Intervalo Mantto-Cat-R1300

SAFETY.CAT.
COM™
R1300
LOAD HAUL DUMP
Maintenance Intervals
Excerpted from Operation & Maintenance Manual ((SEBU7321-03)
© 2007 Caterpillar ®
All Rights Reserved
105
Maintenance Section
Service When Required Fan Bearing - Lubricate ......................................... 142

Drive Shaft Universal Joints, Splines and
Fuses and Circuit Breakers - Replace/reset .......... 106
Bearings - Lubricate .............................................. 143
Windshield Wipers and Washer - Replace
Emergency Shutdown to Idle Protection
blades/fill reservoir ................................................... 107 System - Check operation ..................................... 144
Filter Inspection - Inspect used filter for debris ........ 108
Low Transmission Oil Pressure Automatic Brake
Fuel System - Service when loss of power ............. 136
Application (ABA) System - Test operation ............ 145
Air Conditioner - Test operation/adjust belt ............ 146
Every 10 Service Hours or Daily Fire Extinguisher System - Check ......................... 147
Walk-Around Inspection - Inspect machine ........... 109
Engine Crankcase Oil - Check oil level ................... 111 Every 500 Service Hours or 3 Months*
Transmission System Oil - Check oil level ............. 112
Change ........................... 148
Transmission Oil Filter -
Hydraulic Tank Oil - Check oil level ........................ 112
Hydraulic Oil System - Change filters ..................... 149
Cooling System - Check coolant level ................... 113
Engine Crankcase Breather - Clean ....................... 150
Engine Air Intake System - Service filters ............... 114
Fuel Tank Cap and Fill Screen - Clean .................. 150
Fuel Tank - Drain the water and sediment .............. 118
Fire Extinguisher System - Check ......................... 151
Seat Belt - Inspect ................................................. 118
Indicators and Gauges - Test ................................ 119
Every 1000 Service Hours or 6 Months*
Brakes - Test ......................................................... 119
Steering Lockout - Test operation .......................... 122 Transmission Oil - Change .................................... 152
Backup Alarm - Test .............................................. 123 Front Differential and Final Drives - Change oil ...... 153
Fan and Alternator Belts - Inspect/adjust ............... 124 Rear Differential, Transfer Case and Final
Bucket Pivot Pins - Lubricate ................................ 125 Drives -Change oil ................................................. 154
Bucket Tilt Linkage Bearings - Lubricate ............... 125 Brake Accumulators - Check pressure .................. 156
Bucket Tilt Cylinder and Tilt Lever Ride Control Accumulator - Check pressure ......... 156
Bearings - Lubricate .............................................. 126 Parking Brake Solenoids - Test operation ............. 157
Lift Arm and Cylinder Linkage Transmission and Steering Lock
Bearings - Lubricate .............................................. 127 Pivot -Lubricate/adjust ........................................... 157

Frame Pivot Bearings - Lubricate .......................... 127 FOPS - Inspect ...................................................... 158
Steering Cylinder Bearings - Lubricate .................. 128 Fire Extinguisher System - Check ......................... 158
Rear Axle Trunnion Bearings - Lubricate ............... 128

Centralized Lubrication System - Lubricate Every 2000 Service Hours or 1 Year*
fittings ..................................................................... 129 Engine Valve Lash - Check/adjust .......................... 159
Automatic Lubrication System - Check ................. 130 Engine Valve Rotators - Check .............................. 159
Scrubber Water Tank - Check water level .............. 131 Engine Mounts & Crankshaft Vibration
Fire Extinguisher System - Check ......................... 132 Damper - Check/inspect ........................................ 160
Hydraulic Tank Oil - Change oil ............................. 161
Every 50 Service Hours or Weekly* Hydraulic Tank Vacuum Breaker - Clean ............... 162
Wheel Brakes - Check wear .................................. 163
Cab Air System - Clean filters ................................ 133
Tires -Check inflation pressure .............................. 134
Every 3000 Service Hours or 2 Years*
Every 250 Service Hours or Monthly* Cooling System (Conventional Coolant/Antifreeze) -
Clean/flush/change coolant on machines using
Engine Valve Lash - Adjust on new or reconditioned
conventional coolant/antifreeze only ........................ 164
engines, then at normal interval thereafter ............... 159
Cooling System (Extended Life Coolant/Antifreeze) -
Engine Oil and Filter - Change ............................... 135
Add "Extender". This maintenance procedure is for
Fuel System - Service filters ................................... 136
machines using Extended Life Coolant/Antifreeze
Cooling System (Conventional Coolant/Antifreeze) -
only ........................................................................ 165
Check coolant/add coolant additive. This
maintenance procedure is for machines using
conventional coolant/antifreeze only ........................ 138
Every 6000 Service Hours or 4 Years*
Front Differential and Final Drives - Cooling System (Extended Life Coolant/Antifreeze) -
Check oil level ........................................................ 139 Clean/flush/change coolant on machines using
Rear Differential, Transfer Case and Final Extended Life Coolant/Antifreeze only ........................ 167
Drives - Check oil level ........................................... 140
Batteries - Check ................................................... 141 * First Perform Previous Service Hours Items.
106
Maintenance Section
When Required
Service When Required
You must read and understand the warnings and Reset Circuit Breakers
instructions contained in the Safety Section of this
manual before performing any operation or Circuit Breakers -They protect the electrical
maintenance procedures. system from damage caused by overloaded
circuits. Push the button in to reset the circuit
breaker. If working properly, the button will remain
Fuses and Circuit Breakers depressed. If the button does not stay in or comes out
shortly after being reset, have the appropriate electrical
Replace Fuses circuit checked.
Fuses -They protect the electrical system

NOTICE
from damage caused by overloaded circuits.
Change a fuse if the element separates. If the Replace circuit breakers with the same type and size only.
element of a new fuse separates, have the circuit Otherwise, electrical damage can result.
checked and repaired. If it is necessary to reset circuit breakers frequently, an
electrical problem may exist. Contact your Elphinstone
dealer.
NOTICE
Replace 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 Elphinstone dealer. 1 2 3 4 5 6 7
1 8 9 10 11 12 13 14
The above illustration details circuit breaker layout.
(1) 15 AMP C.B. - Electronic transmission control.

(2) 15 AMP C.B. - Caterpillar Monitoring System, gauge
lights.
Located in battery compartment. (3) 15 AMP C.B. - Spare.
(4) 15 AMP C.B. - Exhaust back pressure control (if
(1) 675 AMP Fuse - Fusible link. equipped), backup alarm, dash panel lights, wipers/
washers (if equipped), residual brake pressure/stop
light (if equipped).
(5) 15 AMP C.B. - Bucket positioner, horn, ejector
bucket control (if equipped), Loadrite (if equipped),
automatic lubrication system (if equipped).
(6) 15 AMP C.B. - Remote control system (if equipped).
(7) 15 AMP C.B. - Ausprotec fire protection control unit
(if equipped).
(8) 30 AMP C.B. - Air conditioning (if equipped).
(9) 15 AMP C.B. - Parking brake control.
(10) 15 AMP C.B. - Throttle control.
107
Maintenance Section
When Required
(11) 15 AMP C.B. - Interior light (if equipped), cassette Windshield Wipers and
player (if equipped).
(12) 15 AMP C.B. - Key start switch, idle timer/fire Washer (If Equipped)
protection control unit (if equipped).
(13) 30 AMP C.B. (Automatic) - Right side lights.
Replace Blades
(14) 30 AMP C.B. (Automatic) - Left side lights, tail light
(if equipped).
15 16
Inspect the front, rear and side windshield wiper

Located below starter motor in engine compartment. blades. Replace any blades that are worn or damaged,
or if streaking occurs.
(15) 80 AMP C.B. - Main.
(16) 80 AMP C.B. - Alternator.
Fill Washer Reservoir
NOTICE
When operating in freezing conditions, use Caterpillar
nonfreezing window washer solvent or equivalent. System
damage can result from freezing.
Remove the cap and fill the windshield washer

reservoir. Refit the cap.
108
Maintenance Section
When Required
Filter Inspection
Inspect Used Filter for Debris
Use a 4C5084 Filter Cutter to cut the filter element

open. Spread pleats apart and inspect the element for
metal and other debris. An excessive amount of debris
in the filter element can indicate a possible failure.
Use a magnet to differentiate between ferrous and

nonferrous metals found in the filter element.
Ferrous metals can indicate wear on the steel and cast

iron parts.
Nonferrous metals can indicate wear on the aluminium

parts of the engine, such as main, rod and/or
turbocharger bearings.
Due to normal wear and friction, it is not uncommon to

find small amounts of debris in the filter element.
Consult your Elphinstone dealer to arrange for further
analysis if an excessive amount of debris is found.
Use of an oil filter element not recommended by

