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Maintenance Intervals - Safety

1. Illustration 149 Type 1 g00821973 Illustration 150 Type 2 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 gasket and the thermostat from the thermostat housing assembly 6 Install a new thermostat and a new gasket Install the thermostat housing assembly on the engine cylinder head 7 Install the hose Tighten the hose clamp See Operation and Maintenance Manual Standard Torque for Worm Drive Band Hose Clamps for the proper torque 8 Refill the cooling system See Operation and Maintenance Manual Refill Capacities Refer to Operation and Maintenance Manual SEBU6250 Cooling System Specifications for coolant information 9 Close the engine access door 110 Maintenance Section Drive Chain Case Oil Change SEBU7468 06 101990833 Drive Chain Case Oil Change SMCS Code 3261 543 OC 3261 544 OC Shi Cn a Je e p t N B ia DY w ai g01025459 Illustration 151 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 All
2. 0 0c 0e 104 Circuit Breakers and Fuses Reset Replace 104 Engine Air Filter Primary Element Clean Replace 0 cccccceeceeeeeeeeeeeceeeeeeeeeeteeeeees 112 Engine Air Filter Secondary Element Replace 113 Engine Compartment Clean 114 Engine Starting with Jump Start Cables 119 Fuel System Priming Pump Operate 122 Fuel Tank Cap Clean c ecceeeeceeeeeeeeeeeeeees 123 Fuel Tank Water and Sediment Drain 123 Lower Machine Frame Clean sinisesse 128 Oil Filter NSpECt iisi iinit 128 Tire Segment Replace 133 Window Washer Reservoir Fill a se 134 Window Wiper Inspect Replace 00 134 Windows Clean cccceceeeeeeeeeeeeeseenaeeees 134 Every 10 Service Hours or Daily Backup Alarm Test c ceeeeeeeeeecceeeeeeeeeeneees 102 Cooling System Level Check nsss 108 Engine Air Filter Service Indicator Inspect 113 Engine Oil Level Check eccceeeeceeeeteeeeeenteees 116 Fuel System Primary Filter Water Separator Drain iieiaeie i aia i Ara ai 121 Hydraulic System Oil Level Check assess 127 Lift Arm and Cylinder Linkage Lubricate 127 Quick Coupler Inspect c ceeeeceeeeeeeeeees 129 Radiator Core Clean csecceceeeeeeeetteeteees 129 Seat Belt Inspect ceee eee eeeeeeteeeeeeeeeeeees 131 Tilt Cylinder Bearings and Bucke
3. 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 the refrigerant system has been open to the outside air without being plugged for more than 30 minutes the receiver dryer must be replaced Moisture will en ter an open refrigerant system and cause corrosion which will lead to component failure Refer to Service Manual SENR5664 Air Conditioning and Heating R 134a For All Caterpillar Machines for the proper procedure to change the receiver dryer assembly and for the procedure to reclaim the refrigerant gas Note The receiver dryer must also be replaced when the air conditioning system is evacuated i01724179 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Insp
4. 101786416 Hydraulic System Oil Level Check SMCS Code 5095 535 FLV Illustration 199 g00956818 Note This film is located near the hydraulic filler cap on machines that are filled with synthetic oil as ma AANA TTT AANA 4 1 UUs ILLIA NAMANA NAANA IAA SOOO Illustration 200 g00926168 sight gauge type 1 NANN MAANA ANANN WOLLI ag IMAN IIA Illustration 201 g00926177 sight gauge type 2 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 101713746 Lift Arm and Cylinder Linkage Lubricate SMCS Code 5102 086 BD 6107 086 BD g00881888 Illustration 202 216 226 236 246 and 248 machines 128 Maintenance Section Lower Machine Frame Clean SEBU7468 06 ADIL ALDI SOULE QUID WORDED V Ee BERBBEEE Illustration 203 g00882013 232 and 242 machines LILLIA Ss IUD SUID QUID WORDED WOOL UEESe QE DDR aAr LI aa al Illustration 204 g008
5. Illustration 172 3044 engine The sampling port for the engine oil is located on the left side of the engine block 101584706 Engine Oil and Filter Change SMCS Code 1308 510 1348 044 The normal oil change interval for the Skid Steer loader is Every 500 Service Hours or every year when the following conditions are met e Caterpillar oil or API Specification CG 4 multigrade oil is used e Caterpillar filters are used e 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 month is required when the following conditions occur e Caterpillar oil or API Specification 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 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 173 g00822183 Type 1
6. 118 Maintenance Section Engine Oil and Filter Change SEBU7468 06 el g00822206 Illustration 174 Type 2 Note The crankcase drain is located on the left side or 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 4 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 175 Type 1 Illustration 176 g00822189 Type 2 5 Remove the filter element with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect 6 Apply a thin film of clean engine oil to the sealing surface of the new filter element 7 Install the new filter element by hand When the gasket contacts the filter base tighten the filter for an additional 3 4 turn g00753155 Type 1 ne ee SE ae ye be d V E A LIAA ee v iz eN 3 H P TS g00822225 Illustration 178 Type 2 SEBU7468 06 119 Maintenance Section Engine Starting with Jump Start Cables 8 Remove the oil filler plug 2 Fill the crankcase with new oil See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Clean the oil filler plug and install the oil filler plug 9 Start the engi
