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SEBU7889-15 129
Maintenance Section
Maintenance Interval Schedule
Fuel System Primary Filter (Water Separator) Every 6000 Service Hours or 6 Years
Element - Replace ............................................ 166
Fuel System Secondary Filter - Replace ............ 167 Cooling System Water Temperature Regulator -
Fuel Tank Cap and Strainer - Clean ................... 168 Replace ............................................................. 149
Hydraulic System Biodegradable Oil Filter Element -
Replace ............................................................. 171 Every 12 000 Service Hours or 6 Years
Hydraulic System Oil Filter - Replace ................. 175
Hydraulic System Oil Sample - Obtain ............... 176 Cooling System Coolant (ELC) - Change ........... 145
Transmission Oil Sample - Obtain ...................... 188
Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 149
Receiver Dryer (Refrigerant) - Replace .............. 179
i03022485
Articulation Bearings -
A pressure hazard is present. Severe personal in-
Lubricate jury or death can result from removing hoses or
Þttings that are under pressure. Relieve the pres-
SMCS Code: 7057-086-BD; 7065-086-BD; sure in the system before you remove hoses or
7066-086-BD Þttings.
g01068678
Illustration 143
Automatic Lubrication Grease 5. Remove the Þller assembly and install the dust
Tank - Fill cap (2).
(If Equipped)
SMCS Code: 7540-544-TNK
i02399602 i01897507
g01119922
Illustration 144
g00881968
Open the access panel on the right side of the Illustration 146
machine in front of the steps.
A three-position switch on the backup alarm regulates
the volume of the alarm.
g01105565
Illustration 145
i02218821 i02185798
g01119949 g00882014
Illustration 147 Illustration 149
i03657099
• A battery supplier
• An authorized battery collection facility
• Recycling facility
i03690607
Belt - Inspect/Adjust/Replace
SMCS Code: 1397-025; 1397-040; 1397-510
g01120034
Illustration 150
(1) Idler Pulley (4) Tensioner (7) Serpentine Belt
(2) Compressor (If Equipped) (5) Square Hole (8) Crankshaft Pulley
(3) Alternator (6) Water Pump (9) Axle Oil Cooler Pump (If Equipped)
136 SEBU7889-15
Maintenance Section
Brake Accumulator - Check
7. Start the engine. Raise the bucket and remove the i02895805
blocking. Lower the bucket to the ground.
Bucket Hinge and Lift
8. After a few hours of operation, check the bolts for
proper torque.
Arm Clearance Shims -
Inspect/Adjust/Replace
Bucket Wear Plates SMCS Code: 6001-025-CLR; 6001-040-CLR;
6001-510-Z4; 6119-025-CLR; 6119-040-CLR;
6119-510-Z4
Personal injury or death can result from the bucket Inspect the Linkage
falling.
g00879740
Illustration 153
i01897623
Integrated Toolcarrier
Wipe off all of the Þttings before you apply any
lubricant.
g01345720
Illustration 155
(2) Bucket
(4) Install washers on lift arm.
g00764050
Illustration 157
Wheel Loader
Wipe off all Þttings before any lubricant is applied.
g01345724
Illustration 156
(2) Bucket
(4) Install washers on tilt arm.
Note: Refer to the Disassembly and Assembly Apply lubricant through Þttings (2) and (3) on both
Manual, “Bucket - Install” for the correct procedure lift cylinders. Apply lubricant through Þttings (5), (6)
for installing the pins in the linkage. and (7).
140 SEBU7889-15
Maintenance Section
Bucket Lower Pivot Bearings - Lubricate
i01897748
g00765618
Illustration 159
g00987389
Illustration 161
Bucket Tips
g00590819
Illustration 164
g00101352 (6) Retainer
Illustration 162
(7) Retaining washer
(1) Usable (8) Adapter
(2) Replace the tip.
(3) Replace the tip.
2. Clean the adapter and the pin.
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip. 3. Fit retainer (6) into retaining washer (7). Install
this assembly into the groove that is in the side
1. Remove the pin from the bucket tip. The pin can of adapter (8).
be removed by one of the following methods.
g00101359
Illustration 165
Illustration 163
g00590670 5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods:
(4) Back of Pin-Master
(5) Extractor
• From the other side of the retainer, drive the
a. Place the Pin-Master on the bucket tooth. pin through the bucket tip, the adapter, and the
retainer.
b. Align extractor (5) with the pin.
• Use a Pin-Master. Follow Step 5.a through Step
c. Strike the Pin-Master at the back of the tool (4) 5.e for the procedure.
and remove the pin.
