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MAINTENANCE INTERVALS

Operation and Maintenance Manual Excerpt

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SEBU7885-12 January 2011

Operation and Maintenance Manual
994F Wheel Loader
4421-Up (Machine)

SAFETY.CAT.COM

SEBU7885-12

91 Maintenance Section Maintenance Interval Schedule

i04174489

Windows - Clean ................................................. 167

Maintenance Interval Schedule
SMCS Code: 7000 Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed. Note: If Cat HYDO Advanced 10 hydraulic oil is used, the hydraulic oil change interval will change. The normal interval of 2000 hours is extended to 3000 hours. S·O·S services may extend the oil change even longer. Consult your Cat dealer for details.

Every 10 Service Hours or Daily
Air Tank Moisture and Sediment - Drain ............... 93 Backup Alarm - Test .............................................. 96 Bucket Cutting Edges - Inspect/Replace ............ 100 Bucket Wear Plates - Inspect/Replace ............... 103 Cooling System Coolant Level - Check .............. 109 Engine Oil Level - Check .................................... 121 Fuel Tank Water and Sediment - Drain ............... 130 Hydraulic System Oil Level (Brake Cooling) Check ................................................................ 147 Hydraulic System Oil Level (Implement) Check ................................................................ 147 Hydraulic System Oil Level (Steering, Brake) Check ................................................................ 149 Oil Renewal System Oil Level - Check ............... 152 Pump Drive (Front) Oil Level - Check ................. 157 Seat Belt - Inspect .............................................. 160 Steering Cylinder Bearings - Lubricate ............... 162 Steering Stop - Check ......................................... 162 Transmission Oil Level - Check .......................... 165

Every 50 Service Hours or Weekly
Cab Air Filter - Clean/Replace ............................ 104 Collet Pin Bolt Torque - Check ............................ 105 Tire Inflation - Check ........................................... 162

Initial 250 Service Hours
Engine Valve Lash and Bridge - Check .............. 125 Engine Valve Rotators - Inspect ......................... 125

When Required
Automatic Lubrication Grease Tank - Fill .............. 94 Automatic Lubrication System Components Check .................................................................. 94 Battery - Recycle .................................................. 97 Battery or Battery Cable - Inspect/Replace .......... 98 Bucket Tips - Inspect/Replace ............................ 101 Circuit Breakers - Reset ...................................... 105 Engine Air Filter Primary Element - Clean/ Replace .............................................................. 116 Engine Air Filter Secondary Element - Replace .. 118 Engine Air Precleaner - Clean ............................. 119 Ether Starting Aid Cylinder - Replace ................. 126 Frame - Inspect ................................................... 127 Fuel System - Prime ........................................... 128 Fuses - Replace .................................................. 130 High Intensity Discharge Lamp (HID) - Replace .. 132 High Pressure Screens - Clean/Replace ............ 133 Hydraulic System Return Screen - Replace ....... 150 Oil Filter - Inspect ................................................ 152 Radiator Core - Clean ......................................... 159 Seat Side Rails - Adjust ...................................... 161 Secondary Steering - Test .................................. 161 Transmission Magnetic Screen - Clean .............. 163 Window Washer Reservoir - Fill .......................... 167 Window Wiper - Inspect/Replace ........................ 167

Every 250 Service Hours
Engine Oil Sample - Obtain ................................ 121

Every 250 Service Hours or Monthly
Alternator - Inspect ............................................... 93 Axle Oscillation Bearings - Lubricate .................... 96 Battery - Clean ...................................................... 97 Belts - Inspect/Adjust/Replace .............................. 98 Braking System - Test ........................................... 99 Differential and Final Drive Oil Level - Check ...... 114 Drive Shaft Spline (Center) - Lubricate ................ 115 Drive Shaft Support Bearing - Lubricate .............. 115 Engine Oil and Filter - Change ........................... 122 Pump Drive Shaft (Front) - Lubricate .................. 158 Pump Drive Shaft Support Bearing (Rear) Lubricate ........................................................... 158

Initial 500 Service Hours
Seat Side Rails - Adjust ...................................... 161

Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) Obtain ................................................................ 110

............. 153 Pump Drive (Front) Oil Filter ......... 95 Brake Accumulator .5 Years Engine Valve Lash and Bridge .....................Change .Change .......... Rebuild/Install Reman...............Replace ... 111 Engine Water Pump ........ 151 Receiver Dryer (Refrigerant) .......Change .......................................Tighten ......................Inspect ..................Clean .... 134 Hydraulic System Oil (Implement) .........Change ..................................... 144 Hydraulic System Oil Filter (Steering Pump Case Drain) .Check .......Clean ....................................................................... 125 Engine Valve Rotators .......................................Change ....................... 119 Every Year Cooling System Coolant Sample (Level 2) Obtain ... 163 Every 9500 Service Hours or 1 892 705 L (500 000 US gal) of Fuel Engine Components ............. 120 Every 1000 Service Hours or 1 Year Hydraulic System Oil (Steering...........Add ................ 136 Hydraulic System Oil Filter (Hydraulic Cooler Screen) ....................... 166 Engine Mounts .....Inspect ............Replace ......................... 109 Differential and Final Drive Oil Sample ..... 129 Fuel Tank Cap and Strainer ...............92 Maintenance Section Maintenance Interval Schedule SEBU7885-12 Every 500 Service Hours Cooling System Coolant Sample (Level 1) Obtain .......................................... 150 Pump Drive Oil Sample ..................Clean/Replace ..... 111 Every 6000 Service Hours or 4 Years VIMS Module Battery .. 159 Every 19 000 Service Hours or 3 785 410 L (1 000 000 US gal) of Fuel Engine Components .Clean .......Clean/Inspect/ Replace .....Inspect .................... 114 Hydraulic System Oil Sample (Implement) Obtain .......... Brake) Obtain .... 129 Hydraulic System Oil Filter (Implement Pump Case Drain) .... 149 Hydraulic System Oil Sample (Steering...... 120 Fuel System Primary Filter . Brake) Change ............. 125 Every 500 Service Hours or 3 Months Engine Crankcase Breather .... 125 Every 1000 Service Hours or 6 Months Battery Hold-Down .....Replace .......Change ............................................Inspect ........ 112 Hydraulic System Oil (Brake Cooling) .........Clean ....................................... 112 ........... 162 Turbocharger ............................Inspect ..............Inspect . 154 Rollover Protective Structure (ROPS) .............................Obtain . 160 Transmission Oil .................................................. 110 Every 3000 Service Hours or 2 Years Crankshaft Vibration Damper ............... 156 Every 5000 Service Hours or 3 Years Starting Motor ...................Replace/Install Reman ..Obtain ............ 145 Hydraulic Tank Breaker Relief Valve .................................Inspect ............. 166 Every 6000 Service Hours or 6 Years Cooling System Water Temperature Regulator Replace ... 143 Hydraulic System Oil Filter (Pilot) ....... 142 Hydraulic System Oil Filter (Steering Cooler Screen) (Brake Cooler Screen) ..... 108 Cooling System Pressure Cap .. 99 Differential and Final Drive Oil ..... 93 Axle Oil Cooler Screens ........Clean/Replace ....................................................................... 146 Power Train Oil Filter (Transmission...........Obtain ............................Replace .. 106 Every 2000 Service Hours or 1 Year Air Dryer Desiccant .....Clean .................Replace ........... 139 Every 12 000 Service Hours or 6 Years Cooling System Coolant (ELC) ...........................Clean/Inspect............. 97 Pump Drive (Front) Oil . 121 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt ............................... 157 Transmission Oil Sample .....Replace .......Replace ....Change .. 166 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender (ELC) ..............Replace .. Install New ........Replace ................................ 161 Every 4000 Service Hours or 2...................... 128 Fuel System Secondary Filter .... Torque Converter) ..................................Check .......................

If there is moisture in the air reservoirs.Replace SMCS Code: 4285-510-DSS Air Tank Moisture and Sediment .Replace i02234802 i02339510 Air Dryer Desiccant . When the desiccant cartridge in the air dryer fails to absorb water. Consult your Caterpillar dealer for information about replacing the desiccant cartridge and for instructions for rebuilding the desiccant cartridge.SEBU7885-12 93 Maintenance Section Air Dryer Desiccant .Inspect SMCS Code: 1405-040 Illustration 80 g01126864 The air dryer is located under the cab platform on the right side of the machine. SENR1123. the batteries may not fully recharge. When the engine is operated only for short periods of time.Drain SMCS Code: 1466-543-M&S Illustration 79 g01138821 Illustration 81 g01167399 The air tank is located on the right side of the cab platform. Inspect the alternator for loose connections and for proper battery charging. “Electrical System” for information about testing the alternator. the desiccant cartridge must be rebuilt or the desiccant cartridge must be replaced. Reference: Refer to Systems Operation/Testing and Adjusting. replace the desiccant cartridge or rebuild the desiccant cartridge. Push down on the drain valve in order to drain the moisture and the sediment from the air tank. i02118879 Alternator . Check for moisture in the air reservoirs. . “3500B and 3500B High Displacement Engines For Caterpillar Built Machines”. Make sure that the alternator is functioning properly.

Fill SEBU7885-12 i02223981 Automatic Lubrication Grease Tank . Relieve the pressure in the system before you remove hoses or fittings. The grease tank can contain 86 kg (190 lb) of lubricant. install a fitting in place of the remote line. Illustration 83 g01121678 The grease tank for the automatic lubrication system is located on the left side of the machine.Fill SMCS Code: 7540-544-TNK If any of the remote lines become damaged.Check SMCS Code: 7540-535 Illustration 82 g01138824 A pressure hazard is present. Lubricate the item at the fittings until the remote lines can be replaced. Reference: Before any service work is performed on the lubrication system. Severe personal injury or death can result from removing hoses or fittings that are under pressure. i02331711 Automatic Lubrication System Components .94 Maintenance Section Automatic Lubrication Grease Tank . refer to Special Instructions. The grease tank provides lubrication for the following items: • Axle oscillation bearings • Linkage bearings • Lift cylinder bearings • Tilt cylinder bearings • Steering cylinder bearings • Articulation bearings • Fan bearing • Belt adjusting pulley • Lower bucket pivot bearings . The grease tank can be filled by the fast fill service group. REHS1394 or consult your Caterpillar dealer.

refer to Special Instructions. i02223943 Axle Oil Cooler Screens Clean/Replace SMCS Code: 1365-070-Z3. maintenance. Check for an excessive buildup of grease at each pin joint.Fill”. Check the grease level at the top vent port of the reservoir. Settings of the the Injectors for the Autolube System”. adjusting and repair of the product. 2. “Automatic Lubrication Grease Tank . . Refer to Special Publication. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Reference: For adjustment information. REHS1394 for system troubleshooting procedures. 1365-510-Z3 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. refer to Operation and Maintenance Manual. Remove any buildup of grease. testing. Reference: If a fresh supply of grease is not present. refer to Operation and Maintenance Manual. Dispose of all fluids according to local regulations and mandates.SEBU7885-12 95 Maintenance Section Axle Oil Cooler Screens . “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Check that each pin joint is receiving a fresh supply of grease. “Capacities (Refill). NENG2500. Reference: For filling procedures. Clean the screens whenever there is a failure in the brake system.Clean/Replace Illustration 84 994F Wheel Loader (A) A-Pin (B) B-Pin (C) C-Pin (D) D-Pin (E) E-Pin (F) F-Pin (G) G-Pin (H) Pin for upper articulation joint (J) Pin for lower articulation joint (K) K-Pin (L) Steering cylinder pins (X) Trunnions (Y) Y-Pin g01163772 1. 3.

Wipe off the fittings before any lubricant is applied. nonflammable solvent.96 Maintenance Section Axle Oscillation Bearings . Loosen the bolts on the tube assemblies and drain the oil from the lines into a suitable container. install a fitting at the bearing in order to lubricate the bearing. Install the screens. 2. 4. Dispose of the oil properly. Tighten the bolts. The alarms will continue to sound until the transmission is placed into neutral or into forward. Make sure that there is no pressure in the lines for the axle oil. Illustration 85 g01121661 1. Place the transmission in reverse. The damaged line must be replaced. Make any necessary repairs. 2. Machines that are not equipped with the automatic lubrication system have two remote fittings near the articulation joint on the left side of the machine. Apply lubricant through the two remote fittings. i02857310 Backup Alarm . the tube assemblies. Remove the tube assemblies and the screens. If any of the lubrication lines are damaged. i02274117 Turn the engine start switch to the ON position in order to perform the test.Lubricate SEBU7885-12 There is a screen for each wheel. 3. 3278-086-BD Note: The axle oscillation bearings are lubricated by the automatic lubrication system. Clean the screens in a clean. There is a total of four screens that must be cleaned. and the new seals. Axle Oscillation Bearings Lubricate SMCS Code: 3268-086-BD. Check for leaks. The backup alarms should start to sound immediately. Illustration 86 g01138825 . 1. Illustration 87 g01423462 The backup alarms are located behind the fan guard on the rear of the machine.Test SMCS Code: 7406-081 Apply the service brake.

Illustration 90 g01127361 Illustration 92 g01127380 Clean the battery terminals and the surfaces of the batteries with a clean cloth.Tighten SMCS Code: 7257-527 Illustration 89 g01138824 Illustration 91 g01138824 Open the battery compartment of the left side of the cab platform. Open the battery compartment on the left side of the cab platform.Clean SMCS Code: 1401-070 Battery Hold-Down . Never discard a battery.SEBU7885-12 97 Maintenance Section Battery . Make sure that the battery cables are installed securely. .Recycle SMCS Code: 1401-561 Always recycle a battery.Clean i00993589 Battery . Always return used batteries to one of the following locations: • A battery supplier • An authorized battery collection facility Illustration 88 g01120547 • Recycling facility i02235575 i02235394 Battery . Coat the battery terminals with petroleum jelly.