7. Bucket and Utility Grapple Fork Illustration 220 g00647980 Apply lubricant to the four grease fittings for the grapples Illustration 221 g00647988 Apply lubricant to the two fittings for the grapple cylinder There are six grease fittings Industrial Grapple Bucket and Industrial Grapple Fork Illustration 222 g00645995 Apply lubricant to the four grease fittings for the fork cylinders Illustration 223 g00646004 136 Maintenance Section Work Tool Lubricate SEBU7468 06 Apply lubricant to the four grease fittings for the two forks There are eight grease fittings Angle Blade Illustration 224 g00648033 Apply lubricant to the grease fitting on the rod end of the angle cylinder Illustration 225 g00648037 Apply lubricant to the grease fitting on the horizontal pivot point of the blade g00648038 Illustration 226 Apply lubricant to the grease fitting on the vertical pivot point of the blade Repeat for opposite side of the blade Illustration 227 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 Dozer Blade Illustration 228 g01073259 Apply lubricant to the grease fitting on both ends of the right hand angle cylinder 1 Repeat for opposite side of the blad
8. 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 JOO aaa IAEA Illustration 218 g00925106 Fill the reservoir with window washer solvent Window Wiper Inspect Replace If Equipped SMCS Code 7305 040 7305 510 Inspect the condition of the windshield wiper blade Replace the windshield wiper blade if the windshield wiper blade is worn or damaged If the window wiper blade streaks the window replace the window wiper blade 101037044 Windows Clean If Equipped SMCS Code 7310 070 Use commercially available window cleaning solutions in order to clean the windows Clean the outside of the windows from the ground unless handholds are available SEBU7468 06 135 Maintenance Section Work Tool Lubricate 102107645 Work Tool Lubricate SMCS Code 6700 086 Multipurpose Bucket Illustration 219 g00534457 Apply lubricant to the grease fitting 1 for the pivot pin of the apron Apply lubricant to the grease fitting 2 for the rod end of the multipurpose bucket cylinder Apply lubricant to the grease fitting 3 for the head end of the multipurpose bucket cylinder Repeat for the other side of the bucket There are six grease fittings Utility Grapple
9. N 4YZ1 Up S N 5FZ1 Up S N 5SZ1 Up S N 6BZ1 Up Note This type of engine crankcase breather is used on naturally aspirated engines only 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 breather hose is installed correctly so that the hose does not contact other parts 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 g00956198 Illustration 167 Breather location 2 116 Maintenance Section Engine Oil Level Check SEBU7468 06 Illustration 168 g00822156 3 Loosen the hose clamps 1 for the breather hose Remove the breather hose 4 Remove the screws 3 Remove the breather cover 4 5 Remove the diaphragm assembly 5 The diaphragm assembly consists of the diaphragm and the locating ring Remove the spring 6 6 Clean the following items with a clean nonflammable solvent e Breather e Breather cover e Diaphragm assembly Location ring assembly e Spring e Breather hose 7 Allow the parts to dry Pressure air may be used to dry the parts 8 Inspect
10. batteries do not fully recharge from the alternator after jump start ing The batteries must be charged to proper voltage with a battery charger Many batteries thought to be unusable are still rechargeable Use only equal voltage for starting Check the battery and starter voltage rating of your machine Use only the same voltage for jump starting Use of a welder or higher voltage damages the electrical system This machine has a 12 volt starting system Use only the same voltage for jump starting Refer to Special Instruction SEHS7633 Battery Test Procedure available from your Caterpillar dealer for complete testing and charging information 1 Determine the reason that the engine will not crank The Caterpillar Electronic Technician ET can be used to aid in troubleshooting if the machine is equipped with the auxiliary hydraulic control module 2 Engage the parking brake Lower the work tools to the ground Refer to Operation and Maintenance Manual Equipment Lowering with Engine Stopped Move all control levers to the HOLD or NEUTRAL position 3 Turn the engine start switch to the OFF position and turn all accessory switches to the OFF position 4 Move the machine that is being used as an electrical source near the stalled machine so that the jump start cables reach the stalled machine Do not allow the machines to contact each other 5 Stop the engine of the machine that is being used as an electric
11. in the lower frame Illustration 194 g00582832 The drain valve is located on the side of the return manifold 7 Open the drain valve and drain the oil into a suitable container 8 Close the drain valve and pull the drain hose back into the machine Install the drain plug into the drain hose 9 Tilt the cab downward and install the bolts for the ROPS Torque the bolts to 125 40 Nm 92 30 Ib ft 10 Remove the supports from the rear of the machine 11 Change the hydraulic system filter Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Change 12 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities 13 Maintain the hydraulic oil level approximately in the middle of the sight gauge Check the oil level with the loader arms in the fully lowered position Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydraulic system Inspect the suction hoses and hose clamps 14 Install the hydraulic tank filler cap i01712710 Hydraulic System Oil Filter Replace SMCS Code 5068 510 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 126 Maintenance Section Hydraulic System Oil Filter Replac
