Vdocuments - MX - Manual Maintenance Interval Cat 416d 420d 42d 428d 430d 432d 442d Backhoe Loaders PDF

8/17/2019 Manual Maintenance Interval Cat 416d 420d 42d 428d 430d 432d 442d Backhoe Loaders
MAINTENANCE INTERVALS
Operation and Maintenance
Manual Excerpt
© 2010 Caterpillar ®
All Rights Reserved
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SEBU7821-04
June 2007
Operation and
Maintenance
Manual
416D, 420D, 424D, 428D, 430D, 432D
and 442D Backhoe Loaders
RXA1-Up (Machine)
BKC920-Up (Machine)
BMC1060-Up (Machine)
BXC1-Up (Machine)
B2D1-Up (Machine)
TBD1-Up (Machine)
BGJ1050-Up (Machine)
SMJ1-Up (Machine)
BNK5900-Up (Machine)
BML4800-Up (Machine)
MBM1-Up (Machine)
BLN10300-Up (Machine)
BFP12900-Up (Machine)
FDP18400-Up (Machine)
WEP1-Up (Machine)
TDR1-Up (Machine)
DSX1-Up (Machine)
CJZ1-Up (Machine)
128 SEBU7821-04
Maintenance Section
Maintenance Interval Schedule
i02738980 Stabilizer and Cylinder Bearings - Lubricate ....... 165

Swing Frame and Cylinder Bearings - Lubricate .. 166
Maintenance Interval Schedule Tire Inflation - Check ........................................... 166
Transmission Oil Level - Check .......................... 169
SMCS Code: 7000 Wheel Nut Torque - Check .................................. 170
Ensure that are

instructions all safety information,
read and warnings
understood before and
any Every 50 Service Hours or Weekly
operation or any maintenance procedures are Cab Air Filter - Clean/Replace ............................ 136
performed. Fuel Tank Water and Sediment - Drain ............... 156
Parking Brake - Check/Adjust ............................. 162
The user is responsible for the performance of
maintenance, including all adjustments, the use of Every 250 Service Hours or Monthly
proper lubricants, fl uids, fi lters, and the replacement
of components due to normal wear and aging. Failure Axle Breathers - Clean/Replace ......................... 130
to adhere to proper maintenance intervals and Axle Universal Joint (Rear) - Lubricate ............... 130
procedures may result in diminished performance of Belts - Inspect/Adjust/Replace ............................ 132
the product and/or accelerated wear of components. Differential Oil Level (Front) - Check .................. 143
Differential Oil Level (Rear) - Check ................... 144
Use mileage, fuel consumption, service hours, or Engine Oil Sample - Obtain ................................ 149
calendar time, WHICH EVER OCCURS FIRST, Extendable Stick Pads
Final Drive Oil - Inspect/Replace
Level (Front) ........... 152
- Check .................. 150
in order to determine the maintenance intervals.
Products that operate in severe operating conditions Final Drive Oil Level (Rear) - Check ................... 152
may require more frequent maintenance. Kingpin Bearings (Rear) - Lubricate ................... 160
Sideshift Stabilizer Wear Pads - Inspect ............. 165
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Initial 500 Hours (for New Systems, Refilled
performed. Systems, and Converted Systems)
When Required Cooling System Coolant Sample (Level 2) -

Obtain ............................................................... 141
Battery or Battery Cable - Inspect/Replace ........ 132
Bucket Cutting Edges - Inspect/Replace ............ 134 Every 500 Service Hours or 3 Months
Bucket Tips - Inspect/Replace ............................ 135
Cab Interior
Engine - Clean
Air Filter ............................................
Primary Element - Clean/ 137 Cooling
Obtain System Coolant Sample (Level 1) -
............................................................... 140
Replace ............................................................. 145 Differential Oil Sample (Front) - Obtain .............. 144
Engine Air Filter Secondary Element - Replace .. 147 Differential Oil Sample (Rear) - Obtain ............... 144
Engine Compartment - Clean ............................. 148 Drive Shaft Spline - Lubricate ............................. 145
Fuel System - Prime ........................................... 153 Engine Oil and Filter - Change ........................... 149
Fuses - Replace .................................................. 156 Final Drive Oil Sample (Front) - Obtain .............. 153
Oil Filter - Inspect ................................................ 162 Final Drive Oil Sample (Rear) - Obtain ............... 153
Radiator Core - Clean ......................................... 163 Fuel System Filter and Water Separator -
Window Washer Reservoir - Fill .......................... 170 Replace ............................................................. 154
Window Wipers - Inspect/Replace ...................... 171 Hydraulic Oil Sample - Obtain ............................ 157
Windows - Clean ................................................. 171 Hydraulic System Oil Filter - Replace ................. 159
Transmission Oil Filter - Replace ........................ 168
Every 10 Service Hours or Daily Transmission Oil Sample - Obtain ...................... 169
Backhoe Boom, Stick, Bucket, and Cylinder Bearings Every 1000 Service Hours
- Lubricate ......................................................... 131
Backup Alarm - Test ............................................ 131 Engine Valve Lash - Check ................................. 150
Brake Reservoir Oil Level - Check ...................... 133
Braking System - Test ......................................... 133 Every 1000 Service Hours or 6 Months
Cooling System Coolant Level - Check .............. 140
Engine Air Filter Service Indicator - Inspect ........ 147 Differential Oil (Front) - Change .......................... 142
Engine Oil Level - Check .................................... 148 Differential Oil (Rear) - Change .......................... 142
Fuel System Water Separator - Drain ................. 155 Final Drive Oil (Front) - Change .......................... 151
Hydraulic System Oil Level - Check ................... 160 Final Drive Oil (Rear) - Change .......................... 152
Loader Bucket, Cylinder, and Linkage Bearings - Rollover Protective Structure (ROPS) - Inspect .. 164
Lubricate ........................................................... 160 Transmission Magnetic Screen - Clean .............. 166
Seat Belt - Inspect .............................................. 164 Transmission Oil - Change ................................. 167
SEBU7821-04 129
Maintenance Section
Maintenance Interval Schedule
Wheel Bearings (Front) - Lubricate ..................... 169
Every 2000 Service Hours

