MAINTENANCE INTERVALS - Safety
Contents
1. 226 Transmission Oil Change sssss 227 Wheel Bearings Front Lubricate 233 Every 2000 Service Hours or 1 Year Engine Valve Lash Check 210 Hydraulic System Oil Change 217 Every 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 196 Cooling System Coolant Extender ELC Add 200 Cooling System Water Temperature Regulator Clean Replace sese 201 Every 6000 Service Hours or 4 Years Cooling System Coolant ELC Change 198 189 Maintenance Section Maintenance Interval Schedule 190 Maintenance Section Air Conditioner Test i00079668 Air Conditioner Test If Equipped SMCS Code 7320 NOTICE Refrigerant in the air conditioner system can cause personal injury Avoid any contact with refrigerant Check the refrigerant before warm weather begins Check the refrigerant when the system does not work properly The system should be checked with pressure gauges by a qualified technician Consult your Caterpillar dealer for proper installation when the system needs refrigerant Operate the air conditioner at least monthly in order to lubricate the compressor seals Set the controls on MAXIMUM for 15 minutes 100595214 Axle Universal Joint Front Lubricate SMCS Code 3251 Illustration 265 g00290595 Illustrati2. 200 Engine Air Filter Service Indicator Inspect 207 Engine Oil Level Check esesss 208 Extendable Stick Pads Inspect Replace 210 Fuel System Water Separator Drain 214 Hydraulic System Oil Level Check 220 Kingpin Bearings Front Lubricate 220 Loader Bucket Cylinder and Linkage Bearings L briCate rtr 221 Seat Belt Inspect ssssssssssss 224 Secondary Steering Test usssse 225 Stabilizer and Cylinder Bearings Lubricate 225 Swing Frame and Cylinder Bearings Lubricate 226 Tire Inflation Check seeeeeeee 226 Transmission Oil Level Check 229 Walk Around Inspection eesssssss 232 Wheel Nut Torque Check sessssss 233 Windows Clean ssee 234 Every 50 Service Hours or Weekly Axle Universal Joint Front Lubricate 190 Cab Air Filter Clean Replace 195 Fuel Tank Water and Sediment Drain 215 Parking Brake Check Adjust 222 Every 250 Service Hours or Monthly Axle Universal Joint Rear Lubricate 190 Cooling System Coolant Additive DEAC Add 199 Differential Oil Level Front Check 203 Differen
3. 15 Open the door for the filter that is located at the bottom of the right hand console 900293553 Illustration 280 16 Remove the filter element 17 Clean the filter element with compressed air or pressure water Direct the air or the water along the pleats of the element You can also wash the element with clean water and nonsudsing household detergent 18 Rinse the filter element thoroughly with clear water 19 Allow the filter element to air dry Inspect the element for damage If the filter element is damaged replace the filter element 20 Install the filter element 21 Close the door 100598002 Cooling System Coolant DEAC Change SMCS Code 1352 1353 1395 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure Note This procedure pertains to Caterpillar Diesel Engine Antifreeze Coolant DEAC only This does not pertain to machines that are shipped from the factory with Extended Life Coolant ELC This does not pertain to machines that are maintained with Extended Life Coolant ELC 197 Maintenance Section Cooling System Coolant DEAC Change NOTICE Do not change the coolant until you read and under stand the material in the Cooling System Specifica tions section 1 Empty the bucket Remove the pin that secures the loader lift arm brace to the left loader lift arm Rais
4. Inspect the filter element for leaks Illustration 394 g00291275 7 Maintain the transmission oil level within the crosshatched region on the CHECK WITH WARM OIL side of the dipstick when the transmission is warm Add transmission oil if necessary 8 Stop the engine 100999735 Transmission Oil Level Check SMCS Code 3030 3080 3081 Check the transmission oil level while the machine is on a level surface Illustration 395 230 Maintenance Section V Belts Inspect Adjust Replace 101035257 V Belts Inspect Adjust Replace SMCS Code 1357 If new belts are installed check belt adjustment after 30 minutes of operation For multiple belt drive applications always replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belts are stretched The additional load on the new belt could cause the new belt to break Illustration 396 900287410 Dai 1 Empty the bucket Remove the pin that secures the loader lift arm brace to the left loader lift arm 1 Pull the h l 1 i une Nope ie east evel A D Iro Open Raise the loader arm to the maximum height the engine access door 2 on the top of the machine 2 Position the loader lift arm brace over the left lift cylinder rod with the flat end against the cylinder end 3 Push the pin through the holes of the loader lift arm brace and install the cotter pin 4 Slowly
5. 371 2 Engage the parking brake 3 If the machine is equipped with the standard transmission move the transmission speed shift lever to THIRD gear Move the transmission direction control lever to FORWARD to NEUTRAL and back to FORWARD If the machine is equipped with a power shift transmission move the transmission control lever to FOURTH SPEED FORWARD to NEUTRAL and back to FOURTH SPEED FORWARD This is done in order to override the transmission neutralizer for this test Note Place machines that are equipped with all wheel drive into two wheel drive mode Note The parking brake indicator light should come on and the parking brake alarm should sound 4 Gradually increase the engine speed to high idle The machine should not move A WARNING If the machine begins to move reduce the engine speed immediately and apply the service brake pedal 5 Reduce the engine speed Move the transmission to NEUTRAL Lower the blade to the ground Stop the engine A WARNING If the machine begins to move reduce the engine speed immediately and apply the service brake pedal 6 Reduce the engine speed Move the transmission to NEUTRAL Lower the bucket to the ground Stop the engine Adjustment Procedure If the machine moved during the test perform the following procedure in order to adjust the parking brake 1 Apply the service brakes g00514571 Illustration 372 2 Disengage the parking brake 3 As you v
6. Bearings Lubricate SMCS Code 5468 7222 a See Illustration 381 900287719 226 Maintenance Section Swing Frame and Cylinder Bearings Lubricate Position the stabilizer as shown Apply lubricant to the grease fitting for the head end of the cylinder Repeat for the other stabilizer There is a total of two grease fittings 100615422 Swing Frame and Cylinder Bearings Lubricate SMCS Code 5105 6506 6507 7063 g00287723 Illustration 382 Apply lubricant to the grease fitting 1 for the top swing pin Apply lubricant to the grease fitting 2 for the bottom swing pin Apply lubricant to the grease fitting 3 for the eye of the swing cylinder Repeat for the other swing cylinder Apply lubricant to the grease fitting 4 for the bearing on the top of the swing cylinder Repeat for the other swing cylinder Apply lubricant to the grease fitting 5 for the bearing on the bottom of the swing cylinder Repeat for the other swing cylinder There is a total of eight grease fittings 100615425 Tire Inflation Check SMCS Code 4203 900287414 Illustration 383 Measure the tire pressure on each tire Consult your Caterpillar dealer for the correct load rating and for the correct operating pressures Inflate the tires if necessary Refer to Operation and Maintenance Manual Tire Inflation with Air and Operation and Maintenance Manual Tire Inflation with Nitrogen i006
7. Replace the cable or the battery as needed 5 Connect the negative battery cable at the battery 6 Connect the battery cable to the frame of the machine 7 Install the engine start switch key i00667135 Brake Reservoir Oil Level Check SMCS Code 4291 535 g00287385 Illustration 274 900287410 Pull the hood release lever 1 in order to open the engine access door 2 on the top of the machine 900292107 Illustration 275 193 Maintenance Section Brake Reservoir Oil Level Check Maintain the oil level between the MIN mark and MAX mark on the brake reservoir Add oil if necessary 100651426 Braking System Test SMCS Code 4251 4267 7000 Service Brake Holding Ability Test Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles Test the brakes on a dry level surface Fasten the seat belt before you test the brakes The following tests are used to determine if the service brake is functional These tests are not intended to measure the maximum brake holding effort The brake holding effort that is required to sustain a machine at a specific engine rom varies depending on the machine The variations are the differences in the engine setting in the power train efficiency and in the brake holding ability etc 1 Start the engine Raise the bucket slightly 2 Apply the service brake Release the parking brake 3 Move the t