Elphinstone can result in severe engine damage to
engine bearings, crankshaft and other parts. This can
result in larger particles in unfiltered oil entering the
lubricating system and causing damage.
109
Maintenance Section
Every 10 Service Hours or Daily
You must read and understand the warnings and

instructions contained in the Safety Section of this
manual before performing any operation or
maintenance procedures.
Walk-Around Inspection
Inspect Machine
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
Inspect the bucket and linkage for damage or
quantity of oil is spilled on a machine.
excessive wear. Repair if damaged.
NOTE: Keep a close watch for leaks. If leaking is Inspect the lights for broken bulbs and lenses. Replace
observed, find the source and correct the leak. Check if broken.
the fluids level more frequently than the recommended
periods if leaking is suspected or observed. Inspect and remove any trash build-up in the engine
compartment.
Inspect the cooling system for leaks, faulty hoses and

trash build-up. Correct any leaks and remove any
trash from the radiator.
Inspect all engine attachment belts for worn, cracked

or frayed edges. Replace if worn, cracked, frayed or
broken.
Inspect the hydraulic system for leaks. Inspect the

tank, cylinder rod seals, hoses, tubes, plugs, joints and
fittings. Correct any leaks.
Inspect the air intake precleaner for damage and rotor

operation. Check the air restriction indicator.
110
Maintenance Section
Window Cleaning
Inspect the differentials and final drives (front and rear)

under the machine for leaks.
Use commercially available window cleaning solutions
Inspect tires (front and rear) for damage and proper to clean the windows. Clean the outside windows from
inflation. Replace any missing valve caps. the ground, unless handholds are available.
Inspect transmission and torque converter updrive for

leaks.
Inspect the wheel brakes for leaks.
Be sure the covers and guards are firmly in place.

Inspect for damage.
Inspect the steps, walkways and handholds for their

condition and cleanliness. Inspect the Falling Objects
Protective Structure (FOPS) for damage. If repair is
necessary, contact your Elphinstone dealer. Tighten
any loose FOPS bolts.
Inspect the operator's compartment for cleanliness.

Keep it clean.
111
Maintenance Section
Engine Crankcase Oil
Check the Oil Level
2
NOTICE
Do not overfill the crankcase. Engine damage can result.
3. Remove oil filler cap (2) and add oil if necessary.
4. Clean and install the filler cap.
The dipstick is located in the right hand side of the

engine compartment.
1. The machine must be level with the parking brake

engaged.
2. Maintain the oil level between the ADD and FULL

marks on the engine running side of dipstick (1) with
the engine running at low idle and the oil warm.
Maintain the oil level between the marks on the engine

stopped side of dipstick (1) with the engine stopped
and the oil cold.
112
Maintenance Section
Transmission System Oil Hydraulic Tank Oil
Check the Oil Level Check the Oil Level
Check the transmission oil level with the machine level,

the engine running at low idle and the oil at normal
operating temperature. 3
The hydraulic oil tank is located on the right hand side

of the machine.
1. Maintain the oil level above the ADD COLD mark

on sight gauge (1) with the engine stopped and the
1. Maintain the oil level between the LOW and FULL bucket level on the ground.
marks on dipstick (1) at LOW IDLE.
2. Open the hydraulic tank access cover located on

2. If oil is to be added, open the access cover located the upper right hand side of the machine.
on the platform behind the operator's station.
3. Relieve the hydraulic tank pressure by pushing on
3. Remove oil filler cap (2) and add oil if necessary. top of relief valve (2) before removing the oil filler cap.
4. Clean and install the filler cap. 4. Remove oil filler cap (3) slowly to relieve any
remaining pressure. Add oil, if necessary, through the
5. Close the access cover. fill tube.
5. Clean and install the filler cap.
6. Close the access cover.

113
Maintenance Section
Cooling System
Check the Coolant Level
5. Inspect the radiator core for debris and clean if

necessary.
Compressed air is preferred, but high pressure water

or steam can be used to remove dust, leaves and
1. Maintain the coolant level in the sight gauge general debris from the radiator. Clean as required by
located on the right hand side of the machine. If it is condition of radiator.
necessary to add coolant daily, check for leaks.
To enable access to the radiator for cleaning purposes,

2. If coolant level is low, remove the radiator cap open the grille at the rear of the machine. Remove the
slowly to relieve pressure. Add coolant as required to locking pin. The hydraulic oil cooler can then be
within 13 mm (1/2 in.) of the bottom of the fill pipe or to swung out to expose the radiator core.
the proper level on the sight gauge.
3. Inspect the cap and cap seal for damage, deposits

or foreign material. Clean the cap with a clean cloth or
replace the cap if it is damaged.
4. Install the cap.

114
Maintenance Section
Engine Air Intake System Service the Filter Elements
Check the Air Intake Precleaner NOTICE

To prevent engine damage, service the air cleaner only with
the engine stopped.
NOTICE
Some machines use radial seal type air cleaners. To avoid
engine damage, use only radial seal replacement filters.
Others will not seal.
Radial seal filter gasket design and location are critical to
proper air cleaner operation. Use only Caterpillar
replacements.
1. Inspect the air intake precleaner visually for

damage.
2. Check the air intake precleaner rotor operation.
3. Periodically check the rotor bearing and replace if

necessary.
Service the air cleaner daily or if the yellow piston in the

filter element indicator moves into the red zone with the
engine running at high idle. Stop the engine.
115
Maintenance Section
Service the Primary Element
3. Clean the inside of the air cleaner housing.
1. Remove air cleaner cover (1). 4. Clean and inspect the primary element. See
Cleaning Primary Elements.
5. Install a clean primary element.
2 6. Clean and install the cover.
2. Remove primary filter element (2) from the air

cleaner housing.
If the yellow piston in the filter element indicator (3)

moves into the red zone after starting the engine, or
the exhaust smoke is still black after installation of a
clean primary element, install a new primary filter
element. If the piston remains in the red zone after
installing a new primary filter element, replace the
secondary element.
The primary filter element should be replaced after

being cleaned a maximum of six times. Replace the
element once a year even though it has not been
cleaned six times.
116
Maintenance Section
Change the Secondary Element Cleaning Primary Elements
NOTICE NOTICE
Always replace the secondary filter element. Never attempt Do not clean the filter elements by bumping or tapping
to reuse it by cleaning. them. Do not use filter elements with damaged pleats,
The secondary filter element should be replaced at the time gaskets or seals. Engine damage could result.
the primary element is serviced for the third time. Make sure the cleaned filter elements are completely dry
The secondary filter element should also be replaced if the before installing into the filter housing. Water remaining in
yellow piston in the filter element indicator enters the red the elements can cause false indications of contamination
zone after the installation of a clean primary element, or if in Scheduled Oil Sampling test results.
the exhaust smoke is still black.
Filter elements can be cleaned with pressure air,
1. Remove the housing cover and the primary pressure water, or detergent washing.
element.
Pressure Air - 205 kPa (30 psi) Maximum
2. Remove bolts (1) that hold the secondary filter

element to the housing. Remove the secondary filter
element. 1. Direct air along pleats inside and outside of filter
element.
3. Cover the air inlet opening. Clean the inside of the
air cleaner housing. 2. Inspect the element.
4. Inspect the gasket between the air inlet pipe and

the housing. Replace it if it is damaged.
5. Uncover the air inlet opening. Install a new

secondary element.
6. Install bolts (1) that hold the secondary filter

element to the housing. Torque the bolts to 47 ± 7
N•m (35 ± 5 lb ft).
7. Install the primary element and cover.

117
Maintenance Section
Pressure Water - 280 kPa (40 psi) Inspecting the Elements

Maximum
1. Inspect the filter elements after cleaning. Do not

1. Direct water along pleats inside and outside of filter use a filter element with damaged pleats, gaskets or
element. seals.
2. Rinse and air dry thoroughly. 2. Wrap and store the clean filter elements in a clean,
dry place.
3. Inspect the element.
Detergent
1. Wash the element in warm water and non-sudsing

household detergent.
2. Rinse with clean water and dry thoroughly.
3. Inspect the element.

118
Maintenance Section
Fuel Tank Seat Belt
Drain the Water and Sediment Inspect for Wear or Damage
The drain valve is located on the right hand side of the Replace the seat belt after three years of usage,
machine under the fuel tank. regardless of appearance.
Typical Example
Seat belt and mounting hardware must be inspected
for wear or damage before operating the machine.
1. Open (turn counterclockwise) drain valve (1) and Replace the belt or mounting hardware if worn or
allow the water and sediment to drain out of opening damaged.
(2) into a suitable container.
2. Close drain valve (1).

