CUSTOMER SERVICES SUPPORT

TECHNICAL INFORMATION SOLUTIONS-INDIA

Service Magazine
SM NO : 94 MAY 2010

Table of Contents
Release of 2021B Wheel Loader Parts
Information for new BS III Engine introduction
(Parts Manual) ............................................... 2

Release of 2021B Wheel Loader Service

Information for new BS III Engine introduction
(Operation and Maintenance Manual) ............ 2

Wheel Loader :
2021B (S/N: L2Z06151-Up)

SM NO : 94, May 2011 1

New BS III Engine is now used
in 2021B Wheel Loader
Wheel Loader :
2021B (S/N: L2Z06151-Up)

Description of Change: As a product improvement,

new Engine 81050050 with BS III compliant is
introduced in 2021B Wheel Loader.

New revised Parts Manual 81805873-03 is

available for 2021B Wheel loader, which is updated
with new BS III Engine.

Affected Parts Sheets are shown in Pages 3 to 36

New revised Operation and Maintenance Manual

81808304-00 is available for 2021B Wheel loader,
which is updated with new BS III Engine.

Affected sheets are shown in pages 37 to 54

200000048128, 200000048845,
200000050452, 200000051147,
200000052058 & 200000051534

2 SM NO : 94, May 2011

 CHASSIS
81050095 FRAME & PIN AS-REAR
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050090 1 FRAME AS-REAR
2 1 81009199 1 OSCILLATION MOUNTING AS
81009198 1 OSCILLATION AS
9205559 2 BUSHING
B 3 1 89211275 1 SHIM
B 4 1 89211276 1 SHIM
B 5 1 81000629 1 SHIM
6 1 81017039 2 WASHER-THRUST
7 1 9012967 2 PIN AS
8 1 0S-1595 4 BOLT
9 1 9411017 4 LOCKWASHER
10 1 89217321 4 WASHER
11 1 118753 4 ELBOW
12 1 81027803 2 GROMMET
13 1 81016134 2 HOSE AS
14 1 9411017 2 FITTING-LUBE
15 1 81001259 1 NUT
16 1 81008268 1 PIN AS
17 1 9193993 1 STOP
18 1 1A-1460 1 BOLT
B-USE AS REQUIRED

GRAPHIC #1 CL 02

1 of 2 CHASSIS 1A
SM NO : 94, May 2011 3
 CHASSIS
81050095 FRAME & PIN AS-REAR (contd.)

GRAPHIC #1

1B CHASSIS 2 of 2
4 SM NO : 94, May 2011
 CHASSIS
81050087 COWL AND GRILL INSTALLATION
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050140 1 RADIATOR COVER
2 1 81047554 1 GRILL AS
3 1 0S-0509 4 BOLT
4 1 8T-4896 4 WASHER
5 1 271556 4 BOLT
6 1 8T-4122 4 WASHER-HARD
7 1 81050086 1 RADIATOR SUPPORT
8 1 0S-1594 8 BOLT
9 1 8T-4121 8 WASHER

GRAPHIC #1 CL 03

1 of 1 CHASSIS 2
SM NO : 94, May 2011 5
 CHASSIS
81050089 HOOD INSTALLATION-REAR
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050088 1 HOOD AS-REAR
2 1 179837 9 BOLT
3 1 81001260 9 NUT
4 1 8T-4896 9 WASHER-HARD

GRAPHIC #1 CL 02

4 CHASSIS 1 of 1

6 SM NO : 94, May 2011

 ENGINE

THIS UNIT IS EQUIPPED WITH KIRLOSKAR OIL ENGINES (KOEL) (DIESEL ENGINE). BY MUTUAL
AGREEMENT WITH THE ENGINE MANUFACTURER WE DO NOT SELL ENGINE OR ENGINE PARTS.
ENGINE PARTS SHOULD BE SECURED FROM THE NEAREST MANUFACTURER'S APPROPRIATE
SALES AND SERVICE OUTLET.

ILLUSTRATIONS AND PART NUMBERS OF ENGINE PARTS ARE OMITTED FROM THIS PARTS BOOK.
WHEN A PARTS BOOK IS FURNISHED WITH NEW UNITS AN ENGINE PARTS BOOK PUBLISHED BY
KOEL WILL BE SUPPLIED WITH IT FOR PARTS COVERAGE ON THE ENGINE. ANY ADDITIONAL
REQUIREMENTS FOR THIS ENGINE PARTS BOOK OR ANY QUESTIONS PERTAINING TO ENGINE
PARTS AND WARRANTY SHOULD BE DIRECTED TO THE ENGINE MANUFACTURER'S APPROPRIATE
SALES AND SERVICE OUTLET THROUGH CATERPILLAR DEALERS.

8 ENGINE 1 of 1
SM NO : 94, May 2011 7
 ENGINE
81050051 ENGINE INSTALLATION
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 2 81050050 1 ENGINE AS
2 1 81050036 1 BRACKET AS-RH
3 1 81050038 1 BRACKET AS-LH
4 2 81050113 2 ANTI VIBRATION MOUNT-ENGINE
5 2 81050081 2 ANTI VIBRATION MOUNT-TRANSMISSION
6 2 81050193 4 BOLT
7 2 2J-3505 4 NUT
8 2 5P-8249 4 WASHER
9 2 81050194 8 BOLT
10 2 81050195 8 WASHER
11 2 81050200 4 RE-BOUND WASHER
12 1,2 81050245 1 ENGINE FAN AS
M 13 2 81026859 12 BOLT (M10X1.5)
14 2 8T-4121 12 WASHER-HARD
F 81050198 8 BOLT
M-METRIC PART
F-NOT SHOWN

GRAPHIC #1 CL 02

1 of 2 ENGINE 9

8 SM NO : 94, May 2011

 ENGINE
81050051 ENGINE INSTALLATION (contd.)

GRAPHIC #2

9A ENGINE 2 of 2
SM NO : 94, May 2011 9
 ENGINE
81050126 AIR CLEANER INSTALLATION
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050052 1 HOSE-MOLD
2 1 81050053 1 HOSE-MOLD
Y 3 1 81050222 1 KIT-AIR CLEANER AS 11
4 1 81050063 1 AIR INTAKE PIPE
5 1 5P-0599 1 CLAMP
6 1 8T-4894 3 CLAMP
7 1 0S-1591 4 BOLT
8 1 9S-8752 4 NUT
9 1 5M-2894 4 WASHER
10 1 454120 1 TEE
11 1 105404 1 NIPPLE
12 1 444687 1 HEX-SOCKET PIPE PLUG
Y-SEPARATE ILLUSTRATION

GRAPHIC #1 CL 04

1 of 1 ENGINE 10

10 SM NO : 94, May 2011

 ENGINE
81050222 KIT-AIR CLEANER AS
S/N:L2Z06151-UP
PART OF 81050126 AIR CLEANER INSTALLATION

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050056 1 AIR CLEANER AS
81050237 1 PRIMARY ELEMENT
81050238 1 SECONDARY ELEMENT
2 1 81050062 1 PRE AIR CLEANER
3 1 81050227 1 PIPE AS-REDUCER
4 1 81050228 1 SLEEVE-RUBBER

GRAPHIC #1 CL 00

11 ENGINE 1 of 1
SM NO : 94, May 2011 11
 ENGINE
81050061 MUFFLER INSTALLATION
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050064 1 MUFFLER AS
2 1 1A-2209 4 BOLT
3 1 3S-2713 4 NUT
4 1 5M-2894 4 WASHER

GRAPHIC #1 CL 02

1 of 1 ENGINE 12
12 SM NO : 94, May 2011
 FUEL SYSTEM
81050144 FUEL TANK INSTALLATION
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050145 1 FUEL TANK AS
2 1 9207028 1 GASKET
3 1 81050142 1 PLATE
4 1 81009089 1 STRAINER
5 1 89370737 1 CAP AS
5A 1 9012144 1 CAP-FUEL
5B 1 9183383 1 BOLT-VENTED
5C 1 81001191 1 NUT
5D 1 9012165 1 PLATE-COVER
5E 1 9370740 1 GASKET
5F 1 81007412 1 WOOL-FILTER
6 1 3B-4506 6 LOCKWASHER
7 1 5P-8167 6 BOLT
8 1 81013777 1 GAUGE-FUEL LEVEL
81005028 1 CAP-FILLER
81013805 1 SEAL
9 1 106268 8 WASHER
10 1 103332 4 LOCKWASHER
11 1 0L-1178 4 BOLT
12 1 219309 1 PIPE PLUG
13 1 81050202 1 TUBE
F 5P-8501 1 PAD LOCK
F-NOT SHOWN