8. decreased to 250 hours Consult your Caterpillar Dealer for detailed information regarding the optimum oil change interval Note Certain machines are equipped with engines that require the engine valve lash to be checked every 1000 service hours or 6 months Refer to the Operation and Maintenance Manual Engine Valve Lash Check for further information When Required Air Conditioner Test ssssssssssss 190 Battery Recycle seeeeeeee 192 Battery Electrolyte Level Check 192 Battery or Battery Cable Replace 192 Bucket Cutting Edges Inspect Replace 194 Bucket Tips Inspect Replace 195 Engine Air Filter Primary Element Clean Replace sse 205 Engine Air Filter Secondary Element Replace 206 Fuel System Prime ssssssssss 213 Fuses Replace entre 216 Oil Filter Inspect seeee 222 Radiator Core Clean sss 223 Window Wipers Inspect Replace 234 Every 10 Service Hours or Daily Backhoe Boom Stick Bucket and Cylinder Bearings Eubricate 2 2 itc Mave ete 191 Backup Alarm Test esee 191 Brake Reservoir Oil Level Check 193 Braking System Test ssssssssss 193 Cooling System Level Check
9. filter element Discard the filter element properly 215 Maintenance Section Fuel System Water Separator Element Replace 2 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 3 Coat the seal of the new filter element with clean diesel fuel 4 Install the new filter element Rotate the locking ring clockwise in order to fasten the filter to the mounting base 5 Prime the fuel system in order to fill the filter element with fuel Refer to Operation and Maintenance Manual Fuel System Prime i00669722 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Illustration 346 g00292670 The fuel tank is located on the left side of the machine g00292671 Illustration 347 Slowly remove the fuel tank cap in order to relieve pressure 216 Maintenance Section Fuses Replace g00292692 Illustration 348 The fuel tank drain valve is located on the lower right corner on the front of the fuel tank Remove the fuel tank drain plug Allow the water and sediment to drain into a suitable container Install the fuel tank drain plug Replace the fuel tank cap i00609834 Fuses Replace SMCS Code 1417 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 Rep
10. lower the loader arms until the loader lift arm brace contacts the top of the lift cylinder and the bosses on the loader arm 5 Stop the engine in order to inspect the belts g00291275 Illustration 397 2 Remove the dipstick fill plug for the transmission 3 Maintain the oil level within the crosshatched region on the CHECK WITH OIL WARM side of the dipstick fill plug when the transmission is warm Add transmission oil if necessary Note The transmission can be checked with cold transmission oil Check the oil level with the cold oil check side of the dipstick The engine must be EM stopped in order to do a cold oil check Illustration 398 3 4 Clean the dipstick fill plug and install the 6 Remove the engine access panel on the left side dipstick fill plug of the machine res Illustration 399 900287234 7 Inspect the condition of the air conditioner belt and the adjustment of the air conditioner belt The air conditioner belt should deflect 10 mm 0 38 inch under 110 N 25 Ib of force 900287235 Illustration 400 8 Loosen the adjusting locknut 1 Loosen the compressor bracket mounting bolt 2 9 Move the compressor until the correct belt tension is reached 10 Tighten the adjusting locknut 1 Tighten the compressor bracket mounting bolt 2 11 Recheck the belt deflection If the amount of deflection is incorrect repeat Step 8 to Step 10 12 Install the engine access pane
11. order to take the pressure away from the lower pad 3 211 Maintenance Section Final Drive Oil Front Change Note Place the bucket on the ground Apply slight pressure toward the ground with the stick Shim the lower pad or replace the lower pad i00609504 Final Drive Oil Front Change SMCS Code 4050 900287533 Illustration 332 1 Position the oil fill drain plug at the bottom Remove the oil fill drain plug and drain the oil into a suitable container Illustration 333 900287534 2 Position the plug hole at a horizontal position Use the line on the final drive as a reference 3 Add oil until the oil is level with the plug threads Refer to Operation and Maintenance Manual Lubricant Specifications and Operation and Maintenance Manual Refill Capacities for the oil 4 Clean the plug and install the plug 5 Repeat the procedure for the other final drive 212 Maintenance Section Final Drive Oil Rear Change i00609505 Final Drive Oil Rear Change SMCS Code 4050 ix Illustration 334 900287536 1 Position the oil fill drain plug at the bottom Remove the oil fill drain plug and drain the oil into a suitable container as Illustration 335 g00287537 2 Position the plug hole at a horizontal position Use the line on the final drive as a reference 3 Add oil until the oil is level with the plug threads Refer to Operation and Maintenance Manual Lubricant Spe
12. solution should be between 6 percent and 10 percent 6 Start the engine Run the engine for 90 minutes Stop the engine Drain the cleaning solution into a suitable container 7 While the engine is stopped flush the system with water Flush the system until the draining water is transparent 8 Close the drain valve 9 Add the coolant solution See the following topics e Operation and Maintenance Manual Cooling System Specifications e Operation and Maintenance Manual Refill Capacities Note If you are using Caterpillar antifreeze do not add the supplemental coolant additive at this time and or change the element at this time 10 Start the engine Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes 11 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe 12 Install the radiator cap Replace the radiator cap if the gasket is damaged 13 Stop the engine 14 Replace the access panel Close the access door 00095660 Cooling System Coolant ELC Change SMCS Code 1353 1395 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 pro
13. the hydraulic system filter Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Change 6 Inspect the hydraulic tank breather that is located on a hose from the overflow container Replace the breather if necessary 7 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities 900290845 Illustration 358 8 Maintain the hydraulic oil level in the sight gauge between the MIN mark and the MAX mark Check the hydraulic oil level with the loader on the ground and with the backhoe in the transport 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 9 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary 10 Install the hydraulic tank filler cap 11 Close the access door 219 Maintenance Section Hydraulic System Oil Filter Replace i00609992 Hydraulic System Oil Filter Replace SMCS Code 5056 5068 Illustration 362 900290721 3 The hydraulic oil filter is located on the left side of the machine Illustration 359 900290851 Illustration 363 4 Remove the filter element with a strap type Illustration 360 900287419 wrench 5 Clean the filter element mounting base Remove any part of the filter ele
14. thermostat drain the cooling system coolant 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 Empty the bucket Remove the pin that secures the loader lift arm brace to the left loader lift arm Raise the loader arm to the maximum height 2 Position the loader lift arm brace over the left lift cylinder rod with the flat end against the cylinder end 3 Push the pin through the holes of the loader lift arm brace and install the cotter pin 4 Slowly lower the loader arms until the loader lift arm brace contacts the top of the lift cylinder and the bosses on the loader arm Po dill J MES Illustration 296 900287241 5 Remove the engine access panel on the right side of the machine 202 Maintenance Section Differential Oil Front Change 900290684 Illustration 297 6 Loosen the hose clamp and remove the hose from the thermostat housing assembly 7 Remove the bolts from the thermostat housing assembly Remove the thermostat housing assembly 8 Remove the gasket the thermostat and the seal from the thermostat housing assembly 9 Install a new seal in the thermostat housing assembly Install a new thermostat and a new gasket Install the thermostat housing assembly on the engine cylinder head The thermostats can be reused under the following conditions e The the
15. 15434 Transmission Magnetic Screen Clean SMCS Code 3030 1 Drain the transmission oil Refer to Operation and Maintenance Manual Transmission Oil Change g00293338 Illustration 384 Magnetic strainer cover for the standard transmission 227 Maintenance Section Transmission Oil Change Illustration 385 g00293340 Magnetic strainer cover for the power shift transmission 2 Remove the magnetic strainer cover 3 Remove the magnets from the housing 4 Remove the screen from the housing 5 Wash the tube and the screen in a clean nonflammable solvent NOTICE Do not drop or rap the magnets against any hard ob jects Replace any damaged magnets 6 Clean the magnets with a cloth with a stiff bristle brush or with pressure air 7 Install the magnets and the tube assembly into the magnetic screen 8 Install the magnetic screen 9 Clean the cover and inspect the seal Replace the seal if the seal is damaged 10 Install the cover Tighten the cover bolts 11 Fill the transmission Refer to Operation and Maintenance Manual Transmission Oil Change 100999666 Transmission Oil Change SMCS Code 3030 3080 Operate the machine for a few minutes in order to warm the transmission oil The machine should be level Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine Illustration 386 900290414 Drain plug for standard trans