Note: To correctly install the pin into the retainer, the
pin must be driven in from the right side of the tooth.
Improper installation of the pin can result in the loss
of the bucket tip.
142 SEBU7889-15
Maintenance Section
Bucket Tips - Inspect/Replace
g00590666 g01175361
Illustration 166 Illustration 168
(4) Back of Pin-Master
(9) Pin setter 1. Use a pry bar in order to disengage retainer (5).
(10) Pin holder
2. Use the pry bar in order to remove retainer (5)
a. Insert the pin through the bucket tooth. from bucket tip (4).
b. Place the Pin-Master over the bucket tooth and 3. Remove bucket tip (4) from adapter (6) with a
locate the pin in the hole of holder (10). slight counterclockwise rotation.
c. Strike the tool with a hammer at the back of the 4. Clean adapter (6).
tool (4) in order to start the pin.
Installation
d. Slide pin holder (10) away from the pin and
rotate the tool slightly in order to align pin setter
1. Clean the adapter and the area around the latch,
(9) with the pin.
if necessary.
e. Strike the end of the tool until the pin is fully
2. Install the new bucket tip onto the adapter with a
inserted.
slight clockwise rotation.
6. After you drive the pin, make sure that the retainer
Þts snugly into the pin groove.
K-Series Tip
Removal
g01124736
Illustration 169
i01897750
g00759048
Illustration 171
Illustration 170
g00987399 2. Open the access door (3) on the left side of the
cab. Remove the Þlter element.
Wipe off the Þtting before any lubricant is applied.
3. Clean the Þlter elements with pressure air or
Apply lubricant through the Þtting. wash the Þlter elements in warm water with a
nonsudsing household detergent.
SMCS Code: 7342-070; 7342-510 Note: If either Þlter element is damaged, install a
new Þlter element.
Note: Clean the cab air Þlters more often if the
machine is being operated in dusty conditions. 5. Install the Þlter elements. Install the Þlter cover
and close the access door.
i02816405
Camera - Clean
(If Equipped)
SMCS Code: 7348-070
Display i02067499
g01223034
Illustration 172
WAVS display
g01223051
4. Dry the case drain screen (3) by using pressurized
Illustration 173 air.
The WAVS camera is located on the rear of the machine in the
center of the fan guard. 5. Inspect the case drain screen (3) for damage.
Use a damp cloth or water spray in order to clean Note: If the case drain screen (3) is damaged,
the camera lens. The camera is a sealed unit. The replace the case drain screen (3).
camera is not affected by high pressure spray.
6. Install the case drain screen (3).
The camera is equipped with an internal heater to
help counteract the effects of condensation, snow, 7. Connect hydraulic line (2).
or ice.
8. Repeat Step 1 through Step 7 for hydraulic line (4)
Note: For more information on WAVS, refer to and case drain screen (5).
Operation and Maintenance Manual, SEBU8157,
“Work Area Vision System”.
SEBU7889-15 145
Maintenance Section
Circuit Breakers - Reset
i03696954
g01988117
Illustration 176
(1) 50 Amp Circuit Breaker
(2) 90 Amp Circuit Breaker
(3) 80 Amp Circuit Breaker
(4) 20 Amp Circuit Breaker
(5) 30 Amp Circuit Breaker
i02219194
Illustration 175
g01988115 Cooling System Coolant (ELC)
Depress the button in order to reset the circuit
- Change
breakers. If the circuit is functioning properly, the SMCS Code: 1350-044-NL
button will remain depressed. If the button will not
remain depressed, check the appropriate electrical
circuit.
NOTICE
Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the ßuid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing ßuids.
NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 speciÞcations reduces
the effectiveness of the coolant and shortens coolant
service life.
Illustration 177
g01120130 6. Start the engine. Run the engine without the
cooling system pressure cap until the water
1. Slowly loosen the cooling system pressure cap in temperature regulator opens and the coolant level
order to relieve system pressure. The pressure stabilizes.
cap is located on top of the radiator tank on the
left side of the machine.
SEBU7889-15 147
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 speciÞcations reduces
the effectiveness of the coolant and shortens coolant
service life.
8. Install the cooling system pressure cap. Stop the Use a 8T-5296 Coolant Conditioner Test Kit to
engine. check the concentration of the coolant.