Engine Crankcase Breather - Replace ............... 148
Every 2000 Service Hours or 1 Year

Hydraulic System Oil - Change ........................... 158
Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 141
Refrigerant Dryer - Replace ................................ 164
Every 3000 Ser vice Hours or 2 Years

Cooling System Water Temperature Regulator -
Clean/Replace .................................................. 141
Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 165
Every 3000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 139
Every 6000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 137
130 SEBU7821-04
Maintenance Section
Axle Breathers - Clean/Replace
i01981945 i01437649
Axle Breathers - Clean/Replace Axle Universal Joint (Rear) -

SMCS Code: 3278-070-BRE; 3278-510-BRE
Lubricate
(All Wheel Steer)
SMCS Code: 3251
g00833319
Illustration 224
The front axle breather is located on the top right side of the
differential housing.
g00753030
Illustration 225
1. Clean the area around the breathers. Remove the
breather from the front axle.
Note: Do not turn the adapter when you remove the

breather.
2. Wash the breather in clean non flammable solvent.

Wipe the breather dry and check the breather for
damage.
3. Install
Replace thethe
clean breather
breather if theback into the
breather axle.
is damaged.
Note: If the adapter is turned make sure that the slot

in the adapter is parallel to the axle housing. g00287244
Illustration 226
Apply lubricant to the grease fi ttings for the universal

joints of each drive shaft to the fi nal drives. There are
two grease fi ttings for each universal joint.
SEBU7821-04 131
Maintenance Section
Backhoe Boom, Stick, Bucket, and Cylinder Bearings - Lubricate
i01877901
Backhoe Boom, Stick, Bucket,

and Cylinder Bearings -
Lubricate
SMCS Code: 6501; 6502; 6503; 6510; 6511; 6512;
6513; 6533
g00723265
Illustration 229
Apply lubricant to the grease fi tting (9) for the head

end of the stick cylinder. Apply lubricant to the grease
fitting (8) for the rod end of the stick cylinder.
Apply lubricant to the grease fitting (10) for the pivot

pin for the stick.
g00723263
Illustration 227 Apply lubricant to the grease fi tting (7) for the head
end of the bucket cylinder. Apply lubricant to the
Position the backhoe into the service position that is grease fi tting (6) for the rod end of the bucket cylinder.
shown above.
Apply lubricant to the grease fi tting (11) for the pivot
pin. There is one grease fi tting on each side of the
machine.
Apply lubricant to the grease fi tting (4) for the bucket

pivot pin.
Apply lubricant to the grease fi tting (5) for the link.
Apply lubricant to the grease fitting (12) for the pivot

pin.
There is a total of thirteen grease fi ttings.
g00287247 i00080741
Illustration 228
Apply lubricant to the grease fitting (1) for the head Backup Alarm - Test
end of the boom cylinder. Apply lubricant to the
grease fi tting (2) for the rod end of the boom cylinder. SMCS Code: 7406
Apply lubricant to the grease fi tting (3) for the boom Turn the engine start switch key to ON in order to
pivot. There is one grease fi tting on each side of the perform the test.
machine.
Apply the service brake. Move the transmission
direction control lever to REVERSE position.
The backup alarm should immediately sound.

The backup alarm will continue to sound until the
transmission direction control lever is moved to the
NEUTRAL position or to the FORWARD position.
132 SEBU7821-04
Maintenance Section
Battery or Battery Cable - Inspect/Replace
i01833495 5. Stop the engine in order to inspect the belts.
Battery or Battery Cable -

Inspect/Replace
SMCS Code: 1401
1. Turn the engine start switch to the OFF position.