12. the breather hose for damage Replace the breather hose if necessary 9 Install the elements of the breather Install the breather element cover assembly 10 Install the breather hose and tighten the hose clamps for the breather hose 11 Tilt the radiator downward 12 Close the engine access door 101589332 Engine Oil Level Check SMCS Code 1348 535 FLV NOTICE Do not overfill the crankcase Engine damage can re sult 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 g00753070 g00822225 Illustration 170 3 While the engine is stopped maintain the oil level between the ADD mark and the FULL mark on the engine oil dipstick 1 4 If necessary remove the oil filler cap 2 and add oil 5 Clean the oil filler cap and install the oil filler cap 6 Tilt the radiator downward 7 Close the engine access door SEBU7468 06 117 Maintenance Section Engine Oil Sample Obtain Engine Oil Sample Obtain SMCS Code 1348 554 SM 7542 008 Illustration 171 g01018202 3024 engine ee Oe Oe L 92 9 il 4 WE d ae eal g01018203
13. 3 Maintenance Section Bucket Cutting Edges Inspect Replace Illustration 133 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 31 Belt Tension Belt Tension Initial Used 534 22 N 120 5 Ib 400 44 N 90 10 Ib 5 Loosen the mounting bolt 2 Loosen the adjusting locknut 3 6 Move the alternator until the correct tension is reached 7 Tighten the adjusting locknut Tighten the mounting bolt 8 Recheck the belt deflection If the amount of deflection is incorrect repeat step 4 to step 7 9 Install the guard for the V belt 10 Close the engine access door 101743875 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket cutting edge is accessible 2 Place blocks under the raised edge of the bucket 3 Remove the bolts Remove the cutt
14. 4 After the stalled engine starts disconnect the negative jump start cable from the stalled machine 15 Disconnect the negative jump start cable from the negative terminal of the electrical source 16 Disconnect the positive jump start cable from the positive terminal of the electrical source 17 Disconnect the positive jump start cable from the positive terminal of the stalled machine 18 Conclude the failure analysis on the starting system of the stalled machine and or on the charging system of the stalled machine Check the machine while the engine is running and the charging system is in operation 101020861 Engine Valve Lash Check SMCS Code 1105 025 Refer to the Service Manual for the complete adjustment procedure for the engine valve lash A qualified mechanic should adjust the engine valve lash and the fuel injector timing because special tools and training are required i00916186 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 fu
15. 589 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 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 battery 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 132 g01017605 3 Remove the guard for the V belt SEBU7468 06 10
16. 8 06 113 Maintenance Section Engine Air Filter Secondary Element Replace 101741365 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary filter element Never attempt to reuse it by cleaning The secondary filter 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 yellow piston in the filter element indicator en ters the red zone after installation of a clean primary element or if the exhaust smoke is still black Illustration 161 g00891467 Illustration 162 g00101864 1 Remove the air cleaner housing cover 1 2 Remove the primary filter element 2 Illustration 163 g00038606 3 Remove the secondary filter element 4 Cover the air inlet opening Clean the inside of the air cleaner housing 5 Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged 6 Uncover the air inlet opening Install a new secondary element 7 Install the primary element and the air cleaner housing cover 8 Reset the engine air filter service indicator Refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect 101584621 Engine Air Filter Service Indicator Ins
17. 82042 252 and 262 machines 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 Illustration 205 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 206 g00100013 The element is shown with debris SEBU7468 06 129 Maintenance Section Quick Coupler Inspect 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 bearing
18. Cooling System Coolant Extender ELC Add 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 Refill Capacities 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 Illustration 143 g00535489 9 Maintain the coolant level in the sight gauge The sight gauge is located on the right side of the radiator 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 and install the retaining pin 12 Remove the retaining pin for the engine access door from
19. E 06 CATERPILLAR sms 208 Operation and Maintenance Manual 216 226 228 232 236 242 246 248 252 and 262 Skid Steer Loaders CAB1 Up Machine CMB1 Up Machine CED1 Up Machine 100 Maintenance Section Maintenance Interval Schedule SEBU7468 06 102418858 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 When Required Battery Recycle 0 0 0 0 eect serene 102 Battery or Battery Cable Inspect Replace 102 Bucket Cutting Edges Inspect Replace 103 Bucket Tips Inspect Replace cceee 103 Cab Air Filter Clean Replace