NOTICE
Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
g01120130
collect the ßuid with suitable containers before open- Illustration 180
ing any compartment or disassembling any compo-
nent containing ßuids. The cooling system pressure cap is located under
the engine hood at the rear of the machine. Tilt the
Refer to Special Publication, NENG2500, “Caterpillar hood in order to access the cooling system pressure
Tools and Shop Products Guide” for tools and supplies cap. The cap is located on the radiator tank on the
suitable to collect and contain ßuids on Caterpillar left side of the machine.
products.
1. Slowly loosen the cooling system pressure cap in
Dispose of all ßuids according to local regulations and order to relieve any system pressure. Remove the
mandates. cooling system pressure cap.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
g01120228
Illustration 181
Note: Level 1 results may indicate a need for
Level 2 Analysis.
Open the service door on the left side of the machine.
The coolant level sight gauge is located on the left
side of the radiator.
g01120318
Illustration 182
• Place the sample in the mailing tube immediately Refer to Operation and Maintenance Manual,
after obtaining the sample in order to avoid “Cooling System Coolant Sample (Level 1) - Obtain”
contamination. for the guidelines for proper sampling of the coolant.
• Never collect samples from expansion bottles. Submit the sample for Level 2 analysis.
• Never collect samples from the drain for a system. Reference: For additional information about coolant
analysis, refer to Special Publication, SEBU6250,
Submit the sample for Level 1 analysis. “Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer.
For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine i02219561
Fluids Recommendations” or consult your Caterpillar
dealer. Cooling System Water
Temperature Regulator -
i02219546
Replace
Cooling System Coolant
SMCS Code: 1355-510; 1393-010
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
Pressurized system: Hot coolant can cause seri-
NOTICE ous burn. To open cap, stop engine, wait until ra-
Always use a designated pump for oil sampling, and diator is cool. Then loosen cap slowly to relieve
use a separate designated pump for coolant sampling. the pressure.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor- NOTICE
rect interpretation that could lead to concerns by both Failure to replace the engine's thermostat on a regu-
dealers and customers. larly scheduled basis could cause severe engine dam-
age.
150 SEBU7889-15
Maintenance Section
Differential and Final Drive Oil - Change
i02765211
NOTICE
Caterpillar engines incorporate a shunt design cooling
Differential and Final Drive Oil
system and require operating the engine with a ther- - Change
mostat installed.
SMCS Code: 3278-044; 4011-044
If the thermostat is installed wrong, it will cause the
engine to overheat. Inspect gaskets before assembly NOTICE
and replace if worn or damaged. Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the ßuid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing ßuids.
g00890574
Illustration 184
g00630605
Illustration 186
Machine with axle oil cooler
1. Remove the drain plugs. Attach a hose to a 4. Remove the magnetic plug on the front Þlter. Clean
suitable drain adapter. Install a drain adapter the magnetic plug with a clean nonßammable
into each drain valve. Allow the oil to drain into a solvent. Install the magnetic plug. Repeat the
suitable container. process for the rear magnetic Þlter.
g00989672
Illustration 189
Dipstick/Þll plug for the front axle
g01384244
Illustration 187
Front Magnetic Oil Filter Illustration 190
g00989674
1. Park the machine on level ground. Lower the 5. Repeat Step 2 through Step 4 for the rear axle.
bucket and apply slight downward pressure.
Engage the parking brake. Stop the engine. i02778954
g00989672
Illustration 191
Dipstick/Þll plug for the front axle
g00667052
Illustration 193
Front axle
g00989674
Illustration 192
Dipstick/Þll plug for the rear axle
Note: Make sure that the plug is installed completely The axles are not equipped with sampling valves.
before you check the oil level. If the plug is not Obtaining a sample of the differential and Þnal drive
installed completely, an incorrect oil level reading can oil will require a vacuum pump or an equivalent.
occur. Withdraw the ßuid through the Þller opening on the
right side of each axle.
SEBU7889-15 153
Maintenance Section
Drive Shaft Spline (Center) - Lubricate
i02445879
g01106848
Note: Check for sealed universal joints that do not
Illustration 195 require lubrication.
3. Apply grease to the Þtting (1). Apply grease until Wipe off all Þttings before any lubricant is applied.
the relief (2) overruns.
NOTICE
Caterpillar recommends certiÞed air Þlter cleaning ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufÞcient Þlter life.
Engine Air Filter Primary Do not use air Þlters with damaged pleats, gaskets, or
Element - Clean/Replace seals. Dirt entering the engine will cause damage to
engine components.
SMCS Code: 1054-070-PY; 1054-510-PY
NOTICE
Service the air Þlter only with the engine stopped. En-
gine damage could result.