To help to prevent loose batteries and the possibility of loose cable connections. the vibration of an operating machine can cause the battery hold-downs to loosen. 4. tighten the locknuts to a torque of 14 ± 2 N·m (10 ± 1. 6. 5. Turn the battery disconnect switch to the OFF position. 3.4 lb ft). Inspect the condition of the alternator belts. Check the tension of the alternator belts. Open the lower rear access doors on both sides of the machine. disconnect the negative battery cables of two of the batteries. 2.5 lb ft). If the machine has four 12 volt batteries. 7.1 ± 7. 8. If the alternator belts require adjustment or replacement. 1357-040. Turn all of the switches to the OFF position. Remove the key. Turn the engine start switch key to the OFF position.Inspect/Replace SEBU7885-12 Over time. 7. Turn adjusting nut (3) until the correct belt tension is reached. Reconnect the positive battery cable at the battery disconnect switch. 6. Note: Do not allow the disconnected battery cable to contact the disconnect switch. The tension of a used alternator belt with more than 30 minutes of operation at rated speed should be 489 ± 44 N (110 ± 10 lb). proceed to Step 4. Reconnect the negative battery cable at the battery that is connected to the battery disconnect switch. i01946377 Alternator Belt Battery or Battery Cable Inspect/Replace SMCS Code: 1401-040. Tighten mounting bolts (1). 3. Install the key and turn the battery disconnect switch to the ON position. Disconnect the negative battery cable at the battery that is connected to the battery disconnect switch. 1357-510 Note: Always stop the engine before you inspect the belts and before you service the belts. Make any necessary repairs or replace the battery. 5. 1402-510 1. Loosen mounting bolts (1) and adjusting locknut (2). . Disconnect the positive battery cable at the battery disconnect switch.Inspect/Adjust/Replace SMCS Code: 1357-025. The battery disconnect switch is connected to the machine frame. i02325339 Illustration 93 g01139046 1. 4. Tighten adjusting locknut (3) to a torque of 110 ± 10 N·m (81. 2.98 Maintenance Section Battery or Battery Cable . The tension of a new alternator belt with 30 minutes of operation or less at rated speed should be 800 ± 22 N (180 ± 5 lb). 1401-510. 1402-040. Illustration 94 g01127387 Belts .

Open the upper forward access door on the left side of the machine. perform the following steps. Move the engine start switch to the ON position.Check 8. Inspect the condition of the air conditioner belt. 8. Install a new belt. 5. 6. Start the engine and run the engine for one minute in order to increase the accumulator pressure. Depress the service brake pedal until the alert indicator for the brake oil pressure comes on. RENR6314. Close the upper forward access door on the left side of the machine. Turn the belt tensioner in order to release the tension from the belt.SEBU7885-12 99 Maintenance Section Brake Accumulator . 4. Note: Your Caterpillar dealer has the appropriate tools for measuring the precharge pressure of the brake accumulator. 2. Stop the engine. Turn the belt tensioner back into the position. The alert indicator for the brake oil pressure should go off. If the alert indicator for the brake oil pressure comes on with less than five applications of the service brake pedal. 4. Inspect the belt for wear and for cracking. 3. Recheck the belt tension. i02857312 Illustration 96 g01127388 3. 2. If the tension is incorrect. If the belt requires replacement. i02113934 Brake Accumulator . Only use dry nitrogen for recharging. Close the lower rear access doors on both sides of the machine. measure the nitrogen precharge pressure of the accumulator. 7. 4267-081 1. Remove the belt. . The alert indicator for the brake oil pressure should come on if the brake system is not at the normal operating pressure. Make sure that the steering frame lock is in the unlocked position. “994F Wheel Loader Braking System” for additional information. repeat the adjustment procedure. Fasten the seat belt.Test SMCS Code: 4251-081. 2. A minimum of five applications should be required. 1. Reference: Refer to Systems Operation/Testing and Adjusting. 9. This will decrease the accumulator pressure.Check SMCS Code: 4263-535 Air Conditioner Belt Illustration 97 g01139046 g01076961 Illustration 95 1. Braking System .

This test is performed when the service brakes are engaged. Engage the parking brake. 4. Gradually increase the engine speed to high idle. Move the hydraulic lockout control to the UNLOCKED position. Lower the work tool to the ground. Lower the work tool to the ground. Make any necessary repairs before the machine is returned to operation. The machine should not move. the brake holding ability. The required brake holding effort for sustaining a machine at a specific engine rpm varies from one machine to another machine. Parking Brake Holding Ability Test Personal injury can result if the machine moves while testing. If the machine begins to move. The parking brake indicator light should come on. Move the hydraulic lockout control to the UNLOCKED position. 3. Place the transmission in THIRD SPEED FORWARD while only the parking brake is engaged. level surface. . Stop the engine. Park the machine on a hard. 4. the power train efficiency. 4. If the machine moved during the test. compare the engine rpm to the engine rpm of a prior test. This will indicate the amount of system deterioration.Inspect/Replace SEBU7885-12 3. Service Brake Holding Ability Test Personal injury can result if the machine moves while testing. Place the transmission in neutral. Place the transmission in THIRD SPEED FORWARD while the service brakes are applied. 6801-510 Personal injury or death can result. i02235700 Bucket Cutting Edges Inspect/Replace SMCS Code: 6801-040. Release the parking brake. 2. compare the engine rpm to the engine rpm of a prior test. Stop the engine. Make any necessary repairs before the machine is returned to operation.100 Maintenance Section Bucket Cutting Edges . These tests are not intended to measure the maximum brake holding effort. then use SECOND SPEED FORWARD. If the machine begins to move. This test is performed when the parking brake is engaged. If the machine begins to move during test. reduce the engine speed immediately and engage the parking brake. Raise the work tool slightly. The following tests are used to determine whether the braking system is functional. if the bucket is not blocked up. Block the bucket before changing cutting edge. If the machine moved during the test. 5. 2. Start the engine. The variations include differences in the engine setting. The machine should not move. Make sure that the machine is clear of personnel and clear of obstacles. 1. Engage the parking brake. consult your Caterpillar dealer for a brake inspection. Apply the service brake. dry. Raise the work tool slightly. consult your Caterpillar dealer for a brake inspection. Start the engine. 3. This will indicate the amount of system deterioration. Reduce the engine speed. Check the area around the machine. Place the transmission in neutral. etc. If the machine begins to move. Gradually increase the engine speed to high idle. Reduce the engine speed to low idle. 5. 1. reduce the engine speed immediately and apply the service brake pedal. Note: If THIRD SPEED FORWARD is locked out.

Block up the bucket enough for removing the cutting edges. Block the bucket before changing bucket tips. use that side. Note: Do not block up the bucket too high. install a new cutting edge. Install bolts (1). Lower the bucket to the ground. 2. Raise the bucket and remove the blocking. Lower the bucket to the blocking.SEBU7885-12 101 Maintenance Section Bucket Tips . After a few hours of operation. use the following procedure to replace the components. Follow Step 1. replace the bucket tip. g00101352 Check the bucket tips for wear. e. Tighten the bolts to the specified torque. Illustration 98 g01127481 Bucket Tips 1. d. Remove cutting edge (2). The pin can be removed by one of the following methods. 1. Raise the bucket and place blocking under the bucket.a through Step . b.Inspect/Replace i03657242 Bucket Tips . Inspect the cutting edges. (3) Replace the tip.Inspect/Replace SMCS Code: 6805-040. Remove the pin from the bucket tip. If wear or damage is evident. “Ground Engaging Tool Torques” for the correct torque. If the bucket tip has a hole. 1. RENR2512. Illustration 99 (1) Usable (2) Replace the tip. Inspect the cutting edge and install the cutting edge.c for the procedure. If the opposite side of the cutting edge is not worn. Reference: Refer to Specification. Replace any missing bolts and tighten any loose bolts. 6805-510 Personal injury or death can result from the bucket falling. • Use a hammer and a punch from the retainer side of the bucket to drive out the pin. Clean the contact surfaces. a. Remove bolts (1). f. check the bolts for proper torque. Check for bolts that are missing or loose. • Use a Pin-Master. c. If both sides of the cutting edge are worn.

Illustration 103 (4) Back of Pin-Master (9) Pin setter (10) Pin holder g00590666 a.e for the procedure. and the retainer. Strike the Pin-Master at the back of the tool (4) and remove the pin. 3. b. • From the other side of the retainer. The pin can be installed by using one of the following methods: a. Illustration 101 (6) Retainer (7) Retaining washer (8) Adapter g00590819 2. b. 5. Follow Step 5. Note: The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration. Install the new bucket tip onto the adapter. Fit retainer (6) into retaining washer (7). the pin must be driven in from the right side of the tooth. Clean the adapter and the pin. Drive the pin through the bucket tip. drive the pin through the bucket tip. 5. Align extractor (5) with the pin.Inspect/Replace SEBU7885-12 Illustration 100 (4) Back of Pin-Master (5) Extractor g00590670 Illustration 102 g00101359 4. Insert the pin through the bucket tooth. c. Place the Pin-Master over the bucket tooth and locate the pin in the hole of holder (10). • Use a Pin-Master. Install this assembly into the groove that is in the side of adapter (8). . Improper installation of the pin can result in the loss of the bucket tip.102 Maintenance Section Bucket Tips . Place the Pin-Master on the bucket tooth. the adapter.a through Step Note: To correctly install the pin into the retainer.

Use a pry bar in order to disengage retainer (5). Illustration 105 g01175361 1. Clean the adapter and the area around the latch. . After you drive the pin. Install the new bucket tip onto the adapter with a slight clockwise rotation. Install the retainer. Installation 1. 4. 2. Clean adapter (6). When working under or around the bucket or linkage. Remove bucket tip (4) from adapter (6) with a slight counterclockwise rotation. Make sure that the latch is properly seated by trying to remove the bucket tip. make sure that the retainer fits snugly into the pin groove. Slide pin holder (10) away from the pin and rotate the tool slightly in order to align pin setter (9) with the pin. 4. d. Use the pry bar in order to remove retainer (5) from bucket tip (4). 3. K-Series Tip Removal Illustration 106 g01124736 3. Strike the end of the tool until the pin is fully inserted. Make sure that the retainer's latch catches under the tip pocket. if necessary. Illustration 104 g01389463 i02274391 Note: Retainers are often damaged during the removal process. 6120-510 Personal injury or death can result from falling bucket. proper support must be provided for the bucket and/or the linkage.Inspect/Replace c. Strike the tool with a hammer at the back of the tool (4) in order to start the pin.SEBU7885-12 103 Maintenance Section Bucket Wear Plates . with the bucket raised. e. Bucket Wear Plates Inspect/Replace SMCS Code: 6120-040. 6. Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced. 2.

Clean/Replace SEBU7885-12 Illustration 107 g01139095 Illustration 109 g01127549 Before damage to the bottom of the bucket occurs. Reference: For more information. Slide pin (2) out of the retainer. 2. 7342-510 Note: The filters must be cleaned more often if the machine is being operated in dusty conditions. Clean the filter elements with pressure air or wash the filter elements in warm water with a nonsudsing household detergent. If water was used to wash the filter elements. 5. Illustration 110 g01127550 3. 1.104 Maintenance Section Cab Air Filter . Close the cover on the outside rear of the cab. Remove fresh air filter (3). Install fresh air filter (3) and retainer (1). Remove retainer (1) from the cover. refer to Specifications. Tighten the bolts to the specified torque. Remove the filter cover behind the seat. . Remove the recirculation filter. Illustration 108 g01127546 1.Clean/Replace SMCS Code: 7342-070. Loosen bolts and remove wear plates. i02235754 2. 6. 7. rinse the filter element in clean water and allow the filter element to air dry thoroughly. repair damaged bucket wear plates or replace damaged bucket wear plates. SENR3130. 3. Install new wear plates. Install the recirculation filter and the filter cover behind the seat. Raise the bucket and block up the bucket. Lift the cover on the outside rear of the cab. Cab Air Filter . 4. “Torque Specifications”.

Reset i02274475 Circuit Breakers . If neither of these conditions exist. (E). If the button does not remain depressed. the button will remain depressed. 1. and (Y). Torque the bolts to 1800 ± 200 N·m (1330 ± 150 lb ft). perform the following maintenance procedure. (D).Check Illustration 111 g01138824 SMCS Code: 6107-535-BC Note: After you operate a new machine for the initial 50 service hours. Illustration 113 g01139157 . Engine Start Switch (1) – 10 amp Engine Control Module (2) – 15 amp Main Circuit (3) – 105 amp Alternator (4) – 80 amp Alternator (5) – 80 amp i02104417 Collet Pin Bolt Torque . (F). Illustration 112 g01139160 Illustration 114 g01071961 Torque the bolts again on the collet pins for pin joints (A). perform the following maintenance procedure. If the system is functioning properly.Reset SMCS Code: 1420-529 Circuit Breaker – Push the button inward in order to reset the circuit breakers.SEBU7885-12 105 Maintenance Section Circuit Breakers . The circuit breakers are located under an access door on the left side of the cab platform. After you operate a machine with a newly installed bucket for the initial 50 service hours. disregard the following maintenance procedure. check the appropriate electrical circuit. (C).

NENG2500. SEBU6250. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specifications for premixed or concentrate coolants.Change SMCS Code: 1350-044-NL Personal injury can result from hot coolant. If ELC cooling system contamination occurs. adjusting and repair of the product. testing. The radiator and all lines to heaters or the engine contain hot coolant or steam. NOTICE Do not change the coolant until you read and understand the material in the Cooling System Specifications section. 5. drain the coolant from the cooling system so that the level of the coolant is below the housing for the water temperature regulator. Use only Cat Extender with Cat ELC. At operating temperature. Always operate Caterpillar engines with a water temperature regulator because these engines have a shunt design cooling system. Do not attempt to tighten hose connections when the coolant is hot. If the coolant is dirty or if you observe any foaming in the cooling system. Failure to follow these recommendations could result in damage to the cooling systems components. 3. Strike the collet until the bolt torque decreases to 1600 N·m (1200 lb ft) or less. “Caterpillar Machine Fluids Recommendations”. maintenance. Strike the collet until the bolt torque decreases to 950 N·m (750 lb ft) or less. Failure to replace the water temperature regulator on a regularly scheduled basis could cause severe engine damage. steam and alkali. Cooling System Coolant Additive contains alkali. Note: If you are only replacing the water temperature regulator.Change SEBU7885-12 NOTICE When striking the collet with a large hammer. Refer to Special Publication. protect the bolt head with a spacer to prevent bolt damage. the hose can come off causing burns. engine coolant is hot and under pressure. . Torque the bolts to 1800 ± 200 N·m (1330 ± 150 lb ft).106 Maintenance Section Cooling System Coolant (ELC) . Dispose of all fluids according to local regulations and mandates. refer to Operation and Maintenance. Cooling System Coolant (ELC) . Reference: If the coolant in the machine is changed to Extended Life Coolant from another type of coolant. 4. It is important to replace the water temperature regulator in order to avoid any unexpected failure of the water temperature regulator. “Extended Life Coolant (ELC)” under the topic ELC Cooling System Contamination. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. 2. i02274489 NOTICE Mixing Cat Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and shortens coolant life. This machine was factory filled with Cat Extended Life Coolant. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. change the coolant before the recommended interval. Avoid contact with skin and eyes. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Torque the bolts to 1800 ± 200 N·m (1330 ± 150 lb ft). refer to Special Publication. This is a good preventive maintenance practice that reduces the chances of unscheduled downtime. Any contact can cause severe burns.

