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MAINTENANCE INTERVALS

Operation and Maintenance Manual Excerpt

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SEBU8287-05 January 2011

Operation and Maintenance Manual
450E Backhoe Loader
EBL1-Up (Machine)

SAFETY.CAT.COM

SEBU8287-05

93 Maintenance Section Maintenance Interval Schedule

i04144192

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. All adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging are included. 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. Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed. Note: If Cat HYDO Advanced hydraulic oils are used, the hydraulic oil change interval is extended to 3000 hours. S·O·S services may extend the oil change even longer. Consult your Cat dealer for details.

Engine Air Filter Service Indicator - Inspect ......... 111 Engine Air Precleaner - Clean ............................. 111 Engine Oil Level - Check ..................................... 112 Fuel System Water Separator - Drain ................. 122 Hydraulic System Oil Level - Check ................... 127 Loader Bucket, Cylinder, and Linkage Bearings Lubricate ........................................................... 127 Seat Belt - Inspect .............................................. 130 Stabilizer and Cylinder Bearings - Lubricate ....... 131 Swing Frame and Cylinder Bearings - Lubricate .. 132 Tire Inflation - Check ........................................... 132 Transmission Oil Level - Check .......................... 134 Wheel Nut Torque - Check .................................. 135

Every 50 Service Hours or Weekly
Cab Filter (Fresh Air) - Clean/Inspect/Replace ... Cab Filter (Recirculation) - Clean/Inspect/ Replace ............................................................. Fuel Tank Water and Sediment - Drain ............... Parking Brake - Check/Adjust ............................. 101 101 122 128

Every 250 Service Hours
Engine Oil Sample - Obtain ................................. 113

Every 250 Service Hours or Monthly
Axle Breathers - Clean/Replace ........................... 95 Belt - Inspect/Adjust/Replace ................................ 97 Differential Oil Level (Front) - Check .................. 107 Differential Oil Level (Rear) - Check ................... 107 Extendable Stick Pads - Inspect/Adjust ............... 114 Final Drive Oil Level (Front) - Check .................. 120

Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 105

When Required
Battery or Battery Cable - Inspect/Replace .......... 96 Bucket Cutting Edges - Inspect/Replace .............. 98 Bucket Tips - Inspect/Replace .............................. 98 Cab Interior - Clean ............................................ 102 Engine Air Filter Primary Element - Clean/ Replace ............................................................. 109 Engine Air Filter Secondary Element - Replace .. 110 Engine Compartment - Clean .............................. 111 Film (Product Identification) - Clean .................... 119 Fuses - Replace .................................................. 123 Oil Filter - Inspect ................................................ 128 Radiator Core - Clean ......................................... 129 Window Washer Reservoir - Fill .......................... 135 Window Wipers - Inspect/Replace ...................... 136 Windows - Clean ................................................. 136

Every 500 Service Hours or 3 Months
Brake Accumulator - Check .................................. 97 Cooling System Coolant Sample (Level 1) Obtain ............................................................... 104 Differential Oil Sample (Front) - Obtain .............. 108 Differential Oil Sample (Rear) - Obtain ............... 108 Drive Shaft Spline - Lubricate ............................. 108 Engine Oil and Filter - Change ............................ 113 Final Drive Oil Sample (Front) - Obtain .............. 120 Fuel System Primary Filter (Water Separator) Replace ............................................................. 121 Fuel System Secondary Filter - Replace ............ 121 Hydraulic Oil Sample - Obtain ............................ 124 Hydraulic System Oil Filter - Replace ................. 126 Transmission Oil Filter - Replace ........................ 134 Transmission Oil Sample - Obtain ...................... 135

Every 10 Service Hours or Daily
Backhoe Boom, Stick, Bucket, and Cylinder Bearings - Lubricate ........................................................... 95 Backup Alarm - Test .............................................. 96 Braking System - Test ........................................... 97 Cooling System Coolant Level - Check .............. 104

Every 1000 Service Hours
Engine Valve Lash - Check .................................. 114

94 Maintenance Section Maintenance Interval Schedule

SEBU8287-05

Every 1000 Service Hours or 6 Months
Differential Oil (Front) - Change .......................... Differential Oil (Rear) - Change .......................... Final Drive Oil (Front) - Change .......................... Ride Control Accumulator - Check ..................... Rollover Protective Structure (ROPS) - Inspect .. Transmission Magnetic Screen - Clean .............. Transmission Oil - Change ................................. 106 106 120 130 130 132 133

Every 2000 Service Hours
Engine Crankcase Breather - Replace ................ 112

Every 2000 Service Hours or 1 Year
Hydraulic System Oil - Change ........................... 125

Every Year
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 105

Every 3000 Service Hours or 2 Years
Cooling System Water Temperature Regulator Clean/Replace .................................................. 105

Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 131

Every 6000 Service Hours or 3 Years
Cooling System Coolant Extender (ELC) - Add .. 103

Every 12 000 Service Hours or 6 Years
Cooling System Coolant (ELC) - Change ........... 102

Bucket. Illustration 115 g01358303 Apply lubricant to the grease fitting (1) for the rod end of the boom cylinder. Illustration 113 g01357541 The rear axle breather is located on the top right side of the rear differential housing. Relieve the hydraulic pressure. 3278-510-BRE Backhoe Boom. 1. Remove the breather from the front axle. 6533-086-BD. Wash the breather in clean nonflammable solvent. Replace the breather if the breather is damaged. . Clean the area around the breathers. Install the clean breather back into the axle. 6503-086-BD. Apply lubricant to the two remote grease fittings (2) for the head end of the boom cylinder. Stick. Illustration 114 g01358265 Position the backhoe into the service position that is shown above. and Cylinder Bearings Lubricate SMCS Code: 6501-086-BD. Lower the bucket to the ground. 3.SEBU8287-05 95 Maintenance Section Axle Breathers .Clean/Replace SMCS Code: 3278-070-BRE. 7562-086-BD Illustration 112 g01216797 The front axle breather is located on the top right side of the front differential housing. 6511-086-BD. 6512-086-BD. Wipe the breather dry and check the breather for damage. 2.Clean/Replace i02706399 i02830830 Axle Breathers . 6502-086-BD.

Apply lubricant to the grease fitting (9) for the bucket pivot pin. There is one grease fitting on each side of the machine. Note: Do not allow the disconnected battery cable to contact the frame of the machine. Connect the battery cable to the frame of the machine. Turn all switches to the OFF position. Apply lubricant to the grease fitting (12) for the pivot pin. 2. Apply lubricant to the grease fitting (10) for the link. There is one grease fitting on each side of the machine.Test SEBU8287-05 Apply lubricant to the grease fitting (3) for the boom pivot. 8. Inspect the battery terminals and inspect the battery cables. Apply lubricant to the grease fitting (8) for the pivot pin. Replace the cable or the battery. Perform the necessary repairs. Install the engine start switch key. Apply lubricant to the grease fitting (7) for the pivot pin for the stick. Battery or Battery Cable Inspect/Replace SMCS Code: 1401 1. There are a total of 17 grease fittings. Apply lubricant to the remote grease fitting (6) for the head end of the stick cylinder. Keep the terminals clean and keep the terminals coated with petroleum jelly. i01833495 Illustration 116 g01358340 Apply lubricant to the grease fitting (4) for the head end of the bucket cylinder. Apply lubricant to the grease fitting (5) for the rod end of the stick cylinder. 5. i00080741 Backup Alarm . Turn the engine start switch to the OFF position. 7. Apply lubricant to the grease fitting (11) for the rod end of the bucket cylinder. Move the transmission direction control lever to REVERSE position. Illustration 117 g01358373 6. Disconnect the negative battery cable at the battery.96 Maintenance Section Backup Alarm . as needed. The backup alarm should immediately sound. Connect the negative battery cable at the battery. Apply the service brake. 4.Test SMCS Code: 7406 Turn the engine start switch key to ON in order to perform the test. 3. . Disconnect the negative battery cable from the frame. The backup alarm will continue to sound until the transmission direction control lever is moved to the NEUTRAL position or to the FORWARD position.

Inspect/Adjust/Replace i02707745 i02704944 Belt . This will decrease the accumulator pressure. Use only dry nitrogen gas for recharging. Make sure that the machine is clear of personnel and clear of obstacles. Fasten the seat belt before you test the brakes. Special equipment is required for testing and charging. Start the engine.a through Step 4. Your authorized dealer can measure the nitrogen gas pressure in the accumulator. 3. instructions in the service manual must be followed. 8. Install the engine access panel. Inspect the belt for wear and for cracking. To remove or repair. measure the accumulator precharge pressure. b. Run the engine at half throttle for two minutes in order to increase the accumulator pressure. Start the engine. Test the brakes on a dry. Refer to Operation and Maintenance Manual. 6. c. Apply the service brake pedal and release the service brake pedal until the alert indicator for brake oil pressure comes on. 2. The alert indicator for brake oil pressure should illuminate if the braking system is not at normal operating pressure. The alert indicator for brake oil pressure should go off. level surface.SEBU8287-05 97 Maintenance Section Belt . Note: If your machine is equipped with the original accumulator.c. 2. 7000 Service Brake Holding Ability Test Check the area around the machine. perform Step 4. 3. Install the lift cylinder brace. Stop the engine. i03478561 Illustration 118 g01358768 a.Inspect/Adjust/Replace SMCS Code: 1397-025. Remove the pin and replace the brace for the loader lift arm to the stored position on the loader lift arm. Install a new belt. Raise the loader arms to the maximum height. 7. 4267. Improper removal or repair procedures could cause severe injury. recharge the accumulator at your dealer. If your machine is equipped with a replacement accumulator. If the alert indicator illuminates before three applications of the brake pedal. Remove the engine access panel on the left side of the machine. If the belt requires replacement. Brake Accumulator . 1397-040. 1. 4.Check SMCS Code: 4263-535 Hydraulic accumulator contains gas and oil under high pressure. Braking System . 1397-510 Note: This engine is equipped with a belt tightener that automatically adjusts the belt to the correct tension. 1. Lower the bucket to the ground.Test SMCS Code: 4251. Turn the belt tensioner in order to release the tension from the belt. Remove the belt. replace the accumulator. Turn the engine start switch to the ON position. 5. 4. “Lift Cylinder Brace Connect and Disconnect” for more information. A minimum of three applications of the service brake pedal are required. .