Burn Hazard: Engine components may be hot dur-
ing and after machine operation.
1. Open the engine compartment. The air Þlter is
located on the right side of the machine.
Hot components can cause serious personal in-
jury. Do not contact hot components with bare
skin.
g00845360
Illustration 198
g00101415
Illustration 199
4. Inspect the primary element. If the pleats, the 7. Place a light bulb inside the Þlter element. Use
gaskets, or the seals are damaged, discard the a 60 watt blue light in a dark room or in a similar
element. Replace a damaged primary element facility. Inspect the primary element for light that
with a clean primary element. may show through the Þlter material.
g00328468
10. Discard a damaged primary element.
Illustration 200
Use Steps 11 through 13 to install a clean
5. If the primary element is not damaged, clean the primary element:
primary element.
12. Clean the cover for the air cleaner housing. Align
the slot on the cover with the pin on the air cleaner
housing. Install the cover.
i02445996
g00864077
Illustration 202
Burn Hazard: Engine components may be hot dur- 2. Remove the secondary element.
ing and after machine operation.
NOTICE
Service the air Þlter only with the engine stopped. En-
gine damage could result.
NOTICE
Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could
result. g00864079
Illustration 203
Note: Replace the secondary element when you 3. Cover the air inlet opening. Clean the inside of
service the primary element for the third time. If the air cleaner housing.
a clean primary element has been installed and
a warning for the air Þlter still occurs, replace the 4. Inspect the gasket between the air inlet pipe and
secondary element. Also if the exhaust smoke the air cleaner housing. Replace the gasket if the
remains black and a clean primary element has been gasket is damaged.
installed, replace the secondary element.
5. Uncover the air inlet opening. Install a new
1. Remove the primary element. secondary element.
Reference: Refer to Operation and Maintenance 6. Install a clean primary element and the cover for
Manual, “Engine Air Filter Primary Element - the air cleaner housing.
Clean/Replace” for the correct procedure.
7. Close the access door.
i02219769 i03652254
7. Inspect the outlet hose for damage. Replace the Note: Your Caterpillar dealer has additional
hose, if necessary. information on these programs.
10. Close the engine hood. VeriÞcation for an Oil Change Interval of 500 Hours
If a sample does not pass the oil analysis, take one Procedure for Changing the Engine
of these actions:
Oil and Filter
• Shorten the oil change interval to 250 hours.
NOTICE
• Proceed to Program B. Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test-
• Change to a preferred oil type in the “Lubricant ing, adjusting and repair of the product. Be prepared to
Viscosities for Ambient Temperatures” Table in this collect the ßuid with suitable containers before open-
Operation and Maintenance Manual ing any compartment or disassembling any compo-
nent containing ßuids.
Program B
Refer to Special Publication, NENG2500, “Caterpillar
Optimizing Oil Change Intervals Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain ßuids on Caterpillar
Begin with a 250 hour oil change interval. The oil products.
change intervals are adjusted by increments. Each
increment is an additional 50 hours. Periodic oil Dispose of all ßuids according to local regulations and
sampling and analysis is done during each interval. mandates.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change Your machine may be equipped with a high speed
the application of the machine. arrangement for changing the engine oil. The high
speed arrangement allows service personnel to
If an oil sample does not pass the analysis, shorten change the oil from the engine access door on
the oil change interval, or change to a preferred the right side of the machine. The high speed
multigrade oil type in the listing above. arrangement allows the oil to be changed faster than
conventional methods.
References
g01120397
Illustration 205
10. Clean the end of the male coupler. Clean the cap
Illustration 206
g01120399 that covers the male coupler and install the cap.
5. Use a strap type wrench to remove the Þlter 11. Start the engine and allow the oil to warm. Check
element. Inspect the Þlter. the machine for oil leaks.
6. Clean the Þlter mounting base with a clean cloth. 12. Check the engine oil level.
Make sure that the used Þlter gasket has been
completely removed. Reference: Refer to Operation and Maintenance
Manual, “Engine Oil Level - Check” for the correct
procedure.
i02097831
NOTICE
Do not under Þll or overÞll engine crankcase with oil.
g00101318 Either condition can cause engine damage.
Illustration 207
g00753678
Illustration 208
2. Remove dipstick (2) and wipe off the dipstick Illustration 209
g01121355
with a clean cloth. Then, reinsert the dipstick and
remove the dipstick again. This will give a more 3. Use the sampling valve in order to obtain a
accurate measurement of the oil level. sample of engine oil.
