Professional Documents
Culture Documents
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Hydraulic System Oil Level - Check ..................... 94 Seat Belt - Inspect ................................................ 98 Transmission Oil Level - Check .......................... 106
When Required
Battery - Recycle .................................................. 68 Battery, Battery Cable or Battery Disconnect Switch Replace ............................................................... 68 Condenser (Refrigerant) - Clean .......................... 71 Cutting Edges and End Bits - Inspect/Replace ..... 77 Engine Air Filter Primary Element - Clean/ Replace ............................................................... 78 Engine Air Filter Secondary Element - Replace ... 79 Engine Air Precleaner - Clean .............................. 80 Ether Starting Aid Cylinder - Replace ................... 83 Fuel System - Prime ............................................. 86 Fuses and Circuit Breakers - Replace/Reset ........ 90 Oil Filter - Inspect .................................................. 96 Radiator Core - Clean ........................................... 96 Radiator Pressure Cap - Clean/Replace .............. 96 Ripper Tip and Shank Protector - Inspect/ Replace ............................................................... 97 Window Washer Reservoir - Fill .......................... 108 Window Wipers - Inspect/Replace ...................... 109 Windows - Clean ................................................. 109
Initial 500 Hours (for New Systems, Relled Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 76
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Every Year
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 76
Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................... 98
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Battery - Recycle
SMCS Code: 1401-561 Always recycle a battery. Never discard a battery. Always return used batteries to one of the following locations:
In order to test the alarm for proper functioning, turn engine start switch (1) to the ON position. Apply both brakes (2). Disengage parking brake (3). Move transmission control lever (4) to the REVERSE position. The backup alarm should sound immediately. The alarm alerts the personnel behind the machine that the machine is backing up. The backup alarm will continue to sound until transmission control lever (4) is moved to the NEUTRAL position or to the FORWARD position. The backup alarm is at the rear of the machine. The nonadjustable backup alarm is set at the appropriate sound level when the machine is shipped from the factory.
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Battery - Inspect
SMCS Code: 1401-040 Tighten the battery retainers on all batteries at every 1000 hour interval. Perform the following procedures at every 1000 hour interval. Check these areas more often, if necessary. 1. Open the battery access cover. The battery access cover is located on the left side or right side of the machine next to the operators compartment. 2. Clean the top of the batteries with a clean cloth. Keep the terminals clean and coated with petroleum jelly. Install the terminal covers after you coat the terminals.
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Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Inspect
1. Open the engine access doors on both sides of the machine, as needed. Note: Even if only one belt is worn or damaged, replace the belts in sets. 2. Inspect the condition of the fan drive belt, the alternator and water pump belt, and the air conditioning compressor belt. The belts should deect 14 to 20 mm (.56 to .81 inch) under 110 N (25 lb) of force. Use a 144-0235 Belt Tension Gauge in order to measure the tension.
Adjust/Replace
Illustration 84 Air conditioning compressor belt (A) Front view (B) Rear view
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1. Loosen bolts (1). 2. Turn adjusting nut (2) until the correct belt tension is reached. To achieve the correct belt adjustment, move the compressor inward or move the compressor outward, as required. 3. Tighten bolts (1). Tighten adjusting nut (2). 4. Close the access doors.
Illustration 83 Alternator and fan drive
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Note: Use the same procedure in order to replace the belts. Note: If new belts are installed, check the belt adjustment again after 30 minutes of engine operation.
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1. Loosen bolts (1). 2. Loosen adjusting nuts (2). To achieve the correct belt adjustment, move the alternator inward or move the alternator outward, as required. Tighten adjusting nuts (2). 3. Tighten bolts (1).
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Illustration 85
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on the gauges, broken indicator lights, broken switches, and other broken components in the cab.
Start the engine. Check the monitor panel for proper operation. See
Operation and Maintenance Manual, Monitoring System. covers or around the hoses.
Illustration 86
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1. Lubricate the three ttings on the left side of the machine. 2. Lubricate the three ttings on the right side of the machine.
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Check for oil leaks. Repair any oil leaks around the Look for inoperative gauges. Turn on all machine lights. Check for proper
operation.
Sound the forward horn. Move the machine forward and test the service
brakes. If the service brakes malfunction, consult your Caterpillar dealer for repairs. forward in order to test the parking brake. If the parking brake malfunctions, consult your Caterpillar dealer for repairs.
Illustration 87
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Lubricate the grease ttings. Lubricate two ttings on each tilt brace, as needed.
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Illustration 88
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1. Remove the cover for the condenser. 2. Inspect the condenser for debris. Clean the condenser, if necessary. 3. Use clean water to wash all of the dust and dirt from the condenser. 4. Install the cover for the condenser.
Illustration 89
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3. Route the drain hose through the left hole in the radiator guard in order to drain the coolant. Direct the drain hose into a suitable container.
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Illustration 92
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Personal injury can result from hot coolant, steam and alkali. At operating temperature, 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. Remove ller cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes. 1. Slowly loosen ller cap (1) in order to relieve system pressure. Remove the ller cap. 2. The drain valve for coolant is located under the left side of the radiator. Open the left engine access door in order to properly access radiator drain valve (2).