Inspect/Replace SEBU8287-05 The following test is used to determine if the service brake is functional. Bucket Cutting Edges Inspect/Replace SMCS Code: 6801 Personal injury or death can result from bucket falling. Move the transmission to NEUTRAL. 2. . 9.Inspect/Replace SMCS Code: 6805 Secondary Brake Holding Ability Test Refer to Operation and Maintenance Manual. The machine should not move. Install the bolts. repair the service brake before returning the machine to operation. The variations are the differences in the engine setting. 1. Use the opposite side of the cutting edge. 6. Block the bucket before changing bucket cutting edges. 3. 10. Have the dealer inspect and. check the bolts for proper torque. “Parking Brake . This test is not intended to measure the maximum brake holding effort. Release the parking brake. Place a block under the bucket. If the machine begins to move. 4. 5.Check/Adjust”. Block the bucket before changing bucket tips. 8. i01920076 Personal injury or death can result from the bucket falling. Lower the bucket to the ground. Block up the bucket so that the bucket is high enough to remove the cutting edges and the end bits. Raise the bucket. Move the transmission control lever to THIRD SPEED FORWARD. Raise the bucket. Lower the bucket to the blocking. Gradually increase the engine speed to high idle. Clean the contact surfaces. i03657242 Bucket Tips . Raise the bucket slightly. The brake holding effort that is required to sustain a machine at a specific engine rpm varies depending on the machine. Reduce the engine speed to low idle. Apply the service brake. Install a new cutting edge. Remove the cutting edge and the end bits. NOTICE If the machine moved while testing the brakes. in the power train efficiency. 2. if both edges are worn. if necessary. contact your Caterpillar dealer. After a few hours of operation. Remove the blocks. Engage the parking brake. Tighten the bolts to the specified torque. if this side is not worn. 7. 4. 5. Lower the bucket to the ground. 1. Start the engine.98 Maintenance Section Bucket Cutting Edges . Do not block up the bucket too high. and in the brake holding ability. Remove the bolts. reduce the engine speed immediately and engage the parking brake. 3. etc. Stop the engine.

(3) Replace the tip. b. Remove the pin from the bucket tip. replace the bucket tip. 5. pin through the bucket tip. Follow Step 5. Clean the adapter and the pin. Improper installation of the pin can result in the loss of the bucket tip. • Use a Pin-Master. Follow Step 1. g00101352 g00590819 (6) Retainer (7) Retaining washer (8) Adapter 2. Drive the pin through the bucket tip. 3. Place the Pin-Master on the bucket tooth. Illustration 120 (4) Back of Pin-Master (5) Extractor g00590670 5. Fit retainer (6) into retaining washer (7). c. 1. If the bucket tip has a hole. 1. The pin can be removed by one of the following methods. • Use a Pin-Master. . Install this assembly into the groove that is in the side of adapter (8).SEBU8287-05 99 Maintenance Section Bucket Tips . Install the new bucket tip onto the adapter.a through Step Note: To correctly install the pin into the retainer. Align extractor (5) with the pin. The pin can be installed by using one of the following methods: • From the other side of the retainer. the pin must be driven in from the right side of the tooth. Note: The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration. • Use a hammer and a punch from the retainer side of the bucket to drive out the pin.a through Step Illustration 122 g00101359 4. the adapter. Strike the Pin-Master at the back of the tool (4) and remove the pin.c for the procedure.Inspect/Replace Bucket Tips Illustration 121 Illustration 119 (1) Usable (2) Replace the tip. drive the a. Check the bucket tips for wear. and the retainer.e for the procedure.

100 Maintenance Section Bucket Tips . Place the Pin-Master over the bucket tooth and locate the pin in the hole of holder (10). Use a pry bar in order to disengage retainer (5). Slide pin holder (10) away from the pin and rotate the tool slightly in order to align pin setter (9) with the pin. if necessary. b. Clean the adapter and the area around the latch.Inspect/Replace SEBU8287-05 Illustration 123 (4) Back of Pin-Master (9) Pin setter (10) Pin holder g00590666 Illustration 125 g01175361 1. Insert the pin through the bucket tooth. . 3. Make sure that the retainer's latch catches under the tip pocket. c. 6. Make sure that the latch is properly seated by trying to remove the bucket tip. 4. 4. d. Remove bucket tip (4) from adapter (6) with a slight counterclockwise rotation. Installation 1. 2. After you drive the pin. e. K-Series Tip Removal Illustration 126 g01124736 3. Strike the tool with a hammer at the back of the tool (4) in order to start the pin. 2. Use the pry bar in order to remove retainer (5) from bucket tip (4). Install the new bucket tip onto the adapter with a slight clockwise rotation. Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced. make sure that the retainer fits snugly into the pin groove. a. Clean adapter (6). Strike the end of the tool until the pin is fully inserted. Install the retainer. Illustration 124 g01389463 Note: Retainers are often damaged during the removal process.

Illustration 129 g02397577 1. use 205 kPa (30 psi) maximum to prevent element damage by too much air pressure. 7342-070.Clean/Inspect/Replace i02705169 Cab Filter (Fresh Air) Clean/Inspect/Replace SMCS Code: 7342-040. Remove the filter element. Do not use an element with damaged pleats. 5. 7342-070. Install the filter element. Use a maximum air pressure of 205 kPa (30 psi). use 280 kPa (40 psi) maximum to prevent element damage. i04218029 Cab Filter (Recirculation) Clean/Inspect/Replace SMCS Code: 7342-040.SEBU8287-05 101 Maintenance Section Cab Filter (Fresh Air) . 7. Install the filter cover. 3. 4. 6. Illustration 127 g01357115 1. Replace damaged filters. Inspect the element for damage. Direct the air or the water along the pleats of the element. When cleaning with pressure water. Clean the filter element weekly. Remove the cover that is over the recirculation filter. Look through the filter toward a bright light. gaskets or seals. 7342-510 NOTICE Do not clean the elements by bumping or tapping them. When cleaning with pressure air. Inspect the element for damage. Install the filter element. replace the filter element. Illustration 128 g01200815 Note: Clean the filters more often in dusty conditions. Allow the filter element to air dry. 4. Clean the filter element with compressed air or pressure water. Inspect the elements after cleaning. 2. 7342-510 The recirculation filter is located to the left of the operators seat. but clean the filter element daily when there is a reduction of air circulation. Open the filter cover that is located on the right fender. You can also wash the element with clean water and nonsudsing household detergent. . 2. The filter element can be cleaned by using compressed air. 3. Inspect the gaskets for damage. Remove the filter element. Direct the air from the clean side to the dirty side. Rinse the filter element thoroughly with clear water. If the filter element is damaged.

2.Clean SMCS Code: 7301-070 1. stop engine. “Maintenance Interval Schedule” in order to determine the service interval. If Caterpillar products are not available and commercial products must be used. Use high pressure air in order to clean the entire cab and the main electrical box.Change SMCS Code: 1353. “Lift Cylinder Brace Connect and Disconnect” for more information. For information about the addition of Extender to your cooling system. After you drain the cooling system. See the Operation and Maintenance Manual. make sure they have passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants and Caterpillar Extender. Drain the coolant whenever the coolant is dirty or whenever foaming is observed. 2. Use caution and minimize the water around electrical connections and the cab roof. If a Extended Life Coolant was previously used. i02705616 Flushing the Extended Life Coolant From the Cooling System Some engines utilize Extended Life Coolant. Flushing a Standard Coolant From the Cooling System If you change the coolant of a machine to Extended Life Coolant from another type of coolant. 1. Then loosen cap slowly to relieve the pressure. use a Caterpillar cleaning agent to flush the cooling system. Extended Life Coolant is recommended for use. All of the cleaning agent must be removed from the cooling system. Open the engine access door on the top of the machine. . Pressurized system: Hot coolant can cause serious burn. This could result in damage to cooling system components. Then loosen cap slowly to relieve the pressure. No other cleaning agents are required. the instrument panel.Clean SEBU8287-05 i01404606 Cab Interior . NOTICE Do not change the coolant until you read and understand the material in the Cooling System Specifications section. 1395 Changing the Coolant Pressurized system: Hot coolant can cause serious burn. To open cap. flush the cooling system with clean water.102 Maintenance Section Cab Interior . see the Operation and Maintenance Manual. wait until radiator is cool. Wash off any remaining dirt and debris. wait until radiator is cool. Refer to Operation and Maintenance Manual. Install the lift cylinder brace. thoroughly flush the cooling system with clean water. “Cooling System Coolant Extender (ELC) Add” or consult your Caterpillar dealer. the windows. NOTICE Mixing ELC with other products will reduce the effectiveness of the coolant. stop engine. Wipe the cab dry. Scrub the floormat. Cooling System Coolant (ELC) . Note: This machine is shipped with Extended Life Coolant. To open cap. 3. and the mirrors.

“Capacities (Refill)” Note: If you are using Caterpillar antifreeze. 10.25 qt) • Special Publication. 13. 8. “Caterpillar Machine Fluids Recommendations”. Start the engine. Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes. 7.Add • Operation and Maintenance Manual. Illustration 130 g01357597 3. Start the engine. Slowly loosen the radiator cap in order to relieve system pressure. While the engine is stopped. “Maintenance Interval Schedule” for the proper service interval. To open cap. Fill the system with a solution which consists of clean water and of cooling system cleaner. Remove the radiator cap slowly. Close the drain valve. The amount of extender is determined by the cooling system capacity. Then loosen the cap slowly to relieve the pressure. 11. 1395 Illustration 131 g01357599 4. Run the engine for 90 minutes. See the Operation and Maintenance Manual.5 inch) of the bottom of the filler pipe. 12. Stop the engine.71 L (. wait until radiator is cool. an extender must be added to the cooling system. Table 18 RECOMMENDED AMOUNT OF EXTENDER BY COOLING SYSTEM CAPACITY Cooling System Capacity 22 to 30 L (6 to 8 US gal) 30 to 38 L (8 to 10 US gal) 38 to 49 L (10 to 13 US gal) 49 to 64 L (13 to 17 US gal) Recommended Amount of Extender 0.57 L (. i03114912 Cooling System Coolant Extender (ELC) . See the following topics: Pressurized system: Hot coolant can cause serious burn. Install the radiator cap. 9.95 qt) 1. “Cooling System Specifications” .Add SMCS Code: 1352. 14. 1353. The concentration of the cooling system cleaner in the solution should be between 6 percent and 10 percent. Lower the tab on the radiator cap. Drain the system into a suitable container.18 L (1. stop engine. When a Caterpillar Extended Life Coolant is used. Close the drain valve. Close the access door. 5. 6.75 qt) 0. Drain the cleaning solution into a suitable container. Add the coolant solution. SEBU6250. Replace the access panel. Stop the engine. do not add the supplemental coolant additive at this time and/or change the element at this time.60 qt) 0. Replace the radiator cap if the gasket is damaged. Flush the system until the draining water is transparent.SEBU8287-05 103 Maintenance Section Cooling System Coolant Extender (ELC) . Maintain the coolant level within 13 mm (0. Open the drain valve. flush the system with water.95 L (.