GRAPHIC #1 CL 02

14 FUEL SYSTEM 1 of 1
SM NO : 94, May 2011 13
 FUEL SYSTEM
81050074 LINES GP-FUEL
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 120148 1 ELBOW
2 1 8040313 1 CONNECTOR
3 1 81000206 2 WASHER
E 4 1 5P-1442 1 HOSE (188 CM)
5 1 81016005 1 HOSE AS
6 1 81050070 1 FUEL FILTER
7 1 81000207 2 ADAPTOR
8 1 8039169 2 ELBOW 90º
9 1 0S-1595 2 BOLT
10 1 3B-4508 2 LOCKWASHER
11 1 81050069 1 HOSE AS
12 1 81043376 1 CLIP
13 1 81025871 2 CLIP
14 1 81048472 1 ELBOW
15 1 1P-4278 7 CLAMP
16 1 81050068 1 HOSE AS
17 1 9131863 1 CLIP
18 1 81050239 1 HAND PRIMER
19 1 0S-1615 1 BOLT
20 1 1B-4330 2 NUT
21 1 3B-4504 1 WASHER
22 1 0S-1616 2 BOLT
23 1 5P-0537 2 WASHER
24 1 9S-8750 2 NUT
25 1 81050241 1 MUD FILTER
E-ORDER BY THE CENTIMETER

GRAPHIC #1 CL 04

16 FUEL SYSTEM 1 of 2
14 SM NO : 94, May 2011
 FUEL SYSTEM
81050074 LINES GP-FUEL (contd.)

GRAPHIC #1

2 of 2 FUEL SYSTEM 16A

SM NO : 94, May 2011 15
 FUEL SYSTEM
81050079 CABLE INSTALLATION-THROTTLE & SHUT OFF
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050105 1 CONTROL CABLE-ACCELERATOR
2 1 81050106 1 BRACKET-THROTTLE CONTROL
3 1 81050108 1 SHUT OFF CABLE AS
4 1 81014233 1 PLATE
5 1 81000405 1 CLAMP
6 1 81000404 1 BUSHING
7 1 0S-1615 3 BOLT
8 1 1B-4330 2 NUT
9 1 3B-4504 4 LOCKWASHER
10 1 9239652 1 PEDAL AS-ACCELERATOR
11 1 9190933 1 ROD
12 1 455735 1 PIN-SPRING
13 1 89190168 1 CLEVIS-MALE
14 1 4F-2294 1 NUT
15 1 81000399 1 CLEVIS
16 1 114784 4 PIN-CLEVIS
17 1 3B-4609 6 PIN-COTTER
H 18 1 89237533 1 BELL CRANK AS
H 148402 2 BEARING
H 19 1 9237271 1 PIN
20 1 108630 2 PIN-COTTER
21 1 89194084 1 CLEVIS
22 1 9056269 1 CLIP
23 1 9353082 1 SPRING
24 1 81000403 1 BRACKET
25 1 0S-1614 1 BOLT
26 1 81000150 1 PIN-CLEVIS
27 1 5P-8244 4 WASHER
H 28 1 81018753 1 BRACKET AS
105604 2 NUT-SQUARE
29 1 8T-4136 3 BOLT
30 1 8T-4121 5 WASHER
31 1 81050224 1 CLEVIS
32 1 81050225 1 PIN
33 1 8T-4196 2 BOLT
34 1 8T-4133 2 NUT
H-ALTERNATE PART, USE 81018744-BELL CRANK AS, 81018860-BEARING, 81018752-BRACKET AS &
81018749-PIN (REPLACE AS A SET ONLY)

CL 03

1 of 2 FUEL SYSTEM 17
16 SM NO : 94, May 2011
 FUEL SYSTEM
81050079 CABLE INSTALLATION-THROTTLE & SHUT OFF (contd.)

GRAPHIC #1

17A FUEL SYSTEM 2 of 2

SM NO : 94, May 2011 17
 COOLING SYSTEM
81050084 INSTALLATION-RADIATOR LINES
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050124 1 PIPE-RADIATOR INLET
2 1 81050133 1 MOLD HOSE
3 1 81050135 1 MOLD HOSE
4 1 81050123 1 MOLD HOSE
5 1 81050134 1 PIPE-RADIATOR OUTLET
6 1 81050110 1 HOSE AS
7 1 81050111 1 HOSE AS
8 1 81011505 2 CONNECTOR AS (EACH INCLUDES)
89188854 1 CONNECTOR
3D-2824 1 O-RING
9 1 5P-2230 2 CLAMP-HOSE
10 1 227-8702 8 CLAMP
11 1 81050211 1 BRACKET
12 1 9131877 2 CLAMP
13 1 0S-1594 2 BOLT
14 1 9S-8752 2 NUT
15 1 5M-2894 2 LOCKWASHER
16 1 9223458 1 HOSE

GRAPHIC #1 CL 04

1 of 1 COOLING SYSTEM 18
18 SM NO : 94, May 2011
 COOLING SYSTEM
81050109 COOLING PACK INSTALLATION
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
Y 1 1 81050131 1 COOLING PACK-RADIATOR 19A
2 1 81050115 4 MOUNT AS-RADIATOR
3 1 0L-2070 4 BOLT
4 1 8T-4222 4 WASHER-PLATED
5 1 443979 1 NIPPLE
6 1 187395 1 COUPLING PIPE
7 1 81000734 1 DRAIN COCK
Y-SEPARATE ILLUSTRATION

GRAPHIC #1 CL 02

19 COOLING SYSTEM 1 of 1
SM NO : 94, May 2011 19
 COOLING SYSTEM
81050131 COOLING PACK-RADIATOR
S/N:L2Z06151-UP
PART OF 81050109 COOLING PACK INSTALLATION

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050212 1 FAN SHROUD
2 1 81050213 1 FAN GUARD
3 1 81050214 1 HYDRAULIC OIL COOLER
4 1 81050215 1 TRANSMISSION OIL COOLER
5 1 81050216 1 FRAME
6 1 81050217 1 RADIATOR AS
7 1 81050218 1 PRESSURE CAP (FILLER)
8 1 81050219 1 DRAIN PLUG
9 1 81050220 1 OVER FLOW PIPE
10 1 81050221 1 CHARGED AIR COOLER
11 1 8T-4189 14 BOLT
12 1 8T-4224 14 NUT

GRAPHIC #1 CL 02

1 of 1 COOLING SYSTEM 19A

20 SM NO : 94, May 2011
 COOLING SYSTEM
81050196 INSTALLATION-CHARGED AIR COOLER LINES
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81050121 1 MOLD HOSE
2 1 81050120 1 MOLD HOSE
3 1 81050122 1 TUBE
4 1 81050117 1 MOLD HOSE
5 1 81050118 1 MOLD HOSE
6 1 81050119 1 TUBE
7 1 144-0367 4 CLAMP
8 1 8T-4984 4 CLAMP
9 1 81050137 1 BRACKET
10 1 81050138 1 CLAMP
11 1 8T-4189 1 BOLT
12 1 1D-4717 2 NUT
13 1 8T-4224 1 WASHER
14 1 81050209 1 BRACKET AS
15 1 81050210 1 CLAMP
16 1 0S-1588 2 BOLT
16 1 4B-5271 2 WASHER
17 1 3B-4506 2 LOCKWASHER