16. 4051 4199 4200 Illustration 406 gogar en Check the torque on new wheels or repaired wheels after every ten service hours until the specified torque is maintained Put a drop of oil on all wheel studs on reassembly Torque the nuts to 400 40 N m 295 30 Ib ft Use a star pattern when you torque the nuts Check the nuts on all four wheels 234 Maintenance Section Windows Clean 100615728 Windows Clean SMCS Code 7310 7340 Illustration 407 g00287727 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 Window Wipers Inspect Replace SMCS Code 7305 Inspect the condition of the wiper blades Replace the wiper blades if the wiper blades are worn or damaged If the wiper blades streak the window replace the wiper blades
17. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved e SEBU7267 CATERPILLAR September 1999 Operation ane Maintenance manual 416C 426C 428C 436C and 438C Backhoe Loaders 5YN16590 Up Machine 7WN1100 Up Machine 8RN4990 Up Machine 9JN1050 Up Machine 9KN1400 Up Machine 1ER900 Up Machine 1GR950 Up Machine 1JR1150 Up Machine 1NR1050 Up Machine 1RR1100 Up Machine 1TR1850 Up Machine 1XR2250 Up Machine 1ZR1000 Up Machine 2BR1000 Up Machine 2CR19310 Up Machine 2DR3450 Up Machine 188 Maintenance Section Maintenance Interval Schedule 01126021 Maintenance Interval Schedule SMCS Code 7000 Note All safety information warnings and instructions must be read and understood before you perform any operation or any maintenance procedure Before each consecutive interval is performed all of the maintenance requirements from the previous interval must also be performed The normal oil change interval is Every 500 Service Hours or Three Months If the engine is operated under severe conditions or if the oil is not Caterpillar oil change the oil after Every 250 Service Hours or after One Month Severe conditions include the following factors high temperatures continuous high loads and extremely dusty conditions Refer to the results of the S O S oil analysis in order to determine if the oil change interval should be
18. SW ETNSS E ten M ERU Illustration 405 900107659 4 Remove the hub cap 1 5 Remove the cotter pin 2 nut 3 and washer 4 6 Pull the hub assembly 5 until the cone and roller assembly come out of the hub assembly Then pull off the hub all the way 7 Clean all of the parts in clean nonflammable solvent and allow the parts to air dry Do not use pressure air 8 Inspect the roller assemblies for heat discoloration and for wear Inspect the seals for damage Replace any damaged parts 9 Make sure that the grease gets packed between the rollers and the cage on both bearings Force the grease through the bearing from the large end of the rollers 233 Maintenance Section Wheel Bearings Front Lubricate 10 Pack a 6 mm 0 25 inch layer of grease between the bearing assemblies in the hub Do not fully pack the hub with grease 11 Apply a 6 mm 0 25 inch thick film of grease on the spindle surface 12 Install the hub the bearings the washer the nut and the wheel 13 While you turn the wheel tighten the nut 3 until a slight drag is noticed Back off the nut to the nearest slot and install the cotter pin 14 All bearing surfaces must make contact The wheel should turn freely within 0 025 to 0 25 mm 0 001 to 0 010 inch end play 15 Install the hub cap 16 Tighten the lug nuts to a torque of 400 40 N m 295 x 30 Ib ft 100615727 Wheel Nut Torque Check SMCS Code
19. 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 ifthe yellow piston in the filter element indicator enters the red zone after installation of a clean primary ele ment or if the exhaust smoke is still black 900287410 Illustration 314 1 Pull the hood release lever 1 in order to open the engine access door 2 on the top of the machine Illustration 315 900101864 2 Remove the air cleaner housing cover 1 3 Remove the primary filter element 2 from the air cleaner housing Illustration 316 900038606 4 Remove the secondary filter element Illustration 317 900101865 5 Cover the air inlet opening Clean the inside of the air cleaner housing 6 Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged 207 Maintenance Section Engine Air Filter Service Indicator Inspect 7 Uncover the air inlet opening Install a new secondary element 8 Install the primary element and the air cleaner housing cover Fasten the clips in order to secure the air cleaner housing cover Illustration 318 900287992 9 Reset the filter element indicator 10 Close the engine access door i00606530 Engine Air Filter Service Indicator Inspect SMCS Code 1051 1054 7452 NOTICE Service the air cleaner only with the engine stopp
20. a diator is cool Then loosen cap slowly to relieve the pressure Note This procedure pertains to Caterpillar Diesel Engine Antifreeze Coolant DEAC only This procedure does not pertain to machines that are shipped from the factory with Extended Life Coolant ELC and machines that are maintained with Extended Life Coolant ELC See Operation and Maintenance Manual Cooling System Specification for all cooling system requirements Use 8T 5296 Coolant Test Kit in order to check the concentration NOTICE Excessive additive greater than the recommended 6 initial fill together with concentrations of antifreeze greater than 60 cause deposits to form and can re sult in radiator tube blockage and overheating 199 Maintenance Section Cooling System Coolant Additive DEAC Add Liquid Supplemental Coolant Additive Illustration 288 g00287385 Illustration 289 g00287410 1 Pull the hood release lever 1 in order to open the engine access door 2 on the top of the machine g00287415 Illustration 290 2 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap 3 If necessary drain enough coolant from the radiator in order to allow the addition of the liquid coolant additive 200 Maintenance Section Cooling System Coolant Extender ELC Add 4 Add 0 24 Liters 50 pint of cooling system additive for every 38 Liters 10 US Gallons of engine cooling ca
21. air 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 you Caterpillar dealer g00287569 Illustration 349 Remove the cover on the steering console in order to access the main fuse panel g00287570 Illustration 350 Engine Start Switch 1 15 Amp Horns 2 10 Amp Lighter 3 10 Amp Hazard Lights 4 10 Amp Backup Alarm 5 10 Amp Transmission 6 10 Amp Bucket Positioner 7 10 Amp All Wheel Steer 8 10 Amp All Wheel Drive 9 10 Amp Heater Fan 10 10 Amp Gauges 11 10 Amp Spare 12 Open Main Lights 13 30 Amp Spare 14 Open Main Air Conditioner 15 25 Amp Main Windshield Wipers 16 20 Amp Note Some of the main fuses are tied together with the fuses in the headliner For example if all of the lights are not functioning check the main fuse for the lights in the steering console If one light is not functioning check the fuse in the headliner for the specific light Illustration 351 900287571 The fuse panel is located in the switch panel on the headliner of the cab Remove the cover in order to access the fuses 900287572 Illustration 352 Spare 1 Open Spare 2 Open Left Tail Light 3 10 Amp Right Tail Light 4 10 Amp Rear Fl
22. between the MIN mark and the MAX mark Kingpin Bearings Front Lubricate Two Wheel Drive SMCS Code 4314 Illustration 366 g00291789 Apply lubricant to the grease fitting on the top of each kingpin Kingpin Bearings Rear Lubricate All Wheel Steer SMCS Code 4314 900291790 Illustration 367 Apply lubricant to the grease fittings for the kingpin bearings of the rear steerable axle There is a total of four grease fittings 101035226 Loader Bucket Cylinder and Linkage Bearings Lubricate SMCS Code 7069 7070 7071 Single Tilt Machines Illustration 368 900291110 Apply lubricant to the grease fittings 1 for the frame and for the lift arm There is a grease fitting for each side of the machine Apply lubricant to the grease fitting 2 for the pivot for the linkage of bucket positioner and lift kickout Apply lubricant to the grease fittings 3 for the head end of the lift cylinder There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 4 for the rod end of the lift cylinder There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 5 for the pivot pin at the loader lift arm There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 6 for the pivot bearings for the bucket tilt cylinder There is a grease fitting in each linkage four total Appl
23. cifications and Operation and Maintenance Manual Refill Capacities for the oil 4 Clean the plug and install the plug 5 Repeat the procedure for the other final drive Final Drive Oil Level Front Check SMCS Code 4050 g00287534 Illustration 336 1 Position the oil fill drain plug at a horizontal position in order to check the oil level 2 Remove the oil fill drain plug in order to check the oil level 3 The oil should be level with the bottom of the plug threads 4 Clean the plug and install the plug 5 Repeat the procedure for the other final drive Final Drive Oil Level Rear Check SMCS Code 4050 me 900287537 Illustration 337 1 Position the oil fill drain plug at a horizontal position in order to check the oil level 2 Remove the oil fill drain plug in order to check the oil level 3 The oil should be level with the bottom of the plug threads 4 Clean the plug and install the plug 5 Repeat the procedure for the other final drive 100609513 Fuel System Prime SMCS Code 1258 Air can enter the system under the following conditions e The fuel tank is drained during normal operation e The low pressure fuel lines are disconnected e A part of the low pressure fuel system leaks during engine operation If air enters the fuel system the air must be eliminated from the system before the engine can be started If the engine has been stoppe