Dispose of the drained water properly. Reference: Refer to Operation and Maintenance Manual. Maintain the coolant within the red range of sight gauges (1). 6. Allow the coolant to drain into a suitable container. Install cooling system pressure caps (2). Slowly remove cooling system pressure caps (2) in order to relieve system pressure. 8. Reference: Refer to Disassembly and Assembly. Flush the cooling system with clean water until the draining water is clean. Add the coolant solution. Allow the radiator to cool sufficiently. Illustration 117 g01139177 . Illustration 118 g01139178 3. Illustration 116 g01139174 2. 4. Run the engine without installing cooling system pressure caps (2) until the water temperature regulator opens and the coolant level stabilizes. “3500B Engines Built for Caterpillar Machines” for the correct procedure. Check the coolant level. Illustration 115 g01139172 5. Dispose of the used coolant properly. Start the engine. Open the access doors on the top of the cab platform at the rear of the machine. SENR1126. 10. Stop the engine. 7. 9.Change Note: Water temperature regulators can be reused if the water temperature regulators meet certain test specifications. Replace the water temperature regulator. Run the engine without cooling system pressure caps (2) until the thermostat opens and the coolant level stabilizes.SEBU7885-12 107 Maintenance Section Cooling System Coolant (ELC) . The tested water temperature regulators must not be damaged and the tested water temperature regulators must not have an excessive buildup of deposits. Open both drain valves under the rear of the machine. Close the drain valves. Start the engine. “Capacities (Refill)” for the capacity of the cooling system. 1.

When a Caterpillar Extended Life Coolant (ELC) is used. Avoid contact with skin and eyes. maintenance. The amount of extender is determined by the cooling system capacity. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. the hose can come off causing burns. Illustration 121 g01139177 Illustration 119 g01139172 Illustration 120 g01139174 2. adjusting and repair of the product. an extender must be added to the cooling system. Stop the engine.Add SMCS Code: 1352-544-NL Personal injury can result from hot coolant. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Any contact can cause severe burns. Refer to Special Publication. Open the access doors on the top of the cab platform at the rear of the machine. engine coolant is hot and under pressure. Reference: Refer toOperation and Maintenance Manual. . 1. “Maintenance Interval Schedule” for the proper service interval. Dispose of all fluids according to local regulations and mandates. Then. At operating temperature. NENG2500. Allow the radiator to cool sufficiently. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.108 Maintenance Section Cooling System Coolant Extender (ELC) . The radiator and all lines to heaters or the engine contain hot coolant or steam. Do not attempt to tighten hose connections when the coolant is hot. Cooling System Coolant Additive contains alkali. slowly remove cooling system pressure caps (2) in order to relieve system pressure. testing.Add SEBU7885-12 i02274534 Cooling System Coolant Extender (ELC) . steam and alkali.

Obtain the sample of the coolant as close as possible to the recommended sampling interval. slowly remove cooling system pressure caps (2) and add coolant. 6.Check SMCS Code: 1350-535-FLV Illustration 123 g01139172 .Check The coolant level gauges are located under access doors on the top of the cab platform at the rear of the machine. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. If it is necessary to add coolant daily. Maintain the coolant level within the red range of the sight gauges (1). i02274527 Illustration 124 g01139174 Maintain the coolant level within the red range of sight gauges (1). perform consistent samplings that are evenly spaced. In order to establish a pertinent history of data. you must establish a consistent trend of data. Illustration 122 g01139178 3. In order to receive the full effect of S·O·S analysis. 4.5 qt) of Extender to the cooling system. i02231902 Cooling System Coolant Sample (Level 1) . If necessary. Use the following guidelines for proper sampling of the coolant: Cooling System Coolant Level . replace cooling system pressure caps (2). 7542 NOTICE Always use a designated pump for oil sampling. Dispose of the used coolant properly. If there is damage or a residue buildup on the caps. 5. Check the condition of cooling system pressure caps (2)and the seal. stop the engine and allow the radiator to cool sufficiently. Then. 7. If necessary. drain enough coolant from the radiator in order to allow the addition of the Extender. Check the coolant level. Install cooling system pressure caps (2). Supplies for collecting samples can be obtained from your Caterpillar dealer. The coolant drain valves are located at the rear of the machine under the engine compartment. check for leaks. Using the same pump for both types of samples may contaminate the samples that are being drawn. and use a separate designated pump for coolant sampling.Obtain SMCS Code: 1350-008. 1395-008. Add 9 L (9.SEBU7885-12 109 Maintenance Section Cooling System Coolant Level . Note: Level 1 results may indicate a need for Level 2 Analysis.

SEBU6250. are ready to collect the sample. Put the caps on the valves. Close the access doors. Reference: Refer to Operation and Maintenance Manual. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.Obtain SEBU7885-12 • Complete the information on the label for the sampling bottle before you begin to take the samples. • Keep the lids on empty sampling bottles until you • Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination. “Cooling System Coolant Sample (Level 1) . and use a separate designated pump for coolant sampling. 1395-008. • Never collect samples from the drain for a system. Obtain the sample of the coolant as close as possible to the recommended sampling interval. refer toSpecial Publication.110 Maintenance Section Cooling System Coolant Sample (Level 2) . SEBU6250. The cooling system is equipped with two sampling valves.Obtain SMCS Code: 1350-008. Submit the samples for Level 1 analysis. Reference: For additional information about coolant analysis. Attach a hose to a couple. “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer. • Never collect samples from expansion bottles. i02126353 • Keep the unused sampling bottles stored in plastic • Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location. bags. 7542 NOTICE Always use a designated pump for oil sampling. Take a sample from each of the sample valves. . Install the threaded end of the coupling into the sample valve in order to unseat the internal drain valve. Open the access doors on the right and the left of the machine. Cooling System Coolant Sample (Level 2) .Obtain” for the guidelines for proper sampling of the coolant. Illustration 125 g01125907 The sampling valve is located on the left side of the machine behind the bottom rear access door. Remove the caps from the sample valves. Using the same pump for both types of samples may contaminate the samples that are being drawn. refer to Special Publication. Supplies for collecting samples can be obtained from your Caterpillar dealer. Reference: For additional information about coolant analysis. Illustration 126 g01125909 The sampling valve is located on the right side of the machine behind the bottom rear access door. Submit the sample for Level 2 analysis. “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer.

Do not attempt to tighten hose connections when the coolant is hot.Clean/Replace i02339536 Cooling System Pressure Cap .Clean/Replace SMCS Code: 1382-070. steam and alkali. 1382-510 1. The radiator and all lines to heaters or the engine contain hot coolant or steam. SENR1126. 4. 2. the hose can come off causing burns. Remove the pressure caps slowly in order to relieve the pressure. “3500B Engines Built for Caterpillar Machines” for the correct procedure for replacing the water temperature regulator. If you only need to replace the water temperature regulator. drain the cooling system coolant to a level that is below the regulator housing.SEBU7885-12 111 Maintenance Section Cooling System Pressure Cap . Cooling System Coolant Additive contains alkali. If the thermostat is installed wrong. for foreign material. Clean the pressure caps with a clean cloth or replace the pressure caps. Replace the water temperature regulator and the regulator housing gasket while the cooling system is being cleaned. Cooling System Water Temperature Regulator Replace SMCS Code: 1355-510. 1393-010 NOTICE Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a thermostat installed. and for deposits. if necessary. Illustration 127 g01167408 Illustration 128 g01126000 . 3. Avoid contact with skin and eyes. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. At operating temperature. it will cause the engine to overheat. Install the pressure caps. engine coolant is hot and under pressure. Inspect the pressure caps for damage. Reference: Refer to Disassembly and Assembly. Any contact can cause severe burns. Inspect gaskets before assembly and replace if worn or damaged. i02100387 Personal injury can result from hot coolant.

Illustration 130 g01127753 • The S·O·S oil analysis detected a worn crankshaft front bearing. The vibration damper can be used again if none of the above conditions are found and the vibration damper is not damaged. Remove the final drive drain plugs and allow the oil to drain into a suitable container. Clean the drain plugs and install the drain plugs. The crankcase vibration damper is located at the rear end of the engine compartment. NENG2500. 2. A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range. “3500B Engines Built for Caterpillar Machines” for more information about replacing the vibration damper. Position the wheels so that the final drive drain plugs are facing downward. Damage to the vibration damper or failure of the vibration damper will increase torsional vibrations. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 1. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.112 Maintenance Section Crankshaft Vibration Damper . 4050-044 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection.Inspect SEBU7885-12 i02274683 i02236207 Crankshaft Vibration Damper .Change SMCS Code: 3278-044. These vibrations will result in damage to the crankshaft and to the other engine components. Reference: Refer to Disassembly and Assembly. maintenance.Inspect SMCS Code: 1205-040 Differential and Final Drive Oil . Dispose of the used oil properly. . adjusting and repair of the product. Caterpillar recommends replacing the vibration damper for any of the following reasons: • The engine has had a failure because of a broken crankshaft. Refer to Special Publication. Illustration 129 g01139244 Dispose of all fluids according to local regulations and mandates. Note: Some wobble on the outer ring of the vibration damper is normal. SENR1126. • The S·O·S oil analysis detected a large amount of gear train wear that is not caused by a lack of oil. 3. testing.

“Lubricant Viscosities and Refill Capacities” for the correct type of oil and for the correct amount of oil. Fill the differentials to the bottom of the filler plug openings. “Lubricant Viscosities and Refill Capacities” for the correct type of oil and for the correct amount of oil. 5. Clean the filler plugs and install the filler plugs.Change Illustration 131 Front Differential g01127754 Illustration 133 g01127757 8. Operate the machine for a few minutes and recheck the oil level. If the specified amount of oil will not fit in the final drives. Remove differential drain plugs (1) and allow the oil to drain into a suitable container. Dispose of the used oil properly. 4. Reference: Refer to Operation and Maintenance Manual. The oil level should reach the bottom of the filler plug opening. install the final drive filler plugs. 12.SEBU7885-12 113 Maintenance Section Differential and Final Drive Oil . 13. . Position each wheel so that the filler plugs for the final drives are flush with the centerline of each wheel. 9. Clean the filler plugs and install the filler plugs. Remove the filler plugs. Illustration 132 Rear Differential g01127756 11. 7. Remove the final drive filler plugs and add the remaining oil. Reference: Refer to Operation and Maintenance Manual. 6. Clean the drain plugs and install the drain plugs. Install the filler plug. Operate the machine on level ground for a few minutes in order to equalize the oil level in the axles. Fill the final drives to the bottom of the filler plug openings. Remove differential filler plugs (2). do not allow the oil to drain to the proper level. Note: If the oil level is higher than the filler plug opening. 10.

Add oil. Install the filler plug. 4070-008. i02237079 Differential and Final Drive Oil Sample . Remove the oil filler plugs. The oil level should be at the bottom of the filler plug openings. Illustration 134 g01127757 1. Note: If the oil level is higher than the filler plug openings. if necessary. do not allow the oil to drain to the proper level. The oil level should be at the bottom of the filler plug openings. do not allow the oil to drain to the proper level. Position the wheels so that the filler plugs for the final drives are flush with the centerline of the wheels. Install the filler plugs.Check SMCS Code: 3278-535-FLV. 4050-008. Note: If the oil level is higher than the filler plug openings. Remove the differential filler plugs. if necessary. Add oil. “Lubricant Viscosities and Refill Capacities” for the correct type of oil and for the correct amount of oil. Reference: Refer to Operation and Maintenance Manual.114 Maintenance Section Differential and Final Drive Oil Level . Reference: Refer to Operation and Maintenance Manual.Check SEBU7885-12 i02236806 Differential and Final Drive Oil Level .Obtain SMCS Code: 3278-008. 7542 Illustration 137 Illustration 135 Front Differential g01128098 g01128098 Front Axle . 2. “Lubricant Viscosities and Refill Capacities” for the correct type of oil and for the correct amount of oil. 4050-535-FLV Illustration 136 Rear Differential g01128101 3.

i01298803 The axles are not equipped with sampling valves. Withdraw the oil through the filler opening of each axle.SEBU7885-12 115 Maintenance Section Drive Shaft Spline (Center) . Obtaining a sample of the differential and final drive oil will require a vacuum pump or an equivalent. Apply lubricant through the fitting on the drive shaft spline until the relief overruns.Lubricate Illustration 138 Rear Axle g01128101 Illustration 140 g01139253 Wipe off the fitting before you apply any lubricant. articulate the machine full right or left. before lubricating the splines. Drive Shaft Support Bearing Lubricate SMCS Code: 3267-086-BD Illustration 141 g00733137 Illustration 139 g01139252 Illustration 142 g00458573 . i02274698 Drive Shaft Spline (Center) Lubricate SMCS Code: 3253-086-SN NOTICE To prevent damage to the seal.

Clean/Replace SMCS Code: 1054-070-PY. 6. Clean the inside of the air filter housing. i02331730 Engine Air Filter Primary Element . Dirt entering the engine will cause damage to engine components. . or seals. Repeat this procedure for the air cleaner on the other side of the machine. Install a clean primary air filter element. 2. Engine damage could result. Observe the following guidelines if you attempt to clean the filter element: Do not tap or strike the filter element in order to remove dust. Install the cover on the air filter housing. gaskets. 1054-510-PY NOTICE Service the air filter only with the engine stopped. Illustration 145 g00039201 3. Take extreme care in order to avoid damage to the pleats. Use low pressure compressed air in order to remove the dust from the filter element. Air pressure must not exceed 207 kPa (30 psi). Do not wash the filter element. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life. Perform this procedure for each primary element. For more information. Remove the primary element from the air filter housing. There is a total of four engine air filters on the top of the cab platform. Do not use air filters with damaged pleats. 4.116 Maintenance Section Engine Air Filter Primary Element . Cleaning the Primary Air Filter Element NOTICE Caterpillar recommends certified air filter cleaning services available at participating Caterpillar dealers. 5. Direct the air flow up the pleats and down the pleats from the inside of the filter element.Clean/Replace SEBU7885-12 Wipe off the fitting before any lubricant is applied. refer to “Cleaning the Primary Air Filter Element”. Illustration 144 g01163939 Illustration 143 g01128393 1. Remove the cover on the air filter housing. Apply lubricant through the fitting on the right side of the articulation joint.

always begin with the inside of the filter in order to force dirt particles toward the outside. Do not use a primary air filter element that has any tears and/or holes in the filter material. Illustration 147 g00281693 Inspect the clean.Clean/Replace The primary air filter element can be used up to six times after the element is properly cleaned and inspected. Inspecting the Primary Air Filter Elements • Pressurized air • Vacuum cleaning Pressurized Air Pressurized air can be used to clean a primary air filter element that has not been cleaned more than two times. and the outer cover. Vacuum cleaning will not remove deposits of carbon and oil. Pressurized air will not remove deposits of carbon and oil. If it is necessary in order to confirm the result. . the primary air filter element can be stored for future use. Inspect the primary air filter element for light that may show through the filter material. When the primary air filter element is cleaned. Inspect the air filter element for damage to the seal. Engine damage could result. The primary air filter element should be replaced at least one time per year. NOTICE Do not clean the air filter elements by bumping or tapping. Dirt could be forced further into the pleats. dusty environment. There are two common methods that are used to clean the primary air filter element: Vacuum Cleaning Vacuum cleaning is another method for cleaning a primary air filter element which requires daily cleaning because of a dry. check for rips or tears in the filter material. Use filtered.SEBU7885-12 117 Maintenance Section Engine Air Filter Primary Element . Do not aim the stream of air directly at the primary air filter element. gaskets. the gaskets. dry air with a maximum pressure of 207 kPa (30 psi). Do not use elements with damaged pleats. Storing Primary Air Filter Elements If a primary air filter element that passes inspection will not be used. Damaged elements will allow dirt to pass through. Cleaning with pressurized air is recommended prior to vacuum cleaning. This could damage the seals. dry primary air filter element. Use a 60 watt blue light in a dark room or in a similar facility. Do not use a primary air filter element with damaged pleats. compare the primary air filter element to a new primary air filter element that has the same part number. Rotate the primary air filter element. Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats. Illustration 146 g00281692 Note: When the primary air filter element is cleaned. This replacement should be performed regardless of the number of cleanings. Place the blue light in the primary air filter element. Visually inspect the primary air filter element before cleaning. or seals. Discard any damaged air filter elements. Inspect the primary air filter element for tears and/or holes. gaskets or seals. Discard damaged primary air filter elements.