GRAPHIC #1 CL 03

19B COOLING SYSTEM 1 of 1

SM NO : 94, May 2011 21
 TRANSMISSION
TRANSMISSION MOUNTING GP
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 181370 12 BOLT
2 1 3B-4506 12 LOCKWASHER
3 1 271642 2 BOLT
4 1 9176228 2 PLAIN WASHER
5 1 9355772 2 NUT
6 1 81050104 2 BRACKET AS-TRANSMISSION
7 1 9236877 2 PAD
8 1 271558 8 SCREW
9 1 3B-4510 8 LOCKWASHER
10 1 103647 2 DRAIN COCK
11 1 81009150 1 MANIFOLD AS
12 1 81048304 1 GASKET
13 1 227-8702 2 CLIP
14 1 9223458 1 HOSE-BULK
15 1 81047486 1 BRACKET & TUBE AS
16 1 9189082 1 GASKET
17 1 9195340 1 CAP
18 1 81049307 1 TRANSMISSION AS

GRAPHIC #1 CL 00

1 of 1 TRANSMISSION (PL0083853) 20

22 SM NO : 94, May 2011

 TRANSMISSION
81050240 TRANSMISSION FILTER LINES & FITTINGS
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
Y 1 1 81025000 1 FILTER AS-TRANSMISSION 23
2 1 81050197 1 BRACKET
3 1 9188754 1 HOSE AS
4 1 81047363 1 HOSE AS
5 1 9183510 2 ELBOW AS (EACH INCLUDES)
9411107 1 ELBOW
3D-2824 1 SEAL-O-RING
6 1 9183502 2 ELBOW AS (EACH INCLUDES)
307950 1 ELBOW
3D-2824 1 SEAL-O-RING
7 1 0S-1591 4 BOLT
8 1 1D-4717 4 NUT
9 1 3B-4506 4 WASHER
10 1 9212811 1 BRACKET
11 1 9174339 1 CLIP
12 1 179795 1 BOLT
13 1 3B-4504 1 LOCKWASHER
14 1 1B-4330 1 NUT-FULL
Y-SEPARATE ILLUSTRATION

GRAPHIC #1 CL 00

1 of 1 TRANSMISSION 22

SM NO : 94, May 2011 23

 TRANSMISSION
81025000 FILTER AS-TRANSMISSION
S/N:L2Z06151-UP
PART OF 81050240 TRANSMISSION FILTER LINES & FITTINGS

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
81010421 1 BOWL AS
1 1 81802467 1 BRACKET
2 1 81802468 1 RELIEF VALVE
3 1 81802469 1 WASHER
4 1 81802470 1 CIRCLIP
5 1 81802471 1 RETAINER
6 1 81802472 1 FELT WASHER
7 1 81802473 1 WASHER
8 1 81802474 1 SPRING
9 1 81802475 1 BOWL
10 1 81802478 1 WASHER
11 1 81802479 1 DRAIN SCREW
12 1 81802476 1 SEALING RING-END
13 1 81802477 1 CENTRE BOLT
14 1 81802480 1 PLUG
15 1 81802481 1 SCREW PLUG
16 1 81803248 1 GASKET
17 1 81805027 1 RETAINER
18 1 81010419 1 ELEMENT

GRAPHIC #1 CL 00

23 TRANSMISSION 1 of 1

24 SM NO : 94, May 2011

 AIR SYSTEM
81050125 AIR LINES & FITTINGS GP
S/N: L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 9357564 1 CONNECTOR
2 1 9357565 2 NUT
3 1 9357566 2 SLEEVE
4 1 81050080 1 STEEL TUBE
5 1 118752 1 CONNECTOR
6 1 126039 1 ELBOW
7 1 127849 1 ELBOW
8 1 81001754 1 CONNECTOR
9 1 81000363 16 WASHER
10 1 81001757 1 ADAPTOR
11 1 81011979 1 DOUBLE CHECK VALVE
12 1 9411742 1 CONNECTOR
13 1 81002631 1 CONNECTOR
14 1 0S-1615 1 BOLT
15 1 1B-4330 1 NUT
16 1 5P-0537 1 LOCKWASHER
17 1 9131863 1 CLAMP
18 1 9188752 1 HOSE AS
19 1 81002766 1 PLUG
20 1 121207 3 NIPPLE
21 1 8039169 2 ELBOW
22 1 8040335 1 ELBOW
23 1 81016009 3 HOSE AS
24 1 118750 6 CONNECTOR
25 1 121619 1 ELBOW
26 1 444013 2 ADAPTOR
27 1 444687 1 PLUG
28 1 118755 2 ELBOW
29 1 81016012 1 HOSE AS
30 1 81016005 2 HOSE AS
31 1 9129588 1 HOSE AS
32 1 81002767 1 PLUG
33 1 118757 7 ELBOW
34 1 81016102 1 HOSE AS
35 1 118753 1 ELBOW
36 1 81002716 1 COUPLING
37 1 81000206 9 WASHER
38 1 9012441 1 HOSE AS
39 1 81000240 8 ADAPTOR
40 1 140675 1 TEE
41 1 8317058 2 COUPLING (EACH INCLUDES)
81004861 1 CONNECTOR
1D-5120 1 NUT-JAM
4F-2299 1 LOCKWASHER
42 1 9121245 1 CONNECTOR
43 1 81008624 1 HOSE AS
47 1 81011985 1 STOP LIGHT SWITCH
48 1 81011984 1 LOW AIR PRESSURE SWITCH
49 1 81000704 1 WASHER
50 1 81011967 1 CONNECTOR
51 1 120281 1 PIPE TEE

CL 05

40 AIR SYSTEM 1 of 3

SM NO : 94, May 2011 25

 AIR SYSTEM
81050125 AIR LINES & FITTINGS GP
S/N: L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
52 1 81001666 6 ADAPTOR
53 1 81001667 3 ADAPTOR
54 1 81012031 1 CONNECTOR
55 1 81011981 1 NON RETURN VALVE
56 1 81011974 1 CONNECTOR
57 1 443979 3 NIPPLE
58 1 105417 2 TEE
59 1 81401549 5 ELBOW
60 1 9121172 1 HOSE AS
61 1 8040341 1 ELBOW
62 1 81001827 1 ADAPTOR
63 1 81016096 2 HOSE AS
64 1 118760 1 TEE
65 1 444029 1 REDUCER
66 1 9120147 1 HOSE AS
67 1 111594 2 CROSS
68 1 9125507 1 HOSE AS
Y 69 1 81011980 1 PRESSURE REGULATOR VALVE 47
70 1 81001178 1 PLUG
71 1 81050205 1 ADAPTOR
72 1 81000414 5 COPPER GASKET
73 1 81050204 1 CONNECTOR
74 1 81050206 1 CONNECTOR
75 1 81011989 3 PLUG
76 1 81046666 1 HOSE AS
77 1 8T-4136 1 BOLT
78 1 8T-4121 1 WASHER
79 1 81050139 1 BRACKET
80 1 3B-4504 1 LOCKWASHER
81 1 9M-6522 1 ADAPTOR
82 1 9L-5254 1 ELBOW
F 103319 1 LOCKWASHER
F 179795 1 BOLT
F 9131853 2 CLIP
F 9131863 1 CLIP
F 81025871 12 CABLE-TIE
F 81043376 6 STRAP-CABLE
Y-SEPARATE ILLUSTRATION
F-NOT SHOWN

GRAPHIC #1 CL 05

2 of 3 AIR SYSTEM 41

26 SM NO : 94, May 2011

 AIR SYSTEM
81050125 AIR LINES & FITTINGS GP (contd.)