24. d by air in the fuel system perform the following procedures e Make sure that fuel has been added to the tank e Make sure that the leakage problem has been corrected e Make sure that the electrical stop control is connected e Operate the starter motor until the engine starts 1 Make sure the electrical stop control is connected Turn the engine start switch key to the ON position Illustration 338 900291785 2 Illustration 339 3 213 Maintenance Section Fuel System Prime Remove the access panel on the right side of the machine 900291786 Operate the lever of the fuel lift pump slowly for approximately two minutes If the drive cam of the fuel lift pump is at the point of maximum cam lift the priming lever will not operate In this situation the crankshaft must be turned one revolution Operate the starter motor until the engine starts Refer to Operation and Maintenance Manual Starting Above 0 C 82 F and Operation and Maintenance Manual Starting Below 0 C 32 F Check for air in the fuel system if the engine runs roughly after the engine runs correctly for a short period of time Check for air in the fuel system if the engine stops after the engine runs correctly for a short period of time If there is air in the fuel system check the low pressure fuel system for a leak Correct the problem and repeat Step3 through Step4 i00609515 Fuel System Filter Rep
25. d of the tilt cylinder There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 8 for the frame and for the lift arm There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 9 for the frame and for the parallel linkage There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 10 for the head end of the lift cylinder There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 11 for the lower pivot pin of the parallel linkage There is a grease fitting for each side of the machine 222 Maintenance Section Oil Filter Inspect Apply lubricant to the grease fittings 12 for the lower pivot pin of the tilt linkage There is a grease fitting for each side of the machine There is a total of 24 grease fittings 100052234 Oil Filter Inspect SMCS Code 1318 3067 5068 Inspect A Used Filter for Debris Illustration 370 900100013 The element is shown with debris Use a 4C 5084 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 a
26. de 3253 SMCS Code 3258 The oil level fill plug is located near the middle of the rear axle Illustration 307 900290705 Access the grease fittings for the drive shaft spline from the bottom of the machine 900290697 Illustration 305 Filler plug on standard rear differential 205 Maintenance Section Engine Air Filter Primary Element Clean Replace Illustration 308 g00290703 Apply lubricant to the grease fitting for the drive shaft spline of the front drive shaft scale Vm e Illustration 310 900287382 Service the air cleaner filter elements when the yellow piston enters the red zone Illustration 309 900290704 Apply lubricant to the grease fitting for the drive shaft spline of the rear drive shaft i01035223 Engine Air Filter Primary Element Clean Replace SMCS Code 1051 1054 NOTICE Never service the air cleaner when the engine is run ning to avoid engine damage Illustration 311 900101864 1 Remove the air cleaner housing cover 1 2 Remove the primary filter element 2 from the air cleaner housing NOTICE Do not clean the filter elements by bumping or tapping them Do not use filter elements with damaged pleats gaskets or seals Engine damage can result Make sure the cleaned filter elements are completely dry before installing into the filter housing Water re maining in the elements can cause false indications of contamination in Scheduled Oil Sampling test resul
27. ducts are not available and com mercial products must be used make sure they have passed the Caterpilar EC 1 specification for pre mixed or concentrate coolants and Caterpillar Extender 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 Flushing the Extended Life Coolant From the Cooling System Some engines utilize Extended Life Coolant See the Operation and Maintenance Manual Maintenance Interval Schedule in order to determine the service interval If a Extended Life Coolant was previously used flush the cooling system with clean water No other cleaning agents are required Flushing a Standard Coolant From the Cooling System If you change the coolant of a machine to Extended Life Coolant from another type of coolant use a Caterpillar cleaning agent to flush the cooling system After you drain the cooling system thoroughly flush the cooling system with clean water All of the cleaning agent must be removed from the cooling system Note See the Operation and Maintenance Manual Cooling System Coolant DEAC Change for the draining procedure and for the flushing procedure i00599502 Cooling System Coolant Additive DEAC Add SMCS Code 1352 1353 1395 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until r
28. e operation the secondary steering system will become active Note With the machine at rest the steering during this test cycle may require more effort than normal steering Both hands may be required to steer Before you start the engine turn the steering wheel while the vehicle weight is on the front wheels Turn the front wheels from the center position to each stop and return to the center position Failure of the front wheels to complete the above cycle indicates a malfunction of the secondary steering system The machine should not be driven until the problem is corrected All Wheel Steer AWS Machines On AWS machines the steering control will default to the front wheels if the steering system hydraulic pressure is lost 225 Maintenance Section Secondary Steering Test i00670147 Sideshift Stabilizer Wear Pads Inspect SMCS Code 7222 040 g00292882 Illustration 380 Check the stabilizers for slop Shim the stabilizer pads in order to maintain an acceptable fit and reduce slop Refer to the Service Manual for the correct procedure Note Do not excessively apply a silicone based lubricant Dirt can be attracted to the lubricant and dirt can cause abrasion to the pad assemblies and wear to the pad assemblies The stabilizer pads do not normally require any lubrication If the stabilizers become noisy a small amount of a silicone based lubricant may be applied 100615050 Stabilizer and Cylinder
29. e the loader arm to the maximum height 2 Position the loader lift arm brace over the left lift cylinder rod with the flat end against the cylinder end 3 Push the pin through the holes of the loader lift Illustration 283 Sunc arm brace and install the cotter pin 2 Slowly loosen the radiator cap in order to relieve 4 Slowly lower the loader arms until the loader lift system pressure Remove the radiator cap arm brace contacts the top of the lift cylinder and the bosses on the loader arm Drain the coolant whenever the coolant is dirty or whenever foaming is observed The radiator cap is located under the access panel on the top of the engine compartment Illustration 284 Illustration 281 900293559 Illustration 285 3 Pull the drain hose for the radiator through the hole under the radiator 900287410 Illustration 282 1 Pull the hood release lever 1 in order to open the engine access door 2 on the top of the machine 198 Maintenance Section Cooling System Coolant ELC Change g00293560 Illustration 287 4 Remove the access panel on the left side of the engine compartment The drain valve is located in an access port of the fan shroud Open the drain valve Allow the coolant to drain into a suitable container 5 Close the drain valve Fill the system with a solution which consists of clean water and of cooling system cleaner The concentration of the cooling system cleaner in the
30. ed Engine damage could result g00287382 Illustration 319 The filter service indicator is located under the engine access door on the top of the machine Start the engine Run the engine at high idle If the yellow piston in the filter service indicator enters the red zone service the air cleaner Stop the engine 208 Maintenance Section Engine Oil Level Check i00606534 Engine Oil Level Check SMCS Code 1302 1318 1326 NOTICE Do not overfill the crankcase Engine damage can re sult Illustration 320 Illustration 321 g00287410 1 Pull the hood release lever 1 in order to open the engine access door 2 on the top of the machine 900287411 Illustration 322 2 While the engine is stopped maintain the oil level between the ADD mark and the FULL mark on the engine oil dipstick 3 3 If necessary remove the oil filler cap 4 and add oil 4 Clean the oil filler cap and install the oil filler cap 5 Close the engine access door i00606560 Engine Oil and Filter Change SMCS Code 1302 1318 1326 Note If the sulfur content in the fuel is greater than 1 5 by weight use an oil with a TBN of 30 With the high sulfur fuel change the oil and the filter element after every 250 hours or after every month If the API category is CF 4 or less change the oil and filter element after every 250 hours or after every month Otherwise change the oil and the filter element a