4. Open the drain valve. Allow the coolant to drain into a suitable container. 5. Flush the system with water. Flush the system until the draining water is clear. Note: If the cooling system is already using ELC, cleaning agents are not required to be used at the specied coolant change interval. Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage. Clean water is the only cleaning agent that is required when ELC is drained from the cooling system. Note: If you change to an ELC from another type of coolant, use a Caterpillar cleaning agent to ush the cooling system. After you drain the cooling system, thoroughly ush the cooling system with clean water. All of the cleaning agent must be removed from the cooling system.. 6. Close the radiator drain valve completely. 7. Replace the drain hose inside the radiator guard.
Capacities (Rell)
Note: Caterpillar antifreeze contains additive. If you are using Caterpillar antifreeze, do not add the supplemental coolant additive at this time. Also, do not change the supplemental coolant additive element at this time.
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2. Start the engine. Run the engine without the ller cap until the thermostat opens and the coolant level stabilizes. 3. Maintain the coolant level at 13 mm (0.5 inch) from the bottom of the ller tube. Add coolant to the ller tube, if necessary. 4. If the gasket is damaged, replace the ller cap. Install the ller cap. 5. Stop the engine.
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Illustration 93
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RECOMMENDED AMOUNT OF EXTENDER BY COOLING SYSTEM CAPACITY Cooling System Capacity 22 to 30 L (6 to 8 US gal) 30 to 38 L (8 to 10 US gal) 38 to 49 L (10 to 13 US gal) 49 to 64 L (13 to 17 US gal) 65 to 83 L (17 to 22 US gal) Recommended Amount of Extender 0.57 L (0.60 qt) 0.71 L (0.75 qt) 0.95 L (1 qt) 1.18 L (1.25 qt) 1.60 L (54 oz)
6. Clean the radiator cores with compressed air. You may need to use water in order to remove debris. 7. Close the engine access door. For additional information about the cooling system coolant, see Operation and Maintenance Manual, SEBU6250, Caterpillar Machine Fluids Recommendations, Cat Extended Life Coolant (ELC) or consult your Caterpillar dealer.
When a Caterpillar Extended Life Coolant (ELC) is used, an extender must be added to the cooling system. See the Operation and Maintenance Manual, Maintenance Interval Schedule for the proper service interval. The amount of extender is determined by the cooling system capacity. For additional information about adding an extender, see Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure.
Illustration 94
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1. The ller cap is located on the top of the engine enclosure. Slowly loosen the ller cap in order to relieve the pressure. Remove the cap. 2. Add the proper amount of ELC Extender. Add ELC (Extended Life Coolant). Drain some coolant from the radiator into a suitable container in order to allow space for the extra ELC. Reference: See Capacities (Rell) in this publication for more information on system capacity. Note: Always discard drained uids according to local regulations. 3. Start the engine. Run the engine without the ller cap until the thermostat opens and the coolant level stabilizes. Check for leaks. 4. Check the coolant level. If necessary, add premixed coolant in order to correct the coolant level. 5. Inspect the ller cap gasket. Replace the ller cap if the gasket is damaged. 6. Install the ller cap.
Illustration 95
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1. Open the radiator access cover on top of the engine enclosure. 2. Remove the cooling system pressure cap slowly in order to relieve the pressure. 3. Maintain the coolant level at 13 mm (0.5 inch) from the bottom of the ller pipe. If it is necessary to add coolant daily, check the system for leaks. 4. Install the cooling system pressure cap. Close the radiator access cover. 5. Inspect the radiator core for debris. Clean the radiator core, if necessary. Reference: See Radiator Core - Clean in the Maintenance Section of this publication for more information.
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2. The cooling system pressure cap (1) is located on the top of the radiator. Remove the cooling system pressure cap slowly in order to relieve system pressure. 3. Obtain the coolant sample from radiator ller pipe (2). Collect the sample into the proper sampling bottle. Note: Always discard drained uids according to local regulations. Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of SOS analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:
Keep the unused sampling bottles stored in plastic Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples from any other location. are ready to collect the sample.
Keep the lids on empty sampling bottles until you Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid contamination.
Never collect samples from expansion bottles. Never collect samples from the drain for a system.
4. Maintain the coolant level at 13 mm (0.5 inch) from the bottom of the ller pipe. 5. Install cooling system pressure cap (1) onto radiator ller pipe (2). Close the radiator access cover on top of the engine enclosure. Submit the sample for Level 1 analysis.
Illustration 96
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For additional information about coolant analysis, see Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
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Note: Always discard drained uids according to local regulations. Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of SOS analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:
Keep the unused sampling bottles stored in plastic Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples from any other location. are ready to collect the sample.
Keep the lids on empty sampling bottles until you Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid contamination.
Never collect samples from expansion bottles. Never collect samples from the drain for a system.