GRAPHIC #1

41A AIR SYSTEM 3 of 3

SM NO : 94, May 2011 27
 HYDRAULIC SYSTEM
81050114 HYDRAULIC LINES & FITTINGS
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81049132 1 MANIFOLD AS
81017572 1 COVER
81017573 1 FLANGE
81047239 1 TUBE
81049131 1 TUBE
2 1 8T-4984 2 CLAMP BAND
3 1 9212752 1 HOSE BULK
4 1 81047242 1 HOSE BULK
5 1 81049001 1 TUBE AS
6 1 81400581 1 CLAMP
7 1 1P-4582 2 SPLIT FLANGE
8 1 4J-0527 1 O-RING
9 1 1P-4579 2 SPLIT FLANGE
10 1 4J-0524 1 O-RING
11 1 0S-1585 1 BOLT
12 1 3B-4508 2 LOCKWASHER
13 1 1P-4577 12 SPLIT FLANGE
14 1 4J-0520 10 O-RING
15 1 0S-1588 20 BOLT
16 1 3B-4506 24 LOCKWASHER
17 1 1P-4576 2 SPLIT FLANGE
18 1 4J-5267 1 O-RING
19 1 1F-7958 2 NUT
20 1 7K-1423 2 SPLIT FLANGE
21 1 81040451 1 ADAPTOR AS
9266200 1 CHECK VALVE POPPET
9425516 1 RETAINING RING
81040476 1 BLANKS
22 1 81049002 1 TUBE AS
23 1 81046663 1 HOSE AS
24 1 81047471 1 HOSE AS
25 1 81049138 1 HOSE AS
Y 26 1 81050066 1 VALVE AS-MOUNTING 82
27 1 81047488 1 HOSE AS
28 1 81049773 1 TUBE AS
29 1 9207028 1 GASKET
30 1 81047167 1 HOSE AS
31 1 81049775 1 TUBE AS
32 1 4J-0522 2 O-RING
33 1 3B-4507 4 LOCKWASHER
36 1 81017874 1 CLAMP
37 1 8T-4223 8 WASHER
38 1 5S-7382 12 BOLT
39 1 8T-4137 4 BOLT
40 1 8T-4121 4 WASHER
41 1 81049796 2 ANGLE PLATE
42 1 5P-8244 4 WASHER
43 1 81049776 1 TUBE AS
44 1 81016862 1 TUBE AS-RH
45 1 81024913 2 HOSE AS
46 1 81016866 1 TUBE AS
CL 01

1 of 3 HYDRAULIC SYSTEM 75

28 SM NO : 94, May 2011

 HYDRAULIC SYSTEM
81050114 HYDRAULIC LINES & FITTINGS
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
47 1 4S-6399 4 CONNECTOR
48 1 81016941 1 PLATE
49 1 81028021 1 TUBE AS
50 1 81016861 1 TUBE AS-LH
51 1 81049777 1 TUBE AS
52 1 81017870 2 CLAMP
53 1 0S-1594 9 BOLT
54 1 81017869 2 BLOCK
55 1 9183503 2 ELBOW AS (EACH INCLUDES)
9410981 1 ELBOW
7M-8485 1 SEAL-O-RING
56 1 81018899 2 TUBE AS
57 1 81024917 4 HOSE AS
58 1 81040569 1 TUBE AS
59 1 81016846 1 TUBE AS
60 1 81016849 1 TUBE AS
61 1 81027816 2 ELBOW
62 1 81040570 1 TUBE AS
63 1 81049778 1 TUBE AS
64 1 81049774 1 TUBE AS
65 1 1P-4578 2 SPLIT FLANGE
66 1 4B-5271 10 WASHER
67 1 81017873 4 CLAMP
68 1 0T-0320 4 BOLT
69 1 8T-4956 4 BOLT
70 1 81026859 4 BOLT
71 1 1D-4717 4 NUT
72 1 7X-7729 4 WASHER
73 1 0L-1351 4 BOLT
74 1 9X-8874 4 BOLT
75 1 0S-1619 8 BOLT
76 1 81047644 4 BOLT
77 1 4F-5192 4 BOLT
78 1 81025579 4 BOLT
79 1 106265 1 WASHER
80 1 81049139 1 BRACKET
81 1 8T-4896 37 WASHER
82 1 9125046 2 CLAMP
83 1 4F-4879 1 BOLT
84 1 9410981 1 ELBOW
85 1 7M-8485 1 O-RING
86 1 81040599 2 ELBOW
87 1 3D-2824 2 O-RING
88 1 0S-1621 2 BOLT
89 1 0S-1595 1 BOLT
90 1 81050044 1 BRACKET AS
91 1 3B-1915 4 BOLT
Y-SEPARATE ILLUSTRATION

CL 01

76 HYDRAULIC SYSTEM 2 of 3
SM NO : 94, May 2011 29
 HYDRAULIC SYSTEM
81050114 HYDRAULIC LINES AND FITTINGS (contd.)

GRAPHIC #1

3 of 3 HYDRAULIC SYSTEM 76A

30 SM NO : 94, May 2011

 HYDRAULIC SYSTEM
81050112 HYDRAULIC LINES-COOLER
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 81025871 5 CLIP
E 2 1 81050132 1 HOSE AS (210 CM)
E 3 1 81049792 1 HOSE AS (277 CM)
4 1 9246415 1 BLOCK
5 1 81050226 1 BLOCK
6 1 9410970 2 O-RING
7 1 179896 4 BOLT
8 1 9402830 1 ELBOW
9 1 3B-4508 4 WASHER-LOCK
10 1 9402828 1 ELBOW
11 1 9131877 6 CLAMP
12 1 0S-1594 4 BOLT
13 1 9S-8752 4 NUT
14 1 5M-2894 4 WASHER
15 1 001-7042 1 ELBOW
16 1 81049934 2 BRACKET
17 1 5P-2230 2 CLAMP-HOSE
E-ORDER BY THE CENTIMETER

CL 01

1 of 2 HYDRAULIC SYSTEM 81
SM NO : 94, May 2011 31
 HYDRAULIC SYSTEM
81050112 HYDRAULIC LINES-COOLER (contd.)

GRAPHIC #1

81A HYDRAULIC SYSTEM 2 of 2

32 SM NO : 94, May 2011

 HYDRAULIC SYSTEM
81050066 VALVE AS-MOUNTING
S/N:L2Z06151-UP
PART OF 81050114 HYDRAULIC LINES & FITTINGS

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
1 1 008-8381 2 ELBOW
2 1 3D-2824 2 O-RING
3 1 030-7946 2 ELBOW
4 1 3J-7354 2 O-RING
Y 5 1 81047286 1 PRIORITY VALVE AS 83
6 1 1F-4111 2 BOLT
7 1 1D-4716 2 NUT
8 1 81050073 1 BRACKET
9 1 3B-4505 2 LOCKWASHER
10 1 81004689 1 CONNECTOR
11 1 3K-0360 1 O-RING
12 1 81050060 1 BLOCK
13 1 8T-4182 3 BOLT
14 1 8T-4121 3 WASHER
Y-SEPARATE ILLUSTRATION

GRAPHIC #1 CL 01

1 of 1 HYDRAULIC SYSTEM 82
SM NO : 94, May 2011 33
 CAB
81009811 INSTRUMENT-INSTALLATION
S/N:L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY PAGE
1 1 81049265 1 PANEL-INSTRUMENT
1 2 3 4 5 6 (PRODUCT LEVEL)