31. every 1000 hours If necessary check the following items more often e Clean the top of the batteries with a clean cloth e Clean the battery terminals As needed coat the battery terminals with petroleum jelly A battery should not require more than 30 cc 1 oz of water per cell per week This should exist with the proper charging rate and with a moderate climate In extreme temperatures check the water in the cells weekly 900282160 Illustration 272 1 Open the battery access cover that is located on the right side of the machine 2 Clean the battery surface with a clean cloth Keep the terminals clean and keep the terminals coated with petroleum jelly Install the post cover after you coat the post with petroleum jelly 3 Inspect the electrolyte level in each battery cell A maintenance free battery does not require inspection Maintain the electrolyte level to the bottom of the filler openings Use distilled water If distilled water is not available use clean drinking water 4 Close the battery access cover 100596682 Battery or Battery Cable Replace SMCS Code 1401 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 frame 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
32. fluid levels more frequently than the recommended intervals If leaks are observed check the fluid levels more frequently than the recommended intervals Illustration 404 900291276 Inspect the backhoe bucket 14 for damage or for excessive wear Inspect the backhoe linkage 1 for damage or for excessive wear Repair the bucket or the linkage if necessary Replace any bucket teeth if necessary Inspect the loader bucket 9 for damage or for excessive wear Inspect the linkage 8 for damage or for excessive wear Repair the bucket or the linkage if necessary Replace any bucket teeth if necessary Inspect the transmission 13 for leaks Inspect the torque converter for leaks Correct any leaks Check the hoses around the transmission Inspect the hydraulic system for leaks Inspect the hydraulic tank 4 cylinder rod seals hoses and tubes Also inspect plugs couplings and fittings Correct any leaks Inspect the engine compartment 6 for trash buildup Remove any trash buildup that is in the engine compartment Clean the screens on the engine access doors Inspect the belts for the engine attachments 12 for worn belts for cracked edges or for frayed edges Replace any damaged belts Inspect the cooling system for leaks for faulty hoses and for trash buildup Correct any leaks and remove any trash buildup from the radiator 7 Inspect the tires 10 for damage and for proper inflation Replace any miss
33. fter every 500 hours or after every three months g00290413 Illustration 323 The crankcase drain plug is on the left side of the oil pan 1 Remove the crankcase drain plug and drain the oil into a suitable container Clean the crankcase drain plug and replace the crankcase drain plug Illustration 324 900287238 2 Remove the engine access panel on the left side of the machine 900290708 Illustration 325 3 Remove the filter element with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect 4 Clean the filter mounting base with a clean cloth Make sure that the old filter gasket has been removed 5 Apply a thin film of clean engine oil to the sealing surface of the new filter element 6 Install the new filter element by hand When the gasket contacts the filter base tighten the filter for an additional 3 4 turn 209 Maintenance Section Engine Oil and Filter Change Illustration 326 Illustration 327 900287410 7 Pull the hood release lever 1 in order to open the engine access door 2 on the top of the machine 900287411 Illustration 328 8 Remove the oil filler cap 4 Fill the crankcase with new oil Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Clean the oil filler cap and install the oil filler cap 9 Start the engine and allow the oil to warm Check fo
34. iew the parking brake adjuster knob from the operator seat turn the knob counterclockwise for one quarter of a turn 4 Repeat steps 1 to 6 in the check procedure 223 Maintenance Section Radiator Core Clean If the machine moves during the parking brake test then perform the adjustment procedure again If you run out of adjustment on the parking brake adjuster knob refer to Systems Operation Testing and Adjusting SENR1259 Parking Brake Control Adjust 100611590 Radiator Core Clean SMCS Code 1353 900287717 Illustration 374 900101939 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 Note If necessary tilt the oil cooler away from the radiator in order to remove dust and debris between the radiator and the oil cooler 224 Maintenance Section Rollover Protective Structure ROPS Inspect 101035235 Rollover Protective Structure ROPS Inspect SMCS Code 7325 Illustration 376 Illustration 377 g00293545 1 Inspect the ROPS for loose bolts or for damaged bolts Replace any damaged bolts or missing bolts with original equipment parts only Tighten the M16 bolts 1 to a torque of 165 30 Nm 122 22 Ib ft Tighten the M24 bolts 2 to a torque of 524 100 Nm 386 74 Ib ft Note Apply oil to all ROPS bolt threads before you install the bolts Failure
35. ing valve caps Tighten any loose bolts Inspect the axles 11 for leaks Inspect the front differential for leaks and the rear differential for leaks Check the torque on new wheels or repaired wheels Refer to Operation and Maintenance Manual Wheel Nut Torque Check Inspect the engine air cleaner 5 for dirt buildup Remove the dirt from the engine air cleaner Service the air filter elements when the yellow piston enters the red zone on the filter service indicator Inspect the steps and handholds 3 These objects must be clean Also these objects must be in good condition Inspect the Rollover Protective Structure ROPS for damage Notify your Caterpillar dealer for repairs if necessary Tighten any loose bolts on the ROPS Make sure that the access covers and the guards are secured Inspect the access covers for damage and the guards for damage Inspect the lights 2 for broken bulbs and for broken lenses Replace the bulbs or lenses if necessary Inspect the operator s compartment for cleanliness Keep the operators compartment clean Adjust the rearview mirrors for best visibility 100615726 Wheel Bearings Front Lubricate Two Wheel Drive SMCS Code 4205 4208 Use the following procedure for both wheels 1 Raise the front wheels slightly off the ground 2 Install sufficient blocking under the frame and lower the machine to the blocking 3 Remove the nuts and both wheels Be
36. ir circulation 195 Maintenance Section Bucket Tips Inspect Replace 900287370 Illustration 276 1 Remove the filter cover that is located at the bottom of the right hand console 2 Remove the filter element 3 Clean the filter element with compressed air or pressure water Direct the air or the water along the pleats of the element You can also wash the element with clean water and nonsudsing household detergent 4 Rinse the filter element thoroughly with clear water 5 Allow the filter element to air dry Inspect the element for damage If the filter element is damaged replace the filter element 6 Install the filter element 7 Install the filter cover 900293554 Illustration 277 8 Remove the filter cover that is located on the headliner by the front windshield 196 Maintenance Section Cooling System Coolant DEAC Change Illustration 278 g00293552 9 Remove the filter element 10 Clean the filter element with compressed air or pressure water Direct the air or the water along the pleats of the element You can also wash the element with clean water and nonsudsing household detergent 11 Rinse the filter element thoroughly with clear water 12 Allow the filter element to air dry Inspect the element for damage If the filter element is damaged replace the filter element 13 Install the filter element 14 Install the filter cover 900293555 Illustration 279
37. ke indicator light should come on and the parking brake alarm should sound 4 Gradually increase the engine speed to high idle The machine should not move A WARNING If the machine begins to move reduce the engine speed immediately and apply the service brake pedal 5 Reduce the engine speed Move the transmission to NEUTRAL Lower the bucket to the ground Stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the parking brakes before returning the machine to oper ation 100058453 Bucket Cutting Edges Inspect Replace SMCS Code 6801 A WARNING Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Raise the bucket Place a block under the bucket 2 Lower the bucket to the blocking Do not block up the bucket too high Block up the bucket so that the bucket is high enough to remove the cutting edges and the end bits 3 Remove the bolts Remove the cutting edge and the end bits 4 Clean the contact surfaces 5 Use the opposite side of the cutting edge if this side is not worn 6 Install a new cutting edge if both edges are worn 7 Install the bolts Tighten the bolts to the specified torque Refer to Operation and Maintenance Manual Torques for Ground Engaging Tool Bolts 8 Raise the bucket Remove the blocks 9 Lowe