4. Maintain the coolant level at 13 mm (0.5 inch) from the bottom of the ller pipe. 5. Install cooling system pressure cap (1) onto radiator ller pipe (2). Close the radiator access cover on top of the engine enclosure. Submit the sample for Level 2 analysis. For additional information about coolant analysis, see Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
Illustration 97
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1. Open the radiator access cover on top of the engine enclosure. 2. The cooling system pressure cap (1) is located on the top of the radiator. Remove the cooling system pressure cap slowly in order to relieve system pressure. 3. Obtain the coolant sample from radiator ller pipe (2). Collect the sample into the proper sampling bottle.
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NOTICE Since Caterpillar engines incorporate a shunt design cooling system, it is mandatory to always operate the engine with a thermostat. Depending on load, failure to operate with a thermostat could result in either an overheating or an overcooling condition. NOTICE If the thermostat is installed incorrectly, it will cause the engine to overheat. 4. Install a new seal in the thermostat housing. Install a new thermostat and a new gasket. Install the thermostat housing on the engine cylinder head. 5. Install the elbow and the hose. Tighten the hose clamp. 6. Close the left engine access door (if equipped).
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1. Open the left engine access door (if equipped). 2. Remove the bolts from the elbow. Remove the elbow and the thermostat housing assembly. 3. Remove the gasket, the thermostat, and the seal from the thermostat housing.
Illustration 99
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1. Raise the bulldozer blade and block up the bulldozer blade. When you remove the cutting edges and the end bits, maintain the bulldozer blade at a minimum height.
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2. Remove the bolts. Then remove the cutting edge and the end bits. 3. Thoroughly clean all contact surfaces. 4. Inspect the opposite side of the cutting edge. If the opposite side of the cutting edge is not worn, turn the opposite side of the cutting edge outward and install the cutting edge. 5. If both sides of the cutting edge are worn, install a new cutting edge section. 6. Repeat Steps 4 and 5 for the end bits. 7. Install all bolts and tighten the bolts to the specied torque. Reference: For more information, refer to Specications, SENR3130, Torque Specications. 8. Raise the bulldozer blade and remove the blocking. Lower the bulldozer blade to the ground. 9. After you operate the machine for a few hours, check all bolts for the proper torque.
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Illustration 101
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3. Remove the primary lter element from the air cleaner housing.
4. Clean the inside of the air cleaner housing. 5. Inspect the primary element. If the pleats, the gaskets, or the seals are damaged, discard the element. Replace a damaged primary element with a clean primary element. NOTICE Do not clean the lter elements by bumping or tapping them. Do not use lter elements with damaged pleats, gaskets or seals. Engine damage can result. Make sure the cleaned lter elements are completely dry before installing into the lter housing. Water remaining in the elements can cause false indications of contamination in Scheduled Oil Sampling test results. 6. If the primary element is not damaged, clean the primary element. The lter elements can be cleaned by using the following methods:
Illustration 100
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Pressure air
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Illustration 103
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7. When you clean the inside pleats and the outside pleats, direct the air along the pleats or direct the water along the pleats. The element can be washed in a solution that consists of warm water and of nonsudsing household detergent. Fully rinse the pleats. Allow the lter to air dry completely. 8. Inspect the lter elements after you clean the lter elements. Do not use a lter if the pleats, the gaskets or the seals are damaged. 9. Cover the clean lter elements. Store the elements in a clean, dry location. A primary element may be cleaned for a maximum of six times. Also replace the primary element if the primary element has been used for one year. 10. Install a clean primary lter element. 11. Clean the cover and install the cover. 12. Close the access door (if equipped). 13. Reset lter element indicator (1) that is located in the cab (if equipped). Start the engine. If the yellow piston in the lter element indicator moves into the red zone, install a new primary lter element. Also if the exhaust smoke is black, install a new primary lter element.
Illustration 104
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5. Remove the secondary lter element. Pull out in order to remove the element.
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6. Install a new secondary lter element. Push the element rmly in order to properly seat the element. Write the date on the element, if the element is replaced. 7. Install the primary lter element and the air cleaner housing cover. 8. Close the engine access door, if equipped.
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1. Loosen breather outlet hose clamp (2) and remove the hose from the breather cover. 2. Loosen the breather retaining bolt (1) and remove breather (3). 3. Inspect the breather seal. Replace the breather seal if the breather is damaged. 4. Wash the breather in clean, nonammable solvent. 5. Use pressure air to dry. 6. Install clean breather (3). 7. Tighten breather retaining bolt (2) to a torque of 14 3 Nm (10 2 lb ft).
Illustration 105
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8. Install the hose to breather (3) and tighten hose clamp (2).
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1. Inspect the cup visually. The cup should be emptied whenever dirt reaches the indicator mark. 2. Loosen the wing nut on the top of the precleaner. Remove the cover and the cup. Empty and clean the cup. Clean the cover. 3. Install the cup and the cover. Finger tighten the wing nut. Do not use a tool.
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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. NOTICE Do not under ll or overll engine crankcase with oil. Either condition can cause engine damage. 1. Open the engine access door on the left side of the machine (if equipped).