Obtain SMCS Code: 1350-008. The radiator cap is located on the top of the radiator on the right side of the machine. Supplies for collecting samples can be obtained from your Caterpillar dealer. adjusting and repair of the product. see Special Publication. Inspect the radiator cap seal. check the cooling system for leaks. 5.5 inch) of the bottom of the filler tube. 2. Close the access panel. 4. Slowly loosen the cap in order to relieve system pressure. you must establish a consistent trend of data. NENG2500. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. In order to receive the full effect of S·O·S analysis. Lower the tab on the radiator cap. 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. i02706505 i02706515 Cooling System Coolant Sample (Level 1) . Cooling System Coolant Level . 3. • Keep the unused sampling bottles stored in plastic .Check SEBU8287-05 For additional information on the addition of extender. Illustration 133 g01357597 Obtain the sample of the coolant as close as possible to the recommended sampling interval. Install the radiator cap. “Cat Extended Life Coolant (ELC) Cooling System Maintenance” or consult your Caterpillar dealer. Maintain the coolant level within 13 mm (0. To open cap. Use the following guidelines for proper sampling of the coolant: • Complete the information on the label for the sampling bottle before you begin to take the samples. Open the engine access door on the top of the hood. testing. Illustration 132 g01357597 1. Check the coolant level in the expansion tank. Replace the radiator cap seal if the radiator cap seal is damaged. wait until radiator is cool. perform consistent samplings that are evenly spaced. Remove the radiator cap slowly.104 Maintenance Section Cooling System Coolant Level . bags.Check SMCS Code: 1350-535-FLV Pressurized system: Hot coolant can cause serious burn. Refer to Special Publication. Then loosen cap slowly to relieve the pressure. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Note: Level 1 results may indicate a need for Level 2 Analysis. In order to establish a pertinent history of data. stop engine. 1395-008. Dispose of all fluids according to local regulations and mandates. SEBU6250. If you need to add coolant daily. maintenance.

The thermostat should be replaced after the cooling system has been cleaned. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. It is mandatory to always operate the engine with a thermostat. Failure to replace the engine's thermostat on a regularly scheduled basis could cause severe engine damage. 2. i02706526 • Never collect samples from expansion bottles. “Lift Cylinder Brace Connect and Disconnect” for more information. “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer. Refer to Operation and Maintenance Manual. adjusting and repair of the product. Note: If you are only replacing the thermostat. i02706518 Cooling System Water Temperature Regulator Clean/Replace SMCS Code: 1355. Refer to Operation and Maintenance Manual. SEBU6250. are ready to collect the sample. • Never collect samples from the drain for a system. Illustration 134 g01357597 . Dispose of all fluids according to local regulations and mandates. 1395-008. refer to Special Publication. maintenance. Install the lift cylinder brace. 1. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. For additional information about coolant analysis. SEBU6250. You should not obtain the samples from any other location. Cooling System Coolant Sample (Level 2) . Submit the sample for Level 2 analysis. Replace the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing. testing.Obtain • Obtain coolant samples directly from the coolant sample port. Submit the sample for Level 1 analysis.Obtain SMCS Code: 1350-008. 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Obtain the sample of the coolant as close as possible to the recommended sampling interval.Obtain” for the guidelines for proper sampling of the coolant. “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer. NENG2500. drain the cooling system coolant to a level that is below the thermostat housing. 1393 Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system. “Cooling System Coolant Sample (Level 1) . see Special Publication.SEBU8287-05 105 Maintenance Section Cooling System Coolant Sample (Level 2) . Caterpillar engines incorporate a shunt design cooling system. • 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. Reference: For additional information about coolant analysis. Refer to Special Publication. Remove the engine access panel on the right side of the machine. Supplies for collecting samples can be obtained from your Caterpillar dealer.

Install a new seal in the thermostat housing assembly.Change SEBU8287-05 i02567860 Differential Oil (Front) . 7. 5. Illustration 136 g01286266 1. Install the thermostat housing assembly on the engine cylinder head. Refer to Operation and Maintenance Manual. • The thermostat is not damaged. Remove the gasket. The thermostats can be reused under the following conditions.Change SMCS Code: 3258 The oil change interval should be decreased to 500 hours if more than 50% of the service hours is used for roading and loading. and the seal from the thermostat housing assembly. Loosen the hose clamp and remove the hose from the thermostat housing assembly. Check the plug for metal. 4. Install a new thermostat and a new gasket. Add oil until the oil is level with the threads for the filler plug. “Lubricant Viscosities” and Operation and Maintenance Manual. • The thermostat does not have excessive buildup of deposits. 8. Clean the drain plug and install the drain plug. 3. i02706610 • The thermostat is tested and the thermostat meets test specifications. Clean the filler plug and install the filler plug. “Capacities (Refill)”. Differential Oil (Rear) . Refill the cooling system. 4. . Refer to Special Publication. 5. Remove the thermostat housing assembly. the thermostat.106 Maintenance Section Differential Oil (Front) .Change SMCS Code: 3258 Illustration 135 g01357635 3. Install the hose. 6. “Cooling System Specifications” and Operation and Maintenance Manual. Tighten the hose clamp. Remove oil drain plug (1) and drain the oil into a suitable container. Remove the bolts from the thermostat housing assembly. 6. 2. The drain plug is magnetic. Remove oil level/fill plug (2). “Capacities (Refill)” for oil.

Clean the oil level/fill plug and install the oil level/fill plug. The oil level should be at the bottom of the plug threads. Clean the filler plug and install the filler plug. Clean the oil plug and install the oil plug. . “Capacities (Refill)” for oil. 5. Add oil until the oil is level with the threads for the filler plug. 1. Refer to Operation and Maintenance Manual.Check 2. “Lubricant Viscosities” and Operation and Maintenance Manual. i02575217 Differential Oil Level (Rear) Check SMCS Code: 3258 Illustration 137 g01357706 The oil level/fill plug is located near the middle of the rear axle. Remove the oil plug in order to check the oil. 2. Remove oil level/fill plug (2). Remove the oil level/fill plug in order to check the oil. Illustration 138 g01180551 1. i02363607 Illustration 139 g01290199 Differential Oil Level (Front) Check SMCS Code: 3258 The oil level/fill plug is located near the middle of the front axle. 1. Remove the three oil drain plugs (1) and drain the oil into a suitable container. The oil level should be at the bottom of the plug threads. 3.SEBU8287-05 107 Maintenance Section Differential Oil Level (Front) . 3. 4. 2. Clean the drain plugs and install the drain plugs. 3.

Refer to the Special Publication. 7542-008 Refer to the Operation and Maintenance Manual. SEBU6250. “Maintenance Interval Schedule”.Lubricate SMCS Code: 3253 Access the grease fittings for the drive shaft spline from the bottom of the machine. Illustration 140 g01180551 Obtain the oil sample according to the Operation and Maintenance Manual. i02706673 Apply lubricant to the grease fitting for the drive shaft spline of the front drive shaft.Obtain SMCS Code: 3258-008. .108 Maintenance Section Differential Oil Sample (Front) . Differential Oil Sample (Rear) . “Maintenance Interval Schedule”. “General Hazard Information” for information that pertains to containing fluid spillage.Obtain SMCS Code: 3258-008. i02363714 Drive Shaft Spline . “S·O·S Oil Analysis” for more information.Obtain SEBU8287-05 i02363692 Differential Oil Sample (Front) . “General Hazard Information” for information that pertains to containing fluid spillage. “S·O·S Oil Analysis” for more information. SEBU6250. Illustration 141 g01290199 Obtain the oil sample according to the Operation and Maintenance Manual. 7542-008 Illustration 143 g01180608 Apply lubricant to the grease fitting for the drive shaft spline of the rear drive shaft. Refer to the Operation and Maintenance Manual. Illustration 142 g01180607 Refer to the Special Publication.

If the piston remains in the red zone replace the secondary element. 8. check for rips or tears in the filter material. 1. 3.Clean/Replace SMCS Code: 1051. Clean the inside of the air filter housing. Visually inspect the primary air filter elements before cleaning. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life. Reset the engine air filter service indicator. Install the cover for the air filter housing. Remove primary filter element (2) from the air filter housing. gaskets. “Engine Air Filter Service Indicator . Refer to Operation and Maintenance Manual. Discard any damaged air filter elements. the gaskets. NOTICE Do not clean the air filter elements by bumping or tapping. 7. or seals. Install the clean filter into the air filter housing.5 cm (25 inch) of water. This could damage the seals. Note: Refer to “Cleaning Primary Air Filter Elements”. When the primary air filter element is cleaned. and the outer cover. Remove cover (1) for the air filter housing . 1054 NOTICE Service the air cleaner only with the engine stopped. Dirt entering the engine will cause damage to engine components. Slide a clean primary air filter element into the filter base.Inspect”. Air pressure must not exceed 207 kPa (30 psi). Every two years replace the primary air filter element at least one time. gaskets. Use low pressure compressed air in order to remove the dust from the filter element. Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning services available at participating Caterpillar dealers. Do not use elements with damaged pleats. 5. 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. There are two common methods that are used to clean primary air filter elements: • Pressurized air . Service the air cleaner filter element when the yellow piston on the engine air filter service indicator enters the red zone or the indicator reads 63. If the yellow piston in the indicator moves into the red zone after starting the engine or the exhaust smoke is still black after installation of a clean primary filter element. install a new primary filter element. Damaged elements will allow dirt to pass through.SEBU8287-05 109 Maintenance Section Engine Air Filter Primary Element . or seals. Inspect the air filter elements for damage to the seal. 6. Do not use air filters with damaged pleats.Clean/Replace i02510477 Engine Air Filter Primary Element . This replacement should be performed regardless of the number of cleanings. Engine damage could result. Illustration 144 g01031497 2. Slide the primary filter element out of the filter base (3). Engine damage could result. Close the access door. Direct the air flow up the pleats and down the pleats from the inside of the filter element. Take extreme care in order to avoid damage to the pleats. Do not wash the filter element. 4. The primary air filter element can be used up to six times if the element is properly cleaned and inspected. Open the engine access door on the top of the machine.