Turn all switches to the OFF position.
2. Disconnect the negative battery cable from the

frame.
Note: Do not allow the disconnected battery cable to

contact the frame of the machine.
g00731568
Illustration 230
3. Disconnect the negative battery cable at the
battery.
6. Remove the engine access panel on the left side
4. Inspect the battery terminals and inspect the of the machine.
battery cables. Keep the terminals clean and keep
the terminals coated with petroleum jelly.
5. Perform the necessary repairs. Replace the cable

or the battery, as needed.
6. Connect the negative battery cable at the battery.
7. Connect the battery cable to the frame of the

machine.
8. Install the engine start switch key.
i01981993
g01029695
Illustration 231
Belts - Inspect/Adjust/Replace
7. Inspect the condition of the air conditioner belt and
SMCS Code: 1357-025; 1357-040; 1357-510 the adjustment of the air conditioner belt. The air
conditioner belt should deflect 10 mm (0.38 inch)
If new belts are installed, check belt adjustment under 110 N (25 lb) of force.
after 30 minutes of operation. For multiple belt drive
applications, always replace the belts in matched 8. Loosen the adjusting locknut (1). Loosen the
sets. Replacing only one belt of a matched set will compressor bracket mounting bolt (2).
cause the new belt to carry more load because the
older belts are stretched. The additional load on the 9. Move the compressor until the correct belt tension
new belt could cause the new belt to break. is reached.
1. Empty the bucket. Remove the pin that secures 10. Tighten the adjusting locknut (1). Tighten the
the brace for the loader lift arm to the left loader lift compressor bracket mounting bolt (2).
arm. Raise the loader arm to the maximum height.
11. Recheck the belt deflection. If the amount of
2. Position the brace for the loader lift arm over the deflection is incorrect, repeat Step 8 to Step 10.
left lift cylinder rod with the fl at end against the
cylinder end. 12. Install the engine access panel.
3. Push the pin through the holes of the brace for the
loader lift arm and install the cotter pin.
4. Slowly lower the loader arms until the brace for the
loader lift arm contacts the top of the lift cylinder
and the bosses on the loader arm.
SEBU7821-04 133
Maintenance Section
Brake Reservoir Oil Level - Check
22. Lower the bucket to the ground.
i01991706
Brake Reservoir Oil Level -

Check
SMCS Code: 4291-535
Open the engine access door on the top of the

machine.
g00731569
Illustration 232
13. Remove the engine access panel on the right

side of the machine.
g01031571
Illustration 234
Maintain the oil level between the “MIN” mark

and “MAX” mark on the brake reservoir. Add oil, if
necessary.
g01029698 i02291147
Illustration 233
14. Inspect the condition of the alternator belts Braking System - Test
and the adjustment of the alternator belts. The
alternator belts should deflect 10 mm (0.38 inch) SMCS Code: 4251; 4267; 7000
under 110 N (25 lb) of force.
Service Brake Holding Ability Test
15. Loosen the mounting bolt (3). Loosen the
adjusting locknut (4). Check the area around the machine. Make sure
that the machine is clear of personnel and clear of
16. Move the alternator until the correct tension is obstacles.
reached.
Test the brakes on a dry, level surface.
17. Tighten the adjusting locknut (4). Tighten the
mounting bolt (3). Fasten the seat belt before you test the brakes.
18. Recheck the belt de flection. If the amount of The following tests are used to determine if the
deflection is incorrect, repeat Step 15 to Step 17. service brake is functional. These tests are not
intended to measure the maximum brake holding
19. Install the engine access panel. effort. The brake holding effort that is required to
sustain a machine at a speci fic engine rpm varies
20. Start the engine. Raise the loader arms to the depending on the machine. The variations are the
maximum height. differences in the engine setting, in the power train
ef ficiency, and in the brake holding ability, etc.
21. Remove the pin and replace the brace for the
loader lift arm to the stored position on the loader 1. Start the engine. Raise the bucket slightly.
lift arm.
134 SEBU7821-04
Maintenance Section
Bucket Cutting Edges - Inspect/Replace
2. Apply the service brake. Release the parking 2. Engage the parking brake.
brake.
3. If the machine is equipped with the standard
3. If the machine is equipped with the standard transmission, move the transmission speed shift
transmission, move the transmission speed shift lever to THIRD gear. Move the transmission
lever to THIRD gear. Move the transmission direction control lever to FORWARD, to
direction control lever to FORWARD, to NEUTRAL, and back to FORWARD. If the
NEUTRAL, and back to FORWARD. If the machine is equipped with a power shift
machine is equipped with a power shift transmission move the transmission control lever
transmission move the transmission control lever to FOURTH SPEED FORWARD, to NEUTRAL,
to FOURTH SPEED FORWARD, to NEUTRAL, and back to FOURTH SPEED FORWARD. This
and back to FOURTH SPEED FORWARD. This is done in order to override the transmission
is done in or der to override the transmission neutralizer for this test.
neutralizer for this test.
Note: Place machines that are equipped with all
Note: Place machines that are equipped with all wheel drive into two-wheel drive mode.
wheel drive into two-wheel drive mode.
Note: The parking brake indicator light should come
4. Gradually increase the engine speed to high idle. on and the parking brake alarm should sound.
The machine should not move.
4. Gradually increase the engine speed to high idle.
The machine should not move.
If the machine begins to move, reduce the engine

speed immediately and engage the parking brake.
speed immediately and apply the service brake
5. Reduce the engine speed to low idle. Move the
pedal.
transmission to NEUTRAL. Engage the parking
brake. Lower the bucket to the ground. Stop the
engine. 5. Reduce the engine speed. Move the transmission
to NEUTRAL. Lower the bucket to the ground.
NOTICE Stop the engine.
If the Caterpillar
your machine moved while
dealer. testing
Have the brakes,
the dealer contact
inspect and, NOTICE
if necessary, repair the service brake before returning If the machine moved while testing the brakes, contact
the machine to operation. your Cater pillar dealer.
Have the dealer inspect and, if necessary, repair the