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2. Check dipstick (2) while the engine is running at LOW IDLE WITH WARM OIL. The oil should be at operating temperature. Maintain the oil level between the ADD mark and the FULL mark. This is the only accurate way to check the oil level. Check dipstick (2) with the ENGINE STOPPED AND COLD OIL. The oil should be cold. Maintain the oil level in the SAFE STARTING RANGE. This method should be used as reference only, before the engine is started. Note: When you operate the machine on severe slopes, the oil level in the engine crankcase must be at the FULL mark on the LOW IDLE side of dipstick (2). 3. Remove oil ller cap (1). If necessary, add oil. 4. Clean the oil ller cap and install the oil ller cap. 5. Close the engine access door (if equipped).
1. Remove the crankcase drain valve access cover, which is in the crankcase guard.
Illustration 109
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2. Remove the drain plug. Then, open drain valve (1). Allow the oil to drain into a suitable container. 3. Close the drain valve after all of the oil has drained. Install the drain plug. 4. Install the crankcase drain valve access cover. 5. Open the left engine access door (if equipped).
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To prevent possible injury, do not use the starter motor to turn the ywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before measuring valve clearance.
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Illustration 110
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6. Remove the used crankcase oil lter element. Make sure that all of the old lter seal is removed from the lter base. 7. Apply a thin lm of clean engine oil to the new lter seal. 8. Install the new oil lter elements by hand. Instructions for the installation of the lters are printed on the side of each Caterpillar spin-on lter. For non-Caterpillar lters, refer to the installation instructions that are provided by the supplier of the lter. 9. Remove the oil ller cap. Fill the crankcase with new oil. See Operation and Maintenance Manual, Capacities (Rell) . Clean the oil ller cap and install the oil ller cap. 10. Always measure the oil level with the dipstick in order to ensure that the correct amount of oil was added. 11. On the dipstick, maintain the oil level between the ADD mark and FULL mark. 12. Close the left engine access door.
NOTICE Operation of Caterpillar engines with improper valve adjustments will reduce engine efciency. This reduced efciency could result in excessive fuel usage and/or shortened engine component life. NOTICE Measure the valve clearance with the engine stopped. To obtain an accurate measurement, allow at least 20 minutes for the valves to cool to engine cylinder head and engine block temperature. Check the valve bridge before setting the valve lash. Ensure that the valve bridge is seated equally on both valve stems. Refer to your machines Service Manual or your Caterpillar dealer for the complete valve adjustment procedure.
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Illustration 111
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Illustration 113
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3. Watch the top surface on each valve rotator. The rotator should turn slightly. If a valve fails to rotate, consult your Caterpillar dealer.
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2. Inspect the rubber pads. Replace the rubber pads if the rubber pad is cracked. Replace the rubber pads if the rubber pad is starting to peel. Install the guards. Consult your Caterpillar dealer for replacements.
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Illustration 112
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Illustration 114
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Illustration 115
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2. Loosen the cylinder retaining clamp from the support that is bolted to the cylinder block casting. Unscrew and remove empty ether starting aid cylinder (not shown). 3. Remove the used gasket. Install the new gasket that is provided with each new ether starting aid cylinder. 4. Install the new ether starting aid cylinder. Tighten the ether starting aid cylinder by hand. Tighten the cylinder retaining clamps securely. 5. Close the left engine access door.
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Illustration 117
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Illustration 118 Rear view Some components are removed for clarity.
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Illustration 116
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.
Illustration 119
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2. Remove the drain plug. Drain the oil in a suitable container. 3. Install the drain plug. 4. Maintain the oil level to the bottom of the plug. 5. Clean the ller plug. Install the ller plug. 6. Repeat the procedure for the other nal drive.
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Illustration 120 Rear view Some components are removed for clarity.
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1. Remove the oil ller plug on the inside of the case and frame. 2. Check the oil level. Oil should be to the bottom of the ller plug opening. If necessary, add oil to the nal drive. 3. Install the ller plug. Repeat this procedure for the other nal drive.
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1. Turn the priming pump plunger to the left. This will unlock the priming pump. 2. Operate the pump until a slight pressure is felt. 3. Turn the priming pump plunger to the right. This will lock the priming pump. 4. Start the engine. Inspect the fuel priming pump for leaks.
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Illustration 121 Rear view of the case and frame Oil sampling
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1. Remove the oil ller plug and obtain the oil sample with a proper suction device. Use a 1U-7683 Suction Gun or use an equivalent pump such as 1U-5718 Vacuum Pump to take the oil sample. 2. Install the oil ller plug. 3. Repeat Step 1 to Step 2 in order to sample the oil in the other nal drive. Refer to Special Publication, PEHP6001 for more information on obtaining a good oil sample. Consult your Caterpillar dealer for complete information and assistance in establishing an SOS program for your machine.
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Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. To help prevent possible injury, turn the start switch off when changing fuel lters or water separator elements. Clean up fuel spills immediately. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.