38. l 231 Maintenance Section V Belts Inspect Adjust Replace DL LF Illustration 401 g00287241 13 Remove the engine access panel on the right side of the machine Illustration 402 900287242 14 Inspect the condition of the alternator belts and the adjustment of the alternator belts The alternator belts should deflect 10 mm 0 38 inch under 110 N 25 Ib of force 900287243 Illustration 403 15 Loosen the mounting bolt 1 Loosen the adjusting locknut 2 16 Move the alternator until the correct tension is reached 232 Maintenance Section Walk Around Inspection 17 Tighten the adjusting locknut 2 Tighten the mounting bolt 1 18 Recheck the belt deflection If the amount of deflection is incorrect repeat Step 15 to Step 17 19 Install the engine access panel 20 Start the engine Raise the loader arms to the maximum height 21 Remove the pin and replace the loader lift arm brace to the stored position on the loader lift arm 22 Lower the bucket to the ground i00615722 Walk Around Inspection SMCS Code 7000 NOTICE Accumulated grease and oil on a machine is a fire haz ard Remove this debris with steam cleaning or high pressure water at least every 1000 hours or each time any significant quantity of oil is spilled on a machine Note Inspect the machine for leaks If leaks are observed find the source of the leak and correct the leak If leaks are suspected check the
39. lace SMCS Code 1261 1 Empty the bucket Remove the pin that secures the loader lift arm brace to the left loader lift arm Raise the loader arm to the maximum height Position the loader lift arm brace over the left lift cylinder rod with the flat end against the cylinder end Push the pin through the holes of the loader lift arm brace and install the cotter pin Slowly lower the loader arms until the loader lift arm brace contacts the top of the lift cylinder and the bosses on the loader arm 214 Maintenance Section Fuel System Water Separator Drain 5 Stop the engine Illustration 340 900287238 6 Remove the access panel from the left side of the machine The machine uses fuel filters with a push and twist collar 900291787 Illustration 341 7 Remove the primary fuel filter that is located next to the crankcase drain plug under the machine Rotate the locking ring counterclockwise in order to remove the filter element Discard the filter properly 8 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 9 Coat the seal of the new filter element with clean diesel fuel 10 Install the new filter element Rotate the locking ring clockwise in order to fasten the filter to the mounting base 900291788 Illustration 342 11 Remove the secondary fuel filter Rotate the locking ring counterclockwi
40. ment gasket that remains on the filter element mounting base 1 Pull the hood release lever 1 in order to open the engine access door 2 on the top of the machine 6 Apply a light coat of oil to the gasket of the new filter element 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 8 Remove the hydraulic tank breather Replace the old breather with a new breather g00290718 Illustration 361 2 Remove the hydraulic tank filler cap that is located under the access panel on the top of the engine compartment 220 Maintenance Section Hydraulic System Oil Level Check Illustration 364 g00290845 9 Maintain the hydraulic oil level in the sight gauge between the MIN mark and the MAX mark Add oil if necessary 10 Inspect the gasket on the hydraulic tank filler cap for damage Replace the gasket if necessary 11 Install the hydraulic tank filler cap 12 Close the access door Hydraulic System Oil Level Check SMCS Code 5056 7479 Illustration 365 g00290845 The sight gauge for the hydraulic tank is located on the left side of the machine Move the backhoe to the transport position and lower the loader bucket to the ground Turn off the engine Wait about five minutes before you check the hydraulic system oil level Maintain the oil level in the sight gauge
41. mission 900291272 Illustration 387 Drain plug for power shift transmission 1 Remove the transmission drain plug Allow the transmission oil to drain into a suitable container Clean the transmission drain plug and install the transmission drain plug 2 Change the transmission oil filter element Refer to Operation and Maintenance Manual Transmission Oil Filter Replace 3 Clean the transmission magnetic screen Refer to Operation and Maintenance Manual Transmission Magnetic Screen Clean 228 Maintenance Section Transmission Oil Change D g00293359 Illustration 388 4 Remove the transmission breather from the top of the transmission case Clean the breather in clean nonflammable solvent and allow the breather to dry Replace the breather Illustration 389 g00287410 Illustration 390 5 Pull the hood release lever 1 in order to open the engine access door 2 on the top of the machine Illustration 391 g00291275 6 Remove the dipstick fill cap and fill the transmission with transmission oil Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities 7 Start the engine and run the engine at low idle Apply the service brake Slowly operate the transmission controls in order to circulate the oil 8 Move the transmission control lever to NEUTRAL and engage the parking brake Inspect the transmissi
42. nd on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 00999998 Parking Brake Check Adjust SMCS Code 4267 Check Procedure Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles Check the brakes on a dry level surface Fasten the seat belt before you check the brakes The following checks are used to determine if the parking brake is functional These checks are not intended to measure the maximum brake holding effort The brake holding effort that is required to sustain a machine at a specific engine rpm varies depending on the machine The variations are the differences in the engine setting in the power train efficiency and in the brake holding ability etc 1 Start the engine Raise the bucket slightly 900514581 Illustration
43. of a silicone based lubricant Dirt can be attracted to the lubricant and dirt can cause abrasion to the pad assemblies and wear to the pad assemblies The extendable stick pads do not normally require any lubrication If the extendable stick becomes noisy a small amount of a silicone based lubricant may be applied Adjustment for Top Upper Wear Pad 1 Extend the extendable stick to one half of the fully extended position 2 Move the stick and move the boom down against the ground This will take pressure off the wear pad Illustration 330 900635137 3 Remove the bolts that secure the wear pad Slide the pad toward the boom There will be enough space in order to remove the pad Either replace the wear pads or stack shims behind the pad 4 Shim the wear pad to 1 mm 0 04 inch Note In order to make adjustments to the remaining upper wear pads refer to Disassembly and Assembly Manual SENR1209 Stick Extendable Stick Extendable Stick Cylinder Adjustment for Lower Pads 1 Extend the extendable stick out until there is enough clearance in order to remove the pads 900635788 Illustration 331 2 The side pads 1 can be shimmed without moving the stick or without moving the boom 3 Adjust the boom and adjust the stick in order to take pressure away from the top pad 2 Adjust the wear pads by shimming or replacing Shim the wear pads to 1 mm 0 04 inch 4 Adjust the boom and adjust the stick in
44. on 266 g00290596 Apply lubricant to the grease fittings for the drive shaft to the final drives There are two grease fittings for each drive shaft Axle Universal Joint Rear Lubricate All Wheel Steer Machines Only SMCS Code 3251 cad Ais Illustration 267 900287245 900287244 Illustration 268 191 Maintenance Section Backhoe Boom Stick Bucket and Cylinder Bearings Lubricate Apply lubricant to the grease fittings for the universal joints of each drive shaft to the final drives There are two grease fittings for each universal joint Backhoe Boom Stick Bucket and Cylinder Bearings Lubricate SMCS Code 6501 6502 6503 6510 6511 6512 6513 6533 g00633021 Illustration 269 Position the backhoe into the service position Illustration 270 900287247 Apply lubricant to the grease fitting 1 for the head end of the boom cylinder Apply lubricant to the grease fitting 2 for the rod end of the boom cylinder Apply lubricant to the grease fitting 3 for the boom pivot There is one grease fitting on each side of the machine Illustration 271 900632950 Apply lubricant to the grease fitting 4 for the head end of the stick cylinder Apply lubricant to the grease fitting 5 for the rod end of the stick cylinder Apply lubricant to the grease fitting 6 for the pivot pin for the stick Apply lubricant to the grease fitting 7 for the head end of the bucket cylinder A