1054 NOTICE Always replace the secondary filter element. 4. The secondary filter element should be replaced everytime the primary element is replaced. 3. Illustration 145 g01031378 1. or plastic as a protective covering for storage. Include the following information: 2. Remove the primary filter element (2) from the air cleaner housing. always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). An air flow restriction may result. 5. If it is necessary in order to confirm the result. compare the primary air filter element to a new primary air filter element that has the same part number. Clean the inside of the air cleaner housing (4) with a wet rag before the secondary filter element (3) is removed. gaskets or seals. Storing Primary Air Filter Elements If a primary air filter element that passes inspection will not be used. Do not use a primary air filter element with damaged pleats. mark the outside of the box and mark the primary air filter element. dry primary air filter element. Replace the gasket if the gasket is damaged. Install a new secondary element. For identification. 7. Store the box in a dry location.Replace SMCS Code: 1051. Inspecting the Primary Air Filter Elements Inspect the clean. Cleaning with pressurized air is recommended prior to vacuum cleaning. Remove the air cleaner housing cover (1). To protect against dirt and damage. 6. Fasten the clips in order to secure the air cleaner housing cover. Vacuum Cleaning Vacuum cleaning is another method for cleaning primary air filter elements which require daily cleaning because of a dry. dry air with a maximum pressure of 207 kPa (30 psi). The secondary filter element should also be replaced if the yellow piston in the filter element indicator enters the red zone after installation of a clean primary element. the primary air filter element can be stored for future use. Use filtered. or if the exhaust smoke is still black. Vacuum cleaning will not remove deposits of carbon and oil. Reset the filter element indicator. Do not use paint.110 Maintenance Section Engine Air Filter Secondary Element . Pressurized air will not remove deposits of carbon and oil. i01991300 Engine Air Filter Secondary Element . • Date of cleaning • Number of cleanings . Inspect the gasket between the air inlet pipe and the air cleaner housing. Note: When the primary air filter elements are cleaned. dusty environment. The secondary filter element should be replaced at the time the primary element is serviced for the third time. Install the primary element and the air cleaner housing cover. a waterproof cover. Discard damaged primary air filter elements. wrap the primary air filter elements in Volatile Corrosion Inhibited (VCI) paper. Inspect the primary air filter element for tears and/or holes. Place the primary air filter element into a box for storage. Never attempt to reuse it by cleaning. Do not use a primary air filter element that has any tears and/or holes in the filter material.Replace SEBU8287-05 • Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air filter elements that have not been cleaned more than two times.

wash the precleaner body with a spray of water. NOTICE Service the air cleaner only with the engine stopped. This loosens up the dirt. Loosen hard deposits of dust on the precleaner body by soaking in an appropriate cleaning agent. Engine Air Precleaner 1. Use pressurized air to clean the tubes. Stop the engine. i02835415 i01404793 Engine Air Precleaner . Remove the air filter housing from the machine.Inspect 8. Run the engine at high idle. Then. Engine Air Filter Service Indicator . Inspect the bottom of the inlet duct and inspect the precleaner tubes for dirt and debris. 1054. Close the left engine access door.SEBU8287-05 111 Maintenance Section Engine Air Filter Service Indicator . Direct the pressurized air into the tubes from the top.Clean SMCS Code: 1000-070 NOTICE Before spraying the engine compartment with high pressure water turn off the engine and allow the engine to cool.Clean SMCS Code: 1055-070 Engine Compartment . If the yellow piston in the filter service indicator enters the red zone. Install the T-bolt. Use a commercially available engine degreaser in order to clean the engine compartment. 4. Engine damage could result. Hand tighten the T-bolt only. The filter service indicator is located under the engine access door in front of the housing for the air filter. Start the engine. 7452 NOTICE Service the air cleaner only with the engine stopped. i02706745 Engine Air Intake Duct 1. Do not spray water directly on a hot fuel injection pump or damage may occur. 2. Install the precleaner. 3. Remove the primary filter elements and remove the secondary filter elements in order to clean the precleaner tubes. Blow dry the precleaner body completely. 5. Illustration 147 g01209854 . g01357732 Illustration 146 8. Close the engine access door. Put the tubes on a flat surface. 6.Inspect SMCS Code: 1051. 7. Engine damage could result. service the air cleaner. Use caution and minimize the water around bearings and electrical connections.

5. follow the established assembly procedure and wear protective equipment. 6. Remove the spring (7). Install the spring (7). 1326 NOTICE Do not overfill the crankcase. 3.Replace SEBU8287-05 i02409844 Engine Crankcase Breather Replace SMCS Code: 1317-510 Improper assembly of parts that are spring loaded can cause bodily injury. 4. Be prepared to hold spring loaded covers as the bolts are loosened. Tighten the clamp (9) to a torque of 5 N·m (44 lb in). Remove the cover (1) from the valve mechanism cover (5). maintain the oil level in the “FULL RANGE ENGINE STOPPED” area on the engine oil dipstick (2). Discard the gasket (13) and the O-ring seal (11). . While the engine is stopped. Illustration 149 g01288406 2. 8. Remove the gasket (13). Install the screws (2). Loosen the clamp (9) and remove the hose (10) from the connector (12). 10. Install the plate (3). Install the cover (1) on the valve mechanism cover. Install the setscrews (8). Remove the plate (3). Discard diaphragm (4). 2.Check SMCS Code: 1302. Remove the O-ring seal (11) from the connector. Remove the screws (2). Open the engine access door on the top of the machine. To prevent possible injury. 1. Illustration 148 g01149576 i02571470 1. Engine Oil Level . 9. Position the connector in the valve mechanism cover. Remove the setscrews (8) and remove the connector (12) from the cylinder head. the cap (6). Engine damage can result. and a new diaphragm (4). Personal injury can result from parts and/or covers under spring pressure. Tighten the setscrews to a torque of 9 N·m (80 lb in). 7. Install the hose (10) on the connector (12). 11. Install a new O-ring seal (11) on the connector (12). Install a new gasket (13) on the connector (12).112 Maintenance Section Engine Crankcase Breather . 1318. Remove the diaphragm (4) and the cap (6). Spring force will be released when covers are removed.

change the oil and the filter element after every 250 hours or after every month. . Install the fuel filter/water separator. 4. Illustration 150 g01359728 Obtain a sample of the engine oil from the sampling port for the engine oil. 5. “How To Take A Good Oil Sample” for more information about obtaining a sample of the engine oil. If necessary. Otherwise. Remove the filter element with a strap type wrench. use an oil with a TBN of 30. 5.SEBU8287-05 113 Maintenance Section Engine Oil Sample . i02708914 Engine Oil Sample . SEBU6250. PEHP6001. For non-Caterpillar filters. change the oil and change the filter element after every 250 hours or after every month. 1318. Remove the fuel filter/water separator. Close the engine access door. 7. 3.Replace”. Refer to Special Publication. change the oil and the filter element after every 500 hours or after every three months. Make sure that the old filter gasket has been removed. remove the oil filler cap (1) and add oil. 6. Clean the filter mounting base with a clean cloth. 7542-008 g01357747 Illustration 151 1. With the high sulfur fuel. Clean the crankcase drain plug and replace the crankcase drain plug. “Fuel System Filter and Water Separator . i02706770 Illustration 152 g01180774 Engine Oil and Filter . The sampling port is located on the engine oil filter base. Refer to Special Publication. 2.Change SMCS Code: 1302.5% by weight. “S·O·S Oil Analysis” for information that pertains to obtaining a sample of the engine oil. If the API category is CF-4 or less. Apply a thin film of clean engine oil to the sealing surface of the new filter element. refer to the installation instructions that are provided by the supplier of the filter.Obtain SMCS Code: 1348-008. Remove the crankcase drain plug and drain the oil into a suitable container.Obtain 3. 4. 1326 Note: If the sulfur content in the fuel is greater than 1. Instructions for the installation of the filter are printed on the side of each Caterpillar spin-on filter. Refer to Operation and Maintenance Manual. Clean the oil filler cap and install the oil filler cap. Install the new oil filter by hand.

Maintain the oil level in the crosshatched region of the engine oil dipstick (2). Check for leaks.4 mm (1 inch) off of the ground. Start the engine and allow the oil to warm. Stop the engine and allow the oil to drain back into the oil pan. Position the machine as shown in figure 154. Do not apply lubricant to the pads. Fully extend the extendable stick. 11. 1209 Note: A qualified service person should perform the valve lash check and/or the valve lash adjustment.2 mm to 101. The wear pads do not require the application of lubricant. Fill the crankcase with new oil. Special tools and training are required. retract the stick 76. Upper Wear Pad Illustration 153 g01288406 9. Engine Valve Lash . 6533-040 Note: The wear pads on the extendable stick are impregnated with a lubricant. if necessary.Check SMCS Code: 1102-082.Check SEBU8287-05 8. 2.114 Maintenance Section Engine Valve Lash . “Capacities (Refill)”. Refer to Operation and Maintenance Manual. i03066310 Extendable Stick Pads Inspect/Adjust (If Equipped) SMCS Code: 6533-025. 5. Clean the oil filler cap and install the oil filler cap. 1209-082. Remove the oil filler cap (1). 1102-535. i01897328 Illustration 154 g01359011 1. 10. “Lubricant Viscosities” and Operation and Maintenance Manual. 3. Replace the engine access panel and close the engine access door. Refer to your machine's Service Manual for complete instructions. Raise the rear of the backhoe so that tires are 25. Lift the stabilizers off the ground. Open the engine access door on the top of the machine. Add oil.6 mm (3 inch to 4 inch). 4. Then. Pull stick in and position the rear bucket so that the bottom of the bucket and the bucket teeth are flat on the ground. 12. . Fully extend the stick. 1102.

