CATERPILLAR’ = eure December 1999 Operation Maintenance Manual 988F Series II Wheel Loader 2ZR1-UPTable of Contents Information Section Foreword Safety Section Important Safety Information Safety Warning Signs General Hazard Information Crushing or Cutting Prevention Burn Prevention Fire or Explosion Prevention Mounting and Dismounting Before Starting the Engine Engine Starting Before Operating the Machine Machine Operation Machine Parking ‘Sound and Vibration information General Section Specifications and Model Views Product Identification, Serial Number and EC Plate Locations Operation Section Monitoring Systems and Cab Features Machine Controls Attachment Controls Before Starting the Engine Engine Starting Machine Operation, Operating Techniques Machine Adjustments Machine Parking ‘Transportation Information Towing Information 8 16 18 44 4a 43, 53 55 Cy a 63 fi Information Section Table of Contents Maintenance Section ‘Tie Inflation Information Torque Specifications Cooling System Specifications Fuel Specifications ‘Scheduled Oil Sampling (S+O+8) Lubricant Specifications Lubricant Viscosities and Refil Capacities Maintenance Intervals When Required Every 10 Service Hours or Daily Every 50 Service Hours or Weekly Every 250 Service Hours or Monthly Every 500 Service Hours or 3 Months, Every 1000 Service Hours or 6 Months Every 2000 Service Hours or 1 Year Every 3000 Service Hours or 2 Years Every 5000 Service Hours or 3 Years Every 6000 Service Hours or 4 Years Literature Reference Section Literature Reference Materials Index Section Index er 70 79 at 82 87 38 89 7 108 110 120 127 132 137 141 143 145 1462 Information Section Foreword Foreword Literature Information ‘The operation and maintenance manual should be sloted in the operator's compartment inthe literature holder or seat back literature storage area. ‘The operation and maintenance manual contains safety, operation, transportation, lubrication and ‘maintenance information Some photographs or illustrations in the operation and maintenance manwal show details or attachments that ‘can be different from your machine, Guards and covers might have been removed for ilustrative purposes. Continuing improvement and advancement of product design might have caused changes to your machine which are not included in the operation and maintenance manual. Read, study and keep the qperation and maintenance manual with the machine. Whenever a question arises regarding the machine, or the operation and maintenance manual, please consult ‘any Caterpilar dealer for the latest available information, Safety The Safety Section lists basic safety precautions. In addition, this section identifies the text and locations of ‘warning ‘signs used on the machine. ead and understand the basic precautions listed in the Safety Section before operating or performing lubrication, maintenance and repair on the machine Operation ‘The operation information is a reference for the new ‘operator and a refresher for the experienced one. This information includes a discussion of gauges, switches, ‘machine contro’s, attachment controls, transportation land towing information, Photographs and illustrations guide the operator through correct procedures of checking, starting, ‘operating and stopping the machine. Operating techniques outlined in the operation and ‘maintenance manual are basic. Skil and techniques develop as the operator gains knowledge of the machine and its capabilities. Maintenance ‘The maintenance information is a guide to equipment ‘care. The illustrated, step-by-step instructions are ‘grouped by servicing intervals. Items without specific intervals are listed under When Required topics. lems in the Maintenance Interval Schedule are referenced to detailed instructions that follow. Maintenance Interval Schedule Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour ‘meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the Maintenance intervals chart might be necessary. Perform service on items at multiples of the original requirement. For example, at Every 500 Service Hours (or 3 Months, also service those items listed under Every 250 Service Hours or Monthly and Every 10 Service Hours or Dally.Machine Description This machine is equipped with a 3408E diesel engine. It has a four-speed forward three-speed reverse transmission and is designed primary for moving material California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm, 3 Information Section Foreword4 Safety Section Important Safety Information Important Safety Information Most accidents involving product operation, maintenance and repair are caused by fallure to observe basic safely rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs, A person must be alert to potential hazards. This person should also have the necessary training, skils and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate o perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons, The hazards are identified by the “Safety Alert Symbol" and followed by a ‘Signal Word" such as "WARNING" as shown below. FN ‘The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning, explaining the hazard, can be either written or pictorially presented, Operations that may cause product damage are identified by NOTICE labels on the product and in this publication Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard, The warnings in this publication and on the product are therefore not all inclusive. I a tool, procedure, work ‘method or operating technique not specifically recommended by Caterpilar is used, you must satisfy yourself that itis safe for you and others, You should also ensure that the product will nt be damaged ‘or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. ‘The information, specifications, and ilustrations in this publication are on the basis of information available atthe time it was written. The specifications, torques, pressures, measurements, adjustments, llustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Caterpiar dealers have the most current information available, For a list of the most current publication form numbers avalable, see the Service Manual Contents Microfiche, REG! 139F.Safety Warning Signs There are several specific warning signs on this machine. Their exact location and description of the hazard are reviewed in this section, Please become familiarized with all warning signs. Make sure all warning signs can be read. Clean of replace the warning signs if the words can not be read, or the illustrations are not clear. When cleaning the warning signs, use a cloth, water and soap. Do not use solvent, gasoline, etc,, to clean the safety signs. Solvents or gasoline, etc., could loosen the sign adhesive and allow the sign to fall of, Replace any safety sign i itis damaged, missing or ‘can not be read. Ifa safety sign is attached to a part that is replaced, make sure a new sign is installed on. the replaced part, Contact any Caterpillar dealer for new safety signs, Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warn- ings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility Located in the cab on the control console, 5 Safety Section Safety Structural damage, an overturn, modification, alter- ation, or improper repair can impair this structure's protection capability thereby voiding this certifc tion. Do not weld on or drill holes in the structure. Consult a Caterpillar dealer to determine this struc- ture’s limitations without voiding its certification. Located on the ROPS.é Safety Section Safety CIT} No clearance for man in this area when machine turns; Severe injury or death from crushing could ‘eccur. Connect steering frame lock link between front and rear frames before lifting machine, transporting ‘on another vehicle, or performing service near center of machine. Disconnect steering frame lock link and secure to retaining plates before resuming operation or ma- chine will not steer. | = Located on the machine at the center pivot. HIGH PRESSURE CYLINDER Donot remove valve, hydraulic fitting, or valve core, nor disassemble any parts until pressure has been relieved. TO RELIEVE PRESSURE: 1. Shut off engine and wait five minutes until hy- draulic system pressure is relieved. 2. Relieve gas pressure in the accumulator cy by opening the charging valve one turn only. CAUTION: CYLINDERS CHARGED WITH DRY NITROGEN. TO CHARGE CYLINDER: CHARGE WITH DRY NI- TROGEN GAS. ‘See your Caterpillar dealer who has tools and de- tailed information required for chat der Located on the brake accumulator.Improper jumper cable connections can cause an explosion re Batteries can be located in separate compartments When using jump start cables always connect positive (+) cable to positive (+) terminal of battery connected to starter solenoid and negative (-) cable trom external source to starter negative (~) terminal. f machine is, not equipped with starter negative terminal, connect to tengine block.) Follow the procedure in the operation manual : AW Located in the battery compartment. 7 Safety Section Safety Before manually releasing parking brake - stop the engine and block the wheels. Before disassembling brake - relieve brake oil pressure by repeatedly applying brakes until brake oll pressure gauge indicates zero. ‘To manually release parking brake ~ remove three bolts from the storage holes in the retainer plate, install them in the three threaded holes and id resistance is felt. Before operating the machine - remove the three bolts and reinstall in the storage holes. Ep oF ae Located on the front cover of the parking brake.a Safety Section Safety General Hazard Information ‘Attach a Do Not Operate, SEHS7332, or similar warning tag to start gwitch or controls before servicing or repairing the machine. This tag is avaliable from your Caterpillar dealer. Know the width of your attachments so proper learance can be maintained when operating near fences, boundary obstacies, etc. Wear a hard hat, protective glasses and other Frotective equipment as required by job conditions. (Do not wear loose clothing or jewelry that can catch on Contrals or other parts of the machine, Make certain all protective guards and covers are secuted in place on the machine. Keep the machine, especially the deck, walkways and steps, free of foreign materia, such as debris, oll, tools ‘and other items which are not part of the machine. ‘Secure all loose items such as lunch boxes, tools and ‘ther items which are not part of the machine. Know the appropriate work site hand signals and who {ves them. Accept signals from one person only Inhaling air conditioner refrigerant gas through a lit ‘cigarette or other smoking method or inhaling fumes. released fram a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do ‘not smoke when servicing air conditioners or wherever refrigerant gas may be present. ever put maintenance fluids into glass containers. Drain all liquids into 2 suitable container. Dispose of all liquids according to local regulations. Use all cleaning solutions with care. Report all needed repair. Do not allow unauthorized personnel on the machine. Perform all maintenance unless otherwise specified as follows: ‘The machine parked on level ground. ‘The attachment controls in HOLD. ‘©The transmission control in NEUTRAL. ‘The parking brake engaged, ‘The engine stopped ‘* The engine start switch key off and the key removed. ‘* The disconnect switch key off and the key removed. Pressure Air Pressure alr can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. ‘The maximum air pressure must be below 205 kPa (30 i) for cleaning purposes, Fluid Penetration Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pin-hole size leak, can penetrate body tissue, causing serious Injury, and possible death. If uidis injected into your skin, it must be treated by a doctor familar with this type of injury immediately. Asbestos Information Caterpillar products and replacement parts shipped ‘rom Caterpilar are asbestos free. Caterpillar recommends the use of only genuine Caterpillar replacement parts. If any replacement parts containing asbestos are used, the following guidelines should be sed in handling these parts and asbestos debris.