45. on for leaks 9 Maintain the transmission oil level within the crosshatched region on the CHECK WITH OIL WARM side of the dipstick when the transmission is warm Add transmission oil through the transmission filler tube if necessary Note The transmission can be checked with cold transmission oil Check the oil level with the cold oil check side of the dipstick The engine must be stopped in order to do a cold oil check 10 Install the dipstick fill cap and install the engine access door 11 Stop the engine i00617243 Transmission Oil Filter Replace SMCS Code 3067 Illustration 392 g00293353 The transmission filter is located on the left side of the machine g00293355 Illustration 393 1 Remove the transmission oil filter element with a strap type wrench 2 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 3 Apply a light coat of oil to the gasket of the new filter element 4 Install the new filter element by hand When the gasket contacts the mounting base tighten the filter element for an additional three quarters of a turn 5 Start the engine and apply the service brake Slowly operate the transmission controls in order to circulate the transmission oil 229 Maintenance Section Transmission Oil Filter Replace 6 Move the transmission control lever to NEUTRAL and engage the parking brake
46. ood Lights 5 10 Amp Auxiliary Rear Flood Lights 6 10 Amp Radio Memory 7 10 Amp Auxiliary Front Flood Lights 8 10 Amp Front Windshield Wiper 9 10 Amp Rear Windshield Wiper 10 10 Amp Spare 11 Open Rotating Beacon 12 10 Amp Dome Light 13 10 Amp 217 Maintenance Section Hydraulic System Oil Change Radio Power 14 10 Amp Air Conditioner Compressor 15 10 Amp Air Conditioner Blower 16 10 Amp i00611301 Hydraulic System Oil Change SMCS Code 5056 Operate the machine for a few minutes in order to warm the hydraulic system oil The machine should be level Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine Illustration 353 900287410 Illustration 354 The hydraulic tank filler cap is located under the access door on the top of the engine compartment 1 Pull the hood release lever 1 in order to open the engine access door 2 on the top of the machine 218 Maintenance Section Hydraulic System Oil Change Illustration 355 900290718 2 Remove the hydraulic tank filler cap Illustration 357 3 900290722 Remove the drain plug on the flange that is located on the hydraulic pump Allow the oil to drain into a suitable container Clean the drain plug and replace the drain plug Tighten the drain plug to a torque of 90 10 Nm 66 x 7 Ib ft Change
47. pacity 900290601 Illustration 291 5 Maintain the coolant level within 13 mm 0 5 inch from the bottom of the filler tube 6 Install the radiator cap Close the access door 100095664 Cooling System Coolant Extender ELC Add SMCS Code 1352 1353 1395 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loose the cap slowly to relieve the pressure When a Caterpillar Extended Life Coolant is used an extender must be added to the cooling system See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval The amount of extender is determined by the cooling system capacity Table 120 RECOMMENDED AMOUNT OF EXTENDER BY COOLING SYSTEM CAPACITY Recommended Amount of Extender 0 57 L 60 qt 0 71 L 75 qt 0 95 L 95 qt 1 18 L 1 25 at Cooling System Capacity 22 to 30 L 6 to 8 US gal 30 to 38 L 8 to 10 US gal 38 to 49 L 10 to 13 US gal 49 to 64 L 13 to 17 US gal For additional information on the addition of extender see Operation and Maintenance Manual Caterpillar Coolant Recommendations or consult your Caterpillar dealer 100599514 Cooling System Level Check SMCS Code 1353 1395 A WARNING Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slo
48. pply lubricant to the grease fitting 8 for the rod end of the bucket cylinder Apply lubricant to the grease fitting 9 for the top of the link Apply lubricant to the grease fitting 10 for the bottom of the link Apply lubricant to the grease fitting 11 for the pivot pin Apply lubricant to the grease fitting 12 for the bucket pivot pin 100080741 Backup Alarm Test SMCS Code 7406 Turn the engine start switch key to ON in order to perform the test Apply the service brake Move the transmission direction control lever to REVERSE position The backup alarm should immediately sound The backup alarm will continue to sound until the transmission direction control lever is moved to the NEUTRAL position or to the FORWARD position 192 Maintenance Section Battery Recycle i01176086 Battery Recycle SMCS Code 1401 1 Always recycle a battery Never discard a battery 2 Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility i00588592 Battery Electrolyte Level Check SMCS Code 1401 Table 119 THE TABLE FOR THE BATTERY ELECTROLYTE Battery Interval Conventional 100 Hours Low Maintenance 250 Hours Maintenance Free Maintenance Free Tighten the battery retainers on all of the machines Tighten the battery retainers at every 1000 hours Check the following items at
49. r the filler plug 5 Clean the filler plug and install the filler plug 203 Maintenance Section Differential Oil Rear Change Rear Axle with All Wheel Steer AWS g00290698 Illustration 302 1 Remove the oil drain plug and drain the oil into a suitable container 2 Clean the drain plug and install the drain plug 900290699 Illustration 303 3 Remove the oil level fill plug Refer to Operation and Maintenance Manual Lubricant Specifications and Operation and Maintenance Manual Refill Capacities for oil 4 Add oil until the oil is level with the threads for the filler plug 5 Clean the filler plug and install the filler plug 00602597 Differential Oil Level Front Check SMCS Code 3258 The oil level fill plug is located near the middle of the front axle 204 Maintenance Section Differential Oil Level Rear Check Illustration 304 g00290688 Illustration 306 900290699 Filler plug on rear differential for All Wheel Steer 1 Remove the oil level fill plug in order to check the oil 1 Remove the oil plug in order to check the oil 2 The oil level should be at the bottom of the plug 2 The oil level should be at the bottom of the plug threads threads 3 Clean the oil level fill plug and install the oil 3 Clean the oil plug and install the oil plug level fill plug 00604375 i00602602 f Drive Shaft Spline Lubricate Differential Oil Level Rear p Check SMCS Co
50. r leaks 210 Maintenance Section Engine Valve Lash Check 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 3 Add oil if necessary 11 Replace the engine access panel and close the engine access door i01010167 Engine Valve Lash Check SMCS Code 1102 082 1102 535 1102 1209 082 1209 Note A qualified service person should perform the valve lash check and or the valve lash adjustment Special tools and training are required Check the engine valve lash after every 1000 service hours or 6 months on machines that are equipped with the following engine arrangements e 122 8803 Primary Engine Arrangement e 122 8804 Engine Arrangement e 122 8805 Engine Arrangement e 122 8806 Engine Arrangement The engine arrangement number is located on the engine serial number plate Check the engine valve lash after every 2000 service hours or 1 year on machines that are not equipped with the engine arrangements that are listed above Refer to your machine s Service Manual for complete instructions i01184251 Extendable Stick Pads Inspect Replace If Equipped SMCS Code 6533 040 JP 6533 510 JP Inspect Wear Pads 2L e Illustration 329 900634728 Check the extendable stick for slop Shim the extendable stick pads in order to maintain an acceptable fit and reduce slop Note Do not apply an excessive amount
51. r the bucket to the ground 10 After a few hours of operation check the bolts for proper torque 100081131 Bucket Tips Inspect Replace SMCS Code 6805 Block the bucket before changing the bucket teeth To prevent possible injury to the eyes wear a pro tective face shield when striking the pin The pin when struck can fly out and cause injury to nearby personnel 1 Drive the pin out of the bucket tip from the retainer side of the bucket tip Remove the bucket tip and the retainer 2 Clean the adapter the pin and the retainer Replace any damaged parts Install the retainer in the groove 3 The bucket tip should be installed over the retainer Install the bucket tip in the runner position or in the digger position 4 Drive the pin through the retainer through the adapter and through the bucket tip from the side that is opposite the retainer i00621342 Cab Air Filter Clean Replace SMCS Code 7311 7342 Clean the Filter Element NOTICE Do not clean the elements by bumping or tapping them Inspect the elements after cleaning Do not use an element with damaged pleats gaskets or seals When cleaning with pressure air use 205 kPa 30 psi maximum to prevent element damage by too much air pressure When cleaning with pressure water use 280 kPa 40 psi maximum to prevent element damage Clean the filter element weekly but clean the filter element daily when there is a reduction of a