Secondary Brake Holding Ability parking br akes before returning the machine to oper-
ation.
Test
Check the area around the machine. Make sure
i01920076
obstacles. Bucket Cutting Edges -
Test the brakes on a dry, level surface. Inspect/Replace
Fasten the seat belt before you test the brakes. SMCS Code: 6801
The following tests are used to determine if the

parking brake is functional. These tests are not
intended to measure the maximum brake holding Personal injury or death can result from bucket
effort. The brake holding effort that is required to falling.
sustain a machine at a speci fic engine rpm varies
depending on the machine. The variations are the Block the bucket before changing bucket cutting
differences in the engine setting, in the power train edges.
ef ficiency, and in the brake holding ability, etc.
1. Start the engine. Raise the bucket slightly. 1. Raise the bucket. Place a block under the bucket.
SEBU7821-04 135
Maintenance Section
Bucket Tips - Inspect/Replace
2. Lower the bucket to the blocking. Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip.
Do not block up the bucket too high. Block up
the bucket so that the bucket is high enough to 1. Remove the pin from the bucket tip. The pin can
remove the cutting edges and the end bits. be removed by one of the following methods.
3. Remove the bolts. Remove the cutting edge and

the end bits.
• Use a hammer and a punch from the retainer
side of the bucket to drive out the pin.
4. Clean the contact surfaces. • Use a Pin-Master. Follow Step 1.a through Step
1.c for the procedure.
5. Use the opposite side of the cutting edge, if this
side is not worn.
6. Install a new cutting edge, if both edges are worn.
7. Install the bolts. Tighten the bolts to the speci fied

torque.
8. Raise the bucket. Remove the blocks.
9. Lower the bucket to the ground.
10. After a few hours of operation, check the bolts

for proper torque.
g00590670
Illustration 236
i02420559
(4) Back of Pin-Master
Bucket Tips - Inspect/Replace (5) Extractor
a. Place the Pin-Master on the bucket tooth.

SMCS Code: 6805
b. Align extractor (5) with the pin.
c. Strike the Pin-Master at the back of the tool (4)

Personal injury or death can result from the bucket and remove the pin.
falling.
Block the bucket before changing bucket tips.
Bucket Tips
g00590819
Illustration 237
(6) Retainer
(7) Retaining washer
(8) Adapter
2. Clean the adapter and the pin.

g00101352
Illustration 235
(1) Usable 3. Fit retainer (6) into retaining washer (7). Install
(2) Replace this assembly into the groove that is in the side
(3) Replace of adapter (8).
136 SEBU7821-04
Maintenance Section
Cab Air Filter - Clean/Replace
c. Strike the tool with a hammer at the back of the

tool (4) in order to start the pin.
d. Slide pin holder (10) away from the pin and

rotate the tool slightly in order to align pin setter
(9) with the pin.
e. Strike the end of the tool until the pin is fully

inserted.
6. After you drive the pin, make sure that the retainer
fits snugly into the pin groove.
i01899383
g00101359
Illustration 238
Cab Air Filter - Clean/Replace
4. Install the new bucket tip onto the adapter.
SMCS Code: 7311; 7342
Note: The bucket tip can be rotated by 180 degrees in
order to allow greater penetration or less penetration. Clean the Filter Element
5. Drive the pin through the bucket tip. The pin can NOTICE
be installed by using one of the following methods: Do not clean the elements by bumping or tapping
them.
• From the other side of the retainer, drive the
pin through the bucket tip, the adapter, and the Inspect the elements after cleaning. Do not use an
retainer. element with damaged pleats, gaskets or seals.
• Use a Pin-Master. Follow Step 5.a through Step When cleaning with pressure air, use 205 kPa (30 psi)
5.e for the procedure. maximum to prevent element damage by too much air
pressure.
Note: To correctly install the pin into the retainer, the
pin must be driven in from the right side of the tooth. When cleaning with pressure water, use 280 kPa
Improper installation of the pin can result in the loss (40 psi) maximum to prevent element damage.
of the bucket tip.
Clean the filter element weekly, but clean the filter

element daily when there is a reduction of air
circulation.
g00590666
Illustration 239
(4) Back of Pin-Master
(9) Pin setter
(10) Pin holder
g00741461
Illustration 240
a. Insert the pin through the bucket tooth.
1. Remove the filter cover that is located at the
b. Place the Pin-Master over the bucket tooth and bottom of the right hand console.
locate the pin in the hole of holder (10).
2. Remove the filter element.
SEBU7821-04 137
Maintenance Section
Cab Interior - Clean
3. Clean the filter element with compressed air or 3. The foam element can also be cleaned with clean
pressure water. Direct the air or the water along water and nonsudsing household detergent.
the pleats of the element. You can also wash
the element with clean water and nonsudsing 4. Rinse the foam element thoroughly with clear
household detergent. water.
4. Rinse the filter element thoroughly with clear 5. Allow the foam element to air dry. Inspect the
water. element for damage. If the foam element is
damaged, replace the foam element.
5. Allow the filter element to air dry. Inspect the
element for damage. If the filter element is 6. Install the foam element.
damaged, replace the fi lter element.
7. Install the filter cover.
6. Install the filter element.
i01404606
7. Install the filter cover.
Cab Interior - Clean
Clean the Precleaner (If Equipped).
SMCS Code: 7301-070
1. Use high pressure air in order to clean the entire