‘Caution should be used to avoid inhaling dust that might be generated when handling components containing asbestos fibers. I this dust is inhaled, it can be hazardous to your health. Components in products that might contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates and some gaskets. The asbestos used in these ‘components is usually bound in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust which contains asbestos is not generated. It dust which can contain asbestos is present, there are several common sense guidelines that should be followed, ‘© Never use compressed air for cleaning, ‘© Avoid brushing or grinding of asbestos containing materials ‘*For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. ** Use exhaust ventilation on permanent machining jobs. ‘* Wear an approved respirator if there is no other way to control the dust. * Comply with applicable ules and regulations for the work place (for example in the US.A., OSHA requirements as set forth in 29 CFR 1910.1001), ‘* Follow environmental rules and regulations for disposal of asbestos. ‘* Avoid areas where asbestos particles might be in the air 9 Safety Section Safety Crushing or Cutting Prevention Connect steering frame lock link between front and rear frames before lifting machine, transporting machine on another vehicle, or performing service near center of machine, Support equipment and attachments properly when working beneath them, Do not depend on hydraulic cylinders to hold them up. An attachment can fallif a Control is moved, or if hydraulic line breaks. over attempt adjustments while the machine is ‘moving or the engine is running unless otherwise specified. \Where there are attachment linkages, the clearance in the linkage area will increase or decrease with movement of the attachment. Stay clear of all rotating and moving parts. Keep objects away from moving fan blades. They will throw or cut any objector tool that falls or is pushed into them. Do not use a kinked or frayed wire rope cable. Wear loves when handling wire rope cable. Retainer pins, when struck with force, can fly out and. injure nearby persons. Make sure the area is clear of people when driving retainer pins. Wear protective glasses when striking a retainer pin to avoid injury to your eyes. CChips or other debris can fy off objects when struck, Make sure no one can be injured by flying debris before striking any object.10 Safety Section Safety Rollover Protective Structure (ROPS) or Falling Objects Protective Structure (FOPS) OPS or FOPS is a guard located above the operator's ‘compartment and secured to the machine, ‘To avoid possible weakening of the ROPS or FOPS, consult a Caterpilar dealer before altering, by adding weight to, welding on, or cutting or driling holes into the structure. Any alteration not specifically authorized by Caterpillar invalidates Caterpilar's ROPS and FOPS certification ‘The protection offered by this ROPS/FOPS will be impaired if it has been subjected to structural damage. Structural damage can be caused by an overturn accident, by falling objects, eto Do not mount any item such as fire extinguishers, frst aid kits and lights by welding brackets to or driling holes in any ROPS/FOPS structure. See your Caterpilar ccealer for mounting guidelines, Burn Prevention Coolant ‘At operating temperature, the engine coolant is hot and under pressure, The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns, Steam can cause personal inury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to remove with your bare hand, Remove the cooling system fil cap slowly to relieve Fressure, Cooling system additive contains alkali that can cause ersonal injury. Avoid contact with the skin, eyes and mouth, Allow cooling syste components to cool before raining, ils Hot oil and components can cause personal injury. Do ‘ot allow hot oil or components to contact the skin. At operating temperature, the hydraulic tank is hot and can be under pressure. Romove the hydraulic tank fll cap only after the engine thas been stopped and the fil cap is cool enough 10 remove with your bare hand, Remove the hydraulic tank fil cap slowly to relieve pressure, Relieve all pressure in ai, oll, fuel or cooling systems before any lines, fitings or related iterns are disconnected or removed. Batteries Batleries give off flammable fumes which can explode. Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it ‘contacts skin or eyes. Always wear protective glasses when working with batteries, Fire or Explosion Prevention Al fuels, most lubricants and some coolant mixtures are flammable. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire Do not smoke while refueling or in a refueling area Do not smoke in areas where batteries are charged, or where flammable materials are stored, Batters can be located in separate compartments \When using jump start cables always connect postive (+) cable to postive (+) termina of batery connected to starter solenoid and negative (-) cable from external source to starter nogative (~) terminal (f net equipped with starter negative (-) terminal, connect to engine Block.) See the Operation Section of this manual for specific starting instructions, Clean and tighten all electrical connections. Check daily for loose or frayed electrical wires. Have all loose or frayed electrical wires tightened, repaired or replaced before operating the machine. Koop all fuels and lubricants stored in properly marked ‘containers and away from all unauthorized persons.Store all oily rags or other flammable material in a protective container. Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nnonfiammable solvent before welding or flame cutting ‘on them, Remove all flammable materials such as fuel, oil and ‘other debris before they accumulate on the machine, Do not expose the machine to flames, burning brush, tc,, if at all possible. Shields, which protect hot exhaust components from oil Cr fue! spray in the event of a line, tube or seal failure, must be installed correctly Fire Extinguisher Have a fire extinguisher avaliable and know how to use it Inspect and have it serviced as recommended on its instruction pate. The recommended place to mount a fire extinguisher is, the handrails. Do not weld on or drill holes in the ROPS structure to mount the fie extinguisher on the ROPS. A fire extinguisher can be mounted to the ROPS legs, by strapping the mounting plate to the leg. Keep the fire extinguisher over 4.5 kg (10 Ib) size, as low as possible on one leg. But, never mount i in the top one third length of the lag, Ether Ether is poisonous and flammable Inhaling ether vapors or repeated contact of ether with ‘skin can cause personal injury. Use ether only in well-ventilated areas, Do not smoke while changing ether cylinders. Use ether with care to avoid fires. Do not store replacement ether cylinders in living areas or in the operators compartment. Do not store ether cylinders in direct sunlight or at temperatures above 40°C (102°F), 1 Safety Section Safety Discard cylinders in a protective place. Do not puncture or burn cylinders, Keep ether cylinders out of the reach of unauthorized Personnel Lines, Tubes and Hoses Do not bend or strike high pressure lines. Oo not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Contact your Caterpillar dealer for repair or replacement. ‘Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. See Fluid Penetration in the Safety Section for more details. Tighten all ‘connections to the recommended torque. Replace it ny of the following conditions are found, ‘*End fittings damaged or leaking. ‘* Outer covering chafed or cut and wire reinforcing exposed, '* Outer covering ballooning locally. ‘* Evidence of kinking or crushing of the flexible part cf hose. ‘* Armoring embedded in the outer cover. ‘End fittings displaced. Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration, rubbing against other parts, and excessive heat during operation. Tire Information Explosions of air inflated fires have resulted from heat: induced gas combustion inside the ties. The heat, {generated by welding or heating rim components, ‘external fire, or excessive use of brakes can cause ‘gaseous combustion. A tire explosion is much more violent than a blowout. The explosion can propel the tire, rim and axle components as far as 500 m (1500 ft) or more from the machine. Both the force of the explosion and the flying debris can cause personal injury or death, and property damage.2 Safety Section Safety (Do not approach a warm tire closer than the outside of the area represented by the shaded area in the ilustration. Dry nitrogen (N2) gas is recommended for inflation of tires. Ifthe tres were originally inflated with air, nitrogen is stil preferred for adjusting the pressure. Nitrogen mnixes properly with ar. Nitrogen inflated tires reduce the potential of a tire explosion, because nitrogen does not support combustion, Also, nitrogen helps prevent oxidation and tne resulting deterioration of rubber and corrosion of rim components, Proper nitrogen inflation equipment and training in its se are necessary fo avoid overinflation. A tire blowout cr ri failure can result from improper or misused equipment, Stand behind the tread and use a self.attaching chuck ‘when inflating a tre Servicing and changing tires and rims can be ‘cangerous and should be done only by trained fersonnel using proper tools and procedures. If correct Procedures are not followed while servicing tres and ‘ms, the assemblies could burst with explosive force znd cause serious personal injury or death, Folow carefully the specific information provided by your tie cr rim servicing personnel or dealer Mounting and Dismounting ‘Mount and dismount the machine only where steps and/or handholds are provided. ‘Inspect, and when necessary, clean and have repairs ‘made to stops and handholds before mounting and dismounting, ‘© Face the machine when mounting and dismounting, ‘© Maintain @ three-point contact (two feet and one hand (or one foot and two hands contact) with the steps and handholds, ‘* Never get on or off a moving machine. ‘* Never jump off the machine. ‘*Do not try to climb on or off the machine when carrying tools or supplies, Use a hand line to pull ‘equipment up onto the platform, '*1o not use any controls as handholds when entering ‘or leaving the operator's station,Alternate Exit Machines equipped with cabs are equipped with alternate exits. For additional alternate exit information, refer to topic Alternate Exit in the Monitoring Systems ‘and Cab Features section of this manual Before Starting the Engine Make sure the steering frame lock link is stored in the Unlocked position as shown. The steering frame lock link rmust be removed to steer the machine. Start the engine only from the operator's station, Never short across the starter terminals or across the batteries, as this could bypass the engine neutral start system as well as damage the electrical system, Ingpect the condition of the seat belt and mounting hardware. Replace any damaged or worn parts, Replace the seat belt regardless of appearance, after three years of use. Do not use a seat belt extension on a