3. Maintain the engine oil between the FULL mark 4. Close the engine hood.
and the ADD mark on dipstick (2). If necessary,
remove Þller cap (1) and add oil. Reference: For more information, refer to Special
Publication, SEBU6250, “Caterpillar Machine Fluids
4. Close the engine access door. Recommendations”, “S·O·S Oil Analysis” and Special
Publication, PEHP6001, “How To Take A Good Oil
i02223451
Sample”.
The normal engine oil change interval is listed in this If an oil sample does not pass the analysis, shorten
Operation and Maintenance Manual, “Maintenance the oil change interval, or change to a preferred
Interval Schedule”. multigrade oil type in the listing above.
Note: Your Caterpillar dealer has additional Reference: Special Publication, PEDP7076,
information on these programs. “Understanding the S·O·S Oil Analysis Tests”
Cat oil Þlters are recommended. Procedure for Changing the Oil
Program A
NOTICE
VeriÞcation for an Oil Change Interval of 500 Hours Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test-
This program consists of three oil change intervals of ing, adjusting and repair of the product. Be prepared to
500 hours. Oil sampling and analysis is done at 250 collect the ßuid with suitable containers before open-
hours and 500 hours for each of the three intervals ing any compartment or disassembling any compo-
for a total of six oil samples. The analysis includes nent containing ßuids.
oil viscosity and infrared (IR) analysis of the oil. If
all of the results are satisfactory, the 500 hour oil Refer to Special Publication, NENG2500, “Caterpillar
change interval is acceptable for the machine in that Dealer Service Tool Catalog” for tools and supplies
application. Repeat Program A if you change the suitable to collect and contain ßuids on Caterpillar
application of the machine. products.
If a sample does not pass the oil analysis, take one Dispose of all ßuids according to local regulations and
of these actions: mandates.
• Shorten the oil change interval to 250 hours. 1. Open the engine hood.
• Proceed to Program B. 2. The drain plug is located on the left side of the
engine oil pan toward the rear of the machine.
• Change to a preferred oil type in the “Lubricant Open the oil drain valve and allow the oil to drain
Viscosities for Ambient Temperatures” Table in this into a suitable container. Close the drain valve.
Operation and Maintenance Manual
Program B
g01125581
Illustration 210
g01125595
Illustration 212
8. Clean the oil Þller cap and install the oil Þller cap.
g00101318 9. Start the engine and allow the oil to warm. Check
Illustration 211
for any oil leaks.
5. Apply a thin coat of oil to the seal on the new 10. Check the oil level on dipstick (2).
engine oil Þlter. Install a new engine oil Þlter hand
tight until the seal of the engine oil Þlter contacts Reference: Refer to Operation and Maintenance
the base. Note the position of the index marks on Manual, “Engine Oil Level - Check” for the correct
the Þlter in relation to a Þxed point on the Þlter procedure.
base.
11. Close the engine hood and stop the engine.
Note: There are rotation index marks on the engine
oil Þlter that are spaced 90 degrees or 1/4 or a turn
away from each other. When you tighten the engine
oil Þlter, use the rotation index marks as a guide.
SEBU7889-15 163
Maintenance Section
Engine Valve Lash - Check
i01181536
i02770364 g00038585
Illustration 214
Engine Valve Rotators - Inspect 2. Watch the top surface of each valve rotator.
SMCS Code: 1109-040 Whenever an inlet valve closes or an exhaust
valve closes, each valve rotator should turn.
g01372247
Illustration 213
i02230611
Keep ether cylinders out of the reach of unautho- The fuel system needs to be primed due to the
rized personnel. following circumstances:
To avoid possible injury, be sure the brakes are ap- • The primary fuel Þlter has been changed.
plied and all controls are in Hold or Neutral when
starting the engine. • The secondary fuel Þlter has been changed.
• The fuel injectors have been removed.
• The engine has run out of fuel.
Note: The volume of air in the water separator is
small. Usually, it is not necessary to prime the fuel
system if only the water separator element has been
changed.
g01106393
Illustration 215
g01125195 g00753954
Illustration 216 Illustration 217
1. Open the engine hood in order to access the fuel 1. Open the engine hood. The water separator is
priming pump. The fuel priming pump is located located on the bottom of the primary fuel Þlter on
on the right side of the machine. the right side of the machine.
2. Place the drain hose (3) into a suitable container 2. Attach a hose to the bottom of the drain valve
in order to catch the fuel. Open the drain valve (2). Open the drain valve (1) on the bottom of the
(2). Move the toggle switch (1) in order to activate water separator bowl. Allow the water and the fuel
the priming pump. to drain into a suitable container.