20. Remove the cover for the fuse panel 13 14 15 16 Illustration 138 g00793941 Type 2 1 Fuel Shutoff 2 Rear Flood Lamps 8 Cold Start and Hydraulic Filter 9 Left Tail Lamp 10 Right Tail Lamp 11 Auxiliary tools 7 Auxiliary Hydraulic Control 12 Fourth Function 15 Miscellaneous Power 16 Key Switch Illustration 137 g00821897 Type 1 1 Fuel Shutoff 2 Wiper 3 Backup Alarm 4 Interlock Control 5 Heater 6 Gauges 7 Lights and Beacon 8 Cold Start and Hydraulic Filter 9 Left Tail Lamp 10 Right Tail Lamp 11 Auxiliary tools 12 Fourth Function 13 Key Switch 14 Horn 15 Miscellaneous Power 16 Auxiliary Hydraulic Control Illustration 139 g00541350 106 Maintenance Section Cooling System Coolant ELC Change SEBU7468 06 The main circuit breaker is located in the engine compartment on the left side 101685306 Cooling System Coolant ELC Change SMCS Code 1395 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Mixing ELC with other products will reduce the effec tiveness of the coolant This could result in damage to cooling system compo nents If Caterpillar products are not available and com mercial products must be used make sure they have passed the Ca
21. S 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 SEBU7468 06 133 Maintenance Section Tire Segment Replace 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 pres sure Tire Inflation with Nitrogen Caterpillar recommends the use of dry nitrogen gas for tire inflation and for tire pressure adjustments This includes all machines with rubber tires Nitrogen is an inert gas that will not aid combustion inside the tire Proper nitrogen inflation equipment and training in using the equipment are necessary to avoid over inflation A tire blowout or rim failure can re sult from improper or misused equipment and per sonal injury or death can occur A tire blowout and or rim failure can occur if the in flation equipment is not used corr
22. ads 2 2 Remove the locknuts 3 and washers 4 There are four locknuts and washers per segment 3 Remove the segment from the rim 134 Maintenance Section Wheel Nuts Tighten SEBU7468 06 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 217 g00756806 3 Tighten the locknuts 1 2 3 and 4 in order Refer to the table below for the correct torque Table 32 The Recommended Torques for the Locknuts All Sizes Except 19 5L 24 19 5L 24 amp 17 5 25 amp 17 5 25 15 1N m 11 1 Ib ft 35 1 N m 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 33 Tightening Torque for Wheels 163 7 N m 120 5 Ib ft 149 7 N m 110 5 Ib ft Airboss and Solid Tires Pneumatic Tires 101810053 Window Washer Reservoir
23. al source If you are using an auxiliary power source turn off the charging system 6 Ensure that battery caps on both machines are tight and correctly placed Ensure that batteries in the stalled machine are not frozen 7 Connect the positive jump start cable to the positive cable terminal of the discharged battery Do not allow the positive cable clamps to contact any metal except for the battery terminals 120 Maintenance Section Engine Valve Lash Check SEBU7468 06 8 Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source 9 Connect one negative end of the jump start cable to the negative cable terminal of the electrical source 10 Connect the other negative end of the jump start cable to the engine block or to the frame of the stalled machine Do not connect the jump start cable to the battery post Do not allow the jump start cables to contact the battery cables the fuel lines the hydraulic lines or any moving parts 11 Start the engine of the machine that is being used as an electrical source or energize the charging system on the auxiliary power source 12 Wait at least two minutes before you attempt to start the stalled machine This will allow the battery in the stalled machine to partially charge 13 Attempt to start the stalled engine See Operation and Maintenance Manual Starting the Engine for the correct starting procedure 1
24. and 7 5 mm 0 3 inch of movement below the straight edge g01025547 Illustration 155 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 158 g00554036 112 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU7468 06 9 Tighten the bolts for the axle housing in the order that is shown above to 50 15 N m 37 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 101741103 Engine Air Filter Primary E
25. ator bowl 2 from the bottom of the water separator element 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 motor oil Place the seal in the water separator bowl 7 Spin the water separator bowl onto the new element by hand until the water separator is snug Do not use tools to tighten the 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 Prime the fuel system in order to fill the fuel filter water separator element with fuel Refer to Operation and Maintenance Manual Fuel System Priming Pump Operate 11 Close the engine access door Fuel System Priming Pump Operate SMCS Code 1258 548 Illustration 183 Fuel Priming Pump Type 1 Illustration 184 Fuel Priming Pump Type 2 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Note On type 1 systems when the cam for the fuel pump is in the maximum lift position the priming lever will not function In this situation the crankshaft must be turned one revolution 2 Push down on the top of the fuel priming pump pl