retractable seat belt. ‘Adjust the seat so that full pedal travel can be obtained with the operator's back against the seat back. Make sure the machine is equipped with a lighting system as required by conditions. Make sure allights are working properly. Make sure no one is working on, underneath or close to the machine before starting the engine or beginning to move the machine. Make sure the area is free of personnel 13 Safety Section Safety Engine Starting Do not start the engine or move any of the controts if there is @ Do Not Operate or similar warning tag attached to the start switch or conto. Move all hydraulic controls to the HOLD position before starting the engine. Move the transmission lock lever into the unlocked (operational) position, Move the STIC transmission direction switch to the NEUTRAL position. Engage the parking brake. Diese! engine exhaust contains products of combustion Which can be harmful to your health, Always start and ‘operate the engine in a well-ventilated area. fin an tenclosed area, vent the exhaust to the outside. Before Operating the Machine Clear all personnel from the machine and the area. Clear all obstaces from the path of the machine. Beware of hazards such as wires, ditches, etc. Be sure all windows are clean. Secure the doors and ‘windows in either the open or shut position. ‘Adjust the rear view mirrors (if equipped) for best vision, especially close to the machine. Make sure the machine horn, the backup alarm (it ‘equipped) and all other warning devices are working propery. Fasten the seat belt securely, Machine Operation Operate the machine only while seated and with the seat belt fastened. Operate the controls only with the engine running, (Check for proper operation of all controls and protective devices while moving slowly in an open area. ‘The operator must be satisfied that no one will be ‘endangered before moving the machine.14 Safety Section Safety Do not allow riders on the machine unless additional seat, seat belt and Rollover Protective Structure (ROPS) are provided. Report any needed repairs noted during operation Carry attachments close to the ground, approximately 40 cm (15 in) above ground level It ride control is engaged, increase the height of the attachments off the ground when traveling, Stay an adequate distance from the edge of cls, ‘overhangs and slide areas. If the machine begins to sideslip on a grade, immediately dispose of the load and turn the machine downhil Be careful to avoid the condition which could lead to tipping when working on hills, Banks or slopes, and when crossing ditches, ridges or other obstructions. Work up and down slopes, rather than sideways, whenever possible, Keep the machine under control and do not work it ‘over its capacity. Be sure hitch points and the towing device are adequate. Connect traling equipment to a drawbar or hitch only. Never straddle a wire rope cable or similar device, nor allow others to do so. No personnel should be between the machine and trailing equipment when maneuvering to connect them. Block the tongue or hitch of trailing equipment to align it with the drawbar or hitch, Know the maximum height and reach of your machine, Always keep the Rollover Protective Structure (ROPS) installed (f equipped) when operating the machine. Machine Parking Park on a level surface. If necessary to park on a trade, block the machine. ‘Apply the service brake to stop the machine, Move the STIC transmission direction switch to NEUTRAL. Engage the parking brake. Lower all attachments to the ground. Move the transmission lock lever to the LOCKED position Stop the engine. ‘Tur the engine start switch key to OFF and remove. Turn the battery disconnect switch key to OFF and remove the key when leaving the machine for an extended period of a month or longer. “his will prevent baatery drain by short circuits or current draw made by ‘some of the components, or by vandalism ‘Sound and Vibration Information ‘Sound Level ‘The operator sound pressure level for this machine with «a property installed and maintained closed cab cconfiguration is 79 dB (A). ‘Measurement is obtained on a static machine with the procedures and cab conditions as described in ISO (6394 or 86/662/EC. Vibration Level Hands/Arms: The weighted root mean square acceleration to which the hands/arms are subjected, is less than 2.5 m/s. Whole Body: The weighted root mean square acceleration to which the whole body is subjected is, less than 0.5 m/s?. Measurements are obtained on a representative machine, using measuring procedures as set forth in the following standards; ISO 2631/1, ISO 5349, and SAE J1166.15 cowaseson [ll Specifications and Model Views Specifications and Model Views Basic machine shipping specitications are listed below. ‘968F Whee! Loader | Weight (approximate) 44 896 kg (98.776 Ib) Leng (sa 10-985 nm G69 Wath (aon tes 645 mm ttt] Height (top of ROPS) 4126 mm (13 ft 6 in) | Operator's compartment (4), hydraulic tank (6), radiator (6), transmission (7), and battery (8)16 General Section Product Identification, Serial Number and EC Plate Locations Product Identification, Serial Number and EC Plate Locations ‘The Product Identification Number (PIN) willbe used to identity @ powered machine that is designed for an ‘operator to ride. Caterpilar products such as engines, transmissions, ‘and major attachments, etc., not designed for an ‘Operator to ride are identified by Serial Numbers. For quick relerence, record the identification numbers in the spaces provided below the illustration. Engine Serial Number Machine PIN. ‘Transmission Serial NumberCE Mark Note: Plate on machines going into EC counties. Plate is located on the cab. Pr Model. Power (kW). Weight kg___ 7 General Section Product Identification, Serial Number and EC Plate Locations Certification Label for Emissions The certification label (it equipped) is used to verify an engine's conformance to the emissions requirements of the EPA. This label is located on the engine. GAT" CATERPILLAR INC. Irom sane omron | sean, /SRMO0001 | SNEon ese oarucewer ene 4 wiles ‘on tga ramer Yercas om Mceaaversco "Sera raven) voc narensress 70" aw Mike Cow nese Too) rat NOC in aes (Sescorsarron cnn Ts NES ame Yo oreue Comic LAR ioe ret ee *mustaion 19| WORST Typical Example (English) CAT’ CATERPILLAR INC. Non wromuTEER TER vostnz SAMO Mouevara 34 or 601 ines Coen umusceworans Tern” Moraes Solar mance tomer ann Seecncienmms, seamen seemoneane anes ustraion 20 (osseszr ‘Typical Example (French)18 eee Monitoring Systems and Cab Features Monitoring Systems and Cab Features Turn the disconnect switch off and remove the key when servicing the electrical system or other components on the machine. Turn the battery disconnect switch key to OFF and remove the key when leaving the machine for an extended period of a month or longer. This will prevent battery drain by short circuits or current draw made by ‘some of the components, or by vandalism, NOTICE Never turn the disconnect key to OFF with the engine running. Electrical system damage could result. The battery disconnect switch is located in the engine ‘compartment, on the right side of the machine, The disconnect switch serves a different function than the start switch. When turned off, the disconnect. switch disables the entire electrical system. When only the start switch is turned off, the battery remains connected to the electrical system,Engine Start Switch Key 19 Operation Section Monitoring Systems and Cab Features Engine Secondary Stop Switch OFF (1) - Insert and remove the start switch key from the OFF position only. No power to ‘most electrical circuits in the cab. The cab lights, panel lights, tal lights and the fuel gauge light, are operational even with the key start switch in the (OFF position. ‘Turn the start switch key to OFF to stop the engine ON (2) - Turn the start switch key clockwise to ON to activate all cab circuits. START (8) - Turn the start switch key Clockwise to START to crank the engine. Release the key after engine starts and the key will return to ON. NOTE: If the engine fails to start after turning the key to the start position, the key must be returned to the off position before another starting attempt is made. ‘open the cover and fip up the switch. Use @ Engine Stop Switch - To stop the engine, fip only in an emergency NOTE: The engine stop switch does not shut off the machines electrical system, Starting Aid (If Equipped) NOTE: Ether will automatically be injected when ‘ambient conditions warrant, NOTICE Inject ether ONLY while cranking the engine. Use the ether sparingly. Excessive ether can cause piston and ring damage. Use when temperatures are below 0°C (+82°F) and for cold weather starting purposes ony. Refer to Engine Starting for further information.20 Operation Section Monitoring Systems and Cab Features Computerized Monitoring System (CMS) 60129 ‘The Computerized Monitoring System (CMS) consists (fan action alarm, an action ight (1) and a monitoring panel (2) with individual alert indicators (3) for each machine system listed on the panel ‘The CMS is designed to alert the operator of an immediate or impending problem in one or more of the machine systems covered. CMS Functional Test (Check operation of the CMS, by observing the self-test ‘each time the start switch key is moved from OFF to (ON prior to cranking The CMS control will perform an automatic sel-test at startup each time the start switch key is turned to the ON position. During this six second test, observe the following: ‘* The action light will nt flash but be steady on ‘© The action alarm will beep once. ‘All alert indicators will flash, «All bars in each circular bargraph willbe illuminated fone bar at a time (power up). The 4 digit tachometer readout wil display ‘Machine code "16" for two seconds, then software version, ke "06", for two seconds, then "8.8.8.0" for the last two seconds, Machine code (if equipped with a steering whee!) “17° for two seconds, then software version, like “06.0°, for two seconds, then "8.8.8.8" for the last two seconds, ‘*"Serv Code" indicator is on for two seconds, then off for two seconds, then back on for the last twa seconds. ‘* Mph/kphy/fpm indicator is off for four seconds, then ‘0n for two seconds. Ii the above tests complete as indicated, turn the: tongine start switch to start the engine. Ii. the above tests are not completed as indicated, the CMS control will not go into the operating mode a if ready to orank the engine. Have the electrical system checked and all necessary repairs made before starting the engine,CMS Warning Categories The CMS provides three warning categories. The first category requires only operator awareness. The second warning category needs operator response. The third warning category requires immediate shutdown of the ‘machine systems Warning Category 1 In this category, only the alert indicators or gauge display will fash, itrequires that the operator is aware that a machine system needs attention. 21 ‘Operation Section Monitoring Systems and Cab Features If this procedure does not cause the alert indicator to turn off, pull to a convenient sion and investigate the cause (ioose/broken alternator belt, defective batteries, etc.) If engine speed is near operating speeds and if ‘electrical loads are light, and the light remains on, pull toa convenient stop and investigate the cause \loose/broken belt, defective batteries or alternator). 