52. ransmission control lever to THIRD SPEED FORWARD 4 Gradually increase the engine speed to high idle The machine should not move If the machine begins to move reduce the engine speed immediately and engage the parking brake 5 Reduce the engine speed to low idle Move the transmission to NEUTRAL Engage the parking brake Lower the bucket to the ground Stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the service brake before returning the machine to operation 194 Maintenance Section Bucket Cutting Edges Inspect Replace Secondary Brake Holding Ability Test Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles Test the brakes on a dry level surface Fasten the seat belt before you test the brakes The following tests are used to determine if the parking brake is functional These tests are not intended to measure the maximum brake holding effort The brake holding effort that is required to sustain a machine at a specific engine rom varies depending on the machine The variations are the differences in the engine setting in the power train efficiency and in the brake holding ability etc 1 Start the engine Raise the bucket slightly 2 Engage the parking brake 3 Move the transmission control lever to THIRD SPEED FORWARD Note The parking bra
53. rmostat is tested and the thermostat meets test specifications e The thermostat is not damaged e The thermostat does not have excessive buildup of deposits 10 Install the hose Tighten the hose clamp 11 Refill the cooling system Refer to Operation and Maintenance Manual Cooling System Specifications and Operation and Maintenance Manual Refill Capacities 100601036 Differential Oil Front Change SMCS Code 3258 Illustration 298 900290687 1 Remove the oil drain plug and drain the oil into a suitable container 2 Clean the drain plug and install the drain plug 900290688 Illustration 299 3 Remove the oil level fill plug Refer to Operation and Maintenance Manual Lubricant Specifications and Operation and Maintenance Manual Refill Capacities for oil 4 Add oil until the oil is level with the threads for the filler plug 5 Clean the filler plug and install the filler plug 100601241 Differential Oil Rear Change SMCS Code 3258 Rear Axle al Illustration 300 g00290691 1 Remove the oil drain plug and drain the oil into a suitable container 2 Clean the drain plug and install the drain plug g00290697 Illustration 301 3 Remove the oil level fill plug Refer to Operation and Maintenance Manual Lubricant Specifications and Operation and Maintenance Manual Refill Capacities for oil 4 Add oil until the oil is level with the threads fo
54. se in order to remove the filter element Discard the filter properly 12 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 13 Coat the seal of the new filter element with clean diesel fuel 14 Install the new filter element Rotate the locking ring clockwise in order to fasten the filter to the mounting base 15 Prime the fuel system in order to fill the filter elements with fuel Refer to Operation and Maintenance Manual Fuel System Prime 16 Replace the access panel 100669721 Fuel System Water Separator Drain SMCS Code 1263 543 1263 Illustration 343 900293550 The water separator is located by the drain plug for the engine crankcase 900293551 Illustration 344 1 Loosen the drain valve on the bottom of the fuel filter Allow the water and the sediment to drain into a suitable container 2 Tighten the drain valve 3 If the engine fails to start change the fuel filter If there is a power loss change the fuel filter 100675934 Fuel System Water Separator Element Replace SMCS Code 1263 510 FQ The water separator element is located next to the crankcase drain plug under the machine The machine uses water separator elements with a push and twist collar g00291787 Illustration 345 1 Remove the water separator element Rotate the locking ring counterclockwise in order to remove the
55. tial Oil Level Rear Check 204 Engine Oil and Filter Change 208 Final Drive Oil Level Front Check 212 Final Drive Oil Level Rear Check 212 Kingpin Bearings Rear Lubricate 220 Sideshift Stabilizer Wear Pads Inspect 225 V Belts Inspect Adjust Replace 230 Every 500 Service Hours or 3 Months Drive Shaft Spline Lubricate 204 Engine Oil and Filter Change 208 Fuel System Filter Replace 213 Fuel System Water Separator Element got 215 Hydraulic System Oil Filter Replace 219 Transmission Oil Filter Replace 229 Every 500 Service Hours or 3 Months for Machines Used in Severe 5096 or more of loader work Applications Differential Oil Rear Change 203 Every 1000 Service Hours or 6 Months Differential Oil Front Change 202 Differential Oil Rear Change 203 Engine Valve Lash Check 210 Final Drive Oil Front Change 211 Final Drive Oil Rear Change 212 Rollover Protective Structure ROPS Inspect 224 Transmission Magnetic Screen Clean
56. to apply oil to the bolt threads can result in improper bolt torque 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 Do not repair the ROPS by welding reinforcement plates to the ROPS Consult your Caterpillar dealer for repair of any cracks in the ROPS 100317205 Seat Belt Inspect SMCS Code 7327 Always check the condition of the seat belt and the condition of the mounting hardware before you operate the machine Replace any parts that are damaged or worn Regardless of the appearance of the seat belt the seat belt should be replaced at every three year interval A date label is attached to each seat belt Use this label in order to determine the age of the seat belt a Illustration 378 g00215958 Inspect the seat belt for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Check the buckle for wear or for damage If the buckle is worn or damaged replace the seat belt and or the buckle Illustration 379 g00038621 Check the seat belt mounting hardware for wear or for damage If the seat belt mounting hardware is worn or damaged replace the seat belt mounting hardware Make sure that the mounting bolts are tight 100615000 Secondary Steering Test If Equipped SMCS Code 4324 If hydraulic pressure is lost during machin
57. ts 3 Clean the primary filter element The filter elements can be cleaned by using the following methods e pressure air e pressure water e detergent washing 206 Maintenance Section Engine Air Filter Secondary Element Replace When you use pressure air the maximum air pressure is 205 kPa 30 psi When you use pressure water the maximum water pressure is 280 kPa 40 psi Illustration 312 900038608 a When you clean the inside pleats and the outside pleats direct the air along the pleats or direct the water along the pleats The element can be washed in a solution that consists of warm water and of nonsudsing household detergent Fully rinse the pleats Allow the filter to air dry completely b Inspect the filter elements after you clean the filer elements Do not use a filter if the pleats the gaskets or the seals are damaged c Cover the clean filter elements Store the elements in a clean dry location Replace the primary element after the primary element has been cleaned six times Also replace the primary element if the primary element has been in service for one year 4 Install a clean filter element and install the cover 5 Tighten the cover screws finger tight Do not use a tool to tighten the cover screws 00606478 Engine Air Filter Secondary Element Replace SMCS Code 1051 1054 NOTICE Always replace the secondary filter element Never at tempt to reuse it by cleaning
58. wly to relieve the pressure Illustration 292 g00287385 g00287410 Illustration 293 Pull the hood release lever 1 in order to open the engine access door 2 on the top of the machine 201 Maintenance Section Cooling System Water Temperature Regulator Clean Replace Illustration 294 g00287415 1 The radiator cap is located on the top of the radiator on the left side of the machine Remove the radiator cap slowly in order to relieve system pressure g00290601 Illustration 295 2 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler tube If you need to add coolant daily check the cooling system for leaks 3 Inspect the radiator cap seal Replace the radiator cap seal if the radiator cap seal is damaged 4 Install the radiator cap Close the access panel 100599779 Cooling System Water Temperature Regulator Clean Replace SMCS Code 1355 1393 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 Note If you are only replacing the
59. y lubricant to the grease fitting 7 for the rod end of the tilt cylinder Apply lubricant to the grease fittings 8 for the lower pivot pins There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 9 for the upper pivot pin There is a grease fitting for each side of the machine There is a total of 17 grease fittings 221 Maintenance Section Loader Bucket Cylinder and Linkage Bearings Lubricate Parallel Lift Machines 900291114 Illustration 369 Apply lubricant to the grease fittings 1 for the lower pivot pin of the quick coupler assembly There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 2 for the upper pivot pin of the quick coupler assembly There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 3 for the upper pivot pin of the tilt linkage There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 4 for the rod end of the tilt cylinder There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 5 for the rod end of the lift cylinder There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 6 for the center pivot pin of the parallel linkage There is a grease fitting for each side of the machine Apply lubricant to the grease fittings 7 for the head en
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