119
Maintenance Section
Indicators and Gauges Brakes
Test for Proper Function Test Service Brake Holding Ability
Personal injury can result if the machine moves

while testing.
If the machine begins to move while testing, reduce
the engine speed immediately, apply the parking
brake and lower the bucket to the ground. Repair the
brake immediately.
NOTICE
Perform the following brake tests at the start of each shift
and before entering a ramp.
Look for broken gauge lenses or indicator lights,
switches, etc. Be sure the area around the machine is clear of
personnel and obstructions.
Move the engine start switch to the ON position and
check the Caterpillar Monitoring System Functional Be sure the steering frame lock pin is in the stored
Test. Refer to the topic Caterpillar Monitoring System position.
Functional Test in the Monitoring Systems and Cab
Features section of this manual. Test the brakes on a dry, level surface.
Start the engine. Fasten the seat belt before testing the brakes.
Look for inoperative gauges. The following tests are to determine if the service brake
is functional. These tests are not intended to measure
Turn all machine lights on. Check for proper operation. maximum brake holding effort. Brake holding effort
required to hold a machine at a specific engine rpm will
Sound the horn. vary from machine to machine. This is due to
differences in engine settings, power train efficiency,
Stop the engine. etc., as well as differences in brake holding ability.
Make any needed repairs before operating. Engine rpm at beginning of machine movement, with
service brake applied, should be compared against a
prior test. Use the test as an indication of system
deterioration.
To carry out the brake test, first start the engine and let
the brake oil pressure build up to the operating range.
The parking brake will stay applied until operating oil
pressure has been reached and the control button is
moved to the OFF position (brake released). Once
operating oil pressure has been reached a test of the
brake system can be commenced.
120
Maintenance Section
1. Start the engine and raise the bucket slightly. Test Parking Brake Holding Ability
NOTICE
The standard park brake control button is a pull-to apply
type. When the button is pulled OUT, the brakes will be
applied.
Certain mining regulations require machines to be equipped
with a push-to-apply parking brake control button. When
the button is pushed IN, the brakes are applied.
Before operating the machine, ensure you are familiar with
the operation of the parking brake control button.
Standard Pull-to-Apply Type
2. Depress the service brake pedal to apply the

service brakes. Release the parking brake.
3. Move the transmission control to 2nd speed

forward.
while testing.
4. Gradually increase the engine speed to high idle. If the machine begins to move, reduce the engine
The machine should not move. speed immediately, apply the service brake and lower
the bucket to the ground. Repair the brake
5. Reduce the engine speed to low idle, move the immediately.
transmission control to NEUTRAL. Engage the parking
brake, lower the bucket to the ground and stop the
Be sure the area around the machine is clear of
engine.
NOTICE Be sure the steering frame lock pin is in the stored

position.
If the machine moved while testing the brakes, contact
your Elphinstone dealer. Have the dealer inspect and, if Test the brakes on a dry, level surface.
necessary, repair the service brakes before returning the
machine to operation. Fasten the seat belt before testing the brakes.
The following tests are to determine if the parking

brake is functional. These tests are not intended to
measure maximum brake holding effort. Brake holding
effort required to hold a machine at a specific engine
rpm will vary from machine to machine. This is due to
differences in engine settings, power train efficiency,
etc., as well as differences in brake holding ability.
Engine rpm at beginning of machine movement, with

parking brake engaged, should be compared against a
prior test. Use the test as an indication of system
deterioration.
1. Start the engine and raise the bucket slightly.

121
Maintenance Section
Optional Push-to-Apply Type

while testing.
If the machine begins to move, reduce the engine
speed immediately, apply the service brake and lower
the bucket to the ground. Repair the brake
immediately.

2. Engage the parking brake by pulling the parking
brake control button OUT to the ON position (brake Be sure the steering frame lock pin is in the stored
applied). position.
3. Shift the transmission to 2nd speed FORWARD. Test the brakes on a dry, level surface.
NOTE: The parking brake indicator and the fault light Fasten the seat belt before testing the brakes.
should flash and the action alarm should sound.
The following tests are to determine if the parking
4. Gradually increase the engine speed to high idle. brake is functional. These tests are not intended to
The machine should not move. measure maximum brake holding effort. Brake holding
effort required to hold a machine at a specific engine
5. Reduce the engine speed to low idle, move the rpm will vary from machine to machine. This is due to
transmission control to NEUTRAL. Lower the bucket to differences in engine settings, power train efficiency,
the ground and stop the engine. etc., as well as differences in brake holding ability.
Engine rpm at beginning of machine movement, with

NOTICE
parking brake engaged, should be compared against a
If the machine moved while testing the brakes, contact prior test. Use the test as an indication of system
your Elphinstone dealer. Have the dealer inspect and, if deterioration.
necessary, repair the parking brake before returning the
machine to operation. 1. Start the engine and raise the bucket slightly.
122
Maintenance Section
Steering Lockout
Test Operation

Be sure the steering frame lock pin is in the stored

position.
Fasten the seat belt before testing the steering lockout

systems.
2. Engage the parking brake by pushing the parking Steering Primary Lockout
brake control button IN to the ON position (brake
applied). 1. Start the engine and raise the bucket slightly.
3. Shift the transmission to 2nd speed FORWARD.
NOTE: The parking brake indicator and the fault light

should flash and the action alarm should sound.
4. Gradually increase the engine speed to high idle.

The machine should not move.
5. Reduce the engine speed to low idle, move the

transmission control to NEUTRAL. Lower the bucket to
the ground and stop the engine.
NOTICE
If the machine moved while testing the brakes, contact
your Elphinstone dealer. Have the dealer inspect and, if
2. Depress the service brake pedal to apply the
necessary, repair the parking brake before returning the
service brakes. Release the parking brake.
machine to operation.
123
Maintenance Section
Backup Alarm
Test
2
1
3. With steering and transmission lock lever (1) in the

LOCKED position (as shown), attempt to steer the
machine in a left or right direction. The machine should
not move.
4. Move transmission directional control switch (2) to The backup alarm is located on the rear of the
either the FORWARD or REVERSE position. The machine.
transmission should not engage.
Turn the engine start switch key to ON to perform the
5. Engage the parking brake. test.
Apply the service brake. Move the transmission

Steering Secondary Lockout direction control switch to REVERSE.
The alarm should start to sound immediately. It will

continue to sound until the transmission control switch
is moved to NEUTRAL or FORWARD.
Personal injury can result if the machine turns
towards the cab door (left turn) with the door open.
Keep clear of the cab door and check the steering
lockout operation using a right hand turn ONLY.
6. Move steering and transmission lock lever (1) to

the UNLOCKED position.
7. Open the cab door approximately 300 mm (12 in)

and attempt to steer the machine in a RIGHT hand
direction only. The machine should not move.
8. Close the cab door. Lower the bucket to the

ground and stop the engine.
The sound level can be adjusted by moving the

NOTICE
adjustment on the back of the alarm to meet operating
If the machine moved while testing the steering lockout requirements. The alarm is set at the highest sound
systems, contact your Elphinstone dealer. Have the dealer level when shipped from the factory. The setting
inspect and repair the steering lockout before returning the should remain on high, unless the job site requires a
machine to operation. lower level.
124
Maintenance Section
Fan and Alternator Belts Alternator Belt Adjustment
Inspect/Adjust
1 2
For maximum engine performance and utilization of
your engine, inspect the belts for wear and cracking.
Check and adjust the belt tension to minimize belt
slippage which will decrease belt life and cause poor
performance of alternator and any driven equipment.
1. Inspect the condition of the belts.
2. Inspect the tension of the belts.
1. Loosen alternator bracket bolt (3). Loosen locknut

(1).
2. Turn adjusting nut (2) until the correct belt tension

is reached. Tighten locknut (1) to 150 ± 20 N•m (110
± 15 lb ft).
3. Tighten alternator bracket bolt (3).
To check the belt tension, apply 110 N (25 lb.) of force

midway between the pulleys. Correctly adjusted belts
will deflect 14 to 20 mm (.56 to .81 in.).
If new belts are installed, check belt adjustment again

after 30 minutes of operation. For multiple belt drive
applications, always replace belts in matched sets.
If only one belt of a matched set is replaced, it will

carry more of a load than the belts not replaced since
the older belts are stretched. The additional load on
the new belt could cause it to break.
125
Maintenance Section
Bucket Pivot Pins Bucket Tilt Linkage Bearings
Lubricate Fittings Lubricate Fittings
Wipe all fittings before lubricating. Wipe all fittings before lubricating.
Lubricate one fitting on each of the bucket pivot Lubricate one fitting for each of the bucket tilt linkage
bearings (2 points). bearings (2 points).
126
Maintenance Section
Bucket Tilt Cylinder and Tilt Lever

Bearings
Lubricate Fittings
Wipe all fittings before lubricating.
Lubricate one fitting for the bearing at the center pivot

point of the tilt lever.
Lubricate one fitting for the bearing at the head end of

the tilt cylinder.
Lubricate one fitting for the bearing on the rod end of

the tilt cylinder.
127
Maintenance Section
Lift Arm and Cylinder Linkage Frame Pivot Bearings

Bearings
Lubricate Fittings
Lubricate Fittings
Lubricate one fitting for the upper pivot bearing.

Lubricate one fitting (1) (obscured) on each side of the
machine for the rear lift arm bearing (2 points).

machine for the bearing at the rod end of the lift
cylinder (2 points).
Lubricate one fitting for the lower pivot bearing.