Illustration 122
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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.
Illustration 123
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1. Open the engine access door on the right side of the machine.
Personal injury or death can result from engine overspeed. If the engine overspeeds, it can cause injury or parts damage. Be prepared to stop the engine by closing the air off to the air inlets or by manually pushing downward on the governor shutdown rod.
Personal injury or death can result from a re. Fuel leaked or spilled onto hot surfaces or electrical components can cause a re.
Illustration 124
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Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel lters. NOTICE Do not ll fuel lter with fuel before installing the fuel lter. Contaminated fuel causes accelerated wear to fuel system parts.
2. Extend drain hose (2) into a suitable container. Drain (1) is located under the primary fuel lter/water separator. 3. Open drain (1). Allow the uid to drain into the container. 4. After the separator is completely drained, close drain (1) by hand pressure only. Dispose of the drained uid in a safe place.
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3. Remove water collection bowl (1). Unscrew the bowl from element (2). 4. Loosen element (2) from base (3). Remove the element. 5. Install new element (2) onto mounting base (3). 6. Clean the water collection bowl. Install bowl (1) on new element (2). Note: The water collection bowl is reusable. When you can no longer see the contents of the water collection bowl, replace the water collection bowl. 7. Open the fuel shutoff valve at the rear of the machine. 8. Prime the fuel system.
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Illustration 125
9. Prime the fuel system. See the Operation and Maintenance Manual, Fuel System - Prime.
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Illustration 126
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1. Open the engine access door on the right side of the machine. 2. Locate the fuel shutoff valve under the fuel tank at the rear of the machine. Turn the handle of the fuel shutoff valve counterclockwise in order to shut off the fuel supply.
Illustration 128
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1. Remove the lter and properly discard the lter. 2. Clean the lter mounting base. Remove all of the old seal. Coat the seal of the new lter with clean diesel fuel. 3. Install the new lter by hand. When the seal contacts the base, tighten 3/4 turn more. 4. Open the fuel supply valve.
Illustration 127
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Illustration 131
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6. Remove the strainer. 7. Wash the strainer in clean, nonammable solvent. 8. Install the strainer.
Illustration 129 Left side view
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1. Remove the lock, if necessary. To remove fuel cap (1), lift up on the lever. Turn the lever to the left until the lever stops. Remove the cap.
Illustration 130
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2. Rotate the fuel cap clockwise until three tabs (6) drop in slots in the adapter. Rotate the lever (4) clockwise until the lever stops. Lower lever (4) over locking tab (5). 3. Replace the lter in the fuel cap. 4. To replace the lter, remove two screws that secure lter (3) to the fuel cap. Remove lter (3), valve (2), and the gaskets. 5. Install new components in the reverse order.
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NOTICE If it is necessary to replace fuses frequently, an electrical problem may exist. Contact your Caterpillar dealer.
Illustration 133
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2. Open the drain valve and allow the moisture and sediment to drain. 3. Close the drain valve. 4. Close the access cover.
Illustration 134
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Open the access door on the left side of the machine to the circuit breakers and the fuses.
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Wipers (10) 20 Amp Gauge (11) 5 Amp Fault Alarm (12) 5 Amp Blower (13) 20 Amp
Circuit Breaker
Illustration 135
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Fuses
Illustration 137
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Circuit Breaker/Reset The 80 Amp main circuit breaker is the only circuit breaker. Push in the button in order to reset the circuit breaker. If the electrical system is working properly, the button will remain depressed. Note: If the button does not remain depressed, check the appropriate electrical circuit. Repair the electrical circuit, if necessary.
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Horn - Test
Illustration 136 Fuse panel block
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SMCS Code: 7402-081 Test the horn on a daily basis. Press downward on the horn button in order to sound the horn. If the horn does not sound, make the necessary repairs before you operate the machine.
Ignition Key (1) 10 Amp Flood Lights (Front) (2) 15 Amp Refrigerant Condenser (3) 15 Amp Operator Monitor (4) 5 Amp Forward Horn (5) 10 Amp Flood Lights (Rear) (6) 10 Amp Refrigerant Condenser (7) 15 Amp Gauge (8) 10 Amp Dome Light (9) 15 Amp
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Illustration 139
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1. To relieve the tank pressure, slowly remove hydraulic oil ller cap (1).
Illustration 138
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The hydraulic control linkage is located on the right side of the machine. Lubricate two ttings.
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2. Open the oil drain valve under the hydraulic oil tank and drain in a suitable container. 3. Close the valve.
Illustration 141
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Illustration 142
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4. Open the right side access door. Change hydraulic oil lter (3). Refer to Operation and Maintenance Manual, Hydraulic System Oil Filter - Replace. 5. See Operation and Maintenance Manual, Capacities (Rell) in order to determine the amount of hydraulic oil that is needed to ll the hydraulic oil tank. Fill the hydraulic oil tank. 6. Inspect the ller cap gasket. Replace the gasket if the gasket is worn or damaged. 7. Install the oil ller cap. 8. Start the engine. Run the engine for a few minutes. 9. Stop the engine. 10. Maintain the oil level to the FULL mark (2) in the sight gauge. See Illustration 142. Add oil, if necessary. 11. Close the right side access door.