3. Operate the priming pump until fuel comes out of 3. Close the drain valve.
the drain hose. Operate the priming pump until
the fuel that ßows from the drain hose has no Note: The water separator is under suction during
air bubbles. Turn off the drain valve. Turn off the normal engine operation. Tighten the drain valve
priming pump. securely in order to prevent air leakage into the fuel
system.
i01439459
4. Close the engine hood.
Fuel System Primary Filter
(Water Separator) - Drain
SMCS Code: 1263-543
NOTICE
Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the ßuid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing ßuids.
NOTICE
Do not Þll fuel Þlters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel g00101318
Illustration 219
system parts. Fuel system should be primed prior to
starting the engine. 6. Lubricate the O-ring seal with clean diesel fuel.
Place the O-ring seal in the water separator bowl.
i02223730
Fuel leaked or spilled onto hot surfaces or electri- 2. The secondary fuel Þlter is inverted. The Þlter
cal components can cause a Þre. must be properly drained before removal. Open
the drain valve (2). Drain the fuel into a suitable
Clean up all leaked or spilled fuel. Do not smoke container. The secondary fuel Þlter can now be
while working on the fuel system. removed.
Turn the disconnect switch OFF or disconnect the 3. Remove the Þlter by using a strap type wrench.
battery when changing fuel Þlters.
4. Inspect the fuel Þlter element for debris by cutting
the Þlter open. Discard the used fuel Þlter element
NOTICE properly.
Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test- 5. Clean the Þlter mounting base. Make sure that
ing, adjusting and repair of the product. Be prepared to all of the used seal is removed from the Þlter
collect the ßuid with suitable containers before open- mounting base.
ing any compartment or disassembling any compo-
nent containing ßuids.
NOTICE
Do not Þll fuel Þlters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts. Illustration 221
g00101318
168 SEBU7889-15
Maintenance Section
Fuel Tank Cap and Strainer - Clean
Fuel Tank Cap and Strainer - 3. Install the strainer into the Þller opening.
g01431287
Illustration 223
Fuel Cap Boot
SEBU7889-15 169
Maintenance Section
Fuel Tank Water and Sediment - Drain
5. Inspect the fuel cap boot(if equipped). If the fuel 2. Allow the water and the sediment to drain into a
cap boot is damaged, replace the fuel cap boot. suitable container.
If your machine does not have a fuel cap boot,
contact your Caterpillar dealer for information 3. Tighten the bolt on the side of the drain.
about the fuel cap boot.
i02200478
6. Wash the fuel cap boot in a clean, nonßammable
solvent. Fuses - Replace
7. Install the fuel cap boot and the fuel tank cap. SMCS Code: 1417-510
i03657251 NOTICE
Replace fuses with the same type and size only. Oth-
Fuel Tank Water and Sediment erwise, electrical damage can result.
- Drain If it is necessary to replace fuses frequently, an electri-
SMCS Code: 1273-543-M&S cal problem may exist. Contact your Caterpillar dealer.
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Illustration 225
g01962163
Illustration 224
(8) ECM Switched Power ...................... 10 Amperes High Intensity Discharge Lamp
(HID) - Replace
(9) Front Cab Floodlights ...................... 15 Amperes
(If Equipped)
(10) Beacon and Heated Mirrors ........... 10 Amperes
SMCS Code: 1434-510
(11) Turn Signal Flasher, Front Flood Relays, and
Rear Flood Relays ........................... 10 Amperes
(12) Machine Security System and Product HID lamps operate at very high voltages. To avoid
Link .................................................. 10 Amperes electrical shock and personal injury, disconnect
power before servicing HID lamps.
(13) LH Indicator Display and RH Indicator
Display ............................................. 10 Amperes
1. Remove the electrical power from the high The hood tilt actuator is located on the right side of
intensity discharge lamp (HID). The electrical the machine.
power must be removed from the HID lamp for
at least Þve minutes, in order to ensure that the 1. Raise the engine hood in order to extend the tilt
bulb is cool. hood actuator.
2. Disassemble the housing for the HID lamp in order 2. Remove the wiper and lubricate the entire length
to have access to the bulb. of the inner post by hand.
Note: On some HID lamps, the bulb is an integral 3. Wipe off the Þttings before you apply any lubricant.
part of the lens assembly. The bulb is not removed Apply lubricant through the two Þttings on the
separately from the lens assembly. Replace the cylinder. Apply approximately 15 to 20 pumps of
entire lens assembly on these HID lamps. grease.