3

machine for the bearing at the head end of the lift
cylinder (2 points).
128
Maintenance Section
Steering Cylinder Bearings Rear Axle Trunnion Bearings
Lubricate Fittings Lubricate Fittings
Wipe all fittings before lubricating. Wipe all fittings before lubricating.
The fittings are located in the right hand side of the

machine hitch area.
1
2
Lubricate one fitting for the bearing at the rod end of

the steering cylinder.
4
3
Lubricate the remote mounted fitting for the bearing at

the head end of the steering cylinder. Lubricate front trunnion bearing (1) through remote
mounted fitting (4).
Lubricate rear trunnion bearing (2) through remote

129
Maintenance Section
Centralized Lubrication System

(If Equipped)
Lubricate Fittings

9 10 11 12 13 14
The fittings are located on the top of the front frame
and on the right hand side of the lift arms.
1 2 3 4 5 6
9. Lubricate the right bucket pivot pin through remote
10. Lubricate the bearing at the rod end of the tilt

cylinder through remote mounted fitting (10).
7 8
11.Lubricate the tilt lever center pivot bearing through
remote mounted fitting (11).
12. Lubricate the bearing at the tilt lever end of the tilt
linkage through remote mounted fitting (12).
1. Lubricate the left bucket pivot pin through remote 13. Lubricate the bearing at the bucket end of the tilt
mounted fitting (1). linkage through remote mounted fitting (13).
2. Lubricate the bearing at the rod end of the left lift 14.Lubricate the right rear lift arm bearing through
cylinder through remote mounted fitting (2). remote mounted fitting (14).
3. Lubricate the left rear lift arm bearing through

remote mounted fitting (3).
4. Lubricate the bearing at the head end of the left lift

5. Lubricate the bearing at the head end of the tilt

6. Lubricate the bearing at the rod end of the right lift

7. Lubricate the bearing at the rod end of the steering

8. Lubricate the bearing at the head end of the right

lift cylinder through remote mounted fitting (8).
130
Maintenance Section
Automatic Lubrication System 7. Inspect the electrical system for worn or frayed
wiring, damaged connectors or a tripped circuit
(If Equipped) breaker.
Check Operation NOTE: For more information on the automatic

lubrication system, refer to Automatic Lubrication
System, Systems Operation, Testing and Adjusting,
Form No. RENR4503 (1DE1818), in the machine
2 Service Manual.
1. Check the grease level in the reservoir. Use a

manual grease gun or pump to fill the reservoir through
filler fitting (1) in the pump body.
2. Fill the reservoir to the MAXIMUM indicator (2) on

the reservoir.
NOTE: When filling the reservoir, caution should be

used as extreme pressure and overfilling can cause
damage to the reservoir assembly.
3. With the battery disconnect switch and the engine

start switch key in the ON position, trigger a lubrication
cycle by pressing switch (3) on the side of the cover
assembly.
4. Observe the stirring paddle in the lubricant

reservoir. When the pump is operating, the stirring
paddle should be rotating.
5. Check all discharge lines for leakage.
6. Check all injectors are operative. Check all

bearings that are lubricated by the automatic
lubrication system for signs of greasing.
131
Maintenance Section
Scrubber Water Tank (If Equipped) 7. If the gases are hot and dry, the water valve should
be turned (opened) further to the ON position.
Check Water Level 8. If there is raw water being blown from the exhaust
outlet, the water valve should be turned (closed) further
to the OFF position. A balance between the two
extremes is ideal.
NOTE: For more information on the water bath

scrubber system, refer to Emission Control Systems
Maintenance Manual, Form No. (RENR4501) 1DE0734,
in the machine Service Manual.
The water scrubber tank is located on the left hand

side of the rear frame.
1. Stop the engine. Remove the water scrubber tank

filler cap.
2. Inspect the water level in the tank. If necessary, fill

the water tank with clean water.
3. Inspect the water tank filler cap. If necessary,

replace the seal. Install the filler cap.
4. Check the operation of the water bath scrubber

system.
5. Turn the scrubber water valve to the ON position.

The scrubber will fill with water until the water reaches
a level where it will flow through an overflow pipe and
discharge onto the ground. If this does not happen,
check for a blockage between the tank and scrubber or
scrubber outlet.
6. When the water is flowing from the overflow pipe,

the machine can be started. Run the machine up to
operating temperature and check the scrubber water
valve adjustment. This can be checked by observing
the moisture content of the exhaust gases leaving the
scrubber outlet when the engine is at high idle.
132
Maintenance Section
Fire Extinguisher System

(If Equipped)
Check System
NOTICE
For detailed information on the fire extinguisher system
service procedures, refer to the fire system manufacturer's
service information.
Perform daily fire extinguisher system checks and

service procedures in accordance with the fire system
manufacturer's service information.
133
Maintenance Section
Every 50 Service Hours or Weekly
You must read and understand the warnings and 4. Periodically remove the precleaner cup and cap
instructions contained in the Safety Section of this and wash them in water.
manual before performing any operation or
maintenance procedures. 5. Loosen clamp bolt (2) and remove the air cleaner
assembly end cover (3). Remove the cab air filter
element.
Cab Air System (If Equipped)
6. Clean the filter element with pressure air or wash
Clean Filters the element in warm water and a nonsudsing
household detergent.
Clean the filter element weekly or when a reduction of 7. If washed, rinse the element in clean water and air
air circulation in the cab is noticed. If working in less dry thoroughly.
dusty conditions, the service interval for the filters can
be extended. 8. Refit the element and cover (3). Tighten the cover
clamp bolt (2) finger tight only. Do not use a tool to
Cab Pressurizer Filter tighten the clamp bolt.
1
3
2
1. Inspect the air conditioning filter precleaner cup (1)

visually. The cup should be emptied whenever dirt
reaches the indicator mark.
2. Loosen the wing nut on top of the cap and remove

the cap. Remove and empty the cup.
3. Install the cup and cap. Tighten the wing nut

finger tight only. Do not use a tool to tighten the wing
nut.
134
Maintenance Section
Tires Fire Extinguisher System

(If Equipped)
Check the Inflation Pressure
Check System
NOTICE
Measure the tire pressure on each tire. Consult your

Elphinstone dealer for correct load rating and operating
pressures.
Inflate the tires, if necessary. See the Tire Inflation

Information section of this manual.
Perform weekly (50 hour) fire extinguisher system

checks and service procedures in accordance with the
fire system manufacturer's service information.
135
Maintenance Section
Every 250 Service Hours or Monthly
You must read and understand the warnings and 5. Install the new filter by hand. When the gasket
instructions contained in the Safety Section of this contacts the filter base, tighten the filter 3/4 of a turn
manual before performing any operation or more.
maintenance procedures.
Engine Oil and Filter
Change the Oil and Filter 1

2
6. Remove oil filler cap (1). Fill the crankcase with

new oil. See Lubricant Viscosities and Refill
Capacities. Clean and install the filler cap.
7. Start the engine and allow the oil to warm. Check

for leaks.
1. Open the crankcase drain valve. Allow the oil to
drain into a suitable container. Close the drain valve. 8. With the engine running, maintain the oil level
between the ADD and FULL marks on the engine
running side of dipstick (2). Add oil if necessary.
2. Remove the filter element with a strap-type

wrench. Inspect the used filter element. Refer to Filter
Inspection in the When Required section.
3. Clean the filter housing base. Make sure all of the

old filter gasket is removed.
4. Apply a light coat of clean engine oil to the gasket

of the new filter.
136
Maintenance Section
Fuel System 11.Retighten the retaining nut to a torque of 24 ± 4

N•m (18 ± 3 lb ft).
Clean and Change Filters 12. Prime the fuel system. See Prime the Fuel System.
13. Start the engine and check for leaks.

NOTICE
Do not fill fuel filters before installing them. Contaminated
fuel will cause accelerated wear to fuel system components.
Fuel system should be primed prior to starting the engine.
Wash the Primary Filter Element
1. Loosen filter case retaining nut (1).
2. Remove case (2) and element from the filter base.
3. Remove the element from the case.
4. Wash the element and case in clean,

nonflammable solvent.
5. Dry the element using pressure air - 205 kPa (30

psi) maximum.
6. Inspect the element and replace if damaged.
7. Clean the filter base.
8. Inspect the seal. Replace if damaged.
9. Insert the clean element into the case.
10. Install the element and case into the filter base.
137
Maintenance Section
Change Secondary Fuel Filter Prime the Fuel System
After changing the fuel filter(s), prime (purge) the fuel

system to fill filters and remove air bubbles from the
system.
1. Remove the fuel filter with a strap-type wrench and

discard the filter.
2. Clean the filter mounting base. Be sure all of the

old seal is removed. 1. Loosen fuel filter air bleed (1) two full turns. Unlock
and operate priming pump plunger (2) until fuel appears
3. Lubricate the seal of a new filter with clean diesel at the fitting. Use a cloth or container to catch excess
fuel. fuel. A considerable amount of pump strokes may be
required to fill filters.
4. Install the new filter by hand. When the seal
contacts the base, tighten 3/4 of a turn more. 2. Tighten fuel filter air bleed (1) and continue to
operate priming pump plunger (2) until a resistance is
5. Prime the fuel system. See Prime the Fuel System. felt. Push the priming pump plunger in and tighten by
hand.
6. Start the engine and check for leaks.
3. Crank the engine promptly after pressurizing fuel
system. The engine should start within 15 seconds.
NOTICE
Do not crank the engine continuously for more than 20
seconds. Allow the starter motor to cool for two minutes
before cranking again.
4. If the engine will not start, allow the starter motor

two minutes to cool and repeat Steps 2 and 3.
5. If the engine starts, but runs rough, or once started

continues to misfire or smoke, further priming is
necessary to help purge fuel lines of air. Continue to
run engine at low idle until fuel flows free without
pockets of air in the fuel lines and the engine runs
smoothly.
138
Maintenance Section
Cooling System (Conventional 3. Add liquid supplemental coolant additive