60130 Parking Brake (1) ~ Indicates parking brake is ‘engaged and transmission is in NEUTRAL. The alert indicator should flash during startup. It should go out when the parking brake is released. Electrical System (2) ~ Indicates a malfunction inthe electrical system. this alert indicator lashes, system votage is ether too high or too low for normal machine operation. Ifthe electrical loads are high (air conditioning and/or lighting) and the engine speed is low or near idle, increase engine speed to high idle. This, wil generate ‘more output from the alternator. Ifthe electrical system alert indicator turns off within about one minute, the electrical system is probably operating normally, but overloaded during periods of low engine speeds. Modify operating cycle to keep from overloading the electrical system and discharging the batteries. Low Idle must be correct. Adjust for high side of Low Idle specification with most often used electrical loads turned on. Reducing loads will also help, by using Medium cab fan speed instead of High Fs0131 Fuel Level (3) - The gauge display will lash when the fuel level reaches 10% of tank Capacity. To avoid being stranded without fuel, refuel as soon as possible within the hour. Warning Category 2 In this category, the alert indicator or the gauge display ‘and the action light (8) will flash. It requires a change in machine operation to reduce excessive temperature in Cone or more of the systems. Do not operate the machine if the alert indicator or the ‘gauge display and the action light continues to flash, alter investigating the cause.22 Operation Section Monitoring Systems and Cab Features e0152 cor Tenge ne ‘Transmission Ot Temperature (5) ~ nioates bcos convertyftanemisson temperature this gauge display hashes, reduce load onthe mactine. ithe gauge display and the action ight continues to fash afer approximately the mines palo convenient sop. Ivestgate he cause, excessive hydraulic ol temperature. If this ‘gauge display flashes, reduce the load on the system. i the gauge display continues to flash, pull the machine to a convenient stop. Investigate the cause, ® Hydraulic Oil Temperature (6) ~ indicates ‘Transmission Oil Filter (7) — Indicates that the transmission oi filter is restricted. Change the transmission oll iter and inspect for debris that could indicate the beginning of a transmission failure. See Transmission Filter in the Every 500 Service Hours or 3 Months section of this manual. eco 0 Terpatie nae © eT ae Sores certran ae, arene Check Engine (10) ~ Indicates an active engine fault Warning Category 3 In this category, the alert indicator or gauge display and the action light wil lash and the action alarm wil ‘sound, It requires immediate shutdown of operation to prevent severe damage to the system andjor the ‘machine, Do not operate the mactine until the cause has been corrected, Parking Brake (1) ~ Indicates the machine is ‘notin neutral and the parking brake is engaged. Ifthe alert indicator flashes during ‘operation, stop the machine immediately. Stop the engine, Investigate the cause. Electrical System (2) ~ indicates a serious malfunction in the electrical system. I this alert indicator flashes during operation, stop the machine immediately, Stop the engine. Investigate the cause. Transmission Gil Filter (7) ~ indicates that the transmission oilfiter is restricted. If this alert indicator and action light flashes, change the transmission ol fier anc inspect for debris that could indicate the beginning of a transmission failure. See ‘Transmission Filter in the Every 800 Service Hours or 3 Months section of this manual Brake Oil Pressure (8) - Indicates low oil pressure to the brakes, If this alert indicator flashes, stop the machine immediately. Engage the parking brake and stop the engine. Investigate the cause.Coolant Flow (11) - Indicates no coolant flow inthe engin, ths rt nestor fess, Sip the machine media. Stop the engine and ivesigate the cause Engine Oil Pressure (12) ~ Indicates low ol pressure, Ht gauge dply ashes stp the machine immediately. Stop the engine and investigate the cause. Pinay Sen) etn pay © SMV oss during operation, stop the machine immediately. Stop the engine and investigate the cause Do not operate the machine until the cause has been corrected, Supplemental steering works only while the machine is moving. When the machine operates under ‘supplemental steering, no directional changes can be made. 23 Operation Section Monitoring Systems and Cab Features Primary Steering Action Light (If Equipped With Supplement Steering) 60134 Primary Steering Action Light = indicates the primary tering has faled and auppemena Stowng is being used tsar ilar tases dunng operation the acon ight shou fash fre the acon arm snoud sount. Stop he machine immed. Stop the engine ang investigate the cause Do not operate the machine until the cause has been. corrected, ‘Supplemental steering works only while the machine is ‘moving. When the machine operates under supplemental steering, no directional changes can be made.24 Operation Section Monitoring Systems and Cab Features Gauge Displays ‘The gauge displays are vacuum fluorescent displays located in the dash. 60135 Engine Coolant Temperature (2) ndeates tho temperature ofthe engine coor: GREEN RANGE is normal operating temperate. FED RANGE i excessive engine coda temperature. Torque Converter Oi Temperature (3) - Incates te empeature a he torque Converter ol, GREEN RANGE ithe normal operating temperature. RED RANGE is excessive oil temperature Hydraule Ol Temperature (4) - Indicates the tomperatre ofthe hyeraue ot GREEN RANGE is the normal operating temperature, RED RANGE Is excessive ol temperature Fuel Level (5) - Shows the amount of fuel in E0136 ‘Should there be a problem between the ECM and ‘CMS, the following things can be observed on the CMS display: ‘The Ol Pressure gauge (1) wil fash, ‘* The Coolant Temperature gauge (2) wil lash ‘The Tachometer (6) will lash and a digital reading of 3000 RPM will be cisplayed ‘© The Check Engine lamp (7) will be turned on, ‘© The Coolant Flow lamp (8) willbe turned on.Service Hour Meter ‘Service Hour Meter ~ Indicates the total ‘operating hours of the engine. it should be Used to determine service hour maintenance intervals. Torque Alert Indicator 60137 The torque alert indicator will come on when there is, full torque to the drive wheels 25 Operation Section Monitoring Systems and Cab Features Tachometer ‘The tachometer is a vacuum fluorescent display located in the dash, ‘Tachometer - The tachometer displays the engine rpm ina digital readout and in a gauge display during operation.6 Operation Section Monitoring Systems and Cab Features Service Code Light Switches +3609) During machine operation, i this indicator comes on, the CMS control has detected and stored information regarding abnormal electrical system conditions in (OMS circuits (inputs or outputs) or in a power train control circut, Diagnostic information is available in the service mode {fr service personnel Refer to the SENR5247 Systems Operation Testing & ‘Adjusting Manual for Computerized Monitoring System With Vacuum Fluorescent Display. Running Lights (1) - Move the switch to the top position to turn on the running lights. Move the switch to the middle position to turn on the side dash lights and the rocker switch lights. Move the ‘switch to the bottom position to turn the lights off. Flood Lights (2) - Move the switch to the top position to turn on the front and rear flood lights Panel Lights (3) ~ Move the switch to the top position to adjust the CMS panel lights.Interior Dome Light ~ Move the switch back to turn the light on, a7 Operation Section Monitoring Systems and Cab Features Windshield Wiper/Washer Front Windshield Wiper and Washer (1) Turn the knob clockwise for a variable, ow or high speed. Push the knob to activate the windshield washer. Spring force will return the knob when released, Rear Windshield Wiper and Washer (2) Turn the knob clockwise to turn on the windshield wiper. Push the knob to activate the windshield washer. Spring force will return the knob when released,28 Operation Section Monitoring Systems and Cab Features Back-up Alarm Horn ~ Push the knob down to sound the horn. Use the hor to alert or to signal personnel. ‘The back-up alarm is located on the rear of the machine, A thvee position switch (high, low and medium) at the rear of the back-up alarm regulates its volume. The alarm is set at the highest sound level when shipped from the factory. The setting should remain on high, unless the job site requires a lower level.Heating and Air Conditioning Controls Floor Heater The floor heater fan control switch is located on the Tight side console. Fan ~ Push the bottom of the switch to stop the heater blower fan. Low Speed ~ Push the switch to the middie position to ‘operate the healer blower fan on low speed. High Speed ~ Push the top of the switch to operate the heater blower fan on high speed. Fan Control The floor heater temperature contra is located on the lower right side of the operator’s compartment 29 Operation Section Monitoring Systems and Cab Features ‘Switch - This switch controls the heating and air conditioning three speed blower fan motor. Off (1) - Move the switch to this position to stop the biower fan. Move the switch clockwise to operate the heating system. ® Heat and Air Conditioning Fan Speed Move the switch counterclockwise to operate the air conditioning system. First Speed ~ Move the switch to this symbol for lowest fan speed. ‘Second Speed - Move the switch to this ‘symbol for a medium fan speed. ‘Third Speed - Move the switch to this symbol for highest fan speed. ‘Temperature Control - Heater ® Temperature Variable (2) ~ Turn the knob anywhere between OFF (lel) and MAXIMUM (tight) heat. © ‘Temperature Control ~ Air Conditioning ‘Temperature Variable (3) ~ Turn the knob anywhere between OFF (left) and MAXIMUM (Cight) cool30 Operation Section Monitoring Systems and Cab Features Heating and Air Conditioning System Operation ‘The heating and air conditioning system can perform four functions: ® Cooling - Turn the fan speed switch to FIRST, control for the desired SECOND or THIRD speed. Adjust the rol for the desired temperature variable 2¢ temperature. Pressurizing ~ Pressure inside of the cab will help keep dust out, when heating or cooling is not desired, Turn the temperature variable control to maximum cool Turn the fan speed switch to either FIRST, SECOND or THIRD speed on the heating sde, depending on the volume of air needed to keep out dust Defogging - Turn the fan speed switch to ether FIRST, SECOND or THIRD speed on the air Conditioning side, depending on the volume of air needed to remove moisture fom the air in the Cab. This will prevent moisture from forming on the windshield and windows. ‘Adjust the temperature variable control unt its comfortable and the windshied and side windows are {ree of moisture, Seat Adjustment Push the height control switch (1) to the desired position RAISE (2), HOLD (3) or LOWER (4). Pull up seat cushion tit lever (5), to adjust the seat Cushion to the desired angle. Release the lever to lock the seat cushion, Pull up fore-at lever (6), to move the seat forward or back to the desired position. Release the lever to lock. the seat in piace. ul up seat recline lever (7), to move the seat back to the desired position. Release the lever to lock the seat back in place. Pull up to remove backrest extension (8) Push lower back support lever (9) (if equipped) to the rear and down to increase support to the lower back. Pll the lever forward and up to decrease support to the lower back. Release the lever to lack the lower back supportSteering Console Adjustment Forward/Aft Knob Push the knob (1) down to slide the entire steering console forward or backward. Release the knob and the steering console wil lock into position. ‘Arm Rest Adjustment Steering Console Arm Rest ~ Lift lever (2), and adjust the arm rest (3) to the desired height. Release the lever to lock the arm rest in place. Right Arm Rest - Turn knobs (4) counterclockwise {and raise right side arm rest (5) to the desired height Turn knabs clockwise to lock the arm rest into position. 