3. Remove the bulb from the HID lamp. 4. Close the engine hood.
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Illustration 227
172 SEBU7889-15
Maintenance Section
Hydraulic System Oil - Change
g01121627
Illustration 228
i03696957
Caterpillar oil Þlters are recommended. The Þlter • The silicon level should not exceed 15 parts per
change interval is listed in this Operation and million for new oil. The particle counts should be
Maintenance Manual, “Maintenance Interval monitored.
Schedule”.
• The recommended level of cleanliness for
Oil Caterpillar machines that are operated in the Þeld
is ISO 18/15 or cleaner. The cleanliness should be
Refer to the Operation and Maintenance Manual, monitored by particle count analysis. The levels
“Lubricant Viscosities Table” for the proper oil to use of contamination should not exceed the normal
in your machine. by more than two ISO codes. Action should be
taken in order to determine the cause of the
Note: Industrial hydraulic oils are not recommended contamination. The system should be returned to
in Caterpillar hydraulic systems. the original levels of contamination.
Procedure for Changing the 5. Inspect the gasket on the hydraulic tank Þller cap
for damage. Replace the gasket, if necessary.
Hydraulic Oil
NOTICE
Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the ßuid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing ßuids.
NOTICE
Never start the engine while the hydraulic oil tank is
being drained or while the hydraulic oil tank is empty.
Excessive wear and damage to the hydraulic compo-
nents can occur.
12. Start the engine and run the engine for at least ten
seconds. Then, stop the engine and add hydraulic
oil to the tank until the oil level is at the “FULL”
mark on the sight gauge. Install the Þller cap.
13. Start the engine and run the engine at low idle.
Cycle the implements so that all hydraulic systems
are Þlled with oil.
14. Add hydraulic oil to the tank until the oil level is at
the “FULL” mark on the sight gauge.
Hydraulic System Oil Filter - 2. Clean the Þlter mounting bases. Make sure that all
of the used seals are completely removed.
Replace
SMCS Code: 5068-510
NOTICE
Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the ßuid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing ßuids.
Dispose of all ßuids according to local regulations and 3. Apply a thin coat of clean hydraulic oil to the seals
mandates. on the new Þlters. Install each new hydraulic Þlter
hand tight until the seals of the hydraulic oil Þlters
contact each base. Note the position of the index
marks on each Þlter in relation to a Þxed point on
each Þlter base.
176 SEBU7889-15
Maintenance Section
Hydraulic System Oil Level - Check
Note: There are rotation index marks on each The lift arms must be lowered with the bucket ßat in
hydraulic oil Þlter that are spaced 90 degrees or 1/4 order to check the hydraulic oil. Check the hydraulic
or a turn away from each other. When you tighten oil level while the engine is stopped. Maintain the oil
the hydraulic oil Þlters, use the rotation index marks level above the “ADD COLD” mark on sight gauge
as a guide. (2). If necessary, remove Þller cap (1) slowly and add
oil.
4. Tighten each Þlter according to the instructions
that are printed on each Þlter. Use the index marks
i02223893
as a guide. For non-Caterpillar Þlters, use the
instructions that are provided with the Þlters. Hydraulic System Oil Sample
Note: You may need to use a Caterpillar strap - Obtain
wrench, or another suitable tool, in order to turn
the Þlters to the amount that is required for Þnal SMCS Code: 5050-008; 5056-008; 7542
installation. Make sure that the installation tool does
not damage the Þlters.
i03696955
g01122430
Illustration 236
g01988179
Illustration 235
i02223896
g01962679
Illustration 238
i02106227
The hydraulic tank breaker relief valve is located on Inspect a Used Filter for Debris
the top of the hydraulic tank behind the cab of the
machine.
g00718871
Illustration 240
i01442049
i02894326
g00101939
Illustration 244
i03657286
g01152685
Illustration 249
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
g00932801
Illustration 248
Consult your Caterpillar dealer for the replacement of
Typical example the seat belt and the mounting hardware.
Check the seat belt mounting hardware (1) for wear If your machine is equipped with a seat belt
or for damage. Replace any mounting hardware that extension, also perform this replacement procedure
is worn or damaged. Make sure that the mounting for the seat belt extension.
bolts are tight.
Check buckle (2) for wear or for damage. If the buckle i03694709
is worn or damaged, replace the seat belt.