2 1 115362 6 SCREW
3 1 81022562 6 WASHER
4 1 81001598 1 ENGINE WATER TEMPERATURE GAUGE
5 1 81001600 1 ENGINE OIL PRESSURE GAUGE
6 1 81001603 1 CONVERTOR OIL TEMPERATURE GAUGE
7 1 81028376 1 TRANSMISSION CLUTCH PRESSURE GAUGE
8 1 81001601 1 AMMETER
9 1 81001599 1 AIR PRESSURE GAUGE
10 1 81001604 1 SENDER UNIT-WATER TEMPERATURE
11 1 362-0288 1 KIT-SERVICE METER
(INCLUDES SERVICE METER & FILM)
304-5303 1 NUT-SERVICE METER
12 1 81001618 1 WARNING LIGHT
14 1 81002493 1 TEMPERATURE SENDER UNIT
15 1 250-4673 2 SWITCH TOGGLE-PANEL & REAR FLOOD LIGHT
16 1 81000215 4 NUT-SWITCH TOGGLE
17 1 81000214 4 RUBBER BOOT
26 1 077-3743 1 PRESSURE SWITCH-ENGINE OIL
27 1 9373545 2 BUTTON PLUG
28 1 81022718 1 ELECTRIC HORN-SIGNALING
32 1 7N-0718 1 BATTERY DISCONNECT SWITCH
2H-3922 2 LOCK WASHER
6F-7045 2 NUT
8H-5303 1 NUT
8H-5306 1 KEY
9F-5644 2 LOCK WASHER
33 1 81011099 1 SWITCH-NEUTRAL START
34 1 454120 1 TEE
35 1 1D-4717 1 NUT
36 1 81016109 1 HOSE AS
37 1 81010280 1 ELBOW
38 1 81016108 1 HOSE AS
39 1 81031117 1 SWITCH-HEAD & TAIL LIGHTS
40 1 81011839 1 INDICATOR-LIGHT
41 1 81012149 1 TWO WAY SWITCH-DIRECTION TURN SIGNAL
42 1 81047380 1 HAZARD SWITCH
43 1 81028508 2 ELBOW
44 1 81002716 1 COUPLING
M 45 1 0S-1594 1 BOLT M6
46 1 7X-7729 1 WASHER HARD
47 1 81012977 1 ADAPTOR
49 1 81009081 1 GASKET
50 1 81017668 1 ELBOW
51 1 4B-2047 2 NUT
52 1 110508 2 SCREW
53 1 4B-4274 2 WASHER
54 1 6V-3507 1 SEAL
55 1 9G-7641 1 SWITCH GP-START
56 1 5P-8500 2 KEY
57 1 81048325 1 WASHER
58 1 3E-8320 1 PLATE-INSTALLATION

CL 04

1 of 2 CAB 105

34 SM NO : 94, May 2011

 CAB
81009811 INSTRUMENT-INSTALLATION
S/N: L2Z06151-UP

REF GRAPHIC PART NAME SEE

NOTE NO REF PART NUMBER QTY 1 2 3 4 5 6 (PRODUCT LEVEL) PAGE
59 1 81049795 1 PLATE
60 1 444588 1 PLUG PIPE-SQUARE HEAD
M-METRIC PART

GRAPHIC #1 CL 04

105A CAB 2 of 3
SM NO : 94, May 2011 35
 CAB
81009811 INSTRUMENT-INSTALLATION (contd.)

GRAPHIC #1

3 of 3 CAB 105B
36 SM NO : 94, May 2011
 15
Product Information Section
Specifications and Model Views

Product Information Machine General Information

Section Engine
Specifications and Model Table 1
Views 6R1080TA3, Bharat Stage III
Model
(CEV) Complaint Engine
Model View Illustrations
Make Kirloskar Oil Engines

Type 4 Stroke, 6 Cylinders

4
7 Bore & Stroke 105 mm X 125 mm

Displacement 6.495 Liter

3 1
Gross Power @ 2300 rpm 115 hp

Net Power @ 2300 rpm 102.5 hp

2 Max.Torque @ 1500 rpm 415 N.m

5 6 Turbo with Charged Air

Aspiration
Cooler
Illustration 19
Electrical System 24 V

Bucket (1), Engine (2), Battery (3),Operator’s

compartment (4), Air tank (5), Lift arm (6) &
Tilt cylinder (7)
Transmission
Twin turbine transmission with an integral torque
converter planetary gear box with single lever
powershift control. Shift from first turbine to second
9
8
10
turbine is automatic upon demand. Soft shift feature
for full powershift between forward and reverse. Two
`

stage, four element torque convertor.

Table 2

TRAVEL SPEEDS FOR 2021 WHEEL LOADER WITH

TWIN TURBINE TRANSMISSION

11 Low Turbine 3.2 Km/h 2.0 M/h

12
FORWARD - 1
Illustration 20 High Turbine 7.2 Km/h 4.4 M/h

Air cleaner (8), Pre cleaner (9), Radiator (10), Low Turbine 12.3 Km/h 7.7 M/h
Hydraulic tank (11) & Fuel tank (12) FORWARD - 2
High Turbine 25.8 Km/h 16.1 M/h

Low Turbine 4.5 Km/h 2.8 M/h

REVERSE - 1
High Turbine 9.3 Km/h 5.8 M/h

SM NO : 94, May 2011 37

 16
Product Information Section
Specification and Model Views

Drive Axles Parking Brake

1. Front axle Fixed Mechanically expanding shoe off transmission output

2. Rear Axle oscillates at ± 11°
3. Full Floating axle shafts – can be removed
independently off wheel and planetary.
4. Conventional heavy duty differential.
shaft, pedal operated.
Emergency Brake
Use service brakes. When air pressure drops below 45
psi, an audible warning horn sounds and the brakes
are applied automatically. Operator can also manually
apply the brakes.

Steering Tires
Pivot Steering
Rims are bolted directly to the wheels for positive non-
Full power steering through orbitrol valve to steering slip retention.
cylinders.
Standard Tire size ……………….14.00 X 25 – 20 PR
80° steering and 50° bucket swing.
Note: In certain applications (such as load-and-
carry work) the loader’s productive capabilities might
Steering Hydraulic System exceed the tires tones-KM/h (TKPH) capabilities. We
recommend that you consult a tire supplier to evaluate
1. Load sensing hydraulic system with priority valve all conditions before selecting a tire model.
to ensure regulated oil supply to steering.

2. Two double acting steering cylinders. Electrical System

3. Common gear pump for steering and hydraulic Negative ground fuse protected system for starting,
system. lighting and accessories. System includes 55A
alternator, automatic voltage regulator and two 12V,
150ampere hour batteries. Key operated electrical
Filters on-off switch with neutral start safety feature. All dash
gauges illuminated.
Table 3

Engine Oil Paper Element Filter

Fuel prefilter - Felt fine filter paper

Fuel System
plus water separator

Transmission Remote mounted full flow oil filter

Wire mesh strainer on the suction

Hydraulic System side and renewable filter on the
return side

Air Intake System Duel element filter with precleaner

Brakes
Service Brakes

Four Wheels air actuated brakes with separate circuit

for front & rear axles. In the event of air pressure loss in
either of the circuit, audible warning sounds. Automatic
trans-declutch on depression of brake pedals.

38 SM NO : 94, May 2011

 18
Product Information Section
Specification and Model Views

Bucket Hydraulic System

The hydraulic system of the Wheel Loader contains
the followings.

• Tandem Gear pump.

• Two double acting Lift cylinders

• One double acting Tilt cylinder.

• Two spool Hydraulic control valve

• Adjustable lift arm kick out control valve

• Bucket leveling valve for automatic loading

position

• Lift arm control positions like Raise, Lower, Hold

and Float

• Hydraulic tank, filter and sump screen are

serviceable without draining tank.

• Pump flow @ 2300 rpm – 215 lpm

Hydraulic Cycle Time

Table 5

Raise 6.0 Seconds

Lower 3.0 Seconds

Tilt 1.0 Seconds

Shipping Information (Approximate)

Table 6

SHIPPING INFORMATION (Approximate)

Bucket General
Machine
Purpose
Including Lift
1.7 cu.m
Arm & Rims
(2.2 cu.yd)

5855 mm 2540 mm
Length
(19 ft 2 in) (8ft 4 in)

Height without 2550 mm

Cab (8 ft 1 in) 1016 mm
Height with 3022 mm (3ft 6 in)
Cab (9 ft 11 in)

2362 mm 1118 mm
Width
(7 ft 9 in) (3ft 8 in)

10940 Kg 700 Kg
Weight
(24112 lb) (1543 lb)

SM NO : 94, May 2011 39

 19
Product Information Section
Product Identification Information

Product Identification
Information
Plate Locations and Film
Locations
262-9024
lllustration 23 (SIN)
The Product Identification Number (PIN) will be
used to identify a powered machine that is designed
for an operator to ride. Part Identification Number Plate (PIN)

Caterpillar products such as Engines, Transmissions Service Information Number Plate (SIN)
and major attachments that are not designed for an
operator to ride are identified by Serial Numbers. Note: The PIN and SIN plates are located on the left
side of the operators compartment above the hydraulic
For quick reference, record the identification tank.
numbers in the spaces that are provided below the
illustration.

lllustration 24

lllustration 21 Engine number is stamped on a lable which is

fastened in left side of the engine. If you need parts,
service or information for your engine, you must give
engine type and CMO number.

lllustration 22 (PIN)
lllustration 25

Transmission Serial number plate.