26. ditional three quarters of a turn On type 2 systems reinstall the water separator bowl 8 Prime the fuel system Refer to Operation and Maintenance Manual Fuel System Priming Pump Operate 9 Close the engine access door 102095894 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 The fuel system water separator is located in the engine compartment at the rear of the machine 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 181 g00582050 2 Loosen the drain valve on the bottom of the water separator Allow the water and the sediment to drain into a suitable container o Tighten the drain valve A Close the engine access door Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ The water separator element for the fuel system is located in the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers g00753251 Illustration 182 122 Maintenance Section Fuel System Priming Pump Operate SEBU7468 06 2 Open the drain on the water separator bowl 3 Allow the water and fuel to drain into a suitable container 3 Support the water separator element and rotate the locking ring 1 counterclockwise Remove the water separator 4 Remove the water separ
27. e Apply lubricant to the grease fitting on the pivot points on each end of the tilt cylinder 2 There are six grease fittings SEBU7468 06 137 Maintenance Section Work Tool Mounting Bracket Inspect 101809997 Work Tool Mounting Bracket Inspect SMCS Code 6700 040 BK Illustration 229 g00925058 Inspect upper angled plate 1 and ensure that the plate is not bent or otherwise damaged Inspect holes 2 for wear and for damage Inspect lower angled plate 3 and ensure that the plate is not bent or otherwise damaged If any wear is suspected or any damage is suspected consult your Caterpillar dealer before you use the work tool
28. e SEBU7468 06 YY Illustration 195 g00533263 2 Remove the hydraulic tank filler cap Illustration 196 g00582847 3 The hydraulic oil filter is located on the right side of the engine compartment 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 Remove the filter with a strap type wrench 5 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 6 Apply a light coat of oil to the gasket of the new filter element gasket 7 Install the new filter element by hand When the gasket contacts the filter element mounting base tighten the filter element for an additional three quarters of a turn Illustration 197 g00541565 sight gauge type 1 g00873188 Illustration 198 sight gauge type 2 8 The sight gauge for the hydraulic oil is located below the hydraulic tank filler cap Maintain the hydraulic oil level to the middle of the sight gauge Do not overfill the hydraulic tank 9 Inspect the gasket on the hydraulic tank filler cap for damage Replace the hydraulic tank filler cap if necessary Install the hydraulic tank filler cap 10 Close the engine access door SEBU7468 06 127 Maintenance Section Hydraulic System Oil Level Check
29. e Use care when you clean the engine compartment Damage to the machine may occur 3 Close the engine access door Air Conditioning Condenser The air conditioning condenser is located at the back of the engine compartment Cleaning the air conditioning condenser will maintain optimum performance of the air conditioning system Use low pressure water in order to clean the condenser SEBU7468 06 115 Maintenance Section Engine Crankcase Breather Closed Circuit Replace 101819955 Engine Crankcase Breather Closed Circuit Replace SMCS Code 1317 510 S N CED1 Up S N 5SZ1 Up S N 6LZ1 Up Illustration 166 g00929163 The breather is located on the left side of the engine on turbocharged machines 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 the breather hoses Ensure that the connections are tight i01878882 Engine Crankcase Breather Clean SMCS Code 1317 070 S N CAB1 Up S N CMB1 Up S N FDG1 Up S N 4NZ1 Up S
30. e gasket Replace the cap if the cap or the gasket is damaged Install the radiator cap 6 Tilt the radiator guard downward SEBU7468 06 109 Maintenance Section Cooling System Water Temperature Regulator Replace I g00954176 Illustration 148 N Maintain the coolant level in the coolant reservoir between the MIN and MAX lines on the reservoir tank 8 Close the engine access door 101584466 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
31. ect SMCS Code 7323 040 7325 040 Illustration 209 g00533511 Front ROPS Retaining Bolt One bolt per side REINKE JEENA UEA i 1 A PMH TT NE PAE Illustration 210 g00583281 Rear ROPS Retaining Bolt One bolt per side SEBU7468 06 131 Maintenance Section Seat Belt Inspect Illustration 211 g00583274 Retaining bolts for the FOPS 2 1 Inspect the ROPS and the FOPS for loose bolts or for damaged 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 repair the ROPS or the FOPS by welding reinforcement plates to the ROPS or the FOPS Consult your Caterpillar dealer for repair of any cracks in the ROPS or the FOPS min sh uth IW ib in MEE d uM int Vif Wy ni WT AN Ail AN ae 7 ii g00583242 Illustration 212 Inspect the Flying Objects Guard Structure if equipped for any damage to the structure or any damage to the window Consult your Caterpillar dealer for repair of any cracks in the Flying Objects Guard Structure Refer to Operation and Maintenance Manual Cab Tilting for additional information 102429589 Seat Belt Inspect SMCS Code 7327 040 Always check the condition of the seat belt and the conditio