or plastic as a protective covering for storage. • Date of cleaning • Number of cleanings Store the box in a dry location. NOTICE Always replace the secondary element.Replace SMCS Code: 1054-510-SE NOTICE Service the air filter only with the engine stopped. replace the secondary element. i02331799 Engine Air Filter Secondary Element . Place the primary air filter element into a box for storage. Note: Replace the secondary element when you service the primary element for the third time. Remove the primary element. wrap the primary air filter elements in Volatile Corrosion Inhibited (VCI) paper. Include the following information: Illustration 149 g01128393 1. Perform this procedure for each secondary element. Reference: Refer to Operation and Maintenance Manual. Engine damage could result. For identification. Do not attempt to reuse it by cleaning. Remove the cover on the air filter housing.118 Maintenance Section Engine Air Filter Secondary Element . Illustration 150 g01163939 2. a waterproof cover. mark the outside of the box and mark the primary air filter element. Engine damage could result. “Engine Air Filter Primary Element Clean/Replace” for the correct procedure for servicing the primary element. To protect against dirt and damage. If a clean primary element has been installed and a warning for the air filter still occurs. An airflow restriction may result.Replace SEBU7885-12 There is a total of four engine air filters on the top of the cab platform. Illustration 151 g01163958 . Illustration 148 g00281694 Do not use paint. replace the secondary element if the exhaust smoke remains black after installation of a clean primary element. Also.

Remove the secondary element From the air cleaner housing. Engine Air Precleaner . Inspect the air inlet screen for dirt and debris. Rebuild/Install Reman. 7. and the cover. Engine damage could result. Rebuild Components and/or Install Remanufactured Components • Cylinder Heads • Fuel Transfer Pump • Injectors • Oil Coolers • Oil Pump • Scavenge Oil Pump . 1000-571-IC Caterpillar recommends additional maintenance for the following components on 3516B-HD Engines.Clean SMCS Code: 1055-070 NOTICE Service the air cleaner only with the engine stopped. 4. 6.Clean 3. 3. Clean the precleaner with compressed air or wash the precleaner in warm water. 4. There is a total of four precleaners. Install a new secondary element. Remove any dirt and debris. Consult your Caterpillar dealer for further information. 6. Stop the engine. 5. Inspect the precleaner tube openings. Cover the air inlet opening. Repeat the procedure for each precleaner. Dry all of the parts. Remove the screen. Remove the precleaner. Install the precleaner screen. Uncover the air inlet opening. Install New SMCS Code: 1000-012-IC. 1000-022-MC. 5. Clean the screen if the screen is dirty. a clean primary filter. Install a clean primary element. i02237503 i02119046 Engine Components Clean/Inspect. Clean Components and Inspect Components for Reusability • Aftercooler Core • Camshaft • Lifters • Connecting Rods • Crankshaft • Cylinder Block • Cylinder Liners • Damper • Gear Train Illustration 152 g01128355 • Pistons • Piston Pins • Spacer Plates • Engine Control Module (ECM) 1. 2.SEBU7885-12 119 Maintenance Section Engine Air Precleaner . Clean the inside of the air filter housing.

Replace/Install Reman SEBU7885-12 Install New Components • All Seals. Shake the element dry or use air pressure. . 3. 1. • Air Starter or Electric Starter • Alternator • Fuel Transfer Pump • Injectors • Turbochargers • Refrigerant Compressor • Air Compressor Illustration 154 g01128608 2. • Main Bearings. Remove the cover from the breather. 6. Remove the hose from the breather cover. Check the condition of the cover seal. 4. replace the seal. 5. Loosen breather outlet hose clamp (1). If the seal is damaged. nonflammable solvent. Rod Bearings and Crankshaft Thrust Bearings • Piston Rings • Engine Mounts • Engine Wiring Harness • New Software • Crankshaft Seals Illustration 153 i02119051 g01139353 Engine Components Replace/Install Reman SMCS Code: 1000-022-MC Caterpillar recommends this additional maintenance for the following components on 3516B-HD Engines. Gaskets and O-rings • Camshaft Bearings • Fuel Pressure Regulating Valve • Fuel Priming Pump • Bushings for Gear Train and Bearings for Gear Train i02274850 Engine Crankcase Breather Clean SMCS Code: 1317-070 There are a total of four engine crankcase breathers (two breathers on each side of the engine). Consult your Caterpillar dealer for further information. Wash the breather element and the cover in clean. Perform this procedure for each breather. Open the upper front access door on the right side of the machine. Loosen breather inlet hose clamp (2) and remove breather (3).120 Maintenance Section Engine Components .

Open the lower rear access door on the right side of the machine. i02239897 Engine Oil Sample . 3. Install the breather element in the cover. 12. Remove the engine oil level gauge and clean the gauge with a clean cloth.Obtain SMCS Code: 1348-008. Make sure that the engine oil level gauge and the filler cap are installed securely. check the “ENGINE STOPPED” side of the engine oil level gauge. When the engine is running at low idle. “Torque Specifications” for the proper bolt torques for the engine mounts. 6. SENR3130. Tighten breather inlet hose clamp (2). Maintain the oil level between the “ADD” mark and the “FULL” mark. replace the hose. Repeat steps 12 to 11 for the left side of the machine. Install breather (3). Inspect the hose for damage. 4. 7542 Illustration 155 g01139353 1. Reinsert the gauge completely and remove the gauge again. check the “LOW IDLE” side of the engine oil level gauge. If necessary. Close the upper front engine access door on the right side of the machine.Check SMCS Code: 1000-535-FLV 5. Close the lower rear access door. This will give a more accurate measurement of the oil level.SEBU7885-12 121 Maintenance Section Engine Mounts . i02274838 2. Install the outlet hose and tighten breather outlet hose clamp (1). Reference: Refer to Specifications. i01947006 Illustration 156 g01129267 Engine Mounts .Inspect 7. 10. remove the filler cap and add oil. 11. Illustration 157 g01129246 . If necessary.Inspect SMCS Code: 1152-040 Caterpillar recommends checking the engine mounts for deterioration and for proper bolt torque. This will help to prevent excessive engine vibration that is caused by improper mounting. 9. Maintain the oil level between the “ADD” mark and the “FULL” mark. Engine Oil Level . 8. When the engine is stopped.

Your machine is equipped with a fast fill service center for changing the engine oil. Reference: Refer to Special Publication. Clean the filter mounting bases with a clean cloth. Lower the bucket to the ground and engage the parking brake. Illustration 160 g01131149 5. “S·O·S Oil Analysis” for information that pertains to obtaining a sample of the engine oil. Turn on the oil pump and withdraw the engine oil from the engine crankcase. Use a strap type wrench in order to remove the four used filter elements.122 Maintenance Section Engine Oil and Filter . . Illustration 159 g01423870 2. Connect an oil pump to the fitting. “How To Take A Good Oil Sample” for more information about obtaining a sample of the engine oil. Park the machine on a level surface. Either condition can cause engine damage. Open both lower access doors on the right side of the machine. 4. Fast Fill Service Center NOTICE Do not under fill or overfill engine crankcase with oil. “Caterpillar Machine Fluids Recommendations”.Change SMCS Code: 1318-510 Note: Some commercial oils that meet API specifications may require shorter oil change intervals. The fast fill service center allows the engine oil to be changed faster than the conventional method. Refer to Special Publication. Caterpillar prefers the scheduled oil sampling as the proper method of checking engine wear metals. Open the door of the fast fill service center and locate the correct fitting. 1. i02857316 Engine Oil and Filter . Dispose of the used oil properly. Ensure that the used gaskets are completely removed.Change SEBU7885-12 The sampling valve for the engine oil is located on the engine oil filter base on the right side of the engine compartment. Illustration 158 (1) Fast Fill Service Center (2) Access Doors g01423856 6. PEHP6001. The oil change intervals are determined by close monitoring of the oil condition and engine wear metals. Consult your Caterpillar dealer for the latest oil recommendations. SEBU6250. 3.

1. Fill the crankcase with new oil. Refer to Special Publication. 12.Check” for the correct procedure. Start the engine and allow the oil to warm. which can cause substantial engine damage. adjusting and repair of the product. use the instructions that are provided with the filter. 8. or another suitable tool. Park the machine on a level surface. Note: Some commercial oils that meet API specifications may require shorter oil change intervals. Connect an oil pump to the male coupler. Either condition can cause engine damage. Do not allow hot oil or components to contact skin. 9. Check the engine oil level. Note the position of the index marks on the filter in relation to a fixed point on the filter base. NOTICE Do not under fill or overfill engine crankcase with oil. Clean the end of the male coupler. Caterpillar prefers the scheduled oil sampling as the proper method of checking engine wear metals. testing. Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base. Check the machine for oil leaks. Reference: Refer to Operation and Maintenance Manual. When you tighten the engine oil filter. Tighten the filter according to the instructions that are printed on the filter. in order to turn the filter to the amount that is required for final installation.SEBU7885-12 123 Maintenance Section Engine Oil and Filter . Lower the bucket to the ground and engage the parking brake. Conventional Method Hot oil and components can cause personal injury. The oil change intervals are determined by close monitoring of the oil condition and engine wear metals. Dispose of all fluids according to local regulations and mandates.Change Reference: Refer to Operation and Maintenance Manual. Close the door to the fast fill service center. Run the engine for a few minutes in order to warm up the oil. 10. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 2. NENG2500. Consult your Caterpillar dealer for the latest oil recommendations. “Lubricant Viscositites and Refill Capacities” for the type of lubricant and for the refill capacity. Make sure that the installation tool does not damage the filter. “Engine Oil Level . Use the index marks as a guide. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Clean the end of the male coupler at the fast fill service center. 11. For non-Caterpillar filters. maintenance. Note: Improper installation of the engine oil filters can result in the loosening of the filter due to vibration. Apply a thin coat of clean engine oil to the seal on the new filter. Note: You may need to use a Caterpillar strap wrench. use the rotation index marks as a guide. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. . 13. Illustration 161 g00101318 7. Note: There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1/4 or a turn away from each other. Close the lower access doors on the right side of the machine.

Illustration 165 g00101318 8. remove the filters when the filters are cool enough to touch with your bare hand. Close the drain valve on the bottom of the oil pan. which can cause substantial engine damage. “Lubricant Viscosities and Refill Capacities” for the correct type of oil and for the correct amount of oil. When you tighten the engine oil filter. Dispose of the used filter elements properly. Apply a thin coat of clean engine oil to the seal on the new filter. Make sure that the installation tool does not damage the filter. To avoid possible burns. 10. Note: There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1/4 or a turn away from each other. 6. Dispose of the used oil properly. Open the drain valve on the bottom of the oil pan. in order to turn the filter to the amount that is required for final installation. use the rotation index marks as a guide. Make sure that all of the used gaskets are removed. use the instructions that are provided with the filter. Illustration 164 g01131397 Illustration 163 g01131145 4. Remove filler cap (2) and fill the crankcase with oil. .Change SEBU7885-12 Note: Oil will be trapped in the filter housing bases. Note: You may need to use a Caterpillar strap wrench. 5.124 Maintenance Section Engine Oil and Filter . Note: Improper installation of the engine oil filters can result in the loosening of the filter due to vibration. Clean the filter housing bases. Open both lower access doors on the right side of the machine. 9. 7. Note the position of the index marks on the filter in relation to a fixed point on the filter base. Tighten the filter according to the instructions that are printed on the filter. Use the index marks as a guide. Reference: Refer to Operation and Maintenance Manual. Allow the oil to drain into a suitable container. Use a strap type wrench to remove four used filter elements (1). Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base. or another suitable tool. Illustration 162 (1) Fast Fill Service Center (2) Access Doors g01423856 3. For non-Caterpillar filters.

Illustration 166 g01129267 12. Whenever an inlet valve closes or an exhaust valve closes. Start the engine and operate the engine at low idle for five minutes. . consult your Cat dealer for service. If you find leaks. Reference: To check the engine valve lash and the bridge.Check SMCS Code: 1102-535. i03952000 Engine Water Pump . Inspect the engine oil filters for oil leaks. Watch the top surface of each valve rotator. RENR2211. Caterpillar recommends replacing valve rotators that are operating improperly.Inspect SMCS Code: 1109-040 When inspecting the valve rotators. if necessary. Maintain the oil level between the “ADD” mark and the “FULL” mark. protective glasses or face shield and protective clothing must be worn. Close both lower access doors on the right side of the machine. SENR1126. “3500B Engines For Caterpillar Built Machines”. to prevent being burned by hot oil or spray. Engine Valve Rotators . metal particles from a damaged valve rotator could fall into the cylinder and damage to the piston head and to the cylinder head may result. i02099172 Engine Valve Lash and Bridge . Check the oil level on the “LOW IDLE” side of the engine oil level gauge. “3500B Engines for Caterpillar Built Machines” for additional information about the water pump. Consult your Caterpillar dealer for any additional information. Add oil. The initial wear of the valve train components and the initial seating of the valve train components makes this valve lash adjustment necessary. Also. 1121-535 Perform the first valve lash adjustment for new engines and for rebuilt engines at the first oil change. refer to Testing And Adjusting. i01947678 Illustration 167 g00882731 Start the engine and run the engine at low idle. 13.Check 11. Make any necessary repairs. An improperly operating valve rotator will shorten valve life because of accelerated wear on the valves.SEBU7885-12 125 Maintenance Section Engine Valve Lash and Bridge . If a valve rotator fails to turn. Visually inspect the water pump for leaks. each valve rotator should turn. Reference: Refer to Disassembly and Assembly. all of the seals on the water pump must be replaced.Inspect SMCS Code: 1361-040 Failure of the engine water pump may cause severe engine overheating problems such as cracks in the cylinder head or piston seizure.