(conditioner) according to the requirements of your
Coolant/Antifreeze) cooling system as determined by the coolant additive
concentration test.
Add Supplemental Coolant Additive/Replace
4. Install the filler cap.
Element
NOTE: This procedure pertains only to machines Change Coolant Additive Element
using conventional coolant/antifreeze.
(If Required)
Refer to the Cooling System Specifications section of

this manual for all cooling system requirements.
To prevent engine damage, never add coolant to an

overheated engine. Allow the engine to cool first. 1
Use the 8T-5296 Test Kit to check for concentration.
NOTICE
Excessive coolant additive (greater than the recommended
6% initial fill) together with concentrations of antifreeze 2
greater than 60% cause deposits to form and may result in
radiator tube blockage and overheating.
1. Close the element inlet valve (not shown) and

Add Liquid Supplemental Coolant
outlet valve (1). Remove and discard element (2).
Additive (If Required)
2. Clean the element mounting base. Make sure all of
the old gasket is removed.
3. Replace with a new Caterpillar maintenance

element.
4. Coat the gasket of a new element with a thin film of

engine oil.
5. Install and turn the element until the seal contacts

the base, then tighten 3/4 of a turn more.
6. Open the inlet and outlet valves.
7. Remove the radiator cap.
8. Start the engine and check for leaks. Allow the

coolant level to stabilise.
1. Loosen the radiator cap slowly to relieve pressure
and remove the cap. 9. Add premixed coolant if necessary to bring the
coolant to within 13 mm (1/2 inch) below the bottom of
2. It may be necessary to drain enough coolant from the fill pipe or to the proper level on the sight glass.
the radiator to allow for the addition of liquid cooling
system additive. 10. Install the radiator cap.
139
Maintenance Section
Front Differential and Final Drives
Check Oil Level
4. Remove the front differential dipstick/fill plug (2).

Observe the lubricant level.
5. Maintain the lubricant level between the ADD and

FULL marks on the dipstick. If necessary, add oil
NOTE: Perform the following procedure to the final through the dipstick/fill opening.
drive on each front wheel.
NOTE: Install the dipstick/fill plug completely in before
1. Wipe covers and surfaces around openings before checking the oil level. If the dipstick/fill plug is not
checking or adding oil. Park on a level surface. completely in, an incorrect oil level can occur.
2. Position the front wheel with final drive level/fill 6. Clean and install the dipstick/fill plug.
plug (1) even with the center line of the wheel. Remove
the plug.
3. Maintain the lubricant level to the bottom of the

level/fill plug opening. If necessary, add oil through the
opening. Clean and install the plug.
140
Maintenance Section
Rear Differential, Transfer Case and

Final Drives
Check Oil Level

2
4. Remove the rear differential and transfer case

dipstick/fill plug (2). Observe the lubricant level.

FULL marks on the dipstick. If necessary, add oil
through the dipstick/fill opening.
NOTE: Perform the following procedure to the final NOTE: Install the dipstick/fill plug completely in before
drive on each rear wheel. checking the oil level. If the dipstick/fill plug is not
completely in, an incorrect oil level can occur.
1. Wipe covers and surfaces around openings before
checking or adding oil. Park on a level surface. 6. Clean and install the dipstick/fill plug.
2. Position the front wheel with final drive level/fill
the plug.
3. Maintain the lubricant level to the bottom of the

level/fill plug opening. If necessary, add oil through the
opening. Clean and install the plug.
141
Maintenance Section
Batteries
Check Electrolyte Level
BATTERY ELECTROLYTE LEVEL

Battery Interval
Conventional 100 Hours
Low Maintenance 250 Hours
Maintenance Free None Required
Tighten the battery retainers every 1000 hours on all

batteries.
2. Clean the battery surface with a clean cloth. Keep
Check the following at least every 1000 hours and the terminals clean and coated with petroleum jelly.
more often as conditions require: Install the post cover after coating.
Clean the top of the batteries with a clean cloth. 3. Inspect the electrolyte level in each battery cell,
except maintenance free. Maintain the level to the
Keep the terminals clean and coated with petroleum bottom of the fill openings with distilled water. If
jelly.
distilled water is not available, use clean drinking water.
At the proper charging rate, in a moderate climate, a
battery should not require more than 30 cc (1 ounce) of
water per cell per week.
Check the cells weekly in extreme temperatures, cell

water usage could be higher.
1. Open the battery access cover located on the right

hand side at the rear of the machine.
142
Maintenance Section
Replacement of Battery, Battery Cable or Fan Bearing

Disconnect Switch
Lubricate Fitting
1. Turn the engine start switch key to OFF. Turn all
switches to the OFF position.
2. Turn the battery disconnect switch key to OFF and
remove the key. NOTICE
3. Open the battery access cover. To avoid seal damage do not over lubricate.
4. Disconnect the negative (-) battery cable first,

followed by the other remaining battery cables.
NOTE: Do not allow the disconnected battery cables

to contact any other terminals apart from the ones that
they were removed from.
5. Make the necessary repairs and cable or battery

replacement.
6. Connect the battery loop and positive (+) cables .
7. Connect the battery negative (-) cable.
8. Close the battery access cover.

1. Lubricate the fitting for the fan bearing.
9. Install the key and turn the battery disconnect
switch to ON.
Battery Recycling
1. A battery should always be recycled and never

discarded.
2. A used battery must be returned to a battery dealer

or to an authorised battery collection or recycling
facility.
143
Maintenance Section
Drive Shaft Universal Joints,

Splines and Bearings
Lubricate Fittings
6 7 9 8
1 2
5. Lubricate one fitting (6) for the front drive shaft
4 universal joint.
3 6. Lubricate one fitting in universal joints (7) and (8)

for the center drive shaft.
7. Fully articulate the machine left or right and

lubricate one fitting (9) for the center drive shaft slip
joint spline.
1. Lubricate one fitting in universal joints (1) and (2)
for the upper drive shaft.
2. Lubricate one fitting (3) for the upper drive shaft

slip joint spline.
3. Lubricate one fitting in universal joint (4) for the rear 10

drive shaft.
8. Lubricate fitting (10) for the front drive shaft

support bearings.
4. Lubricate fitting (5) for the rear drive shaft support

bearings.
144
Maintenance Section
Emergency Shutdown to Idle

Protection System
5
Check Operation
1. Start the engine. 6
2. Depress the throttle control pedal to achieve

engine RPM above low idle.
1
5. Disconnect wiring at connector (5) from coolant flow
switch (6) (if equipped). Engine speed should
reduce to low idle. Reconnect the wiring at the connector.
2 6. Stop the engine.
7
3. Disconnect wiring at connector (1) from coolant
temperature switch (2). Engine speed should reduce to
low idle. Reconnect the wiring at the connector.
7. Disconnect wire (7) from coolant level sensor (8).

Secure the wire to prevent it from touching any metal
4 objects or protruding through the fan guard.
8. Start the engine and depress the throttle. Engine

speed should not increase above low idle.
3
9. Stop the engine. Reconnect the wire to the coolant
level sensor.
10. Seal wiring connectors with CRC Lectra Shield or

4. Disconnect wiring at connector (3) from oil similar electrical corrosion protectant.
pressure switch (4) (obscured). Engine speed should
reduce to low idle. Reconnect the wiring at the 11. Replace any cable ties that were removed when
connector. disconnecting wiring connectors.
NOTE: If the emergency shutdown to idle system does

not function correctly, check the electrical system or
contact your Elphinstone dealer.
145
Maintenance Section
Low Transmission Oil Pressure 4. Start the engine and raise the bucket slightly.
Automatic Brake Application (ABA)