Turn the set screw counterclockwise in order to increase the gap. perform steps 9.SEBU8287-05 115 Maintenance Section Extendable Stick Pads .0394 inch). j. c. 6. Illustration 156 g01359172 g.0 mm (0. Retract the extendable stick halfway. c. When the gap is correct. Tighten two bolts (3) in order to secure the upper wear pad. h. 10.0 mm (0.a through 9.04 inch) proceed to Step 9. b. Loosen two bolts (3) that secure the upper wear pad (1) in place. apply 154-9731 Thread Lock Compound.5 mm (0.g.e. a.02 inch) proceed to Step 8. or more than 1 mm (0. Illustration 155 g01359257 k. If the gap is less than 0. Note: Do not loosen the two bolts that are under the setscrew. Turn set screw (2) clockwise in order to decrease the gap. d. c. d. The gap should be between 0. If necessary. Loosen two bolts (3) that secure the upper wear pad (1) in place. b.a through 8.c. Check extension of the stick after adjusting the upper wear pad. The upper wear pad should slide back to the stop. Set the stick horizontally to the ground. e. perform steps 8.a through 9. If the gap is more than 1. d. continue to “Inspect the Gap of the Lower Wear Pads”. If the gap between the upper wear pad and the bottom surface of the inner stick is less than 0. e. Measure the gap that is between the wedge and the bottom surface of the inner stick. Loosen set screw (2) by two turns. Return the machine to the position that is shown in figure 156. perform steps 9. f. i. a. adjust the upper wear pad to the maximum gap of 1 mm (0. apply 154-9731 Thread Lock Compound to both bolts (3). tighten bolts (3) in order to secure the upper wear pad.0197 inch). If the vibration is evident.0394 inch). 7. Check for clearance on the upper wear pad. When the gap is correct. Note: Do not loosen the two bolts that are under the setscrew.Inspect/Adjust f.5 mm (0. Extend the stick and retract the stick in order to check for any vibrations. After you set the clearance.i. Proceed to Step 10.04 inch). If the vibration continues contact the Dealer Service Network (DSN). . g.5 mm (0. If no vibration is evident. b. Torque bolts (3) to 100 ± 20 N·m (74 ± 15 lb ft). Measure the gap that is between the wedge and the bottom surface of the inner stick. Proceed to Step 10. Use a feeler gauge in order to measure the gap between wedge (1) and the bottom surface of the inner stick. perform steps 8.0197 inch) and 1.a through 8. a. 8. Fully extend the stick. If necessary. 9. Torque bolts (3) to 100 ± 20 N·m (74 ± 15 lb ft).

Illustration 158 g01359277 Illustration 157 g01359314 1. 2. If the gap is correct.5 mm (0. This will create a gap between the lower wear pad and the outer extendable stick. If the gap between the lower wear pad and the bottom surface of the outer stick is less than 0. measure the gap between the top of the flat wear pad that is bolted to the inner stick and the inside surface of the outer stick. If the gap is less than 0.0197 inch). Remove access plate (4) and remove the two caps for the access holes (5).Inspect/Adjust SEBU8287-05 Note: A small amount of vertical movement of the outer slider is acceptable with a gap of 1 mm (0. Position the machine.04 inch). Turn set screw (7) counterclockwise by two turns. Slightly lift the rear of the machine. 6. Ensure that you can access the bolts after the stick has been extended by a few inches. apply 154-9731 Thread Lock Compound to both bolts (6).116 Maintenance Section Extendable Stick Pads . or more than 1 mm (0. perform steps: a. Slide the stick out 25 mm (1 inch) to 75 mm (3 inch). Check for clearance on the lower wear pad. Turn set screw (7) clockwise in order to decrease the gap.0394 inch). Note: Do not loosen the two bolts that are under the setscrew. Return the machine to the position that is shown in figure 158. Note: Ensure that the wear pad is pulled back against the set screw. . Loosen the two bolts (6) that secure the lower wear pad in place. f. b. Measure the gap and make any needed adjustments. Note: Do not loosen the two bolts that are under the setscrew. g. c. Loosen the two bolts (6) that secure the lower wear pad in place.5 mm (0. b.0 mm (0.04 inch) proceed to Step 7. Inspect the Gap of the Lower Wear Pads Illustration 159 g01359416 a. Refer to Illustration 158 3. d.02 inch) proceed to Step 6. Torque the bolts (6) to 100 ± 20 N·m (74 ± 15 lb ft). Note: The lower wear pad should return against the set screw. 7. 5. Fully retract the extendable stick in order to allow access through the nose of the stick. If the gap is more than 1. perform the following steps: e. Tighten the bolts. 4. At access holes (5).

apply 154-9731 Thread Lock Compound to both bolts (6). Measure the gap and make any needed adjustments. e. proceed to “Adjustment of the Side Pad”. Adjustment of the Side Pad • Extended 50.2 mm (3 inch) • Half extended • Fully extended Illustration 160 g01359481 1. Refer to Illustration 160. d. If no vibration is evident. Set the stick so the stick is horizontal to the ground. Check each side wear pad with the outer slider in the following positions.0 mm (0. 4. Torque the bolts (6) to 100 ± 20 N·m (74 ± 15 lb ft). 3. Checking Extension of the Stick 1. 2. 4. Extend and retract the extendable stick in order to check for any vibrations. Illustration 161 g01283762 2. If the gap is correct. Raise the rear of the backhoe and make sure that the boom nose is level with the ground.Inspect/Adjust c.SEBU8287-05 117 Maintenance Section Extendable Stick Pads .8 mm (2 inch) to 76. If the adjustment of the wedge has been performed and vibration is evident proceed to “Adjustment of the Side Pad”. . Note: A small amount of vertical movement of the outer slider is acceptable with a gap of 1. Fully extend the stick and place the curled bucket slightly off the ground.0394 inch). Position the machine. Check for free play between the side wear pads and the inner section of the stick. 3.

5 mm (0.5 mm (0.0098 inch) (9) No gap g01413212 5. b. Reassemble the cover (11) and torque the hex socket screws (10) to 50 ± 10 N·m (37 ± 7 lb ft).25 mm (0. 6.0098 inch) gap is present at the widest part of the three checked positions. If adjustment is too tight.25 mm (0. The top side pad and bottom side pad do not need to have an equal number of shims. d. Repeat steps for the remaining three additional side pads.02 inch) shim to one of the side pads and recheck the adjustment.0098 inch) feeler gauge to check each side wear pad. Note: The amount of shims should be equal on both sides within 0. c. d. e. 8.02 inch) shim to the corresponding pad on the other side and recheck the adjustment.5 mm (0. a. Use a 0.25 mm (0. Check extension of the stick after adjusting the side wear pads. See Illustration 162. The other side should have a 0. Setting the 0.02 inch) shim to the remaining wear pads.02 inch). b.25 mm (0. One side should have no gap between the inner slider and the face of the pad (9). Remove the four hex socket screws (10) and the plate (11).118 Maintenance Section Extendable Stick Pads .0098 inch) or less gap (8).Inspect/Adjust SEBU8287-05 Illustration 163 (10) 284-3615 Hex Socket Screws (11) 233-5165 Plate g01413217 a. Ensure that a 0.25 mm (0. Set the stick horizontally to the ground.0098 inch) gap at a narrow point of the inner slider may allow vibrating as the wear pads travel over the wider points of the slider. If adjustment continues to be too tight. c. This will be the position of the smallest gap between the inner slider and side wear pad. Apply an adequate number of shims in order to make the side lower wear pad flush with shims. e.5 mm (0. perform the following steps: . Note: Choose a pad with the heaviest wear marks. If adjustment is still too tight. Illustration 162 (8) 0. then add a 0. Proceed to Step 8. Extend the stick and retract the stick in order to check for any vibrations. then add a 0. then add a 0. If adjustment is required. 7.

These problems are magnified by wind. Ensure that the surface of the product identification films is flushed with clean water and allow the product identification films to air dry. 7557-070 Power Washing Power washing or washing with pressure may be used in order to clean product identification films. If the stick continues to vibrate. • A maximum pressure of 83 bar (1200 psi) • A maximum water temperature of 50° C (120° F) • Hold the nozzle perpendicular to the product identification film at a minimum distance of 305 mm (12 inch). Use a wet solution with a “pH” value between 3 and 11. Film (Product Identification) Clean SMCS Code: 7405-070. f. Use a soft brush.02 inch) of additional shimming at all four pads. g02175297 • Do not direct a stream of water at a sharp angle to Cleaning of the Films Make sure that all of the product identification films are legible.SEBU8287-05 119 Maintenance Section Film (Product Identification) . i03997106 Hand Washing Use a wet solution with no abrasive material that contains no solvents and no alcohol. These problems are critical for the perforated film on windows. allowing the product identification film to lift or curl. Water lessens the adhesion of the product identification film to the product.5 mm (0. Ensure that all the product identification films are not damaged or missing.Clean Note: Recheck for vibration before the addition of each shim. contact the DSN. follow these important steps: • Use a spray nozzle with a wide spray pattern. Avoid wearing down the surface of the product identification films with unnecessary scrubbing. Excessive pressure during power washing can damage the product identification films by forcing water underneath the product identification films. . Clean the product identification films or replace the films. the edge of the product identification film. aggressive washing can damage the product identification films. Illustration 165 Typical example of the Product Identification Films. Illustration 164 g02174985 To avoid lifting of the edge or other damage to the product identification films. However. Make sure that the recommended procedures are used in order to clean the product identification films. or a sponge in order to clean the product identification films. a rag. Do not exceed 0.

Use the line on the final drive as a reference. Check the plug for an increased amount of metal on the plug. The plug is magnetic. Clean the plug and install the plug. “Capacities (Refill)” for the oil. If any abnormal particles are found. 4. Illustration 169 g01182493 . 5. Clean the plug and install the plug. Add oil until the oil is level with the plug threads. Refer to Operation and Maintenance Manual. Illustration 168 g01182493 1. Remove the oil fill/drain plug in order to check the oil level. Position the plug hole at a horizontal position. “Lubricant Specifications” and Operation and Maintenance Manual. consult your Caterpillar dealer. The plug is magnetic.Obtain SMCS Code: 4050-008-FR. Position the oil fill/drain plug at a horizontal position in order to check the oil level. 4. 7542-008 Illustration 167 g01182493 3. Position the oil fill/drain plug at the bottom. 2.120 Maintenance Section Final Drive Oil (Front) .Change SEBU8287-05 i02369952 i02370034 Final Drive Oil (Front) . Repeat the procedure for the other final drive. 2. The plug will attract metal from the oil. 6.Change SMCS Code: 4050 Final Drive Oil Level (Front) Check SMCS Code: 4050 Illustration 166 g01182475 1. i02370039 Final Drive Oil Sample (Front) . The oil should be level with the bottom of the plug threads. 3. 5. Repeat the procedure for the other final drive. Remove the oil fill/drain plug and drain the oil into a suitable container. Check the plug for metal.