32. ectly 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 pres sure 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 101445212 Tire Segment Replace Removal SMCS Code 4203 510 SEG g00756820 Illustration 216 1 Remove any dirt buildup from the segment 1 Remove any dirt buildup from the stud thre
33. el injection timing 101584831 Fuel System Filter Replace SMCS Code 1261 510 NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts The fuel filter is located in the engine compartment on the left side of the machine 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 179 g00753192 Fuel Filter Type 1 SEBU7468 06 121 Maintenance Section Fuel System Primary Filter Water Separator Drain Illustration 180 g00822253 Fuel Filter Water Separator Type 2 2 On type 2 systems start by opening the drain valve 4 Allow the water and fuel to drain into a suitable container Close the drain valve 3 Support the filter element 2 and rotate the locking ring 1 counterclockwise Remove the locking ring 4 Remove the filter element On type 2 systems remove the water separator bowl 3 from the filter element Inspect the fuel filter for debris by cutting the filter open Discard the filter properly 5 Clean the mounting base of the fuel filter Remove any part of the old seal that remains on the mounting base of the fuel filter 6 Coat the seal of the new fuel filter with clean diesel fuel 7 Install the new fuel filter by hand Rotate the locking ring clockwise When the seal contacts the base tighten the locking ring for an ad
34. he 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 135 g01024691 1 Remove the cover in order to access the air filter element 2 Remove the air filter element and clean the element with soap and water Replace the element if the element is damaged 3 Install the element and replace the cover 101584243 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 SEBU7468 06 105 Maintenance Section Circuit Breakers and Fuses Reset Replace 3 4 oa SO 8 Illustration 136 g00521606
35. he seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 elie Riis 4 g01152685 Illustration 214 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension Tilt Cylinder Bearings and Bucket Linkage Bearings Lubricate SMCS Code 5104 086 BD 6107 086 BD Wipe all of the grease fittings before you apply lubricant ee PY Illustration 215 g00955895 Note Lubricate the fittings with the loader lift arms in the fully lowered position Apply lubricant to the grease fittings 1 for the upper bearings for the tilt cylinders Apply lubricant to the grease fittings 2 for the lower bearings for the tilt cylinders Apply lubricant to the grease fittings 3 for the coupler engagement pins Apply lubricant to the grease fitting 4 for the pivot pin of the quick coupler assembly There are a total of 8 grease fittings 102124717 Tire Inflation Check SMC
36. ing edge and the end bits 4 Clean the contact surfaces 5 Use the opposite side of the cutting edge if this side is not worn 6 Install a new cutting edge if both edges are worn 7 Install the bolts 8 Remove the blocks that are under the bucket 9 After a few hours of operation check the bolts for proper torque 101764331 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket tips are accessible 2 Place blocks under the raised edge of the bucket 3 Remove the mounting bolts Remove the bucket tips 104 Maintenance Section Cab Air Filter Clean Replace SEBU7468 06 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 134 g01019732 2 Remove the filter cover 3 Remove the seal from the cover and inspect the seal If the seal is damaged replace t
37. ive chains should be reduced to Every 100 Service Hours Note There are four drive chains on the skid steer loader that must be checked and adjusted SEBU7468 06 111 Maintenance Section Drive Chain Tension Check Adjust 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 pener AURTEN areia Illustration 156 g01025571 7 Loosen the eight bolts 5 for the axle housing Place 159 3337 Chain Tension Adjuster 7 between the axle housings 6 g01025514 Illustration 154 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 LS eae 3 R S LO Illustration 157 g00867842 8 Rotate the axle in order to ensure that the chain 8 is taut below the sprockets Place a straight edge across the top of the sprockets Measure the total amount of movement in the chain B Set the chain tension so that there is a total of 15 mm 0 6 inch movement in the chain This is equal to 7 5 mm 0 3 inch of movement above the straight edge
38. lement Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Never service the air cleaner when the engine is run ning to avoid engine damage NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following 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 cleaner filter elements when the yellow piston on the engine air filter service indicator enters the red zone Refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect Replace Illustration 159 g00891467 Illustration 160 g00101864 1 Remove the air cleaner housing cover 1 2 Remove the primary filter element 2 3 Install a clean filter element and install the cover 4 Reset the engine air filter service indicator SEBU746
39. 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 130 Maintenance Section Refrigerant Dryer Replace SEBU7468 06 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 help prevent injury Protective goggles must always be worn when re
40. n 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 213 g00932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 132 Maintenance Section Seat Belt Replace SEBU7468 06 102429594 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of t