40 SM NO : 94, May 2011

 20
Operation Section
Before Starting Inspection

Operation Section Engine Oil Level Check

Before Starting Inspection

Before starting the engine, the following inspection
should be performed to make sure that the loader
is ready to operate. The bucket or other attachment
should be completely lowered, and the parking brake
applied before making the inspection.

Daily Inspection
For a maximum service life of the machine, complete
a thorough daily inspection before you mount the lllustration 26
machine and before you start the engine.
Remove the engine crankcase dipstick, wipe it clean
Inspect the area around the machine and under the and reinsert it. Remove it and observe the indicated
machine. Look for loose bolts, trash buildup, oil, coolant crankcase oil level. Add oil if below the “MAX” MARK.
leakage, broken parts, or worn parts. Never operate the engine if the level is below the
“LOW” mark. Do not overfill the crankcase when adding
Note: Watch closely for leaks. If you observe a leak, oil, excess oil causes foaming and other problems.
find the source of the leak and correct the leak. If you
suspect a leak or you observe a leak, check the fluid
levels more frequently. Coolant Level Check
Inspect the condition of the equipment and of the
hydraulic components.

Check the condition of the tires. Adjust the inflation

pressure, if necessary.

Check all of the oil levels, all of the coolant levels, and
all of the fuel levels.

Remove any trash buildup and debris. Make all

necessary repairs before you operate the machine.

Make sure that all covers and guards are securely

attached.
lllustration 27
Adjust the mirrors (If Equipped) for the correct rear Remove the radiator cap and check for radiator coolant
view of the machine. ½” to ¾” above the top tank baffle plate. Add coolant if
needed. In sub-freezing temperature, make sure that
Grease all of the fittings that need to be serviced on
it contains sufficient permanent (ethylene glycol) type
a daily basis.
anti-freeze to prevent freezing.

SM NO : 94, May 2011 41

 21
Operation Section
Before Starting Inspection

Fuel Level Check system, check for flow from Add plug (lower) (2). Make
sure to hold the rpm during this check. If the check is
made at a lower rpm, it may result in a low oil level
during normal operation.

Add oil, if necessary, to bring the level to the Add plug

(lower) (2). Note that the plug level is used for the
cold check. When the transmission reaches operating
temperature, thermal expansion will raise the oil level
to the Full plug (upper) (1).

Hydraulic Oil Level (Cold Check)

lllustration 28 2

Fill the fuel tank to capacity if it was not filled when

the unit was shut down. The fuel tank should be filled
at the end of the shift whenever possible to minimize 1
moisture condensation. Check fuel level, remove the
fuel tank dipstick, wipe it clean and reinsert , remove
it and observe the indicated fuel level. If necessary
add fuel.

Transmission Oil Level

(ColdCheck) lllustration 30

Open the hydraulic tank vent cock (1) to release any

pressure in the tank. Open the hydraulic tank cap (2)
and Check the oil level. Add oil, if necessary to the
1 bottom of the tank fill tube. Replace the cap (2) securely
and close the vent cock (1).

Air Cleaner

lllustration 29

The transmission oil level check plugs are located on

the front of the housing near the lower right side.

Before starting engine, remove the Full plug

(upper) (1). If oil flows from the plug opening, the
transmission has sufficient oil to permit safe starting of
the engine. If no oil flow is present, add sufficient oil to
cause a flow from the opening, and replace the plug.
lllustration 31

Shift the range selector to neutral and start the engine. Check the engine air cleaner dust valve to make sure
Accelerate to 1000 to 1500 rpm. Operate at this rpm for that it is not clogged or blocked. A finger flicked the
approximately one minute to charge the hydraulic rubber dust valve should release any obstruction.

42 SM NO : 94, May 2011

 22
Operation Section
After Starting Inspection

If not, remove the cup from the cleaner and shake any With the engine operating at a fast idle speed, check
excessive dust or obstruction in the cup and valve. for battery charging current on the ammeter and air
Replace the dust cup. tank pressure on the air pressure gauge.

Air Tank Check the engine, transmission, steering and hydraulic

system components for coolant / oil leakages. Tighten
leaking fluid check cocks or drain cocks to stop leakage
and or prevent subsequent loosening. Report leaks
that cannot be stopped to those responsible for unit
maintenance.

Transmission Oil Level

(Hot Check)

1
lllustration 32

Open the drain cocks to drain moisture and water

sediment. Close the drain cocks on the air tank.

Tires
Check the tire pressure with an accurate gauge. Inflate
the tires to the pressures specified. Inspect all tires
carefully for cuts, breaks, imbedded debries or other
damages. Report tire damage to those responsible for
vehicle maintenance.
Visual Inspection
Carefully check for oil, fuel, coolant or lubricant leaks.
Make sure all component fluid level check cocks
and drain cocks are tightened securely to prevent
subsequent loosening. Report any leakage that cannot
be stopped to the mechanic. Clean caked mud or other
materials from hydraulic and steering hoists. Take care
to avoid damaging of hoist piston rods.
After Starting Inspection
Before starting the engine to post-starting inspection,
be sure that all personnel are clear of the unit, the
transmission and hydraulic system controls are in
“Neutral” positions, and the parking brake is in fully
applied condition. Sound the horn.
2
lllustration 33
Shift range selector to neutral, and start the engine.
Operate the vehicle until the transmission reaches a
normal operating temperature. Then idle the engine
and apply the parking brake. Shift through all range
positions slowly to ensure that all areas of the system
are filled with oil.
Shift to neutral and set the engine speed at 1200 to
1500 rpm. Remove the Full plug (upper) (1). The oil
should be at or near the level of the plug opening. Add
or drain oil as necessary to bring it to the Full plug level.
(The transmission may be operated as long as the oil
level is above the ADD plug).
Note: Observe the type of flow from the plug opening.
Foaming or spurting may indicate a false level.

Start the engine (see “Starting the engine”), and

observe the instrument panel gauges. If the engine
lubricating oil pressure gauges does not register oil
pressure within 10 to 15 seconds, shut off the engine
to prevent any damage until the trouble is corrected.

SM NO : 94, May 2011 43

 46
Maintenance Section
Lubricant Viscosities and Refill Capacities

Maintenance Section
Lubricant Viscosities and
Refill Capacities

Lubricant Viscosities
Table 7

Lubricant Viscosities for Ambient Temperatures

°C °F
Oil Type and
Compartment or System Oil Viscosities
Classification
Min Max Min Max

K Oil Premium /
Engine Crankcase SAE 15W40 -15 50 5 122
CATERPILLAR DEO-CI 4

Transmission Caterpillar TDTO SAE 30 0 50 32 122

Hydraulic & Steering EXXON MOBILE SPEC-

ISO VG 68 -20 40 -4 104
System ESSO NUTO H68

Differential and Final

Caterpillar GO (Gear Oil) SAE 90 -20 40 -4 104
Drives

44 SM NO : 94, May 2011

 47
Maintenance Section
Lubricant Viscosities and Refill Capacities

Machine Fluid Recommendations

Factory Fill :

Table 8

LUBRICANT
COMPARTMENT OIL TYPE AMBIENT CHANGE
OIL CAPACITY
OR & TEMPERATURE(2) PERIOD
VISCOSITIES (LITERS)
SYSTEM CLASSIFICATION (HOURS)(1)
Min°C Max°C

K Oil Premium / First 50 &

Engine SAE 15W40 -15 50 11.5
CATERPILLAR DEO-CI 4 Every 500

Caterpillar
Transmission SAE 30 0 35 1000 35
TDTO

Hydraulic and EXXON MOBILE

ISO VG68 -20 40 1000 123
Steering System SPEC-ESSO NUTO H68

Differential and Caterpillar

SAE 90 -20 40 1000 28
Final Drives GO (Gear Oil)

Recommendations :
(1) The Oil Change Hours are given as a guidance for operating under normal conditions and may vary
depending upon site conditions.
(2) If the ambient temperatures are beyond the specified range, contact your CAT Dealers for additional
information on selecting oils.