Replace SEBU7885-12 i02274883 Ether Starting Aid Cylinder Replace SMCS Code: 1456-510-CD Ether is poisonous and flammable. Install the new ether cylinder. Use ether only in well ventilated areas. be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine. Discard cylinders in a safe place. Illustration 170 g00102460 Illustration 169 g00102459 Note: There are two ether cylinders. . Tighten the ether cylinder by hand. Keep ether cylinders out of the reach of unauthorized personnel. To avoid possible injury. Use ether with care to avoid fires. Do not store replacement ether cylinders in living areas or in the operator's compartment. Install the new gasket that is provided with the new ether cylinder. 5. Close the engine access door. Remove the used gasket. Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F). 2. Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Unscrew the empty ether cylinder and remove the empty ether cylinder. Do not smoke while changing ether cylinders. Illustration 168 g01139353 1. Loosen the cylinder retaining clamp. 3. Open the upper front access door on the right side of the machine. 4.126 Maintenance Section Ether Starting Aid Cylinder . Do not puncture or burn cylinders. Tighten the cylinder retaining clamp securely.

Inspect SMCS Code: 7051-040.Inspect i02857319 Frame .SEBU7885-12 127 Maintenance Section Frame . Illustration 171 Engine End Frame g01082021 g01082025 Illustration 174 g01458379 Illustration 172 Engine End Frame g01082024 Inspect the frames. Consult your Caterpillar dealer for repairs if cracks or any damage is found on the frames. . Clean the indicated areas with a wire brush. 7054-040 Illustration 173 Non-Engine End Frame The side covers are removed for clarity.

This will start the pump. Look for leaks around the filter elements. and the filter housing base with a clean. Inspect the filter housing seal. The pump will shutoff when the filter elements are full of fuel. 6.Prime SEBU7885-12 i02233097 i02234284 Fuel System . the filter housing. Wash the filter element. 4. 5. 3. Open the lower rear access door on the left side of the machine. Open the lower rear access door on the right side of the machine. 1260-070. Inspect the filter element. Illustration 177 g01139046 1. 7. If the filter element is damaged. 3. 4. Start the engine. Loosen retaining bolt (1). .128 Maintenance Section Fuel System . Remove filter housing (2) and the filter element. Illustration 178 Illustration 176 g01126322 g01126600 2. If the engine will not start or the engine misfires. 1260-510 Illustration 175 g01139353 1. nonflammable solvent. Use pressure air to dry the filter element. Replace the seal if the seal is damaged. more priming is necessary. replace the filter element.Prime SMCS Code: 1250-548 Fuel System Primary Filter Clean/Inspect/Replace SMCS Code: 1260-040. 2. Pull the toggle out and up. Make sure that the ignition key is in the OFF position.

7. . Illustration 181 g01458390 The fuel tank caps are located on the rear of the machine. 5. Use a strap type wrench to remove the fuel filters. Note: There are rotation index marks on each filter at 90 degree intervals.Replace NOTICE Do not fill fuel filters with fuel before installing them. Install the new fuel filters by hand. Illustration 180 g01126442 2. Contaminated fuel will cause accelerated wear to fuel system parts. Reference: Refer to Operation and Maintenance Manual. Close the lower rear access door. 8. After the gaskets contact the filter mounting base. 6. 3. Clean the filter mounting base. tighten the fuel filters by an additional 3/4 turn.Prime” for the correct procedure. Contaminated fuel will cause accelerated wear to fuel system parts. 1273-070-Z2 Illustration 179 g01139353 1. Tighten the retaining bolt. 10. Install the filter element and filter housing (2) onto the filter housing base. 9. i02857320 Fuel System Secondary Filter Replace SMCS Code: 1261-510-SE Fuel Tank Cap and Strainer Clean SMCS Code: 1273-070-STR. Make sure that all of the used gaskets are removed. NOTICE Do not fill fuel filters with fuel before installing them. Prime the fuel system. Open the lower rear access door on the right side of the machine. Lubricate the gaskets of the new fuel filters with clean diesel fuel. Use these marks as a guide for proper tightening. “Fuel System . i02233286 4.SEBU7885-12 129 Maintenance Section Fuel System Secondary Filter . Close the lower rear access door. Dispose of the used filters properly.

If it is necessary to replace fuses frequently.Drain SMCS Code: 1273-543-M&S Illustration 183 g01458481 Illustration 185 g01138824 The drain valves are located under each fuel tank at the rear of the machine. Fuel Tank Water and Sediment . if necessary. Wash the cap in clean. Remove the strainer from the filler opening. Replace the fuse if the element separates. i02857324 1. Repair the circuit. Install the strainer into the filler opening.Replace SMCS Code: 1417-510 NOTICE Replace the fuses with the same type and size only. electrical damage can result. If necessary. Open the drain valve. 2. Otherwise. Lift lever (1) and turn lever (1) counterclockwise until the cap stops. Allow the water and the sediment to drain into a suitable container. nonflammable solvent. 6. 5. 7. Close the drain valve. replace the seal. 3.130 Maintenance Section Fuel Tank Water and Sediment . check the circuit. Lift the cap straight up in order to remove the cap. 2. Inspect seal (2) for damage. Install the fuel tank cap. Contact your Caterpillar dealer Fuses – Fuses protect the electrical system from damage that is caused by overloaded circuits. 4. If the element of a new fuse separates.Drain SEBU7885-12 Illustration 182 g01386240 Illustration 184 g01130140 1. Wash the strainer in a clean nonflammable solvent. an electrical problem may exist. i02235078 Fuses . .

Replace (7) ROPS HID – 15 amp (8) Front Wipers and Rear Wipers – 15 amp (9) Front ROPS Floodlight – 15 amp Illustration 186 g01126989 The fuse panel is located under an access door on the left side of the cab platform. (10) Front Fender Floodlight – 10 amp (11) Rear Radiator Floodlights – 10 amp (12) ROPS HID – 15 amp (13) Platform Floodlights – 10 amp Illustration 187 g01126992 (1) Spare – 15 amp (14)Converter and Bucket Floodlights – 10 amp (2) Spare – 15 amp (15) Side Wipers – 10 amp (3) Spare – 10 amp (16) Beacon – 10 amp (4) Spare – 10 (17) Implement ECM – 10 amp (5) Spare – 10 (18) Horn – 10 amp (6) Spare – 10 .SEBU7885-12 131 Maintenance Section Fuses .

Disassemble the housing for the HID lamp in order to have access to the bulb. 2. NOTICE Although HID bulb materials may change over time. The electrical power must be removed from the HID lamp for at least five minutes. 3. (23) Spare – 10 HID bulbs become very hot during operation. or any waste that contains mercury. When disposing of this component. install the replacement lens assembly in the HID lamp. HID bulbs produced at the time of the printing of this manual contain mercury. If the bulb is an integral part of the lens assembly. Remove the electrical power from the high intensity discharge lamp (HID). in order to ensure that the bulb is cool. remove power from lamp for at least five minutes to ensure lamp is cool. please use caution and comply with any applicable laws.Replace (If Equipped) SMCS Code: 1434-510 (21) Product Link – 15 amp (22) Spare – 10 HID lamps operate at very high voltages. Replace the entire lens assembly on these HID lamps. 4. the bulb is an integral part of the lens assembly. 1. Remove the bulb from the HID lamp. Install the replacement bulb in the HID lamp. Note: On some HID lamps.132 Maintenance Section High Intensity Discharge Lamp (HID) . Before servicing.Replace SEBU7885-12 (19) Engine Compartment Lamps – 10 amp (32) Rear ROPS Floodlight – 10 amp (20) Prelube Primer and Stair Lamps – 10 amp i02245859 High Intensity Discharge Lamp (HID) . The bulb is not removed separately from the lens assembly. (24) Precleaner – 10 amp (25) Spare – 10 (26) Lighter – 10 amp (27) Seat Air Compressor – 10 amp (28) Fan – 15 amp (29) Power Train Control – 10 amp (30) Vital Information Management System – 10 amp (31) Air Dryer – 10 amp . To avoid electrical shock and personal injury. disconnect power before servicing HID lamps.

avoid touching the bulb's surface with your bare hands.SEBU7885-12 133 Maintenance Section High Pressure Screens . Reattach the electrical power to the HID lamp. Check the HID lamp for proper operation. Screen (3) is for the left implement pump. 6. 5. Screen (2) is for the front implement pump. Screen (1) is for the rear implement pump. i02252336 Illustration 190 g01133992 High Pressure Screens Clean/Replace SMCS Code: 5068-070-Z3. g01133991 g01133993 The high pressure screens for the steering pumps are located behind the cab on the platform. Screen (4) is for the right implement pump. Illustration 188 g01139408 Illustration 191 g01138824 The screens are located behind the front axle from the bottom. Note: Consult your Caterpillar dealer for additional information on HID lamps. Clean any fingerprints from the bulb with alcohol prior to operation. Screen (6) is for the right steering pump. Reassemble the housing for the HID lamp. Ensure that any printing on the lens is oriented correctly with respect to the HID lamp's mounting position on the machine. Screen (5) is for the left steering pump. Illustration 192 Illustration 189 The screens are located at the articulated joint.Clean/Replace Note: In order to avoid failure to the bulb that is premature. Open the access door behind the cab in order to access the screens. . 7. Clean the screens whenever an implement pump fails. 5068-510-Z3 The high pressure screens for the implement pumps are located on the front frame.

Allow the oil to drain from the filter housing into a suitable container. Replace any screen that is damaged. Install the filter housing on the filter mounting base. Use a strap type wrench to remove the filter housing. The fast fill service center allows the hydraulic oil to be changed faster than the conventional method. Inspect the screens for leaks. Check the condition of the filter housing seal. Start the engine and run the engine at low idle. the filter housing.Change SEBU7885-12 Clean the screens whenever a steering pump fails. and the fill plug is cool enough to touch with your bare hand. Fast Fill Service Center Your machine is equipped with a fast fill service center for changing the hydraulic oil. Remove the fill plug only when the engine is stopped. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Engage the parking brake and stop the engine. Install the clean screen in the filter housing. testing. At operating temperature. i02857341 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Remove the plug at the bottom of the filter housing. Park the machine on a level ground. Operate the machine in order to warm the oil. Hot oil can cause burns.134 Maintenance Section Hydraulic System Oil (Brake Cooling) . and the filter mounting base in a clean. 6. Do not allow hot oil or components to contact skin. Replace any seal that is damaged. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Check the condition of the screen. Lower the bucket to the ground and apply slight downward pressure. 3. Refer to Special Publication. Clean the screen. 2. 2. NENG2500. 1. nonflammable solvent.Change SMCS Code: 5056-044-BRK Personal injury can result from hot oil. the hydraulic oil tank is hot and under pressure. Dispose of all fluids according to local regulations and mandates. 4. 5. Hydraulic System Oil (Brake Cooling) . adjusting and repair of the product. maintenance. 7. 1. Illustration 193 g01139416 .

Reference: Refer to Operation and Maintenance Manual. Dispose of the used oil properly.Change Illustration 195 g01135709 9. Lower the bucket to the ground and apply slight downward pressure. Turn off the oil pump. Park the machine on level ground. Conventional Method 1. 4. Inspect the hydraulic suction line and the hose clamps. 10. Replace any damaged hoses. “Lubricant Viscositites” for the type of lubricant. 6.SEBU7885-12 135 Maintenance Section Hydraulic System Oil (Brake Cooling) . 7. Open the door to the fast fill service center that is on the right side of the machine near the articulation joint. Connect the oil pump to the male coupler. Start the engine and run the engine at low idle. Operate the steering and the brakes in order to circulate the oil. air is entering the hydraulic system. Clean the end of the male coupler and close the door to the fast fill service center. Engage the parking brake and stop the engine. 8. “Capacities (Refill)” for the refill capacity. Reference: Refer to Operation and Maintenance Manual. 2. Illustration 194 g01458485 3. Operate the machine in order to warm the oil. If air bubbles are present in the hydraulic oil. tighten any loose clamps or any loose connections. Note: The oil must be free of air bubbles. Locate the correct male coupler and connect an oil pump to the fitting. Turn on the oil pump and withdraw the hydraulic oil from the hydraulic tank for the steering and the brakes. Clean the end of the male coupler. Fill the hydraulic tank with new oil. If necessary. Stop the engine and top off the hydraulic tank so that the oil level is above the halfway mark on sight gauge (2). Illustration 196 g01139419 . 5.

Inspect the hydraulic suction line and the hose clamps. Attach a hose to a pipe nipple that is long. 9. Reference: Refer to Operation and Maintenance Manual. “Hydraulic System Oil Filter (Steering Cooler Screen) (Brake Cooler Screen) . Wash the filler cap and the filler strainer in a clean. Clean the cooling screen.Change SMCS Code: 5056-044 Personal injury can result from hot oil. if necessary. “Lubricant Viscosities” for the correct type of hydraulic oil. Open the access door in the platform behind the cab. Replace any damaged hoses. 14. 6. Note: The oil must be free of air bubbles. 4. 11. Install the pipe nipple into the drain plug opening in order to open the internal drain valve. nonflammable solvent. Reference: Refer to Operation and Maintenance Manual. Ensure that the oil level is above the halfway mark on sight gauge (2). 17. Inspect the gasket on filler cap (1) for damage. air is entering the hydraulic system. Remove the drain plug from the bottom of the hydraulic tank. Slowly loosen filler cap (1) in order to relieve any tank pressure.Change SEBU7885-12 13. Hot oil can cause burns. Replace the gasket. Install filler cap (1). 12. 8. If necessary.Clean” for the correct procedure. “Capacities (Refill)” for the correct amount of hydraulic oil. Operate the steering and the brakes in order to circulate the oil. and the fill plug is cool enough to touch with your bare hand. Fill the hydraulic oil tank with clean oil. 7. Dispose of the used oil properly. Remove the filler cap 1 and the filler strainer. 15. Remove the pipe nipple in order to close the internal drain valve. Install the filler strainer. Do not allow hot oil or components to contact skin. tighten any loose clamps or any loose connections. . If air bubbles are present in the hydraulic oil.136 Maintenance Section Hydraulic System Oil (Implement) . At operating temperature. Remove the fill plug only when the engine is stopped. Reference: Refer to Operation and Maintenance Manual. Start the engine and run the engine for at least ten seconds. 10. stop the engine and add hydraulic oil to the tank until the oil level is above the halfway mark on sight gauge (2). 16. Start the engine and run the engine at low idle. 5. Allow the oil to drain into a suitable container. Stop the engine and top off the hydraulic tank so that the oil level is above the halfway mark on sight gauge (2). the hydraulic oil tank is hot and under pressure. Clean the drain plug and install the drain plug. Then. Hydraulic System Oil (Implement) . i02958014 Illustration 197 g01135709 3.