System (If Equipped)
Test Operation
Certain Elphinstone machines may be equipped with an

optional Automatic Brake Application (ABA) system.
The ABA system warns the operator of an impending

brake application (low transmission oil pressure) and
applies the parking brake if the pressure further
decreases, e.g. engine stalled.
If your machine is equipped with the optional ABA

system, perform the following test to check the system 5. Release the parking brake by moving the control
is functioning correctly. knob to the OFF position (brakes released).
NOTE: Before testing the operation of the Automatic 6. Shift the transmission to 2nd speed FORWARD.
Brake Application (ABA) system, test the holding ability
of the machine parking brake. Refer to the topic 7. Gradually increase the engine speed to high idle.
Brakes under Every 10 Service Hours or Daily. The parking brake should remain engaged and the
machine should not move.
1. Be sure the area around the machine is clear of
personnel and obstructions. NOTE: The parking brake indicator, Impending Brake
Application (IBA) indicator and the fault light should
flash and the action alarm should sound.
8. Reduce the engine speed to low idle, move the

transmission control to NEUTRAL and engage the
parking brake. Lower the bucket to the ground and
stop the engine.
NOTICE
If the parking brake disengaged and the machine moved
while testing the Automatic Brake Application (ABA)
1
system, have the system inspected/repaired immediately
before returning the machine to operation. Contact your
Elphinstone dealer or refer to the Braking Section of the
machine Service Manual.
2. Disconnect hose assembly (1) from the switch
manifold on the right side of the transmission.
9. Remove the plug from hose assembly (1) and
reconnect the hose to the switch manifold.
3. Install a 9S-8927 Plug (9/16-18 JIC) in hose
assembly (1).
146
Maintenance Section
Air Conditioner (If Equipped)
Inhaling air conditioner refrigerant gas through a lit

cigarette or other smoking method or inhaling fumes
released from a flame contacting air conditioner 4
3
refrigerant gas can cause bodily harm or death. Do
not smoke when servicing air conditioners or
whenever refrigerant gas may be present.
Test Operation - Adjust Belt

4. Check for refrigerant in the system as follows:
1. Start the engine. Operate the engine at high idle.
Feel suction line (3) and discharge line (4).
If the system contains refrigerant, the discharge line

2 (the smaller hose of the two) will be warmer than the
suction line.
If the system does not contain, or is very low on

refrigerant, poor cooling will result.
5. Stop the engine to inspect the compressor belt.

1
2. Set air conditioner control (1) for maximum cooling

and fan control (2) on HIGH.
3. Allow 2 minutes for the air conditioning system to

stabilize.
6. Inspect the condition and the adjustment of the

compressor belt. The belt should deflect 14 to 20 mm
(.56 to .81 in) under 110 N (25 lb) force. Adjust if
necessary.
147
Maintenance Section
Air Conditioner Belt Adjustment Fire Extinguisher System

(If Equipped)
Check System
3 NOTICE
1 For detailed information on the fire extinguisher system
1. Loosen compressor locknut (1) and bolt (2).
2. Turn adjusting nut (3) until the correct belt tension Perform monthly (250 hour) fire extinguisher system
is reached. checks and service procedures in accordance with the
3. Tighten the locknut to 150 ± 20 N•m (110 ± 15
lb.ft.). Tighten bolt (2).
4. Recheck the belt adjustment.
5. If necessary, repeat Steps 1 through 3.
6. If poor cooling is still experienced after starting the

engine, turn off the air conditioner. Stop the engine.
Contact your Elphinstone dealer for air conditioner
system service.
148
Maintenance Section
Every 500 Service Hours or 3 Months
You must read and understand the warnings 4. Clean the filter housing with a clean, nonflammable
and instructions contained in the Safety Section solvent.
of this manual before performing any operation
5. Clean the housing base.
or maintenance procedures.
6. Inspect the filter housing seal. Replace the seal, if
Transmission Oil Filter it is damaged.
7. Insert a new element into the filter housing.

Change the Filter
8. Clean and install the filter housing drain plug.
Install the filter housing into the housing base.
9. Start the engine. Apply the service brakes. Use

the right brake pedal only.
10. Release the parking brake. Slowly operate the

transmission controls to circulate the transmission oil.
11.Move the transmission directional control switch to

NEUTRAL. Engage the parking brake.
12. Inspect the transmission filter for leaks.
13. Open the transmission access cover located on

the platform near the operator's station.
The transmission oil filter is located on the left side of
the machine in front of the engine.
14. Maintain the oil level between the LOW and FULL
marks on dipstick (1). Add oil through fill tube (2) if
1. Remove the filter housing drain plug and allow the necessary.
oil to drain into a suitable container.
15. Close the access cover and stop the engine.
2. Use a wrench to remove the filter housing.
3. Remove and discard the used element.

149
Maintenance Section
Hydraulic Oil System
Change the Filters

4
2 2
7. Remove hydraulic tank oil filler screen (4). Wash

the screen and the filter covers in clean, nonflammable
solvent.
8. Install the screen and two new filter elements.

1. Open the hydraulic tank access cover located on
the right hand side of the machine. 9. Install the covers.
2. Relieve the hydraulic tank pressure by pushing on 10. Inspect the filler cap gasket. Replace the gasket if
top of relief valve (1) before changing the filters. it is damaged.
3. Remove filter covers (2). 11. Maintain the hydraulic oil level above the ADD
COLD mark on sight gauge (5) with the engine stopped
4. Inspect the cover seals. Replace if necessary. and the bucket level on the ground. Add oil if
necessary through the fill tube.
5. Remove and discard the two filter elements.
12. Install the oil filler cap.
6. Remove oil filler cap (3).

150
Maintenance Section
Engine Crankcase Breather Fuel Tank Cap and Fill Screen
Clean the Breather Clean
NOTE: Machines equipped with an optional fast-fill

fuel system do not contain a breather filter element in
the fuel cap. Perform Steps 3 and 5 only to standard
2
machines without the fast-fill fuel system.
1. Open the engine access hood.
2. Loosen breather outlet hose clamp (1) and remove

the hose from the breather cover.
3. Loosen bolt (2) and remove the breather. The fuel tank cap is located on the right hand side of
the machine rear frame.
4. Check the condition of the breather cover seal.
Replace with a new seal if the used one is damaged.
1 5
5. Wash the element and cover assembly in a clean,
1
6. Shake, or use pressure air to dry the breather.
7. Inspect the hose for damage. Replace if 4

necessary. 2
8. Install the breather assembly. Tighten bolt (2).
9. Install the hose to the breather and tighten outlet 3

hose clamp (1).
10. Close the engine access hood. 1. Lift and turn lever (5) counterclockwise until it
stops. Lift the cap straight up to remove.
2. Inspect seal (4) for damage. Replace the seal if

necessary.
3. Remove screws (1), filter assembly (2), valve (3)

and gaskets.
151
Maintenance Section
4. Wash the cap in a clean, nonflammable solvent. Fire Extinguisher System

5. Install a new filter kit in the cap. Install (If Equipped)
components in reverse order.
Check System
NOTICE
6. Remove the fill screen from the fill opening.
7. Wash the fill screen in a clean, nonflammable

solvent.
8. Install the fill screen into the fill opening.
9. Install the fuel cap.

Perform 3 monthly (500 hour) fire extinguisher system
checks and service procedures in accordance with the
152
Maintenance Section
You must read and understand the warnings

and instructions contained in the Safety Section
Transmission Oil
Change the Oil
1. Operate the engine long enough to warm the oil.

The machine must be level. Lower the bucket with
slight down pressure.
2. Engage the parking brake. Stop the engine. 6. Remove the magnetic tube assembly from the
screen.
7. Wash the tube assembly and the screen in a clean,

8. Clean the magnets with a cloth, stiff bristle brush

or pressure air.
1
NOTICE
2 Do not drop or rap the magnets against any hard objects.
Replace any damaged magnets.
9. Clean the cover and inspect the seal. Replace the

seal if it is damaged.
3. Remove transmission drain plug (2) and drain the
10. Insert the magnets in the screen.
oil into a suitable container.
11.Insert the screen, tube and magnets in the
4. Change the filter element. See the topic
housing.
Transmission Oil Filter under Every 500 Service Hours
or 3 Months.
12. Install the cover. Tighten the cover bolts.
5. Remove cover (1) and the magnetic screen tube
13. Clean and install the transmission drain plug.
assembly from the housing.
153
Maintenance Section
14. Open the transmission access cover located on Front Differential and Final Drives
the platform behind the operator's station.
Change the Oil
3 5
4
15. Remove transmission breather (3). Wash the

breather in clean, nonflammable solvent. Install the
transmission breather. NOTE: Perform the following procedure to the final
drive on each front wheel.
16. Fill the transmission with oil through fill tube (4).
See the Lubricant Viscosities and Refill Capacities 1. Wipe covers and surfaces around openings before
chart. checking or adding oil. Park on a level surface.
17. Start and run the engine at low idle. Inspect for 2. Position the front wheel with drain plug (1) down.
leaks. Remove the plug and allow the oil to drain into a
suitable container.
18. Slowly operate the transmission controls to
circulate the oil.
19. Maintain the oil level between the LOW and FULL
mark on dipstick (5). Add oil through fill tube (4) if
necessary.
20. Stop the engine.

2
3. Remove drain plug (2) from the front differential

and allow the oil to drain into a suitable container.
4. Clean and install the differential and final drive drain

plugs.
154
Maintenance Section
Rear Differential, Transfer Case and

Final Drives
Change the Oil

3
5. Remove front differential dipstick/fill plug (3).

1
6. Fill and maintain the lubricant level between the
ADD and FULL marks on the dipstick. See the
Lubricant Viscosities and Refill Capacities chart.

checking the oil level. If the dipstick/fill plug is not NOTE: Perform the following procedure to the final
completely in, an incorrect oil level can occur. drive on each rear wheel.
7. Clean and install the differential dipstick/fill plug. 1. Wipe covers and surfaces around openings before
checking or adding oil. Park on a level surface.
2. Position the rear wheel with drain plug (1) down.