The machine uses a fuel filter with a push and twist collar. Fuel System Secondary Filter Replace SMCS Code: 1261-510-SE NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. NOTICE It is extremely important to drain water from the water separator daily. 4. Dispose of all fluids according to local regulations and mandates. “Lift Cylinder Brace Connect and Disconnect” for more information. testing. “How To Take A Good Oil Sample” for more information about obtaining a sample of oil. maintenance. The fuel would not be filtered and could be contaminated. SEBU6250. Coat the seal of the new filter element with clean diesel fuel. Remove primary fuel filter (1) that is located next to the engine oil filter under the left side of the machine. Refer to Special Publication. Illustration 170 g01357777 3. For non-Caterpillar filters. adjusting and repair of the product.Replace SMCS Code: 1261-510. Open drain valve (2) and drain the fuel into a suitable container. 2. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.SEBU8287-05 121 Maintenance Section Fuel System Primary Filter (Water Separator) . or every ten hours. NOTICE Do not fill the primary fuel filter with fuel before installing. Install the lift cylinder brace. PEHP6001. Remove the access panel from the left side of the machine. 6. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 8. 10. 1. Clean the filter element mounting base.Replace Obtain the oil sample from the fill/drain plug. “Caterpillar Machine Fluids Recommendations”. It is also extremely important to drain water from the fuel tank weekly. refer to the installation instructions that are provided by the supplier of the filter. Install the new fuel filter by hand. . Rotate the locking ring counterclockwise in order to remove the filter element. Discard the filter properly. Instructions for the installation of the filter are printed on the side of each Caterpillar spin-on filter. 7. Refer to Special Publication. i03664531 Fuel System Primary Filter (Water Separator) . Refer to Special Publication. Replace the access panel. 1263-510 Some fuel supplies may not meet the minimum standard for fuel lubricity. or every 50 hours. Install the sensor and the wire into the new filter. Refer to Operation and Maintenance Manual. Caterpillar recommends the use of fuels that meet certain minimum specifications. Remove sensor (3) and the wire from the bottom of the filter. SEBU6250. i03671548 5. Remove any part of the filter element gasket that remains on the filter element mounting base. Failure to do so could result in damage to the fuel system. Use a hand priming pump to remove air from the system. Contaminated fuel will cause accelerated wear to fuel system parts. “S·O·S Oil Analysis” for information that pertains to obtaining a sample of the engine oil. 11. 9. NENG2500. Refer to Special Publication.

change the fuel filter. Contaminated fuel will cause accelerated wear to fuel system parts. Install the new secondary fuel filter by hand. Coat the seal for the new secondary fuel filter with clean diesel fuel prior to installation. Instructions for the installation of the filter are printed on the side of each Caterpillar spin-on filter. 1.122 Maintenance Section Fuel System Water Separator . Clean the fuel filter base. Caterpillar recommends the use of fuels that meet certain minimum specifications. 8.Drain SEBU8287-05 Note: Replace the secondary filter in an area that has no airborne dust or dirt. Caterpillar recommends the use of fuels that meet certain minimum specifications. For non-Caterpillar filters. Loosen the drain valve on the bottom of the fuel filter. 2. Refer to Special Publication. 1263 Some fuel supplies may not meet the minimum standard for fuel lubricity. “Lift Cylinder Brace Connect and Disconnect” for more information. 3. Illustration 171 g01357792 4. Refer to the Operation and Maintenance Manual. Park the machine on a level surface. Start the engine and check for leaks. The water separator is located by the drain plug for the engine crankcase. Refer to Operation and Maintenance Manual. SEBU6250. “Caterpillar Machine Fluids Recommendations”. 7. Failure to do so could result in damage to the fuel system. 3. NOTICE It is extremely important to drain water from the water separator daily. . Refer to Special Publication. refer to the installation instructions that are provided by the supplier of the filter. Tighten the drain valve. i02706838 Fuel System Water Separator . Use a strap wrench and remove the secondary fuel filter.Replace”. Remove the access panel from the left side of the machine. SEBU6250. 2. or every 50 hours. i02706870 Fuel Tank Water and Sediment . The fuel would not be filtered and could be contaminated. 6. Ensure that the parking brake is fully engaged. change the fuel filter. It is also extremely important to drain water from the fuel tank weekly. Do not expose new filters to surfaces that are not clean. If the engine fails to start. Illustration 172 g01357814 1. 5. Discard the secondary fuel filter properly. or every ten hours. “Caterpillar Machine Fluids Recommendations”. Install the lift cylinder brace. “Fuel System Primary Filter (Water Separator) . Note: Before you replace the secondary fuel filter. Allow the water and the sediment to drain into a suitable container.Drain SMCS Code: 1273-543-M&S Some fuel supplies may not meet the minimum standard for fuel lubricity.Drain SMCS Code: 1263-543. the primary fuel filter must be replaced. If there is a power loss. NOTICE Do not fill the secondary fuel filter with fuel before installing.

SEBU8287-05 123 Maintenance Section Fuses . Replace the fuel tank cap. Otherwise. Failure to do so could result in damage to the fuel system. Illustration 173 g01357835 Flip up the tab on the fuel cap. Contact your Caterpillar dealer Illustration 175 g01457511 Backup Alarm (1) – Relay Power Port (2) – 10 Amp Machine ECM (3) – 20 Backup Alarm (4) – 15 Amp Roading Lights (5) – 20 Amp Flasher Module (6) – 15 Amp Engine Stop (7) – 10 Amp Horn and Position Lights (8) – 15 Amp Rear Window Wiper and Washer (9) – 20 Amp Laser Mast (10) – 20 Amp . If the element of a new fuse separates. i02940497 Fuses . or every ten hours. or every 50 hours. The fuel tank drain valve (1) is located on the lower right corner on the front of the fuel tank. NOTICE Replace the fuses with the same type and size only. check the circuit. The fuel tank is located on the left side of the machine. Turn the tab counterclockwise on the fuel cap and slowly remove the fuel tank cap (2) in order to relieve pressure. It is also extremely important to drain water from the fuel tank weekly. electrical damage can result.Replace NOTICE It is extremely important to drain water from the water separator daily. If it is necessary to replace fuses frequently. Illustration 174 g01195099 Remove the cover on the front of the right side console in order to access the main fuse panel. Tighten the fuel tank drain plug. Replace the fuse if the element separates.Replace SMCS Code: 1417 Fuses protect the electrical system from damage that is caused by overloaded circuits. an electrical problem may exist. if necessary. Loosen the fuel tank drain plug in order to drain a steady stream of liquid. Repair the circuit. Allow the water and sediment to drain into a suitable container.

Illustration 176 g01262390 Differential Lock (19) – Relay Fuel Pump (20) – 15 Amp Monitor (21) – 5 Amp Rotating Beacon (22) – 15 Amp Air Conditioner (23) – 10 Amp Auxiliary Front Floodlights (24) – 15 Amp Front Window Wiper and Washer (25) – 20 Amp Hydraulic Lockout (26) – Relay Front Floodlights (27) – 15 Amp All Wheel Drive (28) – Relay Ride Control (29) – Relay Taking oil samples under a running machine may cause personal injury or death. The use of a sample tube allows an oil sample to be taken while the person is outside of the tread path of the tires. • The parking brake is applied. . • All implements are lowered to the ground. • The swing lock pin is engaged. The oil sample should then be taken only when the following conditions exist: • The machine transmission is in NEUTRAL. 1. The sample tube should be attached to the sample port when the machine is not running. Attach a hose with a female quick disconnect fitting to the hydraulic quick disconnect fitting. 2.124 Maintenance Section Hydraulic Oil Sample . The hydraulic oil filter housing is located near the rear axle. 7542-008 Illustration 177 g01412119 Obtain a sample of the hydraulic oil from the hydraulic quick disconnect fitting that is located on the hydraulic oil filter housing. Turn off the engine. • The hydraulic lockout switch (if equipped) is applied.Obtain SEBU8287-05 Rear Floodlights (11) – 15 Amp Auxiliary Rear Floodlights (12) – 15 Amp Air Seat (13) – 20 Amp Left Tail Light (14) – 10 Amp Dash Panel Lights (15) – 10 Amp Right Tail Light (16) – 10 Amp Horn (17) – Relay Tail Lights (18) – Relay Ride Control and Hydraulic Lockout (30) – 20 Amp i02830866 Hydraulic Oil Sample . Note: Ensure that all personnel are clear of the machine before starting the engine.Obtain SMCS Code: 5050-008.

SEBU8287-05 125 Maintenance Section Hydraulic System Oil . the hydraulic oil change interval may be extended to 4000 Service Hours or 2 Years.Change 3. 6000 hour oil drain intervals are possible when using S·O·S Services oil analysis. Remove the hydraulic tank filler cap. Refer to Special Publication. Open the engine access door on the top of the machine. 4. Operate the machine for a few minutes in order to warm the hydraulic system oil. Tighten the drain valve. Turn off the engine. Engage the parking brake and stop the engine. Refer to the Operation and Maintenance Manual. Allow the oil to drain into a suitable container. If S·O·S oil analysis is not available. . Contact your Cat dealer for details. The machine should be level . refer to Special Publication. Turn the engine start switch in order to start the engine. Note: Cat HYDO Advanced 10 has a 50% increase in the standard oil drain interval for machine hydraulic systems (3000 hours versus 2000 hours) over second and third choice oils . SEBU6250. The results from the S·O·S oil analysis will determine if the hydraulic oil change interval may be extended. i03211907 The hydraulic tank filler cap is located under the access door on the top of the engine compartment. Illustration 180 g01412174 Illustration 179 g01412119 3. Open the drain valve that is located on the hydraulic pump. PEHP6001. 6. By performing S·O·S oil analysis. For additional information about taking an oil sample. Use the hose in order to obtain a sample of the hydraulic oil. Illustration 178 g01289083 2. Remove the hose that was used to obtain the oil sample. S·O·S oil analysis must be performed at every 500 Service Hours or 3 Months in order to extend the hydraulic oil change interval. the hydraulic oil change interval must remain at every 2000 Service Hours or 1 Year . “S·O·S Oil Analysis” for information that pertains to a sample of the hydraulic oil. Lower the bucket to the ground and apply slight downward pressure. 1.Change SMCS Code: 5056 Note: The normal hydraulic oil change interval is at every 2000 Service Hours or 1 Year. “How To Take A Good Oil Sample”. 4. 5. Note: Allow oil to pass through the hose for 10 seconds before obtaining the sample in order to ensure that no contaminants are in the oil sample.when following the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual for your particular machine. “S·O·S Information”. Hydraulic System Oil .