SM NO : 94, May 2011 45

 48
Maintenance Section
Maintenance Interval Schedule

Maintenance Interval Schedule Steering Cylinder Pins - Lubricate ................... 55

Note: All safety information, warnings, and instructions
must be read and understood before you perform any
operation or any maintenance procedure.
Before each consecutive interval is performed, all of
the maintenance requirements from the previous
interval must also be performed.
When Required
Battery Electrolyte Level - Check ..................... 52
Battery or Battery Cable - Inspect/Replace ..... 52
Bucket Cutting Edges and Tooth -
Inspect/Replace ............................................... 53
Cab Interior - Clean .......................................... 54
Engine Air Filter ( Primary & Secondary) -
Clean/Replace ................................................. 49
Frame Support Structure and Lift Arm -
Inspect for Cracks ............................................ 51
Fuses - Replace ............................................... 63
Hydraulic System Oil Filter Screen - Clean ..... 65
Radiator Core - Clean ...................................... 68
Windows Wipers (Front & Rear) -
Inspect/Replace ............................................... 70
Support Pivot Pins - Lubricate ......................... 55
Every 100 Service Hours
Battery Electrolyte Level - Check/Refill ............ 52
Differential Oil Level (Front & Rear) - Check ... 59
Drive Line Universal Joints (Front & Rear) -
Lubricate .......................................................... 58
Drive Shaft spline (Front & Rear) - Lubricate ... 58
Final Drive Oil Level - Check ........................... 60
Every 200 Service Hours
Brake Cam Shafts - Lubricate .......................... 56
Brake Shoe Anchor Pins - Lubricate ................ 56
Belt - Inspect .................................................... 53
Slack Adjusters - Lubricate .............................. 56
Transmission Oil Filter - Change ..................... 66
Every 250 Service Hours
Breathers - Clean/Replace .............................. 55
Every 300 Service Hours

Every 10 Service Hours Hydraulic System Oil Filter - Change ............... 64

Hydraulic System Oil Filter Screen - Clean ..... 65
Air Tank Water and Sediment - Drain .............. 67
Backup Alarm - Test ......................................... 54 Every 500 Service Hours
Cooling System Coolant Level - Check ........... 54
Engine Air Cleaner - Inspect ........................... 51 Engine Air Filter (Primary Element) -
Engine Oil Level - Check ................................. 61 Clean/Replace ................................................. 49
Fuel Level - Check ........................................... 63 Engine Oil and Filter - Change
Fuel Tank Water and Sediment - Drain ............ 63 (First 50 Hours & Every 500 Hours) ................. 61
Hydraulic System Oil Level - Check ................ 65 Fuel Filter - Replace ......................................... 62
Loader Bucket, Cylinders, Linkage Pins - Fuel Filter (MUD) - Replace ............................. 62
Lubricate .......................................................... 57 Fuel Tank Filler Cap - Clean ............................ 62
Seat Belt - Inspect ............................................ 68
Tire Inflation - Check ........................................ 68 Every 1000 Service Hours
Transmission Oil Level - Check ....................... 67
Walk - Around Inspection ................................. 69 Cooling System - Drain/Flush/Refill ................. 69
Windows - Clean .............................................. 70 Differential Oil (Front & Rear) - Change ......... 59
Final Drive Oil - Change ................................... 60
Every 50 Service Hours Hydraulic System Oil - Change ........................ 64
Transmission Oil - Change .............................. 66
Axle Cradle Mounting Pins - Lubricate ............ 56
Engine Oil and Filter - Change
( First 50 Hours & Every 500 Hours) ................ 61
Hydraulic System Oil and Filter - Change
( First 50 Hours & Every 300 Hours) ................ 64
Hydraulic System Oil Filter Screen - Clean
( First 50 Hours & Every 300 Hours) ................ 65

46 SM NO : 94, May 2011

 49
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

Engine Air Filter (Primary Cleaning Primary Air Filter Elements

Element) - Clean / Replace
NOTICE
Never service the air cleaner when the engine is
running, to avoid engine damage.

lllustration 93

1. Remove the air cleaner housing cover (1).

2. Remove the primary filter element (2) from the

air cleaner housing.
lllustration 91

The air filter alert indicator is mounted on the air outlet

NOTICE
tube of the cleaner body. It shows at a glance, when
Do not clean the filter elements by bumping or tapping
the system airflow is being restricted, the red band them. Do not use filter elements with damaged pleats,
increases in the indicator. When the red band reaches gaskets or seals. Engine damage can result.
top of the indicator window. Service the air cleaner
filter and reset the indicator by pushing plunger to
3. Clean the primary filter element.
downward position. If it is not reset, need to service
the indicator or replace.

Service Pre Cleaner - Clean

lllustration 94

When you use pressure air, the maximum air

lllustration 92 pressure is 3.0 Kg/cm² (43 psi).

Remove the wing nut and lift off the top cover. Remove a. When you clean the inside pleats and the
the slotted plate. outside pleats, direct the air along the pleats.

Clean thoroughly the deflector base plate, bowl,

slotted plate and cover. After cleaning assemble the
service pre cleaner.

SM NO : 94, May 2011 47

 50
Maintenance Section
Engine Air Filter Secondary Element - Replace

b. Inspect the filter elements after you clean the
filter elements. Do not use a filter if the pleats,
the gaskets or the seals are damaged.
c. Cover the clean filter elements. Store the
elements in a clean, dry location.
Replace the primary element after two
cleaning interwals.
4. Install a clean filter element and install the cover.
Engine Air Filter Secondary
Element - Replace
NOTICE
Always replace the secondary filter element. Never
attempt to reuse it by cleaning.
The secondary filter element should be replaced at the
every change of the primary element.

5. Tighten the cover screws finger tight. Do not use

a tool to tighten the cover screws.

Inspecting the Primary Air Filter

Elements

lllustration 96

1. Remove the air cleaner housing cover (1).

2. Remove the primary filter element (2) from the air

cleaner housing.

Illustration 95

Inspect the clean, dry primary air filter element. Use a

bright light in a dark room or in a similar facility. Place
the light in the primary air filter element. Rotate the
primary air filter element. Inspect the primary air filter
element for tears and/or holes. Inspect the primary air
filter element for light that may show through the filter
material. 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.
lllustration 97
Do not use a primary air filter element that has any
tears and/or holes in the filter material. Do not use 3. Remove the secondary filter element.
a primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter 4. Cover the air inlet opening. Clean the inside of the
elements. air cleaner housing.

5. Inspect the gasket between the air inlet pipe and

the air cleaner housing. Replace the gasket if the
gasket is damaged.

48 SM NO : 94, May 2011

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Maintenance Section
Engine Air Filter Secondary Element - Replace

Engine Air Cleaner - Inspect

` 2

` 1

lllustration 98

6. Uncover the air inlet opening. Install a new lllustration 100

secondary element.
Clean the dust cup (1) and check the pre cleaner (2)
7. Install the primary element and the air cleaner for dust collection.
housing cover. Fasten the clips in order to secure
the air cleaner housing cover.
Frame Support Structure and
Lift Arm - Inspect

Before doing any welding on the vehicle, disconnect

the battery cable to prevent damage of the battery
and electrical system.

Maintenance of the frame consists of periodic

inspection for cracks or breaks in the welds, and
fracture or bending of the frame structure. If any of the
Illustration 99 these faults are found it should be remedied at once.
8. Reset the filter element indicator. Check the lift arm and its components for cracks and
bends or any damages.

SM NO : 94, May 2011 49

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Maintenance Section
Bucket Cutting Edge and Tooth - Inspect/Replace

holding effort that is required to sustain a machine at a Bucket Cutting Edges and
specific engine rpm varies depending on the machine.
The variations are the differences in the engine setting, Tooth - Inspect / Replace
in the power train efficiency, and in the brake holding
ability, etc.