Remove the plug and allow the oil to drain into a
suitable container.
8. Position the front wheel with final drive level/fill

the plug.
9. Fill the final drive slowly to the bottom of the level/

fill plug opening. See the Lubricant Viscosities and 3. Remove drain plug (2) from the rear differential and
Refill Capacities chart. Clean and install the plug. allow the oil to drain into a suitable container.
10.Perform Steps 8 and 9 to the final drive on the

opposite side.
155
Maintenance Section
8. Fill the rear differential and transfer case through

dipstick/fill plug opening (4) and/or fill plug opening (5).
See the Lubricant Viscosities and Refill Capacities
chart.

FULL marks on the dipstick.

checking the oil level. If the dipstick/fill plug is not
completely in, an incorrect oil level can occur.
3
10. Clean and install the differential dipstick/fill plug
and the transfer case fill plug.
4. Remove drain plug (3) (obscured) from the transfer

case and allow the oil to drain into a suitable container.
5. Clean and install the differential, transfer case and

final drive drain plugs.
11. Position the rear wheel with final drive level/fill plug
(1) even with the center line of the wheel. Remove the
plug.
12. Fill the final drive slowly to the bottom of the level/
fill plug opening. See the Lubricant Viscosities and
6. Remove rear differential dipstick/fill plug (4).
Refill Capacities chart. Clean and install the plug.
13.Perform Steps 11 and 12 to the final drive on the

opposite side.
7. Remove transfer case fill plug (5).

156
Maintenance Section
Brake Accumulators Ride Control Accumulator

(If Equipped)
Check Brake Accumulator Charge Pressure
Check Accumulator Charge Pressure
Correct brake accumulator charge pressure is

necessary for efficient hydraulic brake operation.
The ride control accumulator, when properly charged,
reduces the fore and aft pitching motion of the
Special tools and equipment are required to test the
machine.
accumulators.
Special tools and equipment are required to test the
For the correct testing and charging procedures for the
accumulator.
hydraulic brake accumulators, refer to R1300 L.H.D.
Braking System, Systems Operation, Testing and
For the correct testing and charging procedures for the
Adjusting, Form No. RENR4508 (9EL9607) in the
ride control accumulator, refer to R1300 L.H.D.
machine Service Manual or contact your Elphinstone
Hydraulic System, Systems Operation, Testing and
dealer.
Adjusting, Form No. RENR4611 (9EL9610) in the
machine Service Manual or contact your Elphinstone
dealer.
157
Maintenance Section
Parking Brake Solenoids Transmission and Steering Lock

Pivot
Test Operation
Lubricate/Adjust
1. Remove the STIC control door cover.
The parking brake solenoids control the release and

application of the parking brake.
Special tools and equipment as well as an assistant are

required to test the solenoids. 2. Lubricate fitting (1) for the transmission and
steering lock pivot.
For the correct testing procedure for the parking brake
solenoids, refer to R1300 L.H.D. Braking System, 3. Check the transmission and steering lock for
Systems Operation, Testing & Adjusting, Form No. correct operation and adjustment. Refer to R1300
RENR4608 (9EL9607) in the machine Service Manual L.H.D. Steering System, Systems Operation, Testing &
or contact your Elphinstone dealer. Adjusting, Form No. RENR4606 (9EL9605) in the
machine Service Manual for the correct adjustment
procedure.
4. Refit the door cover.

158
Maintenance Section
Falling Object Protective Structure Fire Extinguisher System

(FOPS) (If Equipped)
Inspect FOPS/Tighten Bolts Check System
NOTICE
Check for any loose or damaged bolts. Replace

damaged or missing bolts with original equipment parts
only. See the Torque Specifications chart for correct
tightening torques.
NOTE: Apply thread lubricant to all FOPS bolt threads

before installing. Failure to apply lubricant can result in Perform 6 monthly (1000 hour) fire extinguisher system
improper bolt torque. checks and service procedures in accordance with the
Check for damage or cracking of the FOPS. Do not
straighten or repair by welding reinforcement plates to
the FOPS.
Contact your Elphinstone dealer for repair of cracks in

welds, castings or any metal section on the FOPS.
Ensure any certification labels are firmly fixed and

legible.
159
Maintenance Section
Every 2000 Service Hours or 1 Year
You must read and understand the warnings Engine Valve Rotators
of this manual before performing any operation Check
Engine Valve Lash

When inspecting the valve rotators, protective
Check/Adjust glasses or face shield and protective clothing must
be worn, to prevent being burned by hot oil spray.
1. Remove the engine valve covers.

Be sure the engine cannot be started while this
maintenance is being performed. To prevent possible 2. Start the engine and run at low idle.
injury, do not use the starter motor to turn the
flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before checking
valve clearance.
Initial valve lash adjustment on new, rebuilt or

remanufactured engines is recommended at the first oil
change (250 hour) interval due to initial wear and
seating of valve train components. All subsequent
adjustments are to be performed at 2000 Hour intervals
thereafter.
The procedures for engine valve lash adjustment

should be performed according to the information in
the machine Service Manual. Refer to the Service 3. Watch the top surface on each valve rotator. Each
Manual or your Elphinstone dealer for the complete valve rotator should turn slightly each time the valve
valve lash adjustment procedure. closes.
If a valve fails to rotate, contact your Caterpillar or

Elphinstone dealer.
160
Maintenance Section
Engine Mounts & Crankshaft Check/Inspect Engine Mounts

Vibration Damper Elphinstone recommends inspecting the engine mounts
for deterioration and proper bolt torque. This check
Check/Inspect Crankshaft Vibration Damper will prevent excessive engine vibration caused from
deterioration and/or improper or worn mounting.
For correct engine mount torque specifications refer to

the machine Service Manual or contact your
Elphinstone dealer.
Damage to, or failure of the damper will increase

torsional vibrations and result in damage to the
crankshaft and other engine components. A
deteriorating vibration damper will cause excessive
gear train noise at variable points in the engine speed
range.
The vibration damper can have visual wobble

(movement to the front and rear when in rotation) on
the outer ring. This does not mean a replacement is
necessary since some wobble of the outer ring is
normal.
The vibration damper has marks on the hub and ring

that indicate the condition of the damper. These marks
can only be viewed if the pulley assembly is removed
from the vibration damper. If the pulley is removed for
any maintenance/repair purposes, check the alignment
marks. If the marks are not in alignment, install a new
vibration damper.
NOTE: Refer to the Service Manual for the necessary

specifications and replacement procedures.
161
Maintenance Section
Hydraulic Tank Oil
Change the Oil
Operate the engine long enough to warm the oil.
The machine must be level. Lower the bucket to the 3

ground with slight down pressure. Engage the parking
brake and stop the engine.
Wipe covers and surfaces around openings before

checking or adding oil.
4. Remove drain plug (3) and allow the oil to drain

1 into a suitable container.
5. Install the drain plug. Tighten the drain plug to 68

± 7 N•m (50 ± 5 lb ft).
6. Change the hydraulic system filters. See Hydraulic

Oil System in the Every 500 Service Hours or 3 Months
section.
7. Remove the retaining ring and fill screen. Clean

the fill screen in a clean, nonflammable solvent. Shake
dry or use pressure air.
1. Open the hydraulic tank access cover located on 8. Install the fill screen and retaining ring.
the upper right hand side of the machine.
9. Fill the hydraulic oil tank. See Lubricant Viscosities
2. Relieve the hydraulic tank pressure by pushing on and Refill Capacities.
top of relief valve (1) before removing the oil filler cap.
10.Inspect the filler cap gasket. Replace the gasket if
damaged.
2 11. Install the oil filler cap.
12. Start and run the engine for a few minutes.
3. Remove oil filler cap (2) slowly to relieve any

remaining pressure.
162
Maintenance Section
Hydraulic Tank Vacuum Breaker

2
Clean
13. Maintain the oil level above the ADD COLD mark in
sight gauge (4). Add oil through fill tube (2), if
necessary.
NOTE: The oil must be free of bubbles. If bubbles are

present in the oil, air is entering the hydraulic system. 1. Open the hydraulic tank access cover located on
Inspect the suction line hoses and clamps. the upper right hand side of the machine.
14. Stop the engine. 2. Remove the hydraulic tank breaker valve.
15.If necessary, tighten any loose clamps and 3. Clean the breaker valve in a clean, nonflammable
connections. Replace any damaged hoses. solvent. Shake dry or use pressure air.
4. Install the breaker valve. Close the access cover.