Remove the filter element with a strap type wrench. Remove the hydraulic tank filler cap that is located under the access panel on the top of the engine compartment. Remove the hydraulic tank breather. “Capacities (Refill)”. 6. Replace the breather. Replace the gasket.126 Maintenance Section Hydraulic System Oil Filter . Fill the hydraulic system oil tank. i02831278 Illustration 183 g01210154 Note: The hydraulic filter is located next to the rear axle. refer to the installation instructions that are provided by the supplier of the filter. Apply a light coat of oil to the gasket of the new filter element. Check the hydraulic oil level with the loader on the ground and with the backhoe in the transport position. Replace the old breather with a new breather. Inspect the hydraulic tank breather that is located in the breather hose on top of the hydraulic tank.Replace SEBU8287-05 5. 7. if necessary. Tighten the oil filter to a torque of 44. If bubbles are present in the oil. . 5068 1. Hydraulic System Oil Filter Replace SMCS Code: 5056. 10. Note: The oil must be free of bubbles. 3. 6. 7. Illustration 181 g01412213 8. “Lubricant Viscosities” and Operation and Maintenance Manual. Refer to Operation and Maintenance Manual. Inspect the gasket on the hydraulic tank filler cap for damage. Install the new oil filter. Clean the filter element mounting base. For non-Caterpillar filters. Close the access door. Illustration 182 g01289083 2. 5. Instructions for the installation of the filter are printed on the side of each Caterpillar spin-on filter. Refer to Operation and Maintenance Manual. if necessary. Inspect the suction hoses and hose clamps. 4.74 ± 8 N·m (33 ± 6 lb ft).Change”. “Hydraulic System Oil Filter . Open the engine access door on the top of the machine. air is entering the hydraulic system. Install the hydraulic tank filler cap. Change the hydraulic system filter. Remove any part of the filter element gasket that remains on the filter element mounting base. 11. Maintain the hydraulic oil level in the sight gauge between the “MIN” mark and the “MAX” mark. 9.

7071 Illustration 184 g01412213 8. if necessary.Check i02710271 Loader Bucket. Wait about five minutes before you check the hydraulic system oil level. There is a grease fitting for each side of the machine. The sight gauge for the hydraulic tank is located on the left side of the machine. 10. Illustration 185 g01412213 Apply lubricant to grease fitting (6) for the rod end of the tilt cylinder. 7479 Apply lubricant to grease fittings (1) for the frame and for the lift arm. Inspect the gasket on the hydraulic tank filler cap for damage. Maintain the oil level in the sight gauge between the “MIN” mark and the “MAX” mark. There is a grease fitting in each linkage (four total).SEBU8287-05 127 Maintenance Section Hydraulic System Oil Level . if necessary. There is a grease fitting for each side of the machine. There is a grease fitting for each side of the machine. 11. Replace the gasket. 7070.Lubricate SMCS Code: 7069. . 9. Apply lubricant to grease fittings (5) for the pivot bearings for the bucket tilt cylinder. Add oil. Cylinder. There is a grease fitting for each side of the machine. Turn off the engine. Install the hydraulic tank filler cap. There is a grease fitting for each side of the machine. Close the access door. Apply lubricant to grease fitting (9) for the pivot for the linkage of bucket positioner and lift kickout. Apply lubricant to grease fittings (4) for the pivot pin at the loader lift arm. Apply lubricant to grease fittings (3) for the rod end of the lift cylinder. Move the backhoe to the transport position and lower the loader bucket to the ground. Apply lubricant to grease fittings (7) for the upper pivot pin. Maintain the hydraulic oil level in the sight gauge between the “MIN” mark and the “MAX” mark. i02831279 Illustration 186 g01360191 Hydraulic System Oil Level Check SMCS Code: 5056. Apply lubricant to grease fittings (8) for the lower pivot pins. and Linkage Bearings . Apply lubricant to grease fitting (2) for the pivot for the linkage of bucket positioner and lift kickout.

a magnet can be used to differentiate between ferrous metals and nonferrous metals. The particles could enter the lubricating system and the particles could cause damage.Inspect SEBU8287-05 Apply lubricant to grease fittings (10) for the head end of the lift cylinder. If metals are found in the filter element. and to other parts. Check the brakes on a dry. Oil Filter . The parking brake is referred to as the parking brake when used in a holding application. Open the engine access door on the top of the machine. 5068 Inspect a Used Filter for Debris Check Procedure Check the area around the machine. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. i02106227 Parking Brake . and in the brake holding ability. Small amounts of debris may be found in the filter element. to the crankshaft. Ferrous metals can indicate wear on steel parts and on cast iron parts. level surface. g00100013 . etc. 3067. There are a total of 18 grease fittings. in the power train efficiency. rod bearings. The following check is used to determine if the parking brake is functional. There is a grease fitting for each side of the machine. The brake holding effort that is required to sustain a machine at a specific engine rpm varies depending on the machine.Inspect SMCS Code: 1318. Fasten the seat belt before you check the brakes. Spread apart the pleats and inspect the element for metal and for other debris.Check/Adjust SMCS Code: 4267 Note: The parking brake can also be referred to as the secondary brake. An excessive amount of debris in the filter element can indicate a possible failure. This can result in larger particles in unfiltered oil. Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings. This could be caused by friction and by normal wear. Use a filter cutter to cut the filter element open. The parking brake is referred to as the secondary brake when used in a stopping application.128 Maintenance Section Oil Filter . or turbocharger bearings. Illustration 188 The element is shown with debris. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings. i04218069 Illustration 187 g01360192 Apply lubricant to grease fitting (11) for the pivot point for the lift arms. Make sure that the machine is clear of personnel and clear of obstacles. The variations are the differences in the engine setting. This check is not intended to measure the maximum brake holding effort.

2. 6. 3. If the machine moves during the parking brake test. This is done in order to override the transmission neutralizer. and back to FORWARD. If the machine is equipped with the direct drive transmission. As you view the parking brake adjuster knob from the operator seat. i02514305 Illustration 189 g02397596 2. If the machine is equipped with a power shift transmission move the transmission control lever to THIRD SPEED FORWARD. Adjustment Procedure If the machine moved during the test. Engage the parking brake. If the machine is equipped with the direct drive transmission. 4. Stop the engine. Note: The parking brake indicator light should come on and the parking brake alarm should sound. Stop the engine. to NEUTRAL.SEBU8287-05 129 Maintenance Section Radiator Core .Clean 1. Lower the bucket to the ground. Move the transmission direction control to the NEUTRAL position. 5. The machine should not move.Adjust” for your machine. 8. Radiator Core . 1. If you run out of adjustment on the parking brake adjuster knob. Disengage the parking brake. “Parking Brake Control . Testing and Adjusting.Clean SMCS Code: 1353 If the machine begins to move. turn the knob clockwise for one half of a turn. Lower the bucket to the ground. Move the transmission direction control lever to FORWARD. Engage the parking brake. Raise the bucket slightly. Gradually increase the engine speed to high idle. to the NEUTRAL position and back to the FORWARD position. refer to Systems Operation. Start the engine. 7. Gradually increase the engine speed to 2000 rpm. Illustration 190 g01257883 . 9. Apply the service brakes. If the machine is equipped with a power shift transmission. perform the following procedure in order to adjust the parking brake. Reduce the engine speed. Raise the bucket slightly. move the transmission speed control to the THIRD SPEED FORWARD position. Move the transmission to NEUTRAL. Start the engine. move the transmission speed control to THIRD gear. then perform the adjustment procedure again. 5. Note: Place machines that are equipped with all wheel drive into two-wheel drive mode. 3. to NEUTRAL. The machine should not move. 4. This is done in order to override the transmission neutralizer for this test. Reduce the engine speed. reduce the engine speed immediately and apply the service brake pedal. move the transmission speed shift lever to THIRD gear. Move the transmission direction control to the FORWARD. and back to THIRD SPEED FORWARD. to the NEUTRAL position and back to the THIRD SPEED FORWARD position.

high pressure water. . refer to Testing and Adjusting. Do not straighten the ROPS.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. i02429589 Ride Control Accumulator Check SMCS Code: 5077-535-R6 The ride control accumulator reduces the pitching of the machine. Note: i02814826 Illustration 192 g01412225 1. Tighten the M24 bolts (1) to a torque of 524 ± 100 N·m (386 ± 74 lb ft). Replace the ROPS mounting supports if the ROPS rattles. Replace any parts that are damaged or worn before you operate the machine. Note: Special tools and equipment are required to test the accumulator. If the machine seems to be bouncing excessively. However. 2. Seat Belt . Replace the ROPS mounting supports if the ROPS emits a noise. Note: Apply oil to all ROPS bolt threads before you install the bolts. or steam to remove dust and other debris from the radiator fins. Consult your Caterpillar dealer for repair of any cracks in the ROPS.Inspect SMCS Code: 7325 Illustration 191 g00101939 NOTICE Do not spray high pressure water into the radiator while the engine is running.Check SEBU8287-05 i02831284 Rollover Protective Structure (ROPS) . Note: If necessary. Failure to apply oil to the bolt threads can result in improper bolt torque. You can use compressed air.130 Maintenance Section Ride Control Accumulator . Tighten the M16 bolts (2) to a torque of 165 ± 30 N·m (122 ± 22 lb ft). Inspect the ROPS for loose bolts or for damaged bolts. tilt the oil cooler away from the radiator in order to remove dust and debris between the radiator and the oil cooler. RENR6078 or consult your Caterpillar dealer. Replace any damaged bolts or missing bolts with original equipment parts only. Reference: For more information. check the charge in the ride control accumulator. the use of compressed air is preferred. Operate the machine on a rough surface. Do not repair the ROPS by welding reinforcement plates to the ROPS.