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Illustration 143
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Illustration 144
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1. To relieve the tank pressure, slowly remove hydraulic oil ller cap (1).
Illustration 145
2. Open the right side access door. Remove the hydraulic oil lter element and lter housing(3).
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3. Remove the used lter element from the housing. Properly discard the lter element. 4. Clean the inside of lter housing (3) with a clean cloth. 5. Install the new hydraulic oil lter element. 6. Clean hydraulic oil ller cap (1) in a clean nonammable solvent. Install the cap. 7. Maintain oil level to the FULL mark (2) in the sight gauge. 8. Close the right side access door. 9. Start and run the engine at LOW IDLE for a few minutes. 10. Stop the engine.
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Illustration 147
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1. Maintain the oil level to the FULL mark (2) on the sight gauge. 2. Remove hydraulic oil ller cap (1) and add the oil, if necessary. 3. Clean the hydraulic oil ller cap. Install the cap.
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.
Illustration 146
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The hydraulic oil tank is located on the right side of the rear of the machine.
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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the ller cap only when the engine is stopped, and the ller cap is cool enough to touch with your bare hand. Remove the ller cap slowly in order to relieve pressure. 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 incorrect interpretation that could lead to concerns by both dealers and customers. Obtain a sample of the hydraulic oil from the hydraulic tank. The hydraulic tank is located on the right side of the rear of the machine.
Illustration 148
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1. Remove hydraulic tank ller cap (1) slowly in order to relieve any pressure. 2. Remove the ller strainer (not shown). Use a 1U-5718 Vacuum Pump or an equivalent pump. Insert the suction tube into the ller tube and draw a sample of the hydraulic system oil. 3. Replace the ller strainer and the hydraulic tank ller cap. The recommended interval for oil samples is every 500 hours. The recommended hydraulic oil change interval is 2000 hours. Reference: Refer to Lubricant Viscosities in the Maintenance Section of this publication for the correct uid for your machine. Reference: Refer to the Operation and Maintenance Manual, SOS Oil Analysis. Reference: Refer to Special Publication, PEHP6001 for more information on obtaining a good oil sample. Consult your Caterpillar dealer for complete information and assistance in establishing an SOS program for your machine.
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Use a lter cutter to cut the lter element open. Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the lter element can indicate a possible failure. If metals are found in the lter element, a magnet can be used to differentiate between ferrous metals and nonferrous metals. Ferrous metals can indicate wear on steel parts and on cast iron parts. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings, rod bearings, or turbocharger bearings. Small amounts of debris may be found in the lter element. This could be caused by friction and by normal wear. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. Using an oil lter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings, to the crankshaft, and to other parts. This can result in larger particles in unltered oil. The particles could enter the lubricating system and the particles could cause damage.
You can use compressed air, high pressure water, or steam to remove dust and other debris from the radiator core. However, the use of compressed air is preferred. See Special Publication, SEBD0518, Know Your Cooling System for the complete procedure for cleaning the radiator core.
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure.
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Tips
Illustration 151
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1. Open the access cover to the radiator cap on top of the engine enclosure. Slowly remove the radiator cap in order to relieve system pressure. 2. Inspect the radiator cap for damage, for deposits, or for foreign material. Clean the radiator cap with a clean cloth. Replace the radiator cap if the radiator cap is damaged. 3. Install the radiator cap.
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Illustration 153
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When the ripper tip is worn close to the shank, replace the ripper tip. If the tip is too blunt, the tip will not penetrate properly. 1. Raise the ripper. Place blocking under the ripper. Lower the ripper onto the blocking. The ripper should be high enough so that the ripper tip can be removed. Do not place the ripper too high. 2. If the ripper tip is worn, drive out pin (1). Remove tip (2) and the shank pin retainer. 3. Clean the shank pin retainer and the pin. 4. Install the new tip and the retainer. 5. Install pin (1) from the opposite side of the retainer. 6. Raise the ripper and remove the blocking. 7. Lower the ripper to the ground.
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Shank
Illustration 154
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When the ripper shank is worn or damaged, replace the ripper shank. 1. Raise the ripper. Place blocking under the ripper. Lower the ripper onto the blocking. The ripper should be high enough so that the ripper shank can be removed. Do not place the ripper too high. 2. If the shank is worn or damaged, remove cotter pin (3). Then drive out pin (4). Remove shank (5). 3. Install the new shank and pin (4). 4. Install cotter pin (3). 5. Raise the ripper and remove the blocking. 6. Lower the ripper to the ground.