41. ne and allow the oil to warm Check for leaks 10 Stop the engine and allow the oil to drain back into the oil pan Maintain the oil level in the crosshatched region of the engine oil dipstick 1 Add oil if necessary 11 Tilt the radiator downward 12 Close the engine access door 101752164 Engine Starting with Jump Start Cables SMCS Code 1000 7000 Batteries give off flammable fumes that can ex plode resulting in personal injury Prevent sparks near the batteries They could cause vapors to explode Do not allow the jump start cable ends to contact each other or the machine Do not smoke when checking battery electrolyte levels Electrolyte is an acid and can cause personal in jury if it contacts skin or eyes Always wear eye protection when starting a ma chine with jump start cables Improper jump start procedures can cause an ex plosion resulting in personal injury Always connect the positive to positive and the negative to negative Jump start only with an energy source with the same voltage as the stalled machine Turn off all lights and accessories on the stalled machine Otherwise they will operate when the energy source is connected NOTICE To prevent damage to engine bearings and to elec trical circuits when you jump start a machine do not allow the stalled machine to touch the machine that is used as the electrical source Severely discharged maintenance free
42. nt level to the top of the sight gauge with the radiator in the LOWERED position 8 Tilt the radiator guard downward 9 Close the engine access door For additional information on the addition of extender see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 101874850 Cooling System Level Check SMCS Code 1350 040 HX 1350 535 FLV 1382 070 1382 510 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting JEL gt D Illustration 146 g00956179 3 Maintain the coolant to the top of the sight gauge with the radiator in the LOWERED position The sight gauge is located on the right side of the radiator WELLE SAE D g00956151 Illustration 147 4 If you need to add coolant to the radiator the radiator cap is located on the upper left corner of 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 th
43. ocated on the left side of the machine on the bottom of the machine Remove the fuel tank drain plug 3 Allow the water and sediment to drain into a suitable container 4 Apply 169 5464 Quick Cure Primer and 5P 3413 Pipe Sealant to the threads on the drain plug Install the fuel tank drain plug 5 Install the fuel tank cap Note Drain the water and sediment from the fuel tank when the tank is almost empty Removal of the plug will cause all of the contents of the tank to drain out of the tank 124 Maintenance Section Hydraulic Oil Sample Obtain SEBU7468 06 101957445 Hydraulic Oil Sample Obtain SMCS Code 5050 008 7542 008 Illustration 189 g01026057 The sampling port for the hydraulic oil is located on the fan motor Hydraulic System Oil Change SMCS Code 5095 044 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 level 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 cont
44. or 1 Year Fuel Injection Timing Check eeen 120 Every 2000 Service Hours or 1 Year Fuel Injection Timing Check eessen 120 SEBU7468 06 101 Maintenance Section Maintenance Interval Schedule Every 3000 Service Hours or 2 Years Cooling System Coolant Extender ELC Add 107 Cooling System Water Temperature Regulator Replace i ari res aaie aia a aar ai 109 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccccceeeeeeeeeeeeeeeseeeeeees 132 Every 5000 Service Hours Engine Crankcase Breather Closed Circuit ReplaGess aaaea sateen aired attest ee dadanats 115 Every 6000 Service Hours or 4 Years Cooling System Coolant ELC Change 106 102 Maintenance Section Backup Alarm Test SEBU7468 06 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 100993
45. ow the oil to drain into a suitable container 2 Apply 169 5464 Quick Cure Primer and 5P 3413 Pipe Sealant to the threads on the drain plugs Install the drain plugs Illustration 152 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 153 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 101977636 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 The use of rubber tracks that go over the tires is not recommended When you use steel tracks that go over the tires and under severe operating conditions the interval for checking the dr
46. pect SMCS Code 7452 040 NOTICE Service the air cleaner only with the engine stopped Engine damage could result 114 Maintenance Section Engine Compartment Clean SEBU7468 06 Illustration 164 Type 1 g00822120 Illustration 165 Type 2 1 Mount the machine 2 Fasten the seat belt Lower the armrest 3 Start the engine 4 Run the engine at high idle 5 Stop the engine 6 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 7 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting 8 Inspect the engine air filter service indicator If the yellow piston in the filter service indicator enters the red zone service the air cleaner Note See the Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace See the Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 9 Reset the engine air filter service indicator 10 Tilt the radiator downward 11 Close the engine access door i01978979 Engine Compartment Clean SMCS Code 1000 070 Inspect the engine compartment for dirt buildup or debris Remove any dirt or debris from the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Remove any debris or dirt from the engine compartment Not