also perform this replacement procedure for the seat belt extension. A date label for determining the age of the seat belt is attached to the seat belt. replace the seat belt.Replace Illustration 194 Illustration 193 Typical example g00932801 g01152685 (1) (2) (3) (4) Date of installation (retractor) Date of installation (buckle) Date of manufacture (tag) (fully extended web) Date of manufacture (underside) (buckle) Check the seat belt mounting hardware (1) for wear or for damage. replace the seat belt . the seat belt buckle. If your machine is equipped with a seat belt extension.Replace SMCS Code: 7327-510 Within three years of the date of installation or within five years of the date of manufacture. 7222 Seat Belt . also perform this inspection procedure for the seat belt extension. If the buckle is worn or damaged. Illustration 195 g01412237 Position the stabilizer. There are a total of six grease fittings. the seat belt buckle.Lubricate SMCS Code: 5468. Replace the seat belt at the date which occurs first. as shown.SEBU8287-05 131 Maintenance Section Seat Belt . i02429594 Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. Replace the seat belt if the seat belt is worn or frayed. and the seat belt retractor. and the seat belt retractor. Replace the seat belt at the date which occurs first. If your machine is equipped with a seat belt extension. Note: Within three years of the date of installation or within five years of the date of manufacture. Apply lubricant to the grease fitting for the head end of the cylinder and the rod end of the cylinder. Repeat for the other stabilizer. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. A date label for determining the age of the seat belt is attached to the seat belt. Check buckle (2) for wear or for damage. Make sure that the mounting bolts are tight. Inspect the seat belt (3) for webbing that is worn or frayed. Replace any mounting hardware that is worn or damaged. replace the seat belt. . i02831322 Stabilizer and Cylinder Bearings .

with a stiff bristle brush. Remove the screen from the housing. “Tire Inflation with Air”.Check SMCS Code: 4203 Measure the tire pressure on each tire. 6. Drain the transmission oil. “Transmission Oil Change”.Lubricate SMCS Code: 5105. Repeat for the opposite side. The operating pressure is based on the following conditions.132 Maintenance Section Swing Frame and Cylinder Bearings . Apply lubricant to the grease fittings (2) for the bearing on the top of the swing cylinders. Wash the tube and the screen in a clean. 8. Remove the magnetic strainer cover. Apply lubricant to the grease fitting (6) for the eye of the swing cylinder. 6506. Tire Inflation . or with pressure air. Apply lubricant to the grease fitting (5) for the bottom swing pin. Illustration 196 g01412250 Apply lubricant to the grease fitting (1) for the boom lock. i02573936 Transmission Magnetic Screen . Refer to Operation and Maintenance Manual. Tire inflation pressures for each application may vary. Apply lubricant to the grease fitting (4) for the top swing pin. 3.Clean SMCS Code: 3030 1. i02369786 Illustration 197 g00725298 2. Remove the magnets from the housing. NOTICE Do not drop or rap the magnets against any hard objects. Install the magnets and the tube assembly into the magnetic screen. Replace any damaged magnets. Refer to Operation and Maintenance Manual. Tire wear may cause tire slippage. Clean the magnets with a cloth. 7063 • The rated payload • Average operating conditions Contact your tire supplier if your machine is experiencing tire slippage. if necessary. These tire inflation pressures should be obtained from your tire supplier. There are a total of ten grease fittings. Repeat for the other swing cylinder. nonflammable solvent. Install the magnetic screen. 6507. 5. 7. 4. . Repeat for the other swing cylinder. Inflate the tires. Apply lubricant to the grease fitting (3) for the bearing on the bottom of the swing cylinder.Lubricate SEBU8287-05 i02831359 • The weight of a ready-to-work machine at the front tires and at the rear tires Swing Frame and Cylinder Bearings .

Remove the dipstick/fill cap and fill the transmission with transmission oil. Install the cover. 3. Add transmission oil through the transmission filler tube. 7. Allow the transmission oil to drain into a suitable container. .Clean”. Illustration 200 6. 11. “Transmission Oil Change”. Illustration 199 g00725462 4. Replace the seal. 5.Change 9. “Lubricant Viscosities” and Operation and Maintenance Manual. Tighten the cover bolts. Replace the breather. Start the engine and run the engine at low idle. 9. 8. The machine should be level. Move the transmission control lever to NEUTRAL and engage the parking brake. Refer to Operation and Maintenance Manual. Change the transmission oil filter element. Refer to Operation and Maintenance Manual. Clean the breather in clean nonflammable solvent and allow the breather to dry. Open the engine access door on the top of the machine. Refer to Operation and Maintenance Manual. 10. “Transmission Magnetic Screen . Illustration 198 g01204398 g01289187 1.Change SMCS Code: 3030. if necessary. Inspect the transmission for leaks. Slowly operate the transmission controls in order to circulate the oil. Clean the transmission magnetic screen.SEBU8287-05 133 Maintenance Section Transmission Oil . Clean the cover and inspect the seal. “Capacities (Refill)”. Engage the parking brake and stop the engine.Replace”. Refer to Operation and Maintenance Manual. if the seal is damaged. Maintain the transmission oil level within the crosshatched region on the “CHECK WITH WARM OIL” side of the dipstick when the transmission is warm. Remove the transmission drain plug. Clean the transmission drain plug and install the transmission drain plug. i03008642 Transmission Oil . Lower the bucket to the ground and apply slight downward pressure. Apply the service brake. 2. 3080 Operate the machine for a few minutes in order to warm the transmission oil. Fill the transmission. “Transmission Oil Filter . Remove the transmission breather from the top of the transmission case.

8. Install the dipstick/fill cap and install the engine access door. The loader should be resting on the ground. Ensure that the oil level is within the crosshatched region on the “Safe to Start” side of the dipstick/fill plug. Ensure that the oil level is within the crosshatched region on the “Safe To Start” side of the dipstick/fill plug. For non-Caterpillar filters. 1. Install the new oil filter by hand. Inspect the filter element for leaks.Check” for more information. 3. Remove the dipstick/fill plug for the transmission. Remove any part of the filter element gasket that remains on the filter element mounting base. 3. i02573820 Transmission Oil Level . 2. 3080. Stop the engine. Clean the filter element mounting base. refer to the installation instructions that are provided by the supplier of the filter. Add transmission oil. 11. Start the engine and apply the service brake. 4. 6. 4. if necessary. Run the engine for 5 minutes. Stop the engine. if necessary. Check the transmission oil level. Refer to Operation and Maintenance Manual. 5. i02831406 Transmission Oil Filter Replace SMCS Code: 3067 The transmission filter is located on the left side of the machine .134 Maintenance Section Transmission Oil Filter . Start the engine. Instructions for the installation of the filter are printed on the side of each Caterpillar spin-on filter. Add transmission oil. “Transmission Oil Level . . Apply a light coat of oil to the gasket of the new filter element.Replace SEBU8287-05 Note: The transmission can be checked with cold transmission oil. Remove the transmission oil filter element with a strap type wrench. Open the engine access door on the top of the machine.Check SMCS Code: 3030. Move the transmission control lever to NEUTRAL and engage the parking brake. Illustration 202 g01289187 7. Illustration 203 g01289187 2. 10. Slowly operate the transmission controls in order to circulate the transmission oil. Illustration 201 g01412282 1. 3081 Check the transmission oil level while the machine is on a level surface.

Clean the dipstick/fill plug and install the dipstick/fill plug. The nut and the stud should be clean and dry for reassembly. NOTICE When operating in freezing temperatures. SEBU6250. i03480604 Window Washer Reservoir Fill SMCS Code: 7306-544 Illustration 204 g01425123 Obtain a sample of the transmission oil from the transmission oil filler tube. if necessary. maintenance. 4199.Obtain 5. Maintain the oil level within the crosshatched region on the “CHECK WITH WARM OIL” side of the dipstick/fill plug when the transmission is warm and the engine is at low idle. Remove the transmission oil filler cap (1). i02861196 2. Refer to Special Publication. Wheel Nut Torque . Check the torque on new wheels or repaired wheels after every ten service hours until the specified torque is maintained. Add transmission oil. PEHP6001. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Do not allow hot oil or hot components to contact skin. Check the nuts on all four wheels. 4200 Illustration 205 g01263488 Hot oil and hot components can cause personal injury. Use a star pattern when you torque the nuts.SEBU8287-05 135 Maintenance Section Transmission Oil Sample . Torque the nuts to 460 ± 60 N·m (339 ± 44 lb ft). Dispose of all fluids according to local regulations and mandates. Install transmission oil filler cap (1). 6. Refer to Special Publication. Apply one drop of lubricating oil to the stud before installing the nut onto the stud. “How To Take A Good Oil Sample” for more information about obtaining a sample of the transmission oil. NENG2500. testing. . use Caterpillar or any commercially available nonfreezing window washer solvent. 7542-008 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Refer to Special Publication. i02525863 Transmission Oil Sample Obtain SMCS Code: 3030-008. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 3.Check SMCS Code: 4051. Obtain the oil sample with a 1U-5718 Vacuum Pump. adjusting and repair of the product. 1. “S·O·S Oil Analysis” for information that pertains to obtaining a sample of the engine oil.

Window Wipers Inspect/Replace SMCS Code: 7305 Inspect the condition of the wiper blades. unless handholds are available. 2. Never use a cleaning solvent on polycarbonate windows. or damp cloth. Also use plenty of lukewarm water. Dry the windows with a moist chamois or with a moist cellulose sponge. . Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs. of isopropyl alcohol. Allow the cleaner to dry. Soap and Water Use a clean sponge or a soft cloth.136 Maintenance Section Window Wipers . wash the windows with soap and with water. 3. Remove the filler cap. Open the engine access door. Rub the window with moderate pressure until all the dirt is removed. Rinse the windows thoroughly.Inspect/Replace SEBU8287-05 Illustration 206 g01819233 Illustration 207 Typical example g00566124 The washer fluid bottle is located in the engine compartment. Windows .Clean SMCS Code: 7310. Never use a dry cloth or paper towels on polycarbonate windows. i01437556 Cleaning Methods Aircraft Window Cleaner Apply the cleaner with a soft cloth. or of Butyl Cellosolve. Fill the washer fluid bottle with washer fluid through the filler opening. 1. Then. Wash polycarbonate windows with warm water and a soft sponge. i03912371 Stubborn Dirt and Grease Wash the windows with a good grade of naphtha. Close the engine access door. Replace the filler cap. 5. Rinse the windows with a sufficient amount of clean water. 7340 Clean the outside of the windows from the ground. 4. Wash the windows with a mild soap or with a mild detergent. Wipe off the cleaner with a clean soft cloth. Polycarbonate Windows (If equipped) Wash polycarbonate windows with a mild soap or detergent.