cab and the main electrical box.
2. Wash off any remaining dirt and debris. Use

caution and minimize the water around electrical
connections and the cab roof.
3. Scrub the floormat, the instrument panel, the

windows, and the mirrors. Wipe the cab dry.
i01982029
g00987918
Cooling System Coolant (ELC)
Illustration 241
- Change
SMCS Code: 1353; 1395
Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
NOTICE
Mixing ELC with other products will reduce the effec-
g00987920 tiveness of the coolant.
Illustration 242
This could result in damage to cooling system compo-

1. Remove the filter cover that is located under the nents.
cab. The precleaner is located directly beneath
the air conditioner. If Caterpillar products are not available and com-
mercial products must be used, make sure they
2. Remove the foam element. have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants and Caterpillar
Note: Most of the debris can be removed by striking Extender.
the foam element against a hard surface.
138 SEBU7821-04
Maintenance Section
Cooling System Coolant (ELC) - Change
Note: This machine is shipped with Extended Life 4. Slowly lower the loader arms until the brace for the
Coolant. Extended Life Coolant is recommended for loader lift arm contacts the top of the lift cylinder
use. and the bosses on the loader arm.
For information about the addition of Extender to your Drain the coolant whenever the coolant is dirty or
cooling system, see the Operation and Maintenance whenever foaming is observed.
Manual, “Cooling System Coolant Extender (ELC) -
Add” or consult your Caterpillar dealer. The radiator cap is located under the access panel
on the top of the engine compartment.
Flushing the Extended Life Coolant 1. Open the engine access door on the top of the
From the Cooling System machine.
Some engines utilize Extended Life Coolant. See the

Operation and Maintenance Manual, “Maintenance
Interval Schedule” in order to determine the service
interval. If a Extended Life Coolant was previously
used, fl ush the cooling system with clean water. No
other cleaning agents are required.
Flushing a Standard Coolant From

the Cooling System
If you change the coolant of a machine to Extended
Life Coolant from another type of coolant, use a
Caterpillar cleaning agent to fl ush the cooling system.
g01029869
After you drain the cooling system, thoroughly fl ush Illustration 243
the cooling system with clean water. All of the
cleaning agent must be removed from the cooling 2. Lift the tab on the radiator cap in order to relieve
system. system pressure. Remove the radiator cap slowly.
Changing the Coolant
Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
NOTICE
Do not change the coolant until you read and under-
stand the material in the Cooling System Speci fica-
g00726615
tions section. Illustration 244
1. Empty the bucket. Remove the pin that secures

the brace for the loader lift arm to the left loader lift
2. Position the brace for the loader lift arm over the
left lift cylinder rod with the fl at end against the
cylinder end.
SEBU7821-04 139
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
• Special Publication, SEBU6250, “Caterpillar

Machine Fluids Recommendations”, “Cooling
System Specifications”
• Operation and Maintenance Manual, “Capacities

(Refill)”
Note: If you are using Caterpillar antifreeze, do not

add the supplemental coolant additive at this time
and/or change the element at this time.
10. Start the engine. Run the engine without the

radiator cap until the thermostat opens and the
coolant level stabilizes.
g00293559
Illustration 245 11. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe.
3. Pull the drain hose for the radiator through the
hole under the radiator. 12. Install the r adiator cap. Lower the tab on the
radiator cap. Replace the radiator cap if the gasket
is damaged.
13. Stop the engine.
14. Replace the access panel. Close the access door.
i01833638
Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352; 1353; 1395
g01029871
Illustration 246
4. Remove the access panel on the left side of the

engine compartment. The drain valve is located in Pressurized system: Hot coolant can cause seri-
an access port of the fan shroud. Open the drain ous burn. To open cap, stop engine, wait until ra-
valve. Allow the coolant to drain into a suitable diator is cool. Then loose the cap slowly to relieve
container. the pressure.
5. Close the drain valve. Fill the system with a

When a Caterpillar Extended Life Coolant is
solution which consists of clean water and of
cooling system cleaner. The concentration of the used, an extender must be added to the cooling
system. See the Operation and Maintenance
cooling system cleaner in the solution should be
Manual, “Maintenance Interval Schedule” for the
between 6 percent and 10 percent.
proper service interval. The amount of extender is
determined by the cooling system capacity.
6. Start
Stop the engine. Drain
the engine. Run the
theengine forsolution
cleaning 90 minutes.
into a Table 82
suitable container.
RECOMMENDED AMOUNT OF EXTENDER BY
7. While the engine is stopped, fl ush the system with COOLING SYSTEM CAPACITY
water. Flush the system until the draining water Recommended Amount
is transparent. Cooling System Capacity
of Extender
8. Close the drain valve. 22 to 30 L (6 to 8 US gal) 0.57 L (.60 qt)