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Check the seat belt mounting hardware (1) for wear or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting bolts are tight. Check buckle (2) for wear or for damage. If the buckle is worn or damaged, replace the seat belt. Inspect the seat belt (3) for webbing that is worn or frayed. Replace the seat belt if the seat belt is worn or frayed. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. Note: Within three years of the date of installation or within ve years of the date of manufacture, replace the seat belt. Replace the seat belt at the date which occurs rst. A date label for determining the age of the seat belt is attached to the seat belt, the seat belt buckle, and the seat belt retractor. If your machine is equipped with a seat belt extension, also perform this inspection procedure for the seat belt extension.
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Illustration 156 (1) (2) (3) (4) Date of installation (retractor) Date of installation (buckle) Date of manufacture (tag) (fully extended web) Date of manufacture (underside) (buckle)
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Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. If your machine is equipped with a seat belt extension, also perform this replacement procedure for the seat belt extension.
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Illustration 158
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Inspect the sprocket hub bearing on new machines. Inspect the sprocket hub bearing on reconditioned machines. See Operation and Maintenance Manual, Sprocket Hub Bearings - Adjust.
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Illustration 157
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Adjust the preload on the sprocket hub bearings. Refer to the Service Manual or consult your Caterpillar dealer.
Illustration 159
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Check for oil leaks on both sides of the sprocket. If the leakage is noticeable, the seals and/or bearings need to be replaced. Refer to the Service Manualfor this procedure. If the Service Manual is not available, contact your Caterpillar dealer.
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Check the bearing preload. The machine must be put on stands. With the machine off the ground, this will reduce the load on the sprockets. Refer to the Service Manual For this procedure. If the Service Manual is not available, contact your Caterpillar dealer.
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NOTICE Do not attempt to tighten the track when dimension (X) is less than 3 mm (0.12 inch). Consult your Caterpillar dealer for track service or instructions. 2. Measure the X dimension. 3. Stand on the track between the front idler and the track carrier roller in order to produce as much track sag as possible.
Track - Check/Adjust
SMCS Code: 4170-036
Grease is under high pressure. Grease coming out of the relief valve under pressure can penetrate the body causing injury or death. Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened. Loosen the relief valve only one turn.
Check
Check the track adjustment. Check the track for wear and for excessive dirt buildup. 1. Move the machine forward for a distance of two times the length of the machine. Stop the machine on a level surface without the use of the service brake. Lower all the implements. Apply slight down pressure to all the implements. Engage the parking brake lock lever. Place the transmission in NEUTRAL and stop the engine.
Illustration 161
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Points (1, 2) are above the centerlines when the machine is stopped.
4. Attach one end of a string to the grouser tip on the track shoe that is directly above track carrier roller (1). Make the string tight by pulling on the string. Attach the opposite end of the string to the grouser tip on the track shoe (2) that is directly above the front idler . 5. Measure the distance between the string and the tip of the grouser that is on the track shoe directly between the front idler and the track carrier roller in order to obtain dimension (A). 6. Dimension (A) should be approximately 50 mm (2.0 inch). If dimension (A) is not correct, adjust the track.
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Adjust
Grease is under high pressure. Grease coming out of the relief valve under pressure can penetrate the body causing injury or death. Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened. Loosen the relief valve only one turn. 1. Move the machine forward for a distance of two times the length of the machine. Allow the machine to a stop without the use of the service brakes. Shut off the engine. Adjust the tracks while you are in the machines typical operating conditions. If packing conditions prevail on the job, the tracks should be adjusted with packing material.
Illustration 163 (B) Mark on roller frame
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4. Mark the roller frame with a pencil or with a marking pen. Make a mark (B) that is 12 mm (0.50 inch) behind idler bearing support (5). This allows the necessary space for the front idler to retract. 5. Allow the idler to move back by opening relief valve (3) ONE TURN ONLY. Move the machine in REVERSE. This will help move the idler backward. 6. Close relief valve (3). 7. Add grease (MPGM) through adjusting valve (4) until the mark on roller frame (B) is aligned with the rear edge of idler bearing support (5). 8. Install the valve cover plate. Tighten the bolts to a torque of 75 15 Nm (55.5 11.0 lb ft). Note: The track sag after this adjustment procedure should be 50 mm (2.0 inch). If track sag is not 50 mm (2.0 inch), repeat the procedure. 9. Repeat the procedure on adjusting of the other track for the other side.
Illustration 162
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2. Remove the cover for the track adjusting mechanism. 3. Add grease (MPGM) through adjusting valve (4) in order to move the idler forward until the track is fully tight.
Illustration 164
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The torque requirement for track shoe bolts is 300 50 Nm (220 40 lb ft). Tighten the bolts for an additional 120 degrees. If you are using bolts with a master link, tighten the bolts to a torque of 300 50 Nm (220 40 lb ft). Then, tighten the master bolts for an additional 180 degrees.
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NOTICE Striking the end of a track pin introduces a signicant amount of end play into the track joint and can result in early failures. Consult your Caterpillar dealers Custom Track Service expert if you detect dry joints or leaks. Your Caterpillar dealers Custom Track Service expert can perform track inspection.