31 Operation Section Monitoring Systems and Cab Features Seat Belt ‘Always check the condition of the seat belt and ‘mounting hardware before operating the machine. Replace the seat belt atleast once every three years, regardless of appearance. A date label, to determine the age of the bet, is sewn onto each belt Tht eto Inspect for worn or frayed webbing, Check for worn or damaged buckle, Replace the belt, and buckle if they are worn or damaged. Inspect the belt mounting hardware. Replace any ‘damaged or worn hardware. Keep the mounting bolts tight32 Operation Section Monitoring Systems and Cab Features Seat Belt Adjustment The seat bolt is equipped with an automatic locking retractor. This retractor wil lock if the belt is pulled or jerked after belt is pulled out of the retractor. The buckle end of the seat belt is equipped with @ comfort ride sleeve. This sleeve wil allow the operator limited movernent with the seat belt fastened To Fasten the Seat Belt ul the seat belt (1) out of the retractor in a continuous motion, Fasten the seat belt catch (2) into buckle (3). Check to be sure seat belt is placed low across lap/mid:-section of the operator. The retractor will adjust the belt length and lock in place. The comfort ride sleeve wil allow the operator limited movernent To Release the Seat Belt Push the release button on the buckle to release the seat belt. The seat belt will automaticaly retract into the retractor. Seat Belt Extension ‘When using retractable seat belts, do not use seat belt extensions, or personal injury or death can result. ‘The retractor system may or may not lock up de- pending on the length of the extension and the size of the person. If the retractor does not lock up, the seat belt will not retain the person. Caterpillar’s recommendation for extending a retractable seat belt is to replace it with a rnonretractable belt Longer seat belts and seat belt extensions are available, when the seat belt is not of sufficient length for the operator. Contact any Caterpillar dealer for longer seat belt and Seat belt extension information.Lighter (If Equipped) 33 Operation Section Monitoring Systems and Cab Features Alternate Exit Push the lighter in and release. The lighter wall pop out when ready for use. The cab window on the right side serves as an alternate ext. I can be opened from the inside only. Push button (1) and open the window. The window ‘swings out (Open the window as far as desire, then turn kb (2) clockwise to tighten the brace and hol the window in Postion To release the window, turn knob (2) counterclockwise to loosen the brace. Pull the window closed. The knob should be loose when the door is closed to allow the window to be used for a secondary exit. Cab pressurization will be eliminated when the door is open Use commercially available window cleaning solutions to clean the windows.34 Operation Section Machine Controls Machine Controls Parking Brake NOTICE Do not engage the parking brake while the machine is moving unless the primary service brake fails. The use of the parking brake as a service brake in regular operation will cause severe damage to the brake system. Parking Brake ~ The parking brake knob is located in the front of the operator ‘compartment, below the instrument panel. The parking brake is to be used after the machine has been stopped. iC) Parking Brake Engaged - Pull the knob out to engage the parking brake, Parking Brake Disengaged - Push the knob into release the paring brake ‘Secondary Brake - The secondary brake uses the same knob as the parking brake, The secondary brake is to be used if the service brakes fail to stop the machine NOTICE Donot engage the secondary brake while the machine is moving unless the primary service brake fails. The use of the secondary brake as a service brake in regular operation will cause severe damage to the brake system, If the primary service brakes fail and the parking brakes engage, the following procedure will allow the machine to be driven thru the parking brakes toan out of the way location. The action light and the action alarm will sound and continue during this procedure. 41. Make sure the area is clear of personnel and other machines, 2. Shift the transmission into fist gear 3. Increase the engine speed to high ide. 4. Push down and hold in the parking brake knob. 5. Stoor the machine to an out of the way location. Driving the machine thru the parking brakes for an extended period wil cause severe damage to the brake system, and possibly complete loss of any brake controlBrake Pedals Left Brake Pedal (1) ~ The left brake pedal Gisengages the transmission and brakes the machine, ‘This permits higher engine speed for better hydraulic response. eee eens Right Brake Pedal (2) - The right brake pedal slows 2. Maintain the coolant level in the sight gauge. I itis necessary to add coolant daily, check for leaks.100 ‘Maintenance Section Every 10 Service Hours or Daily 3. The radiator cap is located on the top lett rear of the machine. Remove the radiator cap slowly to relieve pressure 4, Inspect the cap and cap seal for damage, deposits Cr foreign material. Clean the cap with a clean cloth or replace the cap i itis damaged. 5. Install the cap, 6. 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 general debris from a radiator. Clean as required by condition of radiator. Fuel System Drain Water Separator Bow! 49280 Ingpect or service the water collection bow! on the bottom of the water separator, 1. Open the drain bowl NOTE: Some models may have a head mounted priming relief valve. if equipped, press the valve in and Fold while pumping the water out 2. Close the drain.Fuel Tank Drain the Water and Sediment Drain valve is located at the left side of the machine under the fuel tank 1. Open the drain valve and allow the water and sediment to drain 2. Close the drain valve 101 Maintenance Section Every 10 Service Hours or Daily Walk-Around Inspection Inspect Mac! NOTICE ‘Accumulated grease and oil on a machine is a fire hazard. Remove this debris with steam cleaning or high pressure water, atleast every 1000 hours or each time any significant quantity of oil is spilled on a machine. NOTE: Keep a close watch for leaks. If leaking is observed, find the source and correct the leak. Check the fluid levels more frequently than the recommended periods if leaking is suspected or observed. Inspect the engine air intake screen for accumulation of dirt and debris. Clean if dirty.102 Maintenance Section Every 10 Service Hours or Daily Inspect the bucket and linkage for damage or excessive wear. Repair it damaged. Inspect the lights for broken bulbs and lenses, Replace it broken, 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 ‘rom the radiator Inspect all engine attachment belts for worn cracked oF frayed edges. Replace if worn, cracked, frayed or broken. Ingpect the hydraulic system for leaks. Inspect the tank, cylinder rod seals, hoses, tubes, plugs, joints and fitings. Correct any leaks Inspect the differentials and final drives (ront and rear) Under the machine for leaks. Ingpect tires ([ront and rear) for damage and proper inflation. Replace any missing valve caps, Inspect transmission for leaks. Inspect the wheel brakes for oil leaks. Be sure the covers and guards are firmly in place. Inspect for damage. Ingpect the steps, walkways and handhold for their condition and cleanliness, Inspect the Rollover Protective Structure (ROPS) (if equipped) for damage. If repair is necessary contact your Caterpillar dealer Tighten any loose ROPS bolts. Ingpect the operator's compartment for cleanliness. Koop it clean ‘Adjust the rear view mirrors for best vision,Window Cleaning 04157 Use commercially available window cleaning solutions to clean the windows. Clean the outside windows from the ground, uniess hancholds are avaliable, Every 10 Service Hours or Daily Seat Belt Inspect for Wear or Damage ain Greed be regardless of appearance, Seat belt and mounting hardware must be {for wear or damage before operating the machine. Replace the belt or mounting Fardware if worn or damaged. Replace the seat belt after three years of usage, inspected104 Maintenance Section Every 10 Service Hours or Daily Brakes, Indicators and Gauges Test for Proper Function Esorst Look for broken gauge lenses or indicator lights, switches, etc. Start the engine Look for inoperative gauges. Turn all machine lights on. Check for proper operation. Sound the forward horn Apply the service brakes, Place the transmission in third gear speed forward. Move the machine forward and test the service brakes. If service brakes do not function properly refer to the topic Brakes in the Every 250 Service Hours or Monthly section of this manual Engage the parking brakes. Place the transmission in third gear speed forward, Move the machine forward and test the parking brakes. if parking brakes do not ‘function properly refer to topic Brakes in Every 250 Service Hours or Monthly section of this manual Stop the engine. Make any needed repairs before operating,Back-up Alarm Test ‘Tum the start switch key to ON to perform the test Apply the service brake. Move the STIC transmission directional control switch into REVERSE, The alarm should start to sound immediatly. I will continue to sound until the STIC transmission directional contral switch is moved into NEUTRAL or FORWARD. The sound level can be adjusted by moving the adjustment on back of alarm to meet operating requirements. The alarm is set at the highest sound level when shipped from the factory. The setting should remain on high, unless the job site requires a lower level. ‘The back up alarm is located on the rear of the machine. 105 Maintenance Section Every 10 Service Hours or Daily Bucket Cylinder and Linkage Bearings Lubricate Fit Wipe all fitings before lubricating, Lubricate one fitting located on the lift arm on left side of machine. Lubricate one fitting located on the lift arm on right side of machine106 Maintenance Section Every 10 Service Hours or Daily wal Lubricate one remote fiting (1) forthe lift arm on each Lubricate four fitings on each side of the machine side of the machine. Total of 16 fitings. Lubricate one remote fiting (2) forthe tilt cylinder located on each side of the machine. Lubricate one remote fiting (2) forthe tit cylinder (4) located on each side of the machine.Steering Cylinder Bearings Lubricate Fittings Wipe al fitings betorehibrcatng, Lubricate one fiting in each eye of the twa rod end steering cylinders. Total of two fitings. Lubricate two remote fitings for the head end of the steering cylinders. One fiting on each side of the machine, Total of four fitings. 107 Maintenance Section Every 10 Service Hours or Daily108 Maintenance Section Every 50 Service Hours or Weekly Every 50 Service Hours or Weekly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Cab Air System Clean Filters NOTE: Clean filters more often in dusty conditions. 1, Remove the filter cover located in the top of the cab, [o4375) 2. Remove the filter elements. Clean the filter flements with pressure air or wash the elements in warm water and @ nonsudsing household detergent. 3, Rinse in clean water and air dry thoroughly. 