NENG2500. if necessary.Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. “Lubricant Viscositites” for the type of lubricant. Reference: Refer to Operation and Maintenance Manual. Lower the bucket to the ground and engage the parking brake. maintenance. Refer to Special Publication. Reference: Refer to Operation and Maintenance Manual. 11. Fill the hydraulic tank with new oil. Dispose of the used oil properly.SEBU7885-12 137 Maintenance Section Hydraulic System Oil (Implement) . Dispose of all fluids according to local regulations and mandates. Quick Fill/Drain Valve Your machine is equipped with a quick fill/drain valve for changing the hydraulic oil for the implements. Stop the engine. Illustration 199 g01134389 . 5. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Note: The oil must be free of bubbles. 3. Illustration 198 g01167682 g01134388 Illustration 200 8. Reference: Refer to Operation and Maintenance Manual. 7. 1. Inspect the hydraulic suction line and the hose clamps. The quick fill/drain valve allows the hydraulic oil to be changed faster than the conventional method. Ensure that the oil level is visible in the top section of the sight gauge. Connect the oil pump to the male coupler. 6. Clean the end of the male coupler. Locate the correct male coupler and connect an oil pump to the fitting. 4. Run the engine for a few minutes. 9. testing. adjusting and repair of the product. Add hydraulic oil. “Capacities (Refill)” for the refill capacity. Replace the oil filter. Maintain the oil level within the top section of the sight gauge. Turn on the oil pump and withdraw the hydraulic oil from the hydraulic tank. “Hydraulic System Oil Filter (Implement Pump Case Drain) . air is entering the hydraulic system. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 2. Start the engine. Park the machine on a level surface.Replace” for the correct procedure. If bubbles are present in the oil. Clean the end of the male coupler. 10. The valve is located on the right side of the machine on the front frame. Turn off the oil pump.

Dispose of the used oil properly. 5. The fast fill service center allows the hydraulic oil to be changed faster than the conventional method.138 Maintenance Section Hydraulic System Oil (Implement) . Park the machine on a level ground. Reference: Refer to Operation and Maintenance Manual. Illustration 201 g01138023 Illustration 202 g01134785 3. 2.Change SEBU7885-12 12.Replace” for the correct procedure. Locate the correct male coupler and connect an oil pump to the fitting. Press the breaker relief valve in order to relieve any pressure. 6. Fill the hydraulic tank with new oil. . Reference: Refer to Operation and Maintenance Manual. 1. “Hydraulic System Oil Filter (Implement Pump Case Drain) . Turn off the oil pump. Replace any damaged hoses. tighten any hose clamps and any hydraulic connections. Lower the bucket to the ground and apply slight downward pressure. Turn on the oil pump and withdraw the hydraulic oil from the hydraulic tank. 7. Engage the parking brake and stop the engine. Remove the filler cap. Replace the oil filter. g01134389 Illustration 203 4. If necessary. The valve is located on the right side of the machine on the front frame. Operate the machine in order to warm the oil. “Lubricant Viscositites” for the type of lubricant. “Capacities (Refill)” for the refill capacity. Reference: Refer to Operation and Maintenance Manual. Clean the end of the male coupler. Illustration 204 g01167711 8. Conventional Method Your machine is equipped with a fast fill service center for changing the hydraulic oil.

Replace any damaged hoses. Brake) . tighten any hose clamps and any hydraulic connections. 11. If bubbles are present in the oil. 9. At operating temperature. Stop the engine. Operate the machine in order to warm the oil. The fast fill service center allows the hydraulic oil to be changed faster than the conventional method. Remove the fill plug only when the engine is stopped. Park the machine on a level ground. Engage the parking brake and stop the engine. Brake) . If necessary.Change SMCS Code: 5056-044-US Illustration 206 g01139416 Personal injury can result from hot oil. Lower the bucket to the ground and apply slight downward pressure. air is entering the hydraulic system. Do not allow hot oil or components to contact skin. 10. Refer to Special Publication. Illustration 205 g01134388 Dispose of all fluids according to local regulations and mandates. Install the filler cap. maintenance. Hot oil can cause burns. and the fill plug is cool enough to touch with your bare hand. 12. if necessary. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Note: The oil must be free of bubbles. .Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Run the engine for a few minutes. testing. Inspect the hydraulic suction line and the hose clamps. 13. Maintain the oil level within the top section of the sight gauge. 2.SEBU7885-12 139 Maintenance Section Hydraulic System Oil (Steering. Start the engine. Hydraulic System Oil (Steering. NENG2500. i02857347 Fast Fill Service Center Your machine is equipped with a fast fill service center for changing the hydraulic oil. the hydraulic oil tank is hot and under pressure. Add hydraulic oil. adjusting and repair of the product. 1. Ensure that the oil level is visible in the top section of the sight gauge.

Replace” for the correct procedure. Inspect the hydraulic suction line and the hose clamps. Connect the oil pump to the male coupler. Brake) .140 Maintenance Section Hydraulic System Oil (Steering. 5. Illustration 208 g01458748 10. Locate the correct male coupler and connect an oil pump to the fitting. Lower the bucket to the ground and apply slight downward pressure. 7. If air bubbles are present in the hydraulic oil. Park the machine on level ground. Turn off the oil pump. 11. Engage the parking brake and stop the engine. tighten any loose clamps or any loose connections. Replace the oil filter. Open the door to the fast fill service center that is on the right side of the machine near the articulation joint. Operate the steering and the brakes in order to circulate the oil. Reference: Refer to Operation and Maintenance Manual. Replace any damaged hoses. air is entering the hydraulic system. Dispose of the used oil properly. 9. Turn on the oil pump and withdraw the hydraulic oil from the hydraulic tank for the steering and the brakes. Reference: Refer to Operation and Maintenance Manual. Operate the machine in order to warm the oil. “Capacities (Refill)” for the refill capacity. 8. Conventional Method 1. Clean the end of the male coupler and close the door to the fast fill service center. “Hydraulic System Oil Filter (Steering and Braking) . . Stop the engine and top off the hydraulic tank so that the oil level is above the “ADD” mark on the sight gauge. Reference: Refer to Operation and Maintenance Manual. Fill the hydraulic tank with new oil. If necessary. 6. Clean the end of the male coupler.Change SEBU7885-12 Illustration 207 g01458585 3. 2. Start the engine and run the engine at low idle. “Lubricant Viscositites” for the type of lubricant. Note: The oil must be free of air bubbles. 4.

Clean the drain plug and install the drain plug. Reference: Refer to Operation and Maintenance Manual. Remove the pipe nipple in order to close the internal drain valve. Start the engine and run the engine for at least ten seconds. Dispose of the used oil properly. nonflammable solvent. “Hydraulic System Oil Filter (Steering and Braking) . Brake) . Operate the steering and the brakes in order to circulate the oil. 11. 12. 10. “Capacities (Refill)” for the correct amount of hydraulic oil. 8. 7. stop the engine and add hydraulic oil to the tank until the oil level is above the “ADD” mark on the sight gauge. 9.SEBU7885-12 141 Maintenance Section Hydraulic System Oil (Steering. Illustration 209 g01139419 Reference: Refer to Operation and Maintenance Manual. Start the engine and run the engine at low idle. Remove the filler cap and the filler strainer. Fill the hydraulic oil tank with clean oil. Reference: Refer to Operation and Maintenance Manual. Attach a hose to a pipe nipple that is long. Press the button on the breaker relief valve in order to relieve any tank pressure. . 4. Allow the oil to drain into a suitable container. Install the pipe nipple into the drain plug opening in order to open the internal drain valve. 13. Open the access door in the platform behind the cab. Install the filler strainer. 14. Replace the oil filter. Illustration 210 (1) Breaker Relief Valve (2) Filler Cap g01458779 3.Change 6. “Lubricant Viscosities” for the correct type of hydraulic oil. Ensure that the oil level is above the “ADD COLD” mark on sight gauge (2).Replace” for the correct procedure. Wash the filler cap and the filler strainer in a clean. Illustration 211 g00454166 5. Then. Remove the drain plug from the bottom of the hydraulic tank.

if necessary. Dispose of all fluids according to local regulations and mandates. 17. Park the machine on level ground. Illustration 212 g01458748 15. Note: The oil must be free of air bubbles. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Hot oil can cause burns. Inspect the hydraulic suction line and the hose clamps. If necessary.Clean SEBU7885-12 i02857349 Hydraulic System Oil Filter (Hydraulic Cooler Screen) Clean SMCS Code: 5068-070-Z3 Personal injury can result from hot oil. Inspect the gasket on filler cap for damage. Refer to Special Publication. air is entering the hydraulic system. Replace any damaged hoses. 2. 16. Engage the parking brake and stop the engine. Do not allow hot oil or components to contact skin. Replace the gasket. Stop the engine and top off the hydraulic tank so that the oil level is above the “ADD” mark on the sight gauge. . Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Lower the bucket to the ground and apply slight downward pressure.142 Maintenance Section Hydraulic System Oil Filter (Hydraulic Cooler Screen) . and the fill plug is cool enough to touch with your bare hand. Operate the machine in order to warm the oil. If air bubbles are present in the hydraulic oil. tighten any loose clamps or any loose connections. 1. Install filler cap. the hydraulic oil tank is hot and under pressure. Remove the fill plug only when the engine is stopped. maintenance. NENG2500. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. adjusting and repair of the product. At operating temperature. testing.

7. Place the cover on the filter housing and screw the nut on the filter housing. Start the engine and run the engine at low idle. Press the breaker relief valve in order to release the pressure in the hydraulic system. 12. Unscrew the nut and remove the cover from the filter housing. Engage the parking brake and stop the engine. Install the clean screen in the filter housing.Replace Illustration 213 g01138023 Illustration 216 g01458764 3. Hydraulic System Oil Filter (Implement Pump Case Drain) . Illustration 215 g01139419 5. Operate the implements in order to circulate the oil. Open the access door in the platform in front of the engine air cleaners. Close the access door in the platform in front of the engine air cleaners. 9. 6. 5091-510-II 1. 10.Replace SMCS Code: 5068-510. Inspect the screens for leaks. Check the condition of the filter housing seal. i02341095 4. Park the machine on level ground.SEBU7885-12 143 Maintenance Section Hydraulic System Oil Filter (Implement Pump Case Drain) . Clean the screen in a nonflammable solvent. Lower the bucket to the ground and apply slight downward pressure. Operate the machine in order to warm the oil. 8. Illustration 214 g01134785 11. The breaker relief valve is located on the platform on the front frame. Replace any seal that is damaged. 2. .

Install the filter housing into the filter mounting base. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Open the access door in front of the cab on the platform. Illustration 219 g01167645 5. Engage the parking brake and stop the engine. 1.Replace SEBU7885-12 7. 8. Inspect the filter housing seal. 10. Close the access door. 13. Illustration 217 g01138023 12. Remove the filter housing from the housing base. Reference: Refer to Operation and Maintenance Manual. 6. . Dispose of the used filter element properly. nonflammable solvent. Clean the filter housing and clean the filter mounting base with a clean. 11. 9. Repeat steps 5 to 8 for each of the filter elements. Check the hydraulic oil level. Stop the engine. Start the engine. 4. Press the breaker relief valve in order to relieve any tank pressure. Replace the seal if the seal is damaged. Run the engine at low idle and check for leaks in the hydraulic system.Replace SMCS Code: 5092-510 Illustration 218 g01134785 3. “Hydraulic System Oil (Implement) Check” for the correct procedure. i02349138 Hydraulic System Oil Filter (Pilot) . Install the new filter element into the filter housing.144 Maintenance Section Hydraulic System Oil Filter (Pilot) . Illustration 220 g01138023 The oil filter is located on the left side of the machine.

Do not allow hot oil or components to contact skin. Dispose of the used filter element properly. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Inspect the filter housing seal. 5. NENG2500. . Inspect the pilot system for leaks. Lower the bucket to the ground and apply slight downward pressure. 3. Clean the filter housing and clean the filter mounting base with a clean. Start the engine and run the engine at low idle. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 2. Refer to Special Publication. Open the access door in the platform in front of the engine air cleaners. 1. Remove the fill plug only when the engine is stopped. Install the new filter element into the filter housing. the hydraulic oil tank is hot and under pressure. Slowly loosen filler cap (2) in order to relieve any tank pressure. Engage the parking brake and stop the engine. and the fill plug is cool enough to touch with your bare hand. adjusting and repair of the product. Remove the filter housing from the housing base. i02857350 Hydraulic System Oil Filter (Steering Cooler Screen) (Brake Cooler Screen) . 6. Park the machine on level ground. testing.Clean NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 4.SEBU7885-12 145 Maintenance Section Hydraulic System Oil Filter (Steering Cooler Screen) (Brake Cooler Screen) . Replace the seal if the seal is damaged. nonflammable solvent. maintenance. Hot oil can cause burns. 2. Personal injury can result from hot oil.Clean SMCS Code: 4295-070. Install the filter housing into the filter mounting base. 7. Illustration 221 g01134916 Dispose of all fluids according to local regulations and mandates. Stop the engine and make any necessary repairs. At operating temperature. Illustration 223 g01458769 4. Operate the machine in order to warm the oil. 431F-070-Z3 Illustration 222 g01139419 3.

Refer to Special Publication. Illustration 226 g01135360 5. Operate the steering and the brakes in order to circulate the oil. NENG2500. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 5091-510-ZH Hot oil and hot components can cause personal injury. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 7. Hydraulic System Oil Filter (Steering Pump Case Drain) Replace SMCS Code: 5068-510-US. Illustration 225 g01458592 3.146 Maintenance Section Hydraulic System Oil Filter (Steering Pump Case Drain) . Replace any seal that is damaged.Replace SEBU7885-12 5. 1. Install the clean screen in the filter housing. Dispose of the used filters properly. 11. i02857351 Illustration 224 g01139419 2. Slowly remove the filler cap in order to relieve any tank pressure. Clean the screen in a nonflammable solvent. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 10. 6. . Open the access door in the platform in front of the engine air cleaners. Dispose of all fluids according to local regulations and mandates. Place the cover on the filter housing and screw the nut on the filter housing. 4. Open the access door in the platform behind the cab. Unscrew the nut and remove the cover from filter housing (1). Check the condition of the filter housing seal. 9. Lower the bucket to the ground and apply slight downward pressure. maintenance. Close the access door in the platform in front of the engine air cleaners. Engage the parking brake and stop the engine. Inspect the screens for leaks. Park the machine on level ground. 8. Start the engine and run the engine at low idle. testing. Use a strap type wrench to remove the filters. adjusting and repair of the product. Do not allow hot oil or hot components to contact skin.

SEBU7885-12 147 Maintenance Section Hydraulic System Oil Level (Brake Cooling) . Install the filler cap. 8. 5056-535-FLV Illustration 229 g01458773 The hydraulic tank can also be filled from the fast fill service center.Check SMCS Code: 5056-535-BRK. Install the new filters by hand. If necessary. Make sure that all of the used gaskets are removed from the filter mounting bases. i02857353 Hydraulic System Oil Level (Brake Cooling) . 9. When the gasket contacts the filter base. tighten the filter by an additional 3/4 turn. Illustration 230 g01167682 Illustration 228 g01135709 Maintain the oil level above the halfway mark of sight gauge (2). 7.Check SMCS Code: 5056-535-FLV Illustration 227 g01139419 The access doors for the hydraulic tank (steering and braking cooling system) are located on the platform in front of the engine air cleaners. Clean the filter mounting bases. remove filler cap (1) and add hydraulic oil. i02857356 Hydraulic System Oil Level (Implement) . 10. Close the access doors. Lubricate the gaskets of the new filters with clean hydraulic oil.Check 6. .