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Illustration 165
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The pins and bushings in a dry joint can become very hot. It is possible to burn the ngers if there is more than brief contact with these components. Use the recommendations in order to extend the life of the undercarriage. Use the recommendations in order to avoid excessive downtime. 1. During the machine operation, listen for unusual squeaking and for unusual squealing. This can indicate a dry joint. 2. Check the machine for dry joints weekly. Immediately after machine operation ,check for any dry joints. After machine operation, lightly touch the end of each track pin or bushing. Touch the track pin or the track bushing with the back of your hand. Make a mark on any dry track pin joint that is very hot to the touch. 3. Do not hit the ends of the track pins with a sledge hammer in order to loosen the track joints.
1. Lubricate the two inner bearings. The bearings are located on each roller frame.
Illustration 167
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2. Lubricate the two outer bearings. The bearings are located on each side of the machine.
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Illustration 170
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Illustration 171 Illustration 169 (1) Cover (2) Screen (3) Magnet assembly
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2. Remove cover (1). 3. Remove screen (2) and magnet assembly (3). 4. Wash the screen and the magnets in clean, nonammable solvent. Clean the magnets with a cloth, stiff bristle brush or pressure air. 5. Install the magnets. 6. Install the screen. 7. Inspect the spring and the seal. If the seal is damaged, install a new seal. 8. Install the cover and the oorplate.
Illustration 172 (A) Cold engine (B) Warm engine
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10. Open the door. Maintain the oil between the ADD mark and the FULL mark on transmission oil dipstick (4).
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11. Remove transmission oil ller cap (5). If necessary, add the oil. 12. Install the oil ller cap and close the door.
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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Operate the engine in order to warm the oil. Park the machine on level ground. Lower all attachments to the ground. Apply slight downward pressure. Engage the parking brake switch. Stop the engine.
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Illustration 174
2. Remove the access cover in the bottom guard assembly. Remove the oil drain plug from the torque converter housing. 3. Allow the oil to drain in a suitable container. 4. Clean the drain plugs. Install the drain plugs.
Drain Oil
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1. Remove the transmission oil drain plug from the bevel gear case. Drain the oil into a suitable container.
Illustration 175
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5. Remove cover (1) and screen (2) from the torque converter housing. 6. Clean the cover and the screen in nonammable solvent. 7. Install the cover and the screen. 8. Change the lter element. See Operation and Maintenance Manual, Transmission Oil Filter Replace.
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9. Clean the transmission magnetic screen. See Operation and Maintenance Manual, Transmission Magnetic Screen - Clean.
Fill Oil
Illustration 178
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3. Add oil. Maintain the oil level to the FULL mark on the dipstick. Note: To determine the correct amount of oil, see Operation and Maintenance Manual, Capacities (Rell).
Illustration 176
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1. Open the access door for the transmission oil ller cap. The access door is on the right side of the machine.
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4. Unscrew the transmission breather and remove the transmission breather. 5. Wash the transmission breather in a clean nonammable solvent.
Illustration 177
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6. Install the transmission breather. 7. Start the engine. Run the engine at LOW IDLE. 8. On the dipstick, maintain the oil level between the ADD mark and FULL mark. 9. Close the access door and stop the engine.
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2. Remove housing drain plug (2) and allow the oil to drain in a suitable container. 3. Remove housing cover (1).
Illustration 182
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4. Remove the used lter element from the housing. 5. Clean the inside of the housing with a clean cloth. 6. Clean the cover. Replace the damaged seal with a new seal. 7. Install the new lter element. 8. Install the housing cover. 9. Clean the drain plug and install the drain plug.
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The transmission oil dipstick is located on the right side of the machine.
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2. Measure the oil level with the engine at LOW IDLE. The oil should be at operating temperature. Maintain the oil level to the FULL mark on transmission oil dipstick (1). 3. Remove transmission oil ller cap (2). 4. Add oil, if necessary. Maintain the oil to the FULL mark on transmission oil dipstick (1). 5. Clean transmission oil ller cap (2). Install the cap. 6. Close the access door.
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1. Open the right side access door. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Illustration 184
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Illustration 186
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Illustration 188
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Window Washer The washer uid bottle is located on the rear of the machine above the fuel tank. Remove the uid bottle cap in order to ll the washer uid bottle.
Illustration 187
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2. Remove the transmission oil ller cap. Use a 1U-5718 Vacuum Pump or an equivalent pump. Insert the suction tube in the ller tube and draw an oil sample. 3. Replace the transmission oil ller cap on the ller tube. 4. Close the access door on the right side of the machine. Reference: Refer to , Lubricant Viscosities in the Maintenance Section of this manual for the correct uid for your machine. Reference: Refer to Special Publication, PEHP6001 for more information on obtaining a good oil sample. Consult your Caterpillar dealer for complete information and assistance in establishing an SOS program for your machine.
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Illustration 190
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Illustration 189
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Inspect the front windshield wiper blade and the rear windshield wiper blade. Replace any wiper blades that are damaged or worn. Replace any wiper blades that streak the windshield.
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Windows - Clean
SMCS Code: 7310-070; 7340-070 Use commercially available window cleaning solutions to clean the windows.