163
Maintenance Section
Wheel Brakes Fire Extinguisher System

(If Equipped)
Check Wheel Brake Wear
Check System
NOTICE
It is necessary to monitor wheel brake wear to maintain

an efficient braking system and prevent unnecessary
wear to brake system components. The wheel brake
disc wear can be checked without having to remove
the wheel brake assembly.
Refer to Check for Disc Brake Wear in Wheel Brakes

(With Wheel Brake Fitted to Machine) in R1300 Brake
System, Systems Operation, Testing and Adjusting, Perform yearly (2000 hour) fire extinguisher system
Form No. RENR4608 (9EL9607) in the machine Service checks and service procedures in accordance with the
Manual. fire system manufacturer's service information.
Excessive brake wear may result in loss of

braking.
164
Maintenance Section
Every 3000 Service Hours or 2 Years
You must read and understand the warnings

Cooling System Coolant

(Conventional Coolant/Antifreeze)
Change Coolant/Clean System
NOTE: This procedure pertains to machines using

conventional coolant/antifreeze only.
2. Open the drain valve and allow the coolant to drain
NOTICE into a suitable container. The drain valve is located on
the bottom radiator pipe.
Do not change the coolant until you read and understand
the material in the Cooling System Specifications section.
NOTICE
Drain the coolant whenever the coolant is dirty or Dispose of used engine coolant properly or recycle. Various
foaming is observed. methods have been proposed to reclaim used coolant for
reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Caterpillar to
reclaim the used coolant. Contact your Elphinstone or
Caterpillar dealer for information regarding disposal and
recycling of used coolant.
3. Close the drain valve. Fill the system with clean

water and a 6 to 10% concentration of cooling system
cleaner.
4. Start and run the engine for 90 minutes. Stop the

engine and drain the cleaning solution into a suitable
container.
5. Flush the system with clean water, with the engine

stopped, until the draining water is clear.
1. Remove the radiator cap slowly to relieve pressure.
6. Close the drain valve.
7. Add the coolant solution. Add coolant slowly to

help avoid air locks, 20 litres (5 US gal) per minute.
See Cooling System Specifications and Refill
Capacities.
NOTE: Do not add supplemental coolant additive or

change the element at this time, unless you are not
using Caterpillar Antifreeze which contains additive.
165
Maintenance Section
8. Start and run the engine with the radiator cap Cooling System Coolant
removed, until the thermostat opens and the level
stabilises. Check for leaks. (Extended Life Coolant/Antifreeze)
9. Inspect the condition of the radiator cap gasket. Add "Extender"
Replace the cap if damaged. If the gasket is not
damaged, use a 9S8140 Service Tool to pressure test
NOTE: This procedure pertains to machines using
the radiator cap. The correct cap relief pressure is
Extended Life Coolant/Antifreeze only.
stamped on the radiator cap or refer to the Engine
Specifications section of your machine Service Manual.
Extender should only be added to ELCA after 3000
If the radiator cap does not hold the correct pressure,
Service Hours or 2 Years, which ever comes first. Add
install a new cap.
Extender to the coolant to obtain a 2.2 ± 0.3%
Extender concentration.
1. Stop the engine and allow to cool.
2. Remove the radiator cap slowly to relieve pressure.
3. The cooling system should be treated with .97 litre

(1 qt) of Extender for every 46 liters (12 US gal) of
cooling system capacity.
4. Install the radiator cap.
For more Extender information, refer to the topic

Caterpillar's Extended Life Coolant/Antifreeze in the
Cooling System Specifications section of this manual.
10. Maintain the coolant level to within 13 mm (1/2 in)
of the bottom of the fill pipe or to the proper level on
the sight gauge.
11. Install the radiator cap.
12. Stop the engine.

166
Maintenance Section
Clean Outside of Radiator Fins
2. Remove pins (2) and (3) from the hydraulic oil

cooler mounting bracket.
Compressed air is preferred, but high pressure water
or steam can be used to remove dust, leaves and
general debris from the radiator fins.
To clean the radiator, perform the following procedure.
3. Swing the hydraulic oil cooler away from the

radiator. This will allow access to the radiator for
cleaning.
4. After cleaning, swing the oil cooler back towards

1. Release latch (1) and open the grille at the rear of the radiator and install pins (3) and (2).
the machine.
5. Close the grille.
167
Maintenance Section
You must read and understand the warnings Flush

of this manual before performing any operation 3. Flush the cooling system with clean water to
remove any debris.
4. Clean and install all drain plugs and close the drain
Cooling System Coolant valve.
(Extended Life Coolant/Antifreeze) 5. Fill the system with clean water. Install the radiator
cap. Operate the engine until warm, 49 to 66°C (120
Clean/Flush/Change Coolant to 150°F).
NOTE: This procedure pertains to machines using 6. Stop the engine and allow to cool. Loosen the
Extended Life Coolant/Antifreeze only. radiator cap slowly to relieve pressure and remove the
cap. Open the drain valve and allow the water to drain.
Flush the cooling system with clean water until the
NOTICE draining water is clear.
Do not change the coolant until you read and understand
the material in the Safety and Cooling System Specifications 7. Close the drain valve.
sections of this manual.
Fill
Caterpillar Extended Life Coolant/Antifreeze should be
replaced every 6000 Service Hours or 4 Years, 8. Fill the cooling system with ELCA. Add coolant
whichever comes first. Only clean water is needed to slowly to avoid air locks, 20 liters (5 US gal) per minute.
clean and flush the cooling system when ELCA is Refer to the Refill Capacities chart in this manual for the
drained and replaced. amount of ELCA needed to refill your system.
9. Start and run the engine with the radiator cap

Drain removed. Allow the ELCA to warm, the thermostat to
open and the coolant level to stabilize. Add ELCA if
1. Stop the engine and allow to cool. Loosen the necessary to bring the coolant to the proper level.
radiator cap slowly to relieve pressure and remove the
cap. 10. Inspect the condition of the radiator cap gasket.
Replace the cap if damaged. If the gasket is not
2. Open the drain valve. Remove the block and oil damaged, use a 9S8140 Service Tool to pressure test
cooler drain plugs. Remove the drain plug from the the radiator cap. The correct cap relief pressure is
bottom of the water pump housing. Allow the coolant stamped on the radiator cap or refer to the Engine
to drain into a suitable container. Specifications section of your machine Service Manual.
If the radiator cap does not hold the correct pressure,
install a new cap.
NOTICE
Dispose of used engine coolant properly or recycle. Various 11. Start the engine and inspect for coolant leaks and
methods have been proposed to reclaim used coolant for proper operating temperature.
reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Caterpillar to
reclaim the used coolant. Contact your Elphinstone or
Caterpillar dealer for information regarding disposal and
recycling of used coolant.

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SAFETY.CAT.

Excerpted from Operation & Maintenance Manual ((SEBU7321-03)

Service When Required Fan Bearing - Lubricate ......................................... 142

Lift Arm and Cylinder Linkage Transmission and Steering Lock

Bearings - Lubricate .............................................. 127 Pivot -Lubricate/adjust ........................................... 157

Rear Axle Trunnion Bearings - Lubricate ............... 128

Service When Required

Fuses -They protect the electrical system

The above illustration details circuit breaker layout.

(1) 15 AMP C.B. - Electronic transmission control.

Inspect the front, rear and side windshield wiper

Remove the cap and fill the windshield washer

Inspect Used Filter for Debris

Use a 4C5084 Filter Cutter to cut the filter element

Use a magnet to differentiate between ferrous and

Ferrous metals can indicate wear on the steel and cast

Nonferrous metals can indicate wear on the aluminium

Due to normal wear and friction, it is not uncommon to

Use of an oil filter element not recommended by

Every 10 Service Hours or Daily

You must read and understand the warnings and

Inspect the cooling system for leaks, faulty hoses and

Inspect all engine attachment belts for worn, cracked

Inspect the hydraulic system for leaks. Inspect the

Inspect the air intake precleaner for damage and rotor

Inspect the differentials and final drives (front and rear)

Inspect transmission and torque converter updrive for

Inspect the wheel brakes for leaks.

Be sure the covers and guards are firmly in place.

Inspect the steps, walkways and handholds for their

Inspect the operator's compartment for cleanliness.

Engine Crankcase Oil

Check the Oil Level

3. Remove oil filler cap (2) and add oil if necessary.

4. Clean and install the filler cap.

The dipstick is located in the right hand side of the

1. The machine must be level with the parking brake

2. Maintain the oil level between the ADD and FULL

Maintain the oil level between the marks on the engine

Transmission System Oil Hydraulic Tank Oil

Check the Oil Level Check the Oil Level

Check the transmission oil level with the machine level,

The hydraulic oil tank is located on the right hand side

1. Maintain the oil level above the ADD COLD mark

2. Open the hydraulic tank access cover located on

5. Clean and install the filler cap.

6. Close the access cover.

Check the Coolant Level

5. Inspect the radiator core for debris and clean if

Compressed air is preferred, but high pressure water

To enable access to the radiator for cleaning purposes,

3. Inspect the cap and cap seal for damage, deposits

4. Install the cap.

Engine Air Intake System Service the Filter Elements

Check the Air Intake Precleaner NOTICE

1. Inspect the air intake precleaner visually for

2. Check the air intake precleaner rotor operation.

3. Periodically check the rotor bearing and replace if

Service the air cleaner daily or if the yellow piston in the

Service the Primary Element

3. Clean the inside of the air cleaner housing.

5. Install a clean primary element.

2 6. Clean and install the cover.