148 Maintenance Section Hydraulic System Oil Level (Implement) . press the button on breaker relief valve (2) in order to relieve any tank pressure.Check SEBU7885-12 Illustration 231 g01134388 The sight gauge for the hydraulic oil level is located in the articulation joint on the right side of the front frame. Maintain the oil level in the center section of the sight gauge. Illustration 232 g01134342 If necessary. Illustration 233 g01458776 The hydraulic tank can also be filled from the fast fill service center. . Remove filler cap (1) and add hydraulic oil.

SEBU7885-12 149 Maintenance Section Hydraulic System Oil Level (Steering. Brake) . Illustration 237 g01166670 The sampling valve is located at the front of the cab platform.Check SMCS Code: 5056-535-US.Check i02857357 Hydraulic System Oil Level (Steering. 7542 The access doors for the hydraulic tank (steering system and braking system) are located on the platform in front of the engine air cleaners. i02857378 Hydraulic System Oil Sample (Implement) . g01458592 Illustration 235 Maintain the oil level between the top of sight gauge and the “ADD COLD” mark. If necessary. . 5056-535-FLV Illustration 236 g01458585 The hydraulic tank can also be filled from the fast fill service center that is located on the right side of the machine. The sight gauge for the hydraulic oil is located on the left side of the machine on the side of the platform. Brake) . 5056-008.Obtain Illustration 234 g01458748 SMCS Code: 5050-008. Take off the front access panel in order to access the sampling valve. remove filler cap (1) and add hydraulic oil.

Obtain SEBU7885-12 i04025996 • Failure of the Steering • Cleaning of the Hydraulic Tank • PCR (Engine Overhaul) 1. Illustration 239 g02208994 2. Replace the cap. i02857360 Illustration 240 g01139419 Hydraulic System Return Screen . Move the hydraulic control levers through all of the positions in order to release pressure. Do not allow hot oil or components to contact skin. 2. 7542 At operating temperature. Brake) . Illustration 238 g01139419 1. Turn the engine start switch key to OFF. Remove the filler cap slowly in order to relieve any remaining pressure. Turn the engine start switch key to ON. press the valve relief button on the hydraulic tank in order to relieve the tank pressure. Hydraulic System Oil Sample (Steering. the hydraulic tank is hot and under pressure. Before removing the filler cap. Hot oil and components can cause personal injury. Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand. 3.150 Maintenance Section Hydraulic System Oil Sample (Steering. Engage the parking brake. 4. Brake) . Open the access door in the platform in front of the engine air cleaners. 3. Close the access door. 5056-008. Obtain an oil sample.Replace SMCS Code: 5068-510-Z3 The screen should be cleaned especially when one of the following situations have occurred: • Failure of the Implement Pump • Failure of the Brake Pump .Obtain SMCS Code: 5050-008. Park the machine on a level surface. Lower the work tool to the ground. 4. Remove filler cap (1).

Clean the screens with a clean. Remove the screens. Remove all of the bolts around the tank. 12. 15. nonflammable solvent.Change”. Remove the hydraulic tank. “Hydraulic System Oil (Steering.Clean SMCS Code: 5118-070 Illustration 242 g01173181 Illustration 244 g01138023 . 13. Drain the hydraulic oil tank. If the screens cannot be cleaned then replace the screens. Reference: For the correct procedure. Fill the hydraulic tank. Install the hydraulic tank. Reference: For the correct procedure. refer to Operation and Maintenance Manual. 7. refer to Operation and Maintenance Manual. 14.SEBU7885-12 151 Maintenance Section Hydraulic Tank Breaker Relief Valve . 8. 10. Assemble the drain lines. 9. If a seal is damaged. i02265629 Hydraulic Tank Breaker Relief Valve .Clean Illustration 241 (1) Breaker Relief Valve (2) Filler Cap g01458779 Illustration 243 g01173183 5. Brake) . Replace return screens. replace the seal. 16. 11. Separate the tank. Press the button on the breaker relief valve in order to relieve any tank pressure. Brake) . “Hydraulic System Oil (Steering. 6. Disconnect the drain lines. Bolt the hydraulic tank together. Inspect all of the O-ring seals.Change”.

to the crankshaft. 1. Engage the parking brake and stop the engine. Small amounts of debris may be found in the filter element. Spread apart the pleats and inspect the element for metal and for other debris. Reference: If the oil level of the makeup oil tank does not decrease daily. 2. Shake the breaker relief valve dry or use compressed air. Install the breaker relief valve. or turbocharger bearings. 5068-507 Oil Renewal System Oil Level Check (If Equipped) SMCS Code: 1348-535-FLV 1. “Troubleshooting” or contact your Caterpillar dealer. 3067-507. nonflammable solvent. Clean the breaker relief valve in a clean. 4. g00100013 . Inspect a Used Filter for Debris Illustration 246 The element is shown with debris.Inspect SMCS Code: 1308-507. This can result in larger particles in unfiltered oil. 2. Ferrous metals can indicate wear on steel parts and on cast iron parts.Inspect SEBU7885-12 Use a filter cutter to cut the filter element open. If metals are found in the filter element. Remove the breaker relief valve. This could be caused by friction and by normal wear. Park the machine on level ground. The particles could enter the lubricating system and the particles could cause damage. a magnet can be used to differentiate between ferrous metals and nonferrous metals. i02106227 Oil Filter . Press the breaker relief valve in order to release the pressure in the hydraulic system. An excessive amount of debris in the filter element can indicate a possible failure. Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings. Check the oil level of the makeup oil tank. and to other parts. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. refer to Systems Operation. 3. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings. Lower the work tool to the ground. 431F-507. RENR8160. i02067046 Illustration 245 g01138044 The breaker relief valve is located on the platform on the front frame. rod bearings.152 Maintenance Section Oil Filter . Note: Keeping a daily maintenance log of all the additions of oil is necessary for determining whether the ORS is working properly. 4295-507.

SEBU7885-12

153 Maintenance Section Power Train Oil Filter (Transmission, Torque Converter) - Replace

i02335628

Power Train Oil Filter (Transmission, Torque Converter) - Replace
SMCS Code: 3004-510; 3067-510

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. 1. Operate the machine in order to warm the oil. 2. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake. Stop the engine.
Illustration 248
g01131970

4. Remove the drain plugs from the filter housings. Allow the oil to drain into a suitable container. Dispose of the used oil properly. Note: The majority of the oil will not drain until the seal around the lid has been broken. 5. Unscrew the bolts on the lids. 6. Remove the lids. The filters are attached to the lids. Unscrew the nuts and slide off the filters. Dispose of the used filter elements properly. 7. Clean the filter housings, the drain plugs, and the filter mounting bases with a clean, nonflammable solvent. 8. Inspect the filter housing seals. Replace the seals if the seals are damaged. 9. Place new filters on the rods that are attached to the lids. Screw on the nuts. Tighten the nut for the high pressure filter to a torque of 15 N·m (11.1 lb ft). Tighten the nut for the low pressure filter to a torque of 30 N·m (22.1 lb ft). Replace the lids on the filter housing. Screw the bolts onto the lids. 10. Install the drain plugs in the filter housings. 11. Start the engine. Apply the service brake. Only use the right brake pedal. 12. Slowly operate the STIC transmission direction control switch in order to circulate the oil. 13. Move the STIC transmission direction control switch to the NEUTRAL position. Engage the parking brake. Inspect the entire transmission system for leaks. 14. Check the transmission oil level.

Illustration 247

g00732990

3. Open the access panel that is located behind the cab.

154 Maintenance Section Pump Drive (Front) Oil - Change

SEBU7885-12

Reference: Refer to Operation and Maintenance Manual, “Transmission Oil Level - Check” for the correct procedure. 15. Close the access panel that is located behind the cab.
i02946576

1. Park the machine on a level surface. Lower the bucket to the ground and engage the parking brake.

Pump Drive (Front) Oil Change
SMCS Code: 3108-044

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 249

g01460733

Illustration 250

g01201282

2. The valve is located on the right side of the machine on the front frame. Locate the correct male coupler and connect an oil pump to the fitting. 3. Turn on the oil pump and withdraw the oil from the tank. Dispose of the used oil properly.

Crushing Hazard. Connect the steering frame lock between front and rear frames before servicing the machine in the articulation area. Disconnect the steering frame lock and secure it in the stored position before resuming operation. Failure to do so could result in serious injury or death. Note: Refer to Operation and Maintenance Manual, “Steering frame Lock” for the correct procedure.

4. Completely drain the front pump drive. 5. Turn off the oil pump. Clean the end of the male coupler.

Quick Drain Valve
Your machine is equipped with a quick drain valve for draining the pump drive oil. The quick drain valve allows the pump drive oil to be drained faster than the conventional method.

SEBU7885-12

155 Maintenance Section Pump Drive (Front) Oil - Change

Conventional Drain

Procedure for Refill
Reference: Please refer to Technical Information Bulletin, TIBU5143 for more information about the Front Pump Drive. Refer to Operation and Maintenance Manual, “Capacities (Refill)” for the correct amount of oil. Refer to Operation and Maintenance Manual, “Lubricant Viscosities” for the correct type of oil.

Illustration 251

g01165669

The pump drive is located inside the front frame near the articulation joint. 1. Park the machine on level ground. Lower the bucket to the ground. Engage the parking brake and stop the engine.

Illustration 253

g01460742

1. Open the access panel on the platform in front of the cab. Remove the dipstick (1) from the pump drive housing. 2. Fill the pump drive with half of the correct amount of oil. 3. Purge any air from the drain line. Collect any oil that is removed from the system. 4. Run the machine for 3 to 5 minutes.
Illustration 252 (1) Dipstick (2) Drain Plug
g01460741

5. Add any oil that was collected back into the system and continue to fill the system to the correct amount of oil according to the table.

2. Remove drain plug (2) from the pump drive housing. Allow the oil to drain into a suitable container. Dispose of the used oil properly. 3. Completely drain the front pump drive. 4. Clean the drain plug and install the drain plug.

Clean the dipstick and install the dipstick. Dispose of the used filter properly. After the gasket contacts the filter mounting base. make sure that the oil level is between the “ADD” and “FULL” marks on the “ENGINE STOPPED” side of the dipstick (1). maintenance. Install the new filter by hand.156 Maintenance Section Pump Drive (Front) Oil Filter .Change SEBU7885-12 Illustration 254 g01100724 Illustration 255 g01138023 6. Take off the front access panel in order to access the filter. Make any necessary repairs. Make sure that all of the used gasket is removed from the filter mounting base. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Do not allow hot oil or components to contact skin. testing. 6. . 5. Stop the engine. i02249398 The filter for the front pump drive is located at the front of the cab platform. Illustration 256 g01132280 1. Inspect the system for leaks. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Start the engine and run the engine at low idle. 2. 7. Use a strap type wrench to remove the filter. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Dispose of all fluids according to local regulations and mandates. While the engine is stopped. tighten the filter by an additional 3/4 turn. adjusting and repair of the product. 4. Lubricate the gasket of the new filter element with clean hydraulic oil. NENG2500. 3. Clean the filter mounting base. Refer to Special Publication. Pump Drive (Front) Oil Filter Change SMCS Code: 3108-510-FI Hot oil and components can cause personal injury.

. Reference: Refer to Special Publication. Pump Drive Oil Sample Obtain SMCS Code: 3108-008. “How To Take A Good Oil Sample” for more information about obtaining a sample of the pump drive oil. “Lubricant Viscosities” for the correct type of oil. PEHP6001.SEBU7885-12 157 Maintenance Section Pump Drive (Front) Oil Level . Install the dipstick (1). 2. make sure that the oil level is between the “ADD” and “FULL” marks on the “ENGINE STOPPED” side of the dipstick (1). Remove the dipstick (1) and add oil through the filler tube. Illustration 257 g01165669 1. Reference: Refer to Operation and Maintenance Manual.Check i02778946 Pump Drive (Front) Oil Level Check SMCS Code: 3108-535-FLV Illustration 259 g01100724 While the engine is stopped. Take off the front access panel in order to access the sampling valve. i02857380 The front pump drive is located inside the front frame near the articulation joint. 7542 Illustration 258 g01388336 Illustration 260 g01132306 The sampling valve for the pump drive is located at the front of the cab platform.

Apply lubricant through one fitting on the right side of the articulation joint. 3267-086-BD Illustration 261 g01165669 Illustration 263 g01458938 Illustration 262 g01458814 1. 2. Illustration 264 g01458935 1. Wipe off the fitting before any lubricant is applied.158 Maintenance Section Pump Drive Shaft (Front) . .Lubricate SMCS Code: 3108-086-D6. 2.Lubricate SEBU7885-12 i02857361 i02857363 Pump Drive Shaft (Front) Lubricate SMCS Code: 3108-086-D6 Pump Drive Shaft Support Bearing (Rear) . Wipe off the fitting before any lubricant is applied. Apply lubricant through fitting for the slip joint on the pump drive shaft.

Refer to Service Manual. SEBD0518. Keep face and hands away to help prevent injury. NOTICE If the refrigerant system has been open to the outside air (without being plugged) for more than 30 minutes. high pressure water. However.SEBU7885-12 159 Maintenance Section Radiator Core . Reference: Refer to Special Publication. can cause bodily harm or death. Protective goggles must always be worn when refrigerant lines are opened. release it slowly in a well ventilated area.Clean i02857366 i02723802 Radiator Core . Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system. the receiver-dryer must be replaced. Personal injury or death can result from inhaling refrigerant through a lit cigarette. even if the gauges indicate the system is empty of refrigerant. If the system is still under pressure. Moisture will enter an open refrigerant system and cause corrosion which will lead to component failure. Illustration 266 g00100062 Compressed air. Contact with refrigerant can cause frost bite. . “Know Your Cooling System” for the complete procedure for cleaning the radiator core. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas. SENR5664. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. or steam can be used to remove dust and other debris from the radiator core.Clean SMCS Code: 1353-070-KO Receiver Dryer (Refrigerant) Replace SMCS Code: 7322-510 Personal injury can result from contact with refrigerant. Slowly loosen the fitting. “Air Conditioning and Heating System with R-134a Refrigerant for All Caterpillar Machines” for the proper procedure to change the receiver-dryer assembly and for the procedure to reclaim the refrigerant gas. Illustration 265 g01458815 Always use precaution when a fitting is removed. the use of compressed air is preferred.