4, Install the fiter elements. Install the filler cover. Collet Pins Torque Bolts The following procedures apply after the intial 50 hours, cof operation on a new machine or 50 hours after a bucket has been installed using either new or old pins. te = Retorque bucket it cylinder, tilt cylinder and bucket linkage collet pins. Total of 14 callet pins. 1. Torque the bolts to 1020 + 68 Nem (750 + 50 Io fh.NOTICE When striking the collet, with a large hammer, protect, the bolt head with a spacer to prevent bolt damage. Se ey a 2. Strike the collet unti the bolt torque falls to 544 Nem (400 Ib ft) or ess. 3. Retorque the bolts to 1020 + 68 Nem (750 + 50 tb 4. 4, Strike the collet until the bolt torque falls to 816 Nem (600 tb ft) oF less, 5, Rotorque the bolts to 1020 + 68 Nem (750 50 I> fh 109 Maintenance Section Every 50 Service Hours or Weekly Tires Check Inflation Pressure Measure the tire pressure on each tire. Consult your Caterpillar dealer for correct load rating and operating pressures. Inflate the tires, if necessary. See the Tire Inflation Information section of this manual110 Maintenance Section Every 250 Service Hours or Monthly Every 250 Service Hours or Monthly You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Engine Oil and Filter Change the Oil and Filter 1. Open the engine access door on the right side of the machine. 2. Open the crankcase drain valve. Allow the oil to drain. Close the drain valve ra 3. Remove the filter elements with a strap-type \wrench, Refer to Filter Inspection in the When Required section, ‘4, Clean the filter housing base, Make sure all of the ld fiter gasket is removed, 5. Apply a light coat of engine oil to the gasket of the new filter, 6. Install the new filter by hand. When the gasket Ccontacts the filter base, tighten the filter three-quarter of a turn more. 7. Remove the oil fill plug (1). Fill the crankcase with new oil, See the Lubricant Viscosities and Refill Capacities, Clean and install the fil plug 8. Start the engine and allow the oil to warm. Check for leaks. 9, With the engine running, maintain the oil on the dipstick (2) between the LOW and FULL marks on the low idle side of the dipstick. Add oll if necessary. 10. Close the engine access door and stop the engine.Engine Valve Lash Check/Adjust Initia valve lash adjustment (at first of change or 250 hours) on new or rebuilt or remanufactured engines is, recommended at the frst oll change interval due to initial wear and seating of valve train components. All subsequent adjustments are to be performed at 3000, Service Hours interval thereafter. ‘VALVE CLEARANGE SETTING intake 0.38 mm (O15 in) Exnaust (0.76 mm (090 in) This maintenance fs recommended as part of lubrication and preventative maintenance schedule to provide maximum engine life, Throughly clean the area around the valve mechanism covers to prevent the entry of foreign matter into the top of the cylinder head and valve mechanism. Refer to the Service Manual or your Caterpilar deeler {or the complete valve adjustment procedure. 11 Maintenance Section Every 250 Service Hours or Monthly Scheduled Oil Sampling (S-O-S) Obtain $-O+S Sample To compliment a good preventative maintenance ‘program, Caterpilar recommends using S+O-S at regular intervals, Normal test results from oll samples should be used to develop a "basdine" which will be Used to determine oll change intervals. Each oll sample should be taken when the oll is warm and well mixed to ‘ensure the sample is representative. ‘There are several methods used te obtain $+O+S. samples, NOTE: Sampling methods recommended are in preference order. If one of the first two methods is not feasible, then use the drain stream method. ‘*Use an insine sampling valve. ‘*Use a sampling gun inserted inte the sump. ‘*Use the drain stream method whan changing oil ‘When using the drain stream method to obtain an oil sample, take the sample after some oil has drained out and before the fina ol. The ol at tie beginning or end is not mixed well enough to be reresentative of circulating olin the compartment and may carry debris that can give false S*O+S analysis results.112 Maintenance Section Every 250 Service Hours or Monthly Cooling System ‘Add Supplemental Coolant Addi Element je/Replace Reter to the Cooling System Specifications section of this manual for all cooling system requirements, Use the 875296 Test Kit to check for concentration. NOTICE Excessive additive (greater than the recommended 6% intial fil) together with concentrations of anti- freeze greater than 60% cause deposits to form and ‘can result in radiator tube blockage and overheating, Liquid Supplemental Coolant Additive 1. Loosen the fil cap slowly to relieve pressure and, remove the cap. 2. tt may be necessary to drain enough coolant trom the radiator to allow forthe addition ofthe liquid cooling system additive 3, Add .24 ters (50 pint) of additive for every 38 ters (10 US. gallons) of cooing system capacity 4, Install the fil cap, Coolant Additive Element 4. Close coolant inlet valve (1) and outlet valve (2) Remove and discard element (3). 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 the new element with a thin flim of engine oil 5. Install and turn the element until the seal contacts, the base, then tighten three-quarter of a turn more. 6. Open the inlet and the outlet valves. 7. Remove the fil cap. 8. Start the engine and check for leaks. Alow the coolant level to stabilize. 9. Add premixed coolant it necessary to bring the Coolant fo within 18 mm (5 in) below the botiom of the fill pipe or to the proper level on the sight glass, it so equippedRear Axle Trunnion Lubricate ings Wipe all itings before lubricating, Lubricate two remote fitings for the rear axle trunnion. lf remote lines have become damaged, lubricate the fitings at the axle trunnion. One fitting on each side of the machine. 113 Maintenance Section Every 250 Service Hours or Monthly Center Drive Shaft Spline Lubricate ing Wipe all fitings before lubricating. NOTICE To prevent damage to the seal, articulate the machine full right or lft, Before lubricating the spline. 1. Start the engine, raise the bucket, release the parking brake and articulate the machine full right or left. 2. Lower the bucket to the ground, engage the parking brake and stop the engine. '3. Lubricate one fitting on the drive shaft spline, 4, Start the engine, raise the bucket, release the parking brake and reposition the machine so that it is straight. 5. Lower the bucket to the ground, apply a slight down pressure, stop the enghie and engage the parking brake114 Maintenance Section Every 250 Servce Hours or Monthly Brakes Test Service Brake Holding Ability Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake. Be sure the area around machine is clear of personnel ‘and obstructions, Be sure the steering frame lock link is in the stored position, Test the brakes on a dry, level surface. Fasten the seat belt before testing the brakes. The following tests are to determine ifthe service brake is functional, These tests are not intended to measure ‘maximum brake holding effort. Brake holding effort required to hold amachine at a specific engine rpm will vary from machine to machine. This is due to differences in engne setting, power train efficiency, etc., as well as differences in brake holding ability. 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. 1. Start the engina, and raise the bucket slightly. ‘Apply the service brake and release the parking brake. 2. Move the STIC transmission control switches to third speed forward direction. 3. Gradually increase the engine speed to high idle, ‘The machine should not move. 4, Reduce the engine speed to low idle, move the STIC transmission directional control switch to NEUTRAL. Engage the parking brake, lower the bucket to the ground and stop the engine, NOTICE Ifthe machine moved while testing the brakes, contact your Caterpillar dealer. Have the dealer inspect and, if ‘necessary, repair the Service brakes before returning the machine to operation Test Parking Brake Holding Ability BBe sure the area around machine is clear of personnel and obstructions, Be sure the steering frame lock lnk isin the stored position, Test the brakes on a dry, level surface. 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 cffort required to hold a machine at a specific engine rpm will vary from machine to machine, This is due to differences in engine setting, power train efficiency, ‘tc,, as well as differences in brake holding abilityEngine rpm at beginning of machine movement, with parking brake encaged, should be compared against a prior test. Use this as an indication of system deterioration 1. Start the engire, and raise the bucket slightly 2. With the parking brake engaged, move the transmission to thrd speed FORWARD. NOTE: The parking brake alert indicator light should ‘come on and the dack-up alarm should sound. 3. Gradually increase the engine speed to high ile. ‘The machine should not move. If the machine begins to move, reduce the engine speed immediately and apply the service brake pedal. 4, Reduce the engine speed, move the STIC transmission directional control switch to NEUTRAL. Lower the bucket to the ground and stop the engine, NOTICE Ifthe machine maved while testing the brakes, contact your Caterpillar dealer. Have the dealer inspect and, if ‘necessary, repair the parking brakes before returning the machine to operation. 115 Maintenance Section Every 250 Service Hours or Monthly Test Brake Accumulator 1. Move the start switch to ON. 60142 2. The brake oil pressure alert indicator ight should ‘Come on i not at normal operating pressure. 3. Start and run the engine at half speed for two ‘minutes to increase the accumulator pressure, The brake oil pressure alert indicator ight should go off. ‘Stop the engine 4, Apply and release the service brake pedal, to decrease the accumulator pressure, unti the brake oll pressure alert indicator light comes on (minimum of five applications). 5. The parking brake indicator light will be on when the brake oil pressure indicator light comes on. 6. | the brake oil alert indicator ligt comes on with less than five applications of the brake, measure the ‘accumulator nitrogen precharge pressure. Your Caterpillar dealer is equipped to measure the nitrogen {gas pressure in the accumulator. Use only dry nitrogen {gas for recharging,116 Maintenance Section Every 250 Service Hours or Monthly Air Conditioner (If Equipped) Inhaling freon gas through a lit cigarette or other ‘smoking method or inhaling fumes released from a flame contacting freon can cause bodily harm or death. Do not smoke when servicing air condi- tioners or wherever freon gas may be present. Test Operation - Adjust Belt 1. Start the engine. Operate the engine at high idle. 2. Set the air conditioner control for maximum cooling, and fan contol on HIGH 3. Allow two minutes for the air conditioning system to stabilize 4. Open the engine access door located on the right side of the machine. 5. Check for refrigerant in the system as follows: Feel the Suction line (1) and the discharge line (2) Ifthe system contains refrigerant, the discharge line will bbe warmer than the suction line. Ifthe system does not contain, oris very low on freon, poor cooling will result. 6. Stop the engine to inspect the compressor belt 7. 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To Adjust 1. Loosen the compressor locknut (1) 2. Turn the adjusting nuts (2) until the correct belt tension is reached, Tighten the adjusting nuts to 150 + 20 Nem (110 + 15 bf 3, Tighten the compressor locknut (1). 4, Recheck the belt adjustment. 5. Repeat stops 1 through 3. 6. | poor cooling is experienced, tum off the air ccondtioner. Stop the engine, Contact your Caterpillar dealer for air conditioner system service, if necessary. 