1. Start the engine. Raise the bucket slightly.

Personal injury or death can result from bucket
2. Engage the parking brake. falling.
3. M o v e t h e t r a n s m i s s i o n c o n t r o l l e v e r t o Block the bucket before changing bucket cutting
FORWARD. edges.
4. Gradually increase the engine speed to high idle.
The machine should not move.

If the machine begins to move, reduce the engine

speed immediately and engage the service

5. Reduce the engine speed to low idle. Move the

transmission to NEUTRAL. Lower the bucket to
the ground. Stop the engine.

Fan Belt - Inspect

lllustration 103

1. Check the area around the machine. Make sure

that the machine is clear of personnel and clear
of obstacles.

2. Test the brakes on a dry, level surface.

3. Raise the bucket. Place a block under the

bucket.

4. Lower the bucket to the blocking.

Do not block up the bucket too high. Block up the

lllustration 102
Stop the engine. Open the engine access door. The
single V-belt is located at the front of the engine.
Inspect the condition of the V-belt. If the V-belt is
cracked or frayed, replace the V-belt.
Check by pressing midway between the pulleys to
see whether the belt deflects by not more than 10 to
15 mm.
If necessary re-tension V-belt by loosening and re-
tightening the battery charging alternator.
bucket so that the bucket is high enough to remove
the cutting edges and the end bits.
5. Clean the contact surfaces.
6. The bucket being of welded construction, it cannot
be disassembled. Inspect cutting edge and tooth
for cracks and wear found. If necessary, It can be
repaired.
7. Raise the bucket. Remove the blocks.
8. Lower the bucket to the ground.

50 SM NO : 94, May 2011

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Maintenance Section
Engine Oil level - Check

Engine Oil Level - Check Engine Oil and Filter - Change

Run the engine until it gets warm. Stop the engine and
NOTICE remove the battery connections.
Do not overfill the crankcase. Engine damage can
result. 1. Place the oil tray under the engine.

2. Unscrew oil drain plug on the end of drain pipe &

drain oil completely. Wait until last drop of oil.

lllustration 130

1. Open the engine access door on the right side of

the machine.
lllustration 132

3. Collect used oil in suitable receptacle ready

for proper disposal to prevent environmental
prevention.

4. Refit oil drain plug with new joint washer and

tighten firmly.

5. Fill in fresh lube oil and do not flush the lube system
with diesel or kerosene. Refer to Operation and
Maintenance Manual, “Refill Capacities”.

6. Replace “Spin-on” lube oil filter cartridge for every

oil change.
lllustration 131
7. Release lube oil filter cartridge with special tool
2. While the engine is stopped, maintain the oil level
and spin off.
between the “LOW” mark and the “MAX” mark on
the engine oil dipstick. 8. Clean sealing surface of filter carrier. Fit the filter
cartridge in dry condition. Do not fill oil in the filter
3. If necessary, add oil.
before assembly.
4. Close the access door.
9. Apply light film of oil to rubber seal of new cartridge.
Screw the cartridge into place by hand until seal
is evenly seated.

10. Tighten lube oil filter cartridge firmly by giving a

final half turn.

11. Check oil level and lube oil pressure. Check seal
of lube oil filter cartridge for leaks.

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Maintenance Section
Fuel Filter - Replace

Fuel Filter - Replace Fuel Filter (MUD) - Replace

lllustration 134
lllustration 133
1. Loosen the centre bolt and remove the bowls and
1. Keep the machine ready to perform the work. discard the elements.
2. Clean the filter assembly externally. 2. Clean the filter bowl with cleaning cloth.
3. Remove the cartridge by rotating in anticlockwise 3. Install the new filter elements. Ensure that the
by hand. rubber gasket between the filter bowls and filter
head is in good condition.
4. Collect driping fuel in a tray.
4. Assemble the filters in the reverse order of
5. Destroy the removed cartridge. dismantling.
6. Clean the sealing surface of filter. 5. Tighten the centre bolts.
7. Apply light film of oil or diesel fuel to the rubber 6. Prime the fuel system in order to fill the filter
gasket of the new fuel filter cartridge. elements with fuel.
8. Screw in the new cartridge finger tight against the
gasket.
Fuel Tank Filler Cap - Clean
9. Tighten the fuel filter cartridge with a final half turn
using commercial tool. Open fuel stopcock and
check for leaks.

lllustration 135

Clean the filler cap in solvent and fix it. Clean the filler
neck screen.

52 SM NO : 94, May 2011

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Maintenance Section
Fuel Tank Water and Sediment - Drain

Fuel Tank Water and Sediment Fuel Level - Check

- Drain

lllustration 138
lllustration 136
Check fuel level, remove the fuel tank dipstick, wipe it
1. Fuel tank is located on the rear side of the clean and reinsert. Remove it and observe the
machine near fan guard. indicated fuel level. If necessary add fuel.

2. Slowly remove the fuel tank cap (1) in order to

relieve pressure. Fuses - Replace
3. Clean the filler cap (1) and filler neck screen.
NOTICE
Replace the fuses with the same type and size only.
Otherwise, electrical damage can result.

If it is necessary to replace fuses frequently, an

electrical problem may exist. Contact your Caterpillar
dealer

lllustration 137

4. The fuel tank drain valve (2) is located on the

bottom of the fuel tank. Remove the fuel tank drain
plug. Allow the water and sediment to drain into a
suitable container. Install the fuel tank drain plug.
If necessary replace the drain plug.
lllustration 139

Fuses – Fuses protect the electrical system from

damage that is caused by overloaded circuits.
Replace the fuse if the element separates. If the
element of a new fuse separates, check the circuit.
Repair the circuit, if necessary.

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Maintenance Section
Walk - Around Inspection

Walk - Around Inspection
NOTICE
Accumulated grease and oil on a machine is a fire
hazard. Remove this debris with steam cleaning or high
pressure water, at least every 1000 hours or each time
any significant quantity of oil is spilled on a machine.
Note: Inspect the machine for leaks. If leaks are
observed, find the source of the leak and correct the
leak. If leaks are suspected, check the fluid levels more
frequently than the recommended intervals. If leaks
are observed, check the fluid levels more frequently
than the recommended intervals.
Inspect the tires (8) for damage and for proper inflation.
Replace any missing valve caps. Tighten any loose
bolts.
Inspect the axles (9) for leaks. Inspect the front and
rear differential for leaks.
Inspect the engine air cleaner (10) for dirt buildup.
Remove the dirt from the engine air cleaner. Service
the air filter elements when enters the red zone on the
filter service indicator.
Inspect the steps and handholds (11). These objects
must be clean. Also, these objects must be in good
condition. Inspect the cab mountings for damage.
Notify your dealer for repairs, if necessary. Tighten any
loose bolts on mountings.

Make sure that the access covers and the guards are
10
5 7 secured. Inspect the access covers for damage and
12 the guards for damage.
2 Inspect the lights (12) for broken bulbs and for broken
1
lenses. Replace the bulbs or lenses, if necessary.
6
Inspect the operator’s compartment for cleanliness.
Keep the operator’s compartment clean.
` `
`
`

4
`

9 9
8 11 3 8
Cooling System - Drain/Flush/
lllustration 154
Refill
Inspect the bucket (1) for damage or for excessive
wear. Inspect the linkage (2) for damage or for
excessive wear. Repair the bucket or the linkage, if
necessary. Replace any bucket teeth, if necessary.

Inspect the transmission (3) for leaks. Correct any

leaks. Check the hoses around the transmission.

Inspect the hydraulic system for leaks. Inspect the

hydraulic tank (4), cylinder rod seals, hoses and tubes.
Also inspect plugs, couplings and fittings. Correct any
leaks.

Inspect the engine compartment (5) for trash buildup.

Remove any trash buildup that is in the engine
compartment. Clean the screens on the engine access
lllustration 155
doors.
Cooling system drain plug is located on the bottom
Inspect the belts for the engine attachments (6) for right side of the radiator. Drain, flush and refill the
worn belts, for cracked edges or for frayed edges. radiator.
Replace any damaged belts.

Inspect the cooling system for leaks, for faulty hoses,

and for trash buildup. Correct any leaks and remove
any trash buildup from the radiator (7).

54 SM NO : 94, May 2011