Replace any mounting hardware that is worn or damaged. Tighten the bolts to a torque of 1600 ± 200 N·m (1200 ± 150 lb ft). replace the seat belt. or in any metal section of the ROPS. Make sure that the mounting bolts are tight. Replace the seat belt if the seat belt is worn or frayed. i02429589 Rollover Protective Structure (ROPS) . also perform this inspection procedure for the seat belt extension. Use only original equipment parts for bolts that are damaged or missing. Note: Within three years of the date of installation or within five years of the date of manufacture. Do not repair the ROPS by welding reinforcement plates to the structure. If the buckle is worn or damaged. 2. Note: Apply oil to the bolt threads before you install the bolt. Inspect the ROPS for bolts that are damaged. Inspect the seat belt (3) for webbing that is worn or frayed. loose. Replace any parts that are damaged or worn before you operate the machine. Seat Belt .160 Maintenance Section Rollover Protective Structure (ROPS) . If your machine is equipped with a seat belt extension. Remove the access covers from both sides of the Rollover Protective Structure (ROPS). Check buckle (2) for wear or for damage. Failure to apply oil can result in improper bolt torque.Inspect SMCS Code: 7325-040 NOTICE Do not attempt to straighten the ROPS structure. consult your Caterpillar dealer for repairs. and the seat belt retractor. or missing. the seat belt buckle. . Illustration 268 g01129835 1. in the castings. A date label for determining the age of the seat belt is attached to the seat belt. Illustration 269 Typical example Illustration 267 g01166758 g00932801 Check the seat belt mounting hardware (1) for wear or for damage.Inspect SMCS Code: 7327-040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine. If there are any cracks in the welds. Replace the seat belt at the date which occurs first. replace the seat belt. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware.Inspect SEBU7885-12 i02337495 3. Install the access covers.

4324 The service brake must be checked in order to ensure proper operation before you test the supplemental steering system. also perform this replacement procedure for the seat belt extension. death. Ensure that all air tanks and accumulators are properly charged. the seat belt buckle. Allow the machine to coast. Apply the parking brake. Apply the service brakes and put the engine at low idle. 4300-081-SST. Ensure that there are no hazards in the test area. Caterpillar recommends adjusting the side rails after the initial 500 hours of machine operation. Ensure that The area around the machine is clear of personnel.Replace i02429594 Seat Belt . and the seat belt retractor.Test SMCS Code: 4300-081-SE. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. After the initial 500 service hours. Illustration 270 (1) Date (2) Date (3) Date (4) Date of installation (retractor) of installation (buckle) of manufacture (tag) (fully extended web) of manufacture (underside) (buckle) g01152685 Test the service brake before you test the supplemental steering system. 4324-081. The test area must be unobstructed and level. Replace the seat belt at the date which occurs first. Personal injury. Stop the machine with the service brakes. Turn the ignition to the OFF position. Perform the following procedure if your machine is equipped with a ground driven supplemental steering and if the procedure is required by local regulations. “Contour Series Seat” for the adjustment procedure. SENR6615. The machine can then be returned to normal operation. Ensure that there is no load in the work tool. Shift the transmission to neutral. If your machine is equipped with a seat belt extension. turn the machine to the left and to the right. Reference: Refer to Service Manual. Release the parking brake. the supplemental steering system is operating. If the machine responds to the steering input. Operate the machine in second gear. i03694709 Secondary Steering .Replace SMCS Code: 7327-510 Within three years of the date of installation or within five years of the date of manufacture.Adjust SMCS Code: 7312-025 Illustration 271 g00804394 . i01547608 Seat Side Rails . Position the machine with the bucket or the work tool in the carry position with the machine in neutral. perform this procedure when it is necessary. replace the seat belt . A date label for determining the age of the seat belt is attached to the seat belt. While the machine is in motion. Shift the transmission to second gear forward and slowly release the service brakes. or property damage could occur if the supplemental steering system is tested and the service brake is not operational. Moderately increase the engine speed to high idle.SEBU7885-12 161 Maintenance Section Seat Belt .

Check for loose electrical connections Reference: Refer to Systems Operation/Testing and Adjusting. If the steering stops have been contacting each other. If any of the lubrication lines are damaged.Check SMCS Code: 4203-535-AI Illustration 272 g01173772 1.Inspect SEBU7885-12 If there is no response to the steering input. i02857368 Illustration 273 g01131473 Steering Cylinder Bearings Lubricate SMCS Code: 4303-086-BD The steering cylinder bearings are lubricated by the automatic lubrication system.162 Maintenance Section Starting Motor .Inspect SMCS Code: 1451-040. Stop the machine immediately. the steering neutralizer valve needs to be adjusted. . Apply lubricant through the fitting for the head end of each steering cylinder. The damaged line must be replaced. 1453-040 Caterpillar recommends a scheduled inspection of the starting system. Check the starting motor and the battery charger for proper operation. “Steering Neutralizer Valve . “Electric Starting System” for information about testing the starting system. Wipe off all fittings before any lubricant is applied. i02119057 2. i02243191 Tire Inflation .Adjust” for the correct procedure. the supplemental steering system is not operating. “3500B and 3500B High Displacement Engines For Caterpillar Built Machines”. Inflate the tires. Repair the supplemental steering system before returning the machine to service. Illustration 274 g01130702 Measure the tire pressure on each tire. install a fitting at the bearing and lubricate the bearing.Check SMCS Code: 4330-535-SQ Starting Motor . SENR1123. “994F Steering System”. RENR6325. Reference: Refer to Testing and Adjusting. Note: There are a total of four fittings. Apply lubricant through the fitting for the rod end of each steering cylinder. if necessary. Adjusting the steering system should be done by a qualified Caterpiller product support representative. Check for contact between the steering stops. i02246969 Steering Stop .

“Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Lower the bucket to the ground and apply slight downward pressure. Do not allow hot oil or components to contact skin. nonflammable solvent. Install seals (2) and cover assemblies (1). Reference: Refer to Operation and Maintenance Manual. “Tire Inflation Information” for more information or consult your Caterpillar dealer. 5. Illustration 276 g00274755 . Wash the screen tube assemblies and the suction screens in a clean. Dispose of all fluids according to local regulations and mandates. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 3.Clean SMCS Code: 3030-070-MGS. 2. Inspect seals (2). Transmission Oil . Park the machine on level ground. Remove screen tube assemblies (3) and suction screens (4). 4.Change” for the procedure to drain the transmission oil.SEBU7885-12 163 Maintenance Section Transmission Magnetic Screen . Refer to Special Publication. Install screen tube assemblies (3) and suction screens (4). i02857369 Transmission Magnetic Screen . NENG2500. “Transmission Oil .Change SMCS Code: 3030-044 Hot oil and components can cause personal injury. i02337526 1. if necessary. The fast fill service center allows the transmission oil to be changed faster than the conventional method. testing. 6. maintenance. Fast Fill Service Center Your machine is equipped with a fast fill service center for changing the transmission oil. 7. Drain the transmission oil before you remove the transmission magnetic screen. Replace the seals. Engage the parking brake and stop the engine. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. adjusting and repair of the product. Illustration 275 g01139562 The two transmission magnetic screens are located in the transmission case at the center of the machine.Clean Reference: Refer to Operation and Maintenance Manual. Remove cover assemblies (1) and seals (2). 3159-070-MGS Clean the transmission magnetic screens if the transmission oil pump fails or the transmission is disassembled. Allow the components to air dry.

Dispose of the used oil properly. Start the engine. Lower the bucket to the ground and apply slight downward pressure. Park the machine on a level surface. Change the filter element. 2. . “Transmission Magnetic Screen . Clean the end of the male coupler and close the door to the fast fill service center. Close the drain valve for the transmission oil tank. “Power Train Oil Filter (Transmission and Torque Converter) . Reference: Refer to Operation and Maintenance Manual. Engage the parking brake. 7. Turn on the oil pump and withdraw the transmission oil from the transfer gear case.Check” for the correct procedure.164 Maintenance Section Transmission Oil . Turn off the oil pump. 3. Cycle the transmission control in order to warm the oil. Clean the end of the male coupler. “Transmission Oil Level . Conventional Method Illustration 277 g01139416 1. Reference: Refer to Operation and Maintenance Manual.Clean” for the correct procedure. Illustration 278 g01458830 Illustration 279 g01131638 2. Operate the machine in order to warm the oil. “Lubricant Viscositites” for the type of lubricant. Reference: Refer to Operation and Maintenance Manual. Lower the bucket to the ground and engage the parking brake. Open the door to the fast fill service center that is on the right side of the machine near the articulation joint. Connect the oil pump to the male coupler. Locate the correct male coupler and connect an oil pump to the fitting. Open the drain valve and allow the oil to drain into a suitable container. Stop the engine. The drain valve for the transmission oil tank is located on the bottom of the transmission case near the center of the machine. 8. Check the transmission for oil leaks. 5. Check the transmission oil level in sight gauge (1). 6. 4. Fill the transfer gear case with new oil. Reference: Refer to Operation and Maintenance Manual. Dispose of the used oil properly.Replace” for the correct procedure. 5. Clean the transmission magnetic screen. Reference: Refer to Operation and Maintenance Manual. 4. Park the machine on level ground. “Capacities (Refill)” for the refill capacity.Change SEBU7885-12 1. 6. 3.

Maintain the oil level between the marks on the oil level sight gauge. Clean the filler cap and install the filler cap. Install the transmission breather. 8. “Capacities (Refill)” for the correct amount of oil. If necessary. remove the transmission oil filler cap and add oil. The transmission oil filler tube is located behind the cab. Inspect the transmission for leaks. Engage the parking brake. Wash the breather in a clean. 10. Check the transmission oil level in the sight gauge on the right side of the articulation joint. Reference: Refer to Operation and Maintenance Manual. 12.SEBU7885-12 165 Maintenance Section Transmission Oil Level . Illustration 283 g01131660 The transmission sight gauge is located on the right side of the machine in the articulation joint.Check Illustration 280 g01138824 Illustration 282 g01131660 13. Remove filler cap (1) and fill the transmission with oil. 11. “Lubricant Viscosities” for the correct type of oil. Reference: Refer to Operation and Maintenance Manual. Start and run the engine at low idle. Slowly operate the STIC transmission direction control switch in order to circulate the oil. Inspect the entire transmission system for leaks. Allow the breather to dry or use air pressure to dry the breather. maintain the oil level between the marks on the sight gauge. i02337511 Transmission Oil Level . While the engine is running at low idle. . Move the STIC transmission direction control switch to the NEUTRAL position.Check SMCS Code: 3030-535-FLV Illustration 281 g01131640 7. nonflammable solvent. 9. Remove transmission breather (2).

Inspect SMCS Code: 1052-040 If the turbocharger fails during engine operation. “Caterpillar Machine Fluids Recommendations”. “S·O·S Oil Analysis” for information that pertains to obtaining a sample of the transmission oil.Obtain SEBU7885-12 Obtain the sample for the torque converter from port (1). An example of the stored information is the payload data. 7542 Illustration 285 g01138824 i02093570 The sampling valve is located behind the cab. “3500B and 3500B High Displacement Engines For Caterpillar Built Machines ”. Reference: Refer to Special Publication. Do not continue to operate the engine when a turbocharger bearing failure is accompanied by a significant loss of engine performance. refer to System Operation. remove transmission oil filler cap (1) and add oil. “How To Take A Good Oil Sample” for more information about obtaining a sample of the pump drive oil. Lift the access panel in order to obtain the samples. Turbocharger bearing failures can cause large quantities of oil to enter the intake system and the exhaust system. Close the access panel once the samples have been obtained. Engine smoke and speeding up of the engine with no load are characteristics of a loss of engine performance. Loss of engine oil can result in serious engine damage. VIMS Module Battery . Obtain the sample for the transmission from port (2). Reference: Refer to Special Publication.Replace SMCS Code: 7601-510-B11 A lithium battery is contained inside the main module of the VIMS. Transmission Oil Sample Obtain SMCS Code: 3080-008. SEBU6250. “Air and Inlet Exhaust System”. PEHP6001. Reference: For additional information about inspecting the turbocharger. Illustration 286 g01165517 . i02334728 Turbocharger . Illustration 284 g01131640 i02119071 If necessary. SENR1123.166 Maintenance Section Transmission Oil Sample . The internal battery also retains the time and the date. severe damage to the turbocharger compressor wheel and to the entire engine can result. The internal battery prevents the loss of stored information.

Note: If the Vital Information Management System (VIMS) detects a failed battery. use Caterpillar nonfreezing window washer solvent or equivalent. Remove the battery from the back of the VIMS module. Tighten securely against the housing. The real time clock format in the main module is powered by this battery. When the fault code is present. Remove the cap and fill the reservoir with window washer solvent. The lithium battery fails quickly. the internal battery will begin to retain the stored data. Note: To prevent the loss of stored information. Note: If ECM BKUP BATT ERR is displayed in the message area of the VIMS. If necessary. 7305-510 Inspect the condition of the wiper blades. Turn the engine start switch to the ON position or turn the keyswitch for the VIMS to the ON position. If the ambient temperature is continuously in the range of 0 to −40°C (32 to −40°F). do NOT turn the engine start switch to the OFF position. i01391802 Windows . loss of the stored data can occur within several hours. Install a new internal battery. Keep the area clean. . If power is removed from the main module of the VIMS during this fault code. A dead battery will cause the date to be lost and a dead battery will cause the time to be lost. Then replace the internal battery without turning off the engine start switch or the battery disconnect switch. The window washer reservoir is located behind the cab on the right side. Be careful to align the pins of the new battery with the sockets. 7. a fault code will indicate that the battery needs a replacement. Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs. System damage can result from freezing. Leave the battery disconnect switch in the ON position. Go to Step 3. Use a clean cloth or a squeegee to clean the windows from the cab platform. 6.Clean SMCS Code: 7310-070 Use commercially available window cleaning solutions in order to clean the windows. Stop the machine and turn off the engine. Check the O-ring seal. The internal battery retains the time and the date when the engine start switch is in the OFF position. Note: Do not allow dirt or water into the opening. use the service tool for the VIMS to set the time and the date. “Vital Information Management System (VIMS)” for additional information. Use the service tool for the VIMS to download all of the stored information. Failure to perform this step may result in the loss of stored data. 8. cut the service interval in half. SENR6059. 3. Also. Refer to Service Manual. Leave the battery disconnect switch in the ON position. 1. the date will default to “01/01/00”.SEBU7885-12 167 Maintenance Section Window Washer Reservoir . Power is removed from the main module of the VIMS when the battery disconnect switch is in the OFF position.Fill If power is removed from the main module of the VIMS. 5. immediately download the stored data. This will occur regardless of the position of the battery disconnect switch. i01258249 Window Wiper Inspect/Replace SMCS Code: 7305-040. i02275845 Window Washer Reservoir Fill SMCS Code: 7306-544 NOTICE When operating in freezing temperatures. 4. Note: If these switches remain in the ON position during replacement. The service tool for the VIMS is not part of the machine. the time will default to “00:00:00”. After the battery has been replaced. Leave the engine start switch in the ON position or leave the keyswitch for the VIMS in the ON position. the date and the time of day are less likely to require programming. replace the internal battery at the service interval. 2.