Nitrogen reduces the corrosion of rim components Nitrogen also reduces problems that result from disassembly A tire blowout or a rim failure can cause personal injury Use a self attaching inflation chuck and stand be hind the tread when inflating a tire to prevent per sonal injury NOTICE Set the tire inflation equipment regulator at no more than 140 kPa 20 psi over the recommended tire pressure Use 6V 4040 Inflation Group or an equivalent inflation group to inflate tires with a nitrogen gas cylinder Reference For tire inflation instructions refer to Special Instruction SMHS7867 Nitrogen Tire Inflation Group For nitrogen inflation use the same tire pressures that are used for air inflation Consult your tire dealer for operating pressures SEBU7731 08 143 Maintenance Section Tire Segment Replace i014452
43. r Install the breather cover 10 Tilt the radiator downward 11 Close the engine access door 101959002 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 2 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 3 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting Illustration 134 901018561 3024 engine Illustration 135 901018171 3044 engine SEBU7731 08 127 Maintenance Section Engine Oil Sample Obtain Illustration 136 900850465 4 Maintain the oil level to the FULL mark 3 on the dipstick 1 5 f necessary remove the oil filler cap 2 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 Engine Oil Sample Obtain SMCS Code 1348 554 SM 7542 008 Illustration 137 g01018202 3024 engine A Q ee TM es iH ae el oe Dl g01018203 Illustration 138 3044 engine The sampling port for the engine oil is located on the left side of the engine
44. r Caterpillar dealer before you use a work tool 101488851 Radiator Core Clean SMCS Code 1353 070 KO The radiator is located at the rear of the machine above the engine compartment 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 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 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 3 Clean the radiator core NOTICE Do not clean a running fan with high pressure water Fan blade failure can result 4 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 5 Tilt the radiator guard downward 6 Close the engine access door 101968724 Refrigerant Dryer Replace If Equipped SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to
45. s 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 SEBU7731 08 117 Maintenance Section Cooling System Coolant ELC Change 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 DULL SAF D Illustration 107 900956151 Note The radiator cap is located on the left side of the radiator on machines that are equipped with the 3024 engine The radiator cap is located on the right side of the radiator on machines that are equipped with the 3044 engine 3 Slowly loosen t
46. se The element serves as a water separator and a fuel filter 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers a Illustration 149 g01017292 Fuel Filter Water Separator for the 3024 engine that is located on the left side of the engine compartment Illustration 150 g01017293 Fuel Filter Water Separator for the 3044 engine that is located on the right 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
47. se fittings for the two grapples There are eight grease fittings Angle Blade g00648033 Illustration 184 Apply lubricant to the grease fitting on the rod end of the angle cylinder Illustration 185 g00648037 Apply lubricant to the grease fitting on the horizontal pivot point of the blade Illustration 186 g00648038 Apply lubricant to the grease fitting on the vertical pivot point of the blade Repeat for opposite side of the blade Illustration 187 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 SEBU7731 08 147 Maintenance Section Work Tool Mounting Bracket Inspect Dozer Blade Illustration 188 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 189 900925058 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
48. se 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 Refer to Operation and Maintenance Manual Radiator Tilting JEL gt D g00956179 Illustration 113 Note The sight gauge for the coolant level is located on the right side of the radiator on machines that are equipped with the 3024 engine The sight gauge for the coolant level is located on the left side of the radiator on machines that are equipped with the 3044 engine 3 Maintain the coolant to the top of the sight gauge with the radiator in the LOWERED position AUU A D g00956151 Illustration 114 Note The radiator cap is located on the left side of the radiator on machines that are equipped with the 3024 engine The radiator cap is located on the right side of the radiator on machines that are equipped with the 3044 engine 4 If you need to add coolant to the radiator Remove the radiator cap slowly in order to relieve system pressure Note Inspect the cooling system hoses for any leaks cracks or signs of deterioration Replace any damaged hoses 5 Inspect the radiator cap and the gasket Replace the cap if the cap or the gasket is damaged In
49. stall the radiator cap 6 Tilt the radiator guard downward Illustration 115 901018341 7T The coolant reservoir is located on the left side of the engine compartment or the left side of the engine access door Maintain the coolant level in the coolant reservoir between the MIN and MAX lines 8 Close the engine access door 120 Maintenance Section Cooling System Water Temperature Regulator Replace SEBU7731 08 101958427 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system Failure to replace the engine s thermostat on a regularly scheduled basis could cause severe engine damage The thermostat should be replaced after the cooling system has been cleaned Replace the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing Caterpillar engines incorporate a shunt design cooling system It is mandatory to always operate the engine with a thermostat 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Drain the coolant from the machine See Operation and Maintenance Manual Cooling System Coolant ELC Change for the procedure to drain the cooling system