17 tenance Section Every 250 Service Hours or Monthly Alternator Belts Inspect/Adjust/Replace 1. Open the engine access door on the right side of the machine, | 2 reas were NOTE: Replace the belts in sets only, if one or more belts are worn or damaged. 2. Inspect the condition and the adjustment of alternator belts, The belts should deflect 14 to 20 mm {(56 to 81 in) under 110 N (25 Ib) force.118 Maintenance Section Every 250 Service Hours or Monthly Alternator Belt Adjustment 1. Loosen alternator bracket bolt (1). Loosen the adjusting locknut (2). 2. Tighten the adjusting nut (3) unti the belt tension is reached. Tighten the adjusting locknut (2) to 10 ++ 20, Nem (110 15 ib fh) 3, Tighten the alternator bracket bolt (1). 4. Close the engine access door. Batteries Check Electrolyte Level ‘BATTERY ELECTROLYTE CHART Battery Inerval ‘Conventional 300 Hour Low taintenance 250 Hours Maintenance Free ‘None Requred Tighten the battery retainers every 1000 hours on all batteries, ‘Check the following at least every 1000 hours, and more often as conditions require: ‘Clean the top of the batteries with a clean cloth ‘© Keep the terminals clean and coated with petroleum aly ‘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, coll water usage could be higher. 1, Open the battery access doors located at the rear of the machine. 2. Clean the battery surface with a clean cloth. Keep the terminals clean and coated with petroleum jelly Install the post cover after coating3. Inspect the electroyte level in each battery cell, ‘except maintenance free. Maintain the level to the: bottom of the fill openings with cistilled water. If isilled water is not avaliable, use clean drinking water. 4, Close the access doors, Replacement of Battery, Battery Cable or Disconnect Switch 1. Turn the engine start switch to OFF. Turn all switches to the OFF position 2. Tutn the battery disconnect switch key to OFF and remove the key. 3. Disconnect the negative (~) battery cable, at the battery disconnect switch, that is connected to the machine frame, NOTE: Do not allow the disconnected battery cable to contact the disconnect switch, 4. Disconnect the negative (—) battery cable at the battery. 5. Make necessary repairs or battery replacement 6. Connect the negative (-) battery cable at the battery. 7. Connect the battery cable atthe battery disconnect, switch, }. Install the key and turn the battery disconnect, switch to ON. 119 Maintenance Section Every 250 Service Hours or Monthly120 Maintenance Section Every 500 Service Hours or 3 Months Every 500 Service Hours or 3 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Transmission Oil Filter Change Filter 2. Use a straptype wrench or a cross bar to remove the fter housing, 3. Remove and discard the used element. 4. Clean the fer housing with a clean, nonflanmable solvent. 5. Clean the housing base. 6. insert a new fiter element into the filter housing. The transmission filter is located at the center of the ‘machine behind the operator's compartment. 7. Inspect the filter housing seal, Replace the seal, if it is damaged. 8. Install the filter housing into the housing base. 1. Open the access door. 9. Start the engine. Apply the service brake. Use the right brake pedal ony. 10. Slowly operate the STIC transmission contiols to circulate the transmission ol 11. Move the STIC transmission directional control switch into NEUTRAL. Engage the parking brake. Inspect for leaks.121 Maintenance Section Every 500 Service Hours or 3 Months Hydraulic System Change Filters 12. Maintain the ol level between the marks on dipstick (1). Add the oil through fill tube (2) if necessary. 13. Stop the engine and close the access doors, 1. Open the access cover. 2. 1 the hydraulic tank contains a relief valve breather, relieve the tank pressure pushing on top of the relief valve before changing the filters. Ifthe hydraulic tank does not have a relief valve breather, remove the ol fil cap slowly to relieve the tank pressure hafore changing the filters122 Maintenance Section Every 500 Service Hours or 3 Months Hydraulic Tank Filter 4. Remove the filter cover. 2. Inspect the cover seal. Replace if necessary 3. Remove and discard the two filter elements 4. Remove the screen. Wash screen in clean, rnonfiammable solvent, 5. Install the screen and two new filter elements, 6. Install the cover Hydraulic Filter (Open the access door located behind the operator ‘compartment on the right side of the machine 1. Use a straptype wrench or a cross bar to remove the filter housing, 2. Discard the filter element. 3. Wash the filter housing in clean, nonflammable solvent. 4, Clean the fter housing base 5. Inspect the filter housing seal. Replace i necessary, 6. Install the new filter element and fiter housing. 7. Close the access docr. Fan Drive Piston Pump and Motor Case Drain Filter 1, Open the access door located on the right side of the machine,2. Use a straptype wrench or a cross bar to remove the filter housing, 3. Discard the filter element 4, Wash the fier housing in clean, nonflammable solvent 5. Clean the fiter housing base 6. Inspect the filter housing seal. Replace it necessary 7. Install the new filter element and fiter housing, After Changing Filters 4. Ingpect the fil cap gasket. Replace the gasket, if damaged. Install he oi fil cap 2. Start and run the engine at low idle. Inspect for leaks. 3. Maintain the hydraulic ol level above the ADD COLD mark in the sight gauge. 4, Stop the engine. Close the access cover. 123 Maintenance Section Every 500 Service Hours or 3 Months Fuel System Clean and Change Filters NOTICE Do not fil uel filters with fuel before installing them. Contaminated fue! will cause accelerated wear to fuel system parts. Fuel system should be primed prior to starting the engine, Primary Filter/Water Separator 1. Close the fuel main supply valve. 2. Open the engine access door 3, Open the bow! drain and then open the head ‘mounted vent plug to drain the unit. 4, Remove the filter element from the mounting head with the bowl attached,124 ‘Maintenance Section Every 500 Service Hours or 3 Months Le STH 4g279 5. Remove the bow (3) from the filter element. Clean the bow! and oring gland, NOTE: The bow! is reusable, Do not discard. 6. Lubricate the oring with clean diesel fuel or motor cl and place in bow! gland. 7. Spin the bow! (2) onto the new filter element snuggly by hand. 00 NOT use tools to tighten. 8. Lubricate filter op seal with clean diesel fuel or ‘motor oil and spin onto head with beveled side up, if present. Tighten fimmly by hand. Do not prefll the fiter element 9. Loosen the head] mounted vent plug, NOTE: On models equipped with the head mounted priming relief valve. press valve in and hold while Pumping, 10. When fuel purges at head vent plug, the fier is primed. Tighten the head vent plug. 11. Prime the fuel system. (See Fue! Priming Pump). 42. Close the engine access door 13. Start the engine and check for leaks. Change Secondary Fuel Filters 41. Open the engine access cover on the lett side of the machine, 2, Remove and discard the fiter. 3. Clean the filter mounting base, Be sure all of the Old seal is removed, 4, Coat the seal of the new fiter vith clean diese! fuel 5. Install the new filter by hand. When the seal Ccontacts the base, tighten three-quarter of a turn more. ‘There are rotation index marks 90° apart on the filter. Use them as a guide for proper tightening. 6. Prime the fuel system. (See next topic). 7, Close the engine access cover.Fuel Priming Pump Filters and Pump Housing 1. Open the engine access cover on the left side of the machine. Om be 049278 2. Open the fuel system purge valve (1) on the pump housing, 3. Unlock the priming pump plunger (2) and operate pump. 4, When fuel flows free of air bubbles, close pump and lock the plunger. 5. Close the purge valve 6. Start the engine and check for leaks. 7. Close the engine access cover. 125 Maintenance Section Every 500 Service Hours or 3 Months Fuel Tank Cap and Fill Screen Clean The fuel cap is located on the left side of the machine. 3 557] 1. Lift and turn the lever (5) counterclockwise until it stops. Lift the cap straight up to remove. 2. Inspect the seal (4) for damage. Replace the seal it necessary, 3. Remove the screws (1), fier assembly (2), valve (3) and gaskets, 4, Wash the cap in a clean nontlammable solvent 5. Install the new filter kit. Install components in reverse order 6. Remove the fill screen from the fil opening, 7. Wash the fil screen in a clean nonflammable solvent. 8. Install the fil screen into the fil opening. 9. Install the fuel cap.126 Maintenance Section Every 500 Service Hours or 3 Months Engine Crankcase Breathers Clean Breathers 41. Loosen the breather outlet hose clamp and remove the hase from the breather cover. 2. Loosen the breather inlet hose clamp and remove (Open the engine access door located on the right side the breather. of the machine 3, Check the condition of cover seal. Replace with ‘new seal if the used one is damaged, 4, Wash the element and cover assembly in clean, nonflammable solvent. 5. Shake, or use pressure alr, to dry the element. 6. Inspect the hose for damage, Replace if necessary 7, Install the breather element cover assembly. 8. Install the hose and clamps. 9. Repeat procedure for second crankcase breather. 10. Close the engine access door.127 Maintenance Section Every 1000 Service Hours or 6 Months Every 1000 Service Hours or 6 Months You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Transmission Oil Change the Oil Operate the engine long enough to warm the ol. The machine must be level. Lower the bucket with sight down pressure Engage the parking brake. Stop the engine, 1, Remove the transmission drain plug and drain the oll 2. Change the filter element. So the topic Transmission Oil Filter under Every 600 Service Hours 3 Months. 3, Remove the magnetic strainer cover 4, Remove the magnets from the housing. 5, Remove the screen from the housing 6. Wash the tube and the screen in a clean, nonflammable solvent. 7. Clean the magnets with a cloth, ast bristle brush oF pressure ai. NOTICE Do not drop or rap the magnets against any hard ‘objects. Replace any damaged magnets. '8. Clean the cover and inspect the seal. Replace the seal, ifit is damaged. 9, Insert the magnets in the screen, 10. Insert the screen, tube and magnets in the housing, 11. instal the cover. Tighten the cover bolts. 12. Clean and install the transmission drain plug128 Maintenance Section Every 1000 Service Hours or 6 Months 14. Fill the transmission with oll through the fill tube, Seé the Lubricant Viscosities and Refill Capacities, chart 15, Remove the transmission breather. Wash the breather in clean, nonflammable solvent. Install the transmission breather. 16. Remove the transfer gear housing breather. Wash the breather in clean, nonflammable solvent, Install the transfer gear housing breather. 7. Close the access cover. 48, Start and run the engine at low idle, Inspect for leaks. 19. Siowly operate the STIC transmission controls to circulate the cil 20. Maintain the oil level between the marks on dipstick (1). Add the ol through fil tube (2) i necessary. 21. Stop the engine.129 Maintenance Section Every 1000 Service Hours or 6 Months Drive Shaft Universal Joints - Lower Lubricate Fittings Wipe all fitings before lubricating, Wipe all fitings before lubricating NOTE: Do not use multipurpose grease containing NOTE: Do not use multipurpose grease containing Molybdemum Disulfide Molybdemum Disulfide, se277 Lubricate a total of two fittings. 1. Lubricate one fiting on each of the universal joints of the rear drive shaft. Total of two fittings.130 Maintenance Section Every 1000 Service Hours or 6 Months 2. Lubricate one fiting on the front end of the center dive shaft universal joint. 