47. rol if equipped in order to relieve hydraulic pressure Move the engine start switch key to the OFF position 4 Illustration 190 g00533263 The hydraulic tank filler cap is located on the right side of the machine above the fuel filler cap 1 Remove the hydraulic tank filler cap 2 Place supports under the rear of the machine in order to support the machine while the cab is in the raised position Note The hydraulic oil drain is located under the cab Note Empty the water tank if equipped before you raise the cab 3 Tilt the cab upward Refer to Operation and Maintenance Manual Cab Tilting g00669784 Illustration 191 4 If the machine is a 228 or 248 Skid Steer Loader then you may need to remove the four bolts 1 that hold the control assembly You may need to remove the control assembly in order to reach the drain hose and the drain valve SEBU7468 06 125 Maintenance Section Hydraulic System Oil Filter Replace Illustration 192 g00669799 5 Move the control console 2 toward the hydraulic tank This will help you to be able to reach the hydraulic drain hose and the hydraulic drain valve on the 228 or 248 Skid Steer Loader g00582823 Illustration 193 The drain hose is located in the rear right rear corner of the lower frame in the hydraulic motor compartment 6 Remove the plug from the end of the drain hose Put the drain hose through the hole
48. s 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 101227341 Quick Coupler Inspect SMCS Code 6129 040 Illustration 207 g00656007 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 Illustration 208 g00656021 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 your Caterpillar dealer before you use a work tool i01488851 Radiator Core Clean SMCS Code 1353 070 KO The radiator is located at the rear of the
49. t Linkage Bearings Lubricate isiru it aa a dice 132 Tire Inflation Check cccccceeceeeeeeeeeeeeenteeaeees 132 Wheel Nuts Tighten oisein 134 Work Tool Lubricate cceeeeeeeseeeeeeereteees 135 Work Tool Mounting Bracket Inspect 137 Every 250 Service Hours Engine Oil Sample Obtain a se 117 Every 250 Service Hours or Monthly Belts Inspect Adjust Replace ee 102 Every 500 Service Hours Hydraulic Oil Sample Obtain eee 124 Every 500 Service Hours or 3 Months Drive Chain Tension Check Adjust e 110 Fuel System Primary Filter Water Separator Element Replace ccccccceeseeeeeeeeeeeeeeeneees 121 Every 500 Service Hours or 6 Months Fuel System Filter Replace 120 Hydraulic System Oil Filter Replace 125 Every 500 Service Hours or 1 Year Engine Oil and Filter Change cee 117 Every 1000 Service Hours Engine Valve Lash Check seese 120 Every 1000 Service Hours or 6 Months Drive Chain Case Oil Change eeeeeeeree 110 Engine Crankcase Breather Clean a an 115 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 130 Every 1000 Service Hours or 1 Year Hydraulic System Oil Change 0008 124 Every 2000 Service Hours Refrigerant Dryer Replace eeeeee 130 Every 2000 Service Hours
50. terpillar 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 Extended Life Coolant Extender Add or consult your Caterpillar dealer NOTICE Do not change the coolant until you read and under stand the material in the Cooling System Specifica tions section Drain the coolant whenever the coolant is dirty or whenever the coolant is foaming The radiator cap is located under the radiator guard on the top of the engine compartment Allow the machine to cool before you change the coolant 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Remove the retaining pin for the radiator guard Raise the radiator guard Refer to Operation and Maintenance Manual Radiator Tilting Illustration 140 g00522611 3 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap Illustration 141 Type 1 g00821964 Illustration 142 Type 2 4 The drain plug for the coolant is located on the left side of the engine block Remove the drain plug and allow the coolant to drain into a suitable container SEBU7468 06 107 Maintenance Section
51. the locked position and place the pin in the stored position Close the engine access door i01896556 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 WELLE SAF D g00956151 Illustration 144 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 108 Maintenance Section Cooling System Level Check SEBU7468 06 WE gt D g00956179 Illustration 145 7 Check the coolant level in the sight gauge on the radiator The sight gauge is located on the right side of the radiator Maintain the coola
52. unger 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 SEBU7468 06 123 Maintenance Section Fuel Tank Cap Clean 3 Start the engine If the engine does 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 4 If the engine starts but the engine runs rough continue to run the engine at low idle Continue to run the engine at low idle until the engine runs smoothly 5 Close the engine access door 101014038 Fuel Tank Cap Clean SMCS Code 1273 070 Z2 Illustration 185 g00522993 1 Remove the fuel cap Illustration 186 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 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Illustration 187 g00531159 1 Slowly remove the fuel tank cap in order to relieve tank pressure Illustration 188 g00531160 2 The fuel tank drain is l

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