50. t the engine This operation only starts the fuel pump 2 Leave the engine start switch in the ON position for thirty seconds 3 Attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate the engine at low idle until the engine runs smoothly If the engine fails to start or if the engine continues to misfire or smoke repeat the priming procedure 101819309 Fuel Tank Cap Clean SMCS Code 1273 070 Z2 1 Remove the fuel cap Illustration 152 g00104238 2 Inspect the cap Replace the cap if the cap is damaged 3 Wash the fuel cap in a clean nonflammable solvent and dry the fuel cap 4 Put a light coating of fuel on the cap gasket 5 Install the fuel cap 134 Maintenance Section Fuel Tank Water and Sediment Drain SEBU7731 08 101971189 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 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 Not
51. ttery 6 Connect the battery cable to the starter of the machine 7 Install the engine start switch key Repeat the process for the positive battery cable 101957641 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 If a new belt is installed check the belt adjustment after 30 minutes of operation A belt is considered to be used after 30 minutes of operation 1 Stop the engine in order to inspect the belt 2 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 98 901017605 3 Remove the guard for the V belt 112 Maintenance Section Blade Frame Adjust SEBU7731 08 Illustration 99 g01017632 4 Inspect the condition of the belt 1 and the adjustment of the belt The belt should deflect 10 mm 0 39 inch under a straight pull of 44 N 10 Ib This measurement should be taken between the alternator pulley and the crankshaft pulley Note A 144 0235 Borroughs Belt Tension Gauge may be used to measure belt tension This measurement should be taken between the alternator pulley and the crankshaft pulley Refer to the following table for belt tension Table 39 Belt Tension Belt Tension Initial Used 534 22 N 120 5 Ib 400 44 N 90 x 10 Ib 5 Loosen the mounting bolt 2 Loosen the adjusting locknut 3 6 Move the alternator until the correct tension is reached 7 T
52. uckle 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 101970036 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation 2 or within five years of the date of manufacture 1 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 each seat belt mmn Wwe T E Illustration 172 901022746 1 Date of Manufacture 2 Date of Installation Contact your Caterpillar dealer for the replacement of the seat belt Tilt Cylinder Bearings and Bucket Linkage Bearings Lubricate SMCS Code 5104 086 BD 6107 086 BD Wipe all of the grease fittings before you apply lubricant 3 Illustration 173 900955895 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 142 Maintenance Section Tire Inflation Check SEBU7731 08 Apply lubricant to the grease fittings 2 for the lower bearings for the tilt cylinders Apply lubricant to the grease fittings 3
53. unting bolts Remove the bucket tips 114 Maintenance Section Cab Air Filter Clean Replace SEBU7731 08 4 Clean the mounting surface 5 Replace the bucket tips 6 Install the bolts 7 Remove the blocks that are under the bucket 8 After a few hours of operation check the bolts for proper torque 101962545 Cab Air Filter Clean Replace If Equipped SMCS Code 7342 070 7342 510 Fresh Air Filter 1 Raise the loader lift arms Install the brace for the loader lift arm Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation Illustration 102 901019732 2 Remove the filter cover 3 Remove the seal from the cover and inspect the seal If the seal is damaged replace the seal 4 Remove the air filter element from the cover and clean the filter element with low pressure air Replace the element if the element is damaged 5 Install the seal onto the filter cover and install the filter element 6 Install the filter cover on the machine 7 Remove the brace for the loader lift arms and return the brace to the stored position Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation Recirculation Filter Illustration 103 g01024691 1 Remove the cover in order to access the air filter element 2 Remove the air filter element and clean the element with soap and water Replace the element if the element is dam
54. ve and drain the oil into a suitable container 4 Close the drain valve and pull the drain hose back into the machine Install the drain plug into the drain hose 5 Change the hydraulic system filter Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Change 6 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 7 Maintain the hydraulic oil level approximately in the middle of the sight gauge Check the oil level with the loader arms in the fully lowered position 136 Maintenance Section Hydraulic System Oil Filter Replace SEBU7731 08 Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction hoses and hose clamps 8 Install the hydraulic tank filler cap 102742828 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
55. y 169 5464 Quick Cure Primer and 5P 3413 Pipe Sealant to the threads on the drain plugs Install the drain plugs q4 e p d RY B dio Le 9 eae ai Illustration 119 g01025470 3 Remove the filler plug for the right side drive chain case Fill the drive chain case with oil to the bottom of the threads on the fill port Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities 4 Apply 169 5464 Quick Cure Primer and 5P 3413 Pipe Sealant to the threads on the filler plug Install the filler plug 5 Repeat the process for the left side drive chain case Drive Chain Case Breathers Illustration 120 g01031152 The breathers for the drive chain cases are located underneath the cab 1 Refer to Operation and Maintenance Manual Cab Tilting Remove the breathers and inspect the breathers when the oil in the drive chain cases is changed In order to clean the breathers use solvent and low pressure air If the breather is badly plugged replace the breather 102711772 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 th
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