Secondary Steering - Test
Inspect the seat belt (3) for webbing that is worn or
frayed. Replace the seat belt if the seat belt is worn SMCS Code: 4300-081-SE; 4300-081-SST;
or frayed. 4324-081; 4324
If your machine is equipped with a seat belt Test the service brake before you test the supple-
extension, also perform this inspection procedure for mental steering system.
the seat belt extension.
182 SEBU7889-15
Maintenance Section
Service Brake Wear Indicator - Check
If there is no response to the steering input, the 1. Hold the steering wheel with both hands.
supplemental steering system is not operating. Stop
the machine immediately. Repair the supplemental 2. Try to move the steering wheel from one side to
steering system before returning the machine to the other side. The maximum allowed movement
service. in the steering column should not exceed 25 mm
(1.0 inch). If the value is not within the limit,
perform the following steps:
i02197967
Service Brake Wear Indicator - a. Inspect the pivot joint for loose bolts.
Check b. Tighten the bolts if the bolts are loose.
SMCS Code: 4255-535-IND Note: Apply 9S-3263 Thread Lock Compound to
the bolts before tightening.
Reference: For information about checking the
service brake wear indicator, refer to Testing and c. Inspect the pivot joint for excessive wear.
Adjusting, “Braking System” for the machine that is
being serviced or consult your Caterpillar dealer. d. Replace the bushings if there is excessive
wear.
i02585698
g00812993
Illustration 251
2. Wipe off all of the Þttings before any lubricant is Illustration 252
g01350605
applied.
HMU in the articulation joint
i02690920
g01136858
Illustration 254
(1) Location of the grease Þttings for the rod ends
(2) Remote location of the grease Þttings for the head ends
g01350606
Illustration 253
(1) HMU
(2) Bolts
(3) Steering Column
i02399608
SMCS Code: 4304-070-Z3; 4304-510-Z3 7. Install two connectors (2) and two hoses (1).
i02305841
Personal injury can result from working with Tire Inßation - Check
cleaning solvent.
SMCS Code: 4203-535-AI
Because of the volatile nature of many cleaning
solvents, extreme caution must be exercised
when using them. If unsure about a particular
cleaning ßuid, refer to the manufacturer's instruc-
tions and directions.
g01160201
Illustration 258
g00765737
Illustration 257
i03347900
NOTICE
Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the ßuid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing ßuids.
NOTICE
Do not drop or rap the magnets against any hard sur-
face. Replace any damaged magnets.
g00766059
Illustration 259
Typical example 8. Clean the cover and inspect the cover seal.
Replace the seal, if necessary.
Note: Remove the bolts (1) that hold the transmission
guard (2). Remove the transmission guard on the 9. Install three magnets (5) on the tube. Insert
underside of the machine in order to access the suction screen (4) and tube (6) in the housing.
magnetic strainer.
10. Install the cover and the cover bolts.
i02225200
NOTICE
Care must be taken to ensure that ßuids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the ßuid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing ßuids.
5. Use a strap type wrench to remove the Þlter 2. Park the machine on a hard, level surface. Put the
housing. transmission control into the NEUTRAL position.
Lower the bucket to the ground with a slight
6. Remove the used Þlter element. Dispose of the downward pressure. Engage the parking brake.
used Þlter element properly.
Note: Before the machine is started, the transmission
7. Clean the Þlter housing and the Þlter housing base oil level should be above “MIN START” mark (1) on
with a clean, nonßammable solvent. the upper end of the sight gauge.
8. Inspect the Þlter housing seal. Replace the seal 3. Check the oil level while the engine is running at
if the seal is damaged. low idle.
9. Install a new Þlter element into the transmission While the engine is running at low idle, the
Þlter housing. Clean the Þlter housing drain plug transmission oil level should be between the “MIN”
and install the drain plug. mark (3) and the “MAX” mark (2).
10. Start the engine. Slowly operate the transmission 4. If necessary, remove the Þller cap and add oil.
controls in order to circulate the transmission oil.
Check the machine for oil leaks.
i02195036
i01468938
NOTICE
Care must be taken to ensure that ßuids are contained
Transmission Oil Level - Check during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
SMCS Code: 3030-535-FLV collect the ßuid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing ßuids.
g00766406
Illustration 263
i02266578
NOTICE
g00766456
When operating in freezing temperatures, use Illustration 266
Caterpillar nonfreezing window washer solvent or
equivalent. System damage can result from freezing. Inspect the wiper blades. Replace the wiper blades if
the wiper blades are worn or damaged or if streaking
occurs.
i00037755
Windows - Clean
SMCS Code: 7310-070
g01136879
Illustration 265