30 to 38 L (8 to 10 US gal) 0.71 L (.75 qt)
9. Add the coolant solution. See the following topics:
38 to 49 L (10 to 13 US gal) 0.95 L (.95 qt)
49 to 64 L (13 to 17 US gal) 1.18 L (1.25 qt)
140 SEBU7821-04
Maintenance Section
Cooling System Coolant Level - Check
For additional information on the addition of extender, i02436215

see Special Publication, SEBU6250, “Cat Extended
Life Coolant (ELC) Cooling System Maintenance” or Cooling System Coolant
consult your Caterpillar dealer. Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
i01982091
Cooling System Coolant Level NOTICE
- Check Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
SMCS Code: 1350-535-FLV ing, adjusting and repair of the product. Be prepared to
collect the fl uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Pressurized system: Hot coolant can cause seri- Refer to Special Publication, NENG2500, “Caterpillar
ous burn. To open cap, stop engine, wait until ra- Dealer Service Tool Catalog” for tools and supplies
diator is cool. Then loosen cap slowly to relieve suitable to collect and contain fluids on Caterpillar
the pressure. products.
Open the engine access door on the top of the hood. Dispose of all fl uids according to local regulations and
mandates.
Note: Level 1 results may indicate a need for

Level 2 Analysis.
g01029869
Illustration 247
1. The radiator cap is located on the top of the

radiator on the left side of the machine. Lift the
tab on top of the cap in order to relieve system Illustration 248
g01029869
pressure. Remove the radiator cap slowly.

Obtain the sample of the coolant as close as possible
2. Maintain the coolant level within 13 mm (0.5 inch) to the recommended sampling interval. In order
of the bottom of the fi ller tube. If you need to add to receive the full effect of S·O·S analysis, you
coolant daily, check the cooling system for leaks. must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
3. Inspect the radiator cap seal. Replace the radiator consistent samplings that are evenly spaced.
cap seal if the radiator cap seal is damaged. Supplies for collecting samples can be obtained from
your Caterpillar dealer.
4. Install the radiator cap. Lower the tab on the
radiator cap. Close the access panel. Use the following guidelines for proper sampling of
the coolant:
• Complete the information on the label for the

sampling bottle before you begin to take the
samples.
• Keep the unused sampling bottles stored in plastic

bags.
SEBU7821-04 141
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
• Obtain coolant samples directly from the coolant Obtain the sample of the coolant as close as possible
sample port. You should not obtain the samples to the recommended sampling interval. Supplies
from any other location. for collecting samples can be obtained from your
Caterpillar dealer.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample. Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain”
• Place the sample in the mailing tube immediately for the guidelines for proper sampling of the coolant.
after obtaining the sample in order to avoid
contamination. Submit the sample for Level 2 analysis.
• Never collect samples from expansion bottles. Reference: For additional information about coolant
analysis, refer to Special Publication, SEBU6250,
• Never collect samples from the drain for a system. “Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer.
Submit the sample for Level 1 analysis.
i02360639
For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
Cooling System Water
dealer. Temperature Regulator -
Clean/Replace
i02436220
SMCS Code: 1355; 1393
Cooling System Coolant
Replace the thermostat on a regular basis in order to
Sample (Level 2) - Obtain reduce the chance of unscheduled downtime and of
problems with the cooling system. Failure to replace
SMCS Code: 1350-008; 1395-008; 7542
the engine’s thermostat on a regularly scheduled
basis could cause severe engine damage.
NOTICE
Care must be taken to ensure that fluids are contained The thermostat should be replaced after the cooling
during performance of inspection, maintenance, test- system has been cleaned. Replace the thermostat
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- while the cooling
while the cooling system
system coolant
is completely drained
is drained to a or
level
ing any compartment or disassembling any compo- that is below the thermostat housing.
nent containing fluids.
Note: If you are only replacing the thermostat, drain
Refer to Special Publication, NENG2500, “Caterpillar the cooling system coolant to a level that is below
Dealer Service Tool Catalog” for tools and supplies the thermostat housing.
suitable to collect and contain fluids on Caterpillar
products. Caterpillar engines incorporate a shunt design
cooling system. It is mandatory to always operate the
Dispose of all fl uids according to local regulations and engine with a thermostat.
mandates.
1. Empty the bucket. Remove the pin that secures
the lift arm brace to the left loader lift arm. Raise
the loader arm to the maximum height.
2. Position the lift arm brace over the left lift cylinder
rod with the fl at end against the cylinder end.
3. Push the pin through the holes of the lift arm brace
and install the cotter pin.
4. Slowly lower the loader arms until the lift arm

brace contacts the top of the lift cylinder and the
bosses on the loader arm.
5. Remove the engine access panel on the right side

g01029869
Illustration 249 of the machine.
142 SEBU7821-04
Maintenance Section
Differential Oil (Front) - Change
i02567860
Differential Oil (Front) - Change