8. Lubricate one fitting on the rear of the center drive shaft universal joint. 4, Lubricate one fitting on the front drive shaft universal joint. Total of five fittings. Drive Shaft Support Bearing Lubricate Fitting Wipe al ftings before kibrcating, NOTE: Do not use multipurpose grease containing Molybdemum Disulfide. Lubricate one fiting on the drive shaft support tearing,Frame Pivot Bearings Lubricate Fittings Wipe all fittings before lubricating, Lubricate one fiting in the upper pivot bearing IO Lubricate one fiting inthe lower pivat bearing Total of two fittings. 131 Maintenance Section Every 1000 Service Hours or 6 Months Rollover Protective Structure (ROPS) Inspect ROPS/Tighten Bolts 1. Remove acess covers trom both sides of the ROPS. 2. Inspect lor any loose or damaged bolts. Replace ‘damaged bolts or missing bolts with original equipment parts only, “ighten bolts to a torque of 1300 + 150 Nem (960 + 110 bb ft Note: Apply oil to all ROPS bolt threads before installing, Failure to apply of can result in improper bolt torque: 3. Replace ROPS mounting supports if the ROPS rattles or makes a noise when the machine is operated (on a rough surface. 4, Install access covers. Do not straighten or repair by welding reinforcement plates to the ROPS, Contact your Caterpilar dealer for repair of cracks in welds, castings or any metal section on the ROPS.132 Maintenance Section Every 2000 Service Hours or 1 Year Every 2000 Service Hours or 1 Year You must read and understand the warnings ‘and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Hydraulic Tank Change the Oil ‘Operate the machine long enough to warm the ol ‘The machine should be level. All attachments should be lowered to the ground with a sight down pressure. The parking brake should be engaged, and the engine stopped, 1. Open the access cover. 2. I the hydraulic tank contains a relief valve breather, relieve the tank pressure pushing on top of the relief valve before removing the fill cap. It the hydraulic tank does not have a reli valve breather, remove the ail fil cap slowly to relieve the tank pressure, 3. Remove the drain plug, located inthe bottom ofthe hydraulic tank. 4, Install a 1 inch NPT pipe nipple, 100 mm (4 in) long, to open the internal drain valve and drain the oil 5. Remove the pipe ripple and instal the drain plug 6. Change the hydraulic system fters. See Hydraulic System in the Every 600 Service Hours or 3 Months section 7. Remove the fil screen. Clean and instal fil screen, 8, Fill the hydraulic system oll tank. See Lubricant Viscosites and Refill Capacities. 9. Inspect the fil cap gasket. Replace the gasket if damaged 10. instal the ol fil cap. 11, Start and run the engine fora few minutes.133 Maintenance Section Every 2000 Service Hours or 1 Year Differentials and Final Drives ‘Change the Oil Front 42. Maintain the ail level above the ADD COLD mark. in the sight gauge (1). Add oll through the fil tube (2), i necessary, NOTE: The oll must be free of bubbles. f bubbles are present in the oil, air is entering the hydraulic system. Dee te BESGH s ness ond los 1. Position each front whee! with the drain plug down. Remove the plugs and allow the oil to drain. 13. Stop the engine. 14. | necessary, tighten any loose clamps and connections. Replace any damaged hoses, 2. Remove the front differential dain plug and allow the oll to drain. 3. Clean and install the differentia and final drive drain plugs.134 Maintenance Section Every 2000 Service Hours or 1 Year Rear 4, Remove the front diferent! fil plug. 1. Position each rear wheel with the drain plug cown. 5, Fill the front differential to the bottom of the fll Lied ell aad peter ‘openings. See the Lubricant Viscosities and Refi Capacities. Clean and install the fill pug. 2, Remove the rear differential drain plug and alow the oll to drain 6. Position the front wheels so the fil plugs are even ‘with the center ine of the wheel, Remove the fil pups. 3. Clean and install the differential and final drive drain 7. Fill both front final drives slowly to the bottom of the Plugs: fil openings. See the Lubricant Viscosities and Refill Capacities,4, Remove the differential fil plug, 5. Position the rear wheels so the fil pugs are even with the center line of the wheel. Remove the fill plugs. 6. Fill both rear final drives slowly to the bottom of the {ill openings. See the Lubricant Viscosities and Refill Capacities. 135 ‘Maintenance Section Every 2000 Service Hours or 1 Year Bucket Pivot Pins Lubricate the Lower Pins Wipe all fitings before lubricating, 1. Remove the access plugs from the inner and outer collets ‘2. Remove the oil plugs from the ends of the pin. 3. Install a special iting (BD-0838) in the outer end of the pin, NOTICE Use a new grease gun or thoroughly wash a grease {gun and nozzle in clean, nonflammable solvent ‘Thoroughly dry the grease gun and nozzle, Make sure rho grease remains in the gun or the nozzle. 4, Pump the cil into the pin through the special fitting and allow the excess oil to come out the other end of the pin. Flush the pin thoroughly with ol 5. Wipe excess oll from the end ofthe pin. Install a clean ol pig inthe pin. 6. installa clean access plug in the inner collet, 7. Remove the special fitting from the pin. install a clean plug in the pin, 8. Install a clean access plug in the outer collet 8. Lubricate the remaining bucket pivot pins. 10. Total of four bucket pivot pins.136 ‘Maintenance Section Every 2000 Service Hours or 1 Year Brake Accumulator Check Pressure Contact your Caterpillar dealer to have the brake accumulator precharge pressure checked. Use only dry nitrogen gas for recharge.137 Maintenance Section Every 3000 Service Hours or 2 Years Every 3000 Service Hours or 2 Years You must read and understand the warnings and instructions contained in the Safety section of this manual, before performing any operation or maintenance procedures. Cooling System Coolant (Standard Antifreeze) Clean/Flush/Change coolant and replace thermostat NOTICE Do not change the coolant until you read and under- stand the material in the Cooling System Specifica- tions section. Drain the coolant earlier whenever the ccolant is dirty Cr foaming is observed. Replacing your thermostat prior to failure is a good preventive maintenance practice becaus it reduces your chances for unscheduled downtime. Failure to ‘eplace your thermostat on a regularly scheduled basis ‘could cause severe engine damage and cost you money. NOTE: If replacing thermostat ONLY, drain the coolant ‘rom the cooling system to a level below the thermostat housing, Since Caterpillar engines incorporate a sunt design Cooling system, it is mandatory to always operate the engine with a thermostat NOTE: The thermostats can be reused i they are tested and meet the test specifications and are not damaged or have excessive buildup of deposits 1. Stop the engine and allow to cool 2. Remove the radiator cap slowly to relieve pressure {and open the dain valve and allow the coolant to drain into an approved container. Drain valve & located under the radiator. 3. Remove the bolts (1) that fasten the thermostat housing (2) to the cyfinder head and remove the thermostat housing and gaskets. 4, Remove the thermostat and the seal from the housing, 5. Install the seal gasket and thermostat to the housing, 6. Install the housing to the cylinder head. 7. Close the drain valve. Fill the system with clean water and a 6 to 10% concentration of cooling system cleaner. 8. Start and run the engine for 90 minutes. Stop the engine and drain the cleaning solution 9, Flush the system with water, with the engine stopped, until the draining water is clear. 10. Close the drain valve. 11. Add the coolant solution, See Cooling System ‘Specifications and Lubricant Viscosities and Refi Capacities NOTE: Do not add supplemental coolant additive or change element at this time, unless you are not using Caterpillar Antitreeze which contains additive 12. Slart the engine and operate it wth the radiator ‘cap off, until the thermostat opens and the level stabilizes, 13, Maintain the coolant level to within 13 mm (5 in) of the bottom ofthe fill pipe. 14, Install the cap, 15. Stop the engine.138 Maintenance Section Every 3000 Service Hours or 2 Years Clean the Cooling System Relief Valve Clean or replace the relief valve if the system overheats oF loss of coolant is observed. 1. Remove radiator cap (1) slowly to relieve pressure. 6 2. Remove bolts (2) from the valve and remove the valve assembly, 3. Inspect vaive (6), valve seals (4) and gasket (3). Replace if necessary. 4. Inspect valve cover (6) and mounting bolts (2) 5. Install the relief valve assembly 6. Check the coolant level. Maintain the coolant level to within 13 mm (5 in) of the bottom of the fil pipe. 7. Install the radiator cap, Clean Outside of Radiator Fins ee Compressed ai is preferred, but high pressure water or steam can be used to remove dust, leaves and general debris from radiator fins.Cooling System Coolant (Extended Life Coolant) Add “Extender” NOTE: Extender should only be added at the 3,000, Service Hour interval 1. Stop the engine and allow to coo 2. Remove the radiator cap slowly to relieve pressure. 3. Treat the cooling system with one quart of 119-5152 Extender for every 12 gallons of cooling system capacity 4, Install the radiator cap. 139 Maintenance Section Every 3000 Service Hours or 2 Years Engine Mounts & Crankshaft Vibration Damper Damage to, oF failure of, the damper will increase torsional vibrations and result ii damage to the Crankshaft and other engine components. A, deteriorating vibration damper wil cause excessive {gear train noise at variable ponts in the speed range. ‘The vibration damper weight ic located inside a fluid filed case. The weight moves in the case to limit torsional vibration. Inspect the dampers for evidence of dons, cracks or leaks of fui. Caterpillar recommends checking the engine mounts, {or deterioration and proper bat torque. This will prevent excessive engine vibration caused from Improper mounting,140 Maintenance Section Every 3000 Service Hours or 2 Years Engine Valve Lash ‘Check/Adjust Initial valve lash adjustment (at first oll change or 250 hours) on new or rebuilt or remanufactured engines is recommended at the first oll change interval due to initial wear and seating of valve train components. All ‘subsequent adjustments are to be performed at 3000 Service Hours interval thereafter. ‘VALVE CLEARANCE SETTING intake 0.38 mm (O15 im) Exhaust 0.78 mm (030 ir) This maintenance is recommended as part of a lubrication and preventative maintenance schedule to provide maximum engine life. Throughly clean the area around the valve mechanism ‘covers to prevent the entry of foreign matter into the top of the cylinder head and valve mechanism, Refer to the Service Manual or your Caterpilar dealer for the complete valve adjustment procedure. Engine Valve Rotators Check When inspecting the valve rotators, protective glasses or face shield and protective clothing must be worn, to prevent being burned by hot oil spray. 1. Start the engine and run at Low idle. 2. Watch the top surface on each valve rotator. Each ‘valve rotator should turn slightly each time the valve closes. Ifa valve fails to rotate, contact your Caterpillar dealer. NOTE: Caterpillar recommends replacement of improperly operating valve rotators. An improperly ‘operating valve rotator wil shorten valve life through accelerated valve face and valve seat wear, It a damaged rotator is not replaced, valve face {uttering could result. Metal particles of the valve could fall into the cylinder and cause piston and cylinder head damage.