SMCS Code: 3258
g01179553
Illustration 250
6. Loosen the hose clamp and remove the hose from

the thermostat housing assembly.
g01286266
Illustration 251
7. Remove the
assembly. bolts from
Remove the the thermostat
thermostat housing
housing
assembly. 1. Remove oil drain plug (1) and drain the oil into a
suitable container.
8. Remove the gasket, the thermostat, and the seal
from the thermostat housing assembly. 2. The drain plug is magnetic. Check the plug for
metal.
9. Install a new seal in the thermostat housing
assembly. Install a new thermostat and a new 3. Clean the drain plug and install the drain plug.
gasket. Install the thermostat housing assembly
on the engine cylinder head. 4. Remove oil level/fill plug (2).
The thermostats can be reused under the following 5. Add oil until the oil is level with the threads for the
conditions. filler plug. Refer to Operation and Maintenance
Manual, “Lubricant
Maintenance Manual,Viscosities” and(Re
“Capacities Operation and
fill)” for oil.
• The thermostat is tested and the thermostat
meets test specifications.
6. Clean the fi ller plug and install the filler plug.
• The thermostat is not damaged.
i01982218
• The thermostat does not have excessive
buildup of deposits. Differential Oil (Rear) - Change
10. Install the hose. Tighten the hose clamp. SMCS Code: 3258
11. Refill the cooling system. Refer to Special The oil change interval should be decreased to 500
Publication, “Cooling System Specifications” and hours if more than 50% of the service hours is used
Operation and Maintenance Manual, “Capacities for roading and loading.
(Refill)”.
SEBU7821-04 143
Maintenance Section
Differential Oil Level (Front) - Check
Rear Axle Rear Axle with All Wheel Steer

(AWS)
g00290691
Illustration 252
g00290698
1. Remove the oil drain plug and drain the oil into a Illustration 254
suitable container.
1. Remove the oil drain plug and drain the oil into a
suitable container.
2. Clean the drain plug and install the drain plug.
2. Clean the drain plug and install the drain plug.
g00290697
Illustration 253
g00290699
3. Remove the oil level/fill plug. Refer to Special Illustration 255
Publication, “Lubricant Specifications” and
Operation and Maintenance Manual, “Capacities 3. Remove the oil level/ fill plug. Refer to
(Refill)” for oil. Operation and Maintenance Manual, “Lubricant
Specifications” and Operation and Maintenance
4. Add oil until the oil is level with the threads for Manual, “Refill Capacities” for oil.
the filler plug.
4. Add oil until the oil is level with the threads for
5. Clean the fi ller plug and install the fi ller plug. the filler plug.
5. Clean the fi ller plug and install the filler plug.
i02363607
Differential Oil Level (Front) -

Check
SMCS Code: 3258
The oil level/fill plug is located near the middle of

the front axle.
144 SEBU7821-04
Maintenance Section
Differential Oil Level (Rear) - Check
i02363692
Differential Oil Sample (Front)

- Obtain
SMCS Code: 3258-008; 7542-008
g01180551
Illustration 256
1. Remove the oil level/fill plug in order to check the

oil.
2. The oil level should be at the bottom of the plug

threads. g01180551
Illustration 258
3. Clean the oil level/ fill plug and install the oil
Obtain the oil sample according to the Operation
level/fill plug.
and Maintenance Manual, “Maintenance Interval
Schedule”.
i01355918
Refer to the Operation and Maintenance Manual,
Differential Oil Level (Rear) - “General Hazard Information” for information that
pertains to containing fl uid spillage.
Check
Refer to the Special Publication, SEBU6250, “S·O·S
SMCS Code: 3258
Oil Analysis” for more information.
The oil level/fill plug is located near the middle of the

rear axle. i02436599
Differential Oil Sample (Rear)

- Obtain
SMCS Code: 3258-008; 7542-008
g00290697
Illustration 257
Filler plug on standard rear differential
1. Remove the oil plug in order to check the oil.
2. The oil level should be at the bottom of the plug Illustration 259
g00290697
threads.
3. Clean the oil plug and install the oil plug. and Maintenance Manual, “Maintenance Interval
Schedule”.
SEBU7821-04 145
Maintenance Section
Drive Shaft Spline - Lubricate

“General Hazard Information” for information that
pertains to containing fluid spillage.

i01356061
Drive Shaft Spline - Lubricate

SMCS Code: 3253
g00290704
Illustration 262
Apply lubricant to the grease fi tting for the drive shaft

spline of the rear drive shaft.
i02510477
Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1051; 1054
g00724029
Illustration 260
NOTICE
Access the grease fi ttings for the drive shaft spline Service the air cleaner only with the engine stopped.
from the bottom of the machine. Engine damage could result.
Service the air cleaner filter element when the

yellow piston
indicator entersonthe
thered
engine or fithe
zoneair lterindicator
service
reads 63.5 cm (25 inch) of water. Refer to
Operation and Maintenance Manual, “Engine Air
Filter Service Indicator - Inspect”.
1. Open the engine access door on the top of the

machine.
g00290703
Illustration 261
Apply lubricant to the grease fi tting for the drive shaft

spline of the front drive shaft.
g01031497
Illustration 263
2. Remove cover (1) for the air fi lter housing .
146 SEBU7821-04
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
3. Remove primary filter element (2) from the air

filter housing. NOTICE
Do not clean the air fi lter elements by bumping or tap-
4. Slide the primary filter element out of the filter ping. This could damage the seals. Do not use ele-
base (3). ments with damaged pleats, gaskets, or seals. Dam-
aged elements will allow dirt to pass through. Engine
5. Clean the inside of the air fi lter housing. damage could result.
6. Slide a clean primary air filter element into the
filter base. Install the clean filter into the air fi lter Visually inspect the primary air fi lter elements before
housing. Install the cover for the air fi lter housing. cleaning. Inspect the air fi lter elements for damage
to the seal, the gaskets, and the outer cover. Discard
Note: Refer to “Cleaning Primary Air Filter Elements”. any damaged air filter elements.
7. Reset the engine air fi lter service indicator. There are two common methods that are used to
clean primar y air filter elements:
8. Close the access door.
• Pressurized air
If the yellow piston in the indicator moves into the red
zone after starting the engine or the exhaust smoke • Vacuum cleaning
is still black after installation of a clean primary fi lter
element, install a new primary filter element. If the Pressurized Air
piston remains in the red zone replace the secondary
element. Pressurized air can be used to clean primary air fi lter
elements that have not been cleaned more than two
Cleaning Primary Air Filter times. Pressurized air will not remove deposits of
carbon and oil. Use fi ltered, dry air with a maximum
Elements pressure of 207 kPa (30 psi).
NOTICE Note: When the primary air filter elements are

Caterpillar recommends certified air filter cleaning ser- cleaned, always begin with the clean side (inside)
vices available at participating Caterpillar dealers. The in order to force dirt particles toward the dirty side
Caterpillar cleaning process uses proven procedures (outside).
to assure consistent quality and suf ficient fi lter life.
Vacuum Cleaning
Observe the following guidelines if you attempt to
clean the filter element: Vacuum cleaning is another method for cleaning
primary air fi lter elements which require daily cleaning
Do not tap or strike the filter element in order to re- because of a dry, dusty environment. Cleaning with
move dust. pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
Do not wash the fi lter element. of carbon and oil.
Use low pressure compressed air in order to remove

the dust fr om the fi lter element. Air pressure must not Inspecting the Primary Air Filter
exceed 207 kPa (30 psi). Direct the air flow up the Elements
pleats and down the pleats from the inside of the fi lter
element. Take extreme care in order to avoid damage fi
to the pleats. Inspect the primary
clean, dry
air primary air lter
fi lter element forelement.
tears and/or
holes. If it is necessary in order to con firm the result,
Do not use air fi lters with damaged pleats, gaskets, or compare the primary air filter element to a new
seals. Dirt entering the engine will cause damage to primary air filter element that has the same part
engine components. number.
Do not use a primary air fi lter element that has any

The primary air filter element can be used up to
tears and/or holes in the filter material. Do not use
six times if the element is properly cleaned and
a primar y air filter element with damaged pleats,
inspected. When the primary air filter element is
gaskets or seals. Discard damaged primary air fi lter
cleaned, check for rips or tears in the fi lter material.
elements.
Every two years replace the primary air fi lter element
at least one time. This replacement should be
performed regardless of the number of cleanings.
SEBU7821-04 147
Maintenance Section
Engine Air Filter Secondary Element - Replace
Storing Primar y Air Filter Elements 1. Remove the air cleaner housing cover (1).
If a primary air filter element that passes inspection 2. Remove the primary filter element (2) from the air
will not be used, the primary air filter element can cleaner housing.
be stored for future use.
3. Clean the inside of the air cleaner housing (4) with
Do not use paint, a waterproof cover, or plastic as a a wet rag befor e the secondary filter element (3)
protective covering for storage. An air fl ow restriction is removed.
may result. To protect against dirt and damage, wrap
the primary air fi lter elements in Volatile Corrosion 4. Inspect the gasket between the air inlet pipe and
Inhibited (VCI) paper. the air cleaner housing. Replace the gasket if the
gasket is damaged.
Place the primary air filter element into a box for
storage. For identification, mark the outside of the 5. Install a new secondary element.
box and mark the primary air filter element. Include
the following information: 6. Install the primary element and the air cleaner
housing cover. Fasten the clips in order to secure
• Date of cleaning the air cleaner housing cover.
• Number of cleanings 7. Reset the fi lter element indicator.
Store the box in a dry location. 8. Close the engine access door.
i01991300 i01991054
Engine Air Filter Secondary Engine Air Filter Service

Element - Replace Indicator - Inspect
SMCS Code: 1051; 1054 SMCS Code: 1051; 1054; 7452
NOTICE NOTICE
Always replace the secondary filter element. Never Service the air cleaner only with the engine stopped.
attempt to reuse it by cleaning. Engine damage could result.
The secondary filter element should be replaced at

the time the primary element is serviced for the third
time. The secondary filter element should be replaced
everytime the primary element is replaced.
The secondary fi lter element should also be replaced

if the yellow piston in the filter element indicator en-
ters the red zone after installation of a clean primary
element, or if the exhaust smoke is still black.
g01031316
Illustration 265
The fi lter service indicator is located under the engine

access door in front of the housing for the air fi lter.
Start the engine. Run the engine at high idle. If the

yellow piston in the fi lter service indicator enters the
red zone, service the air cleaner. Stop the engine.
g01031378
Illustration 264
148 SEBU7821-04
Maintenance Section
Engine Compartment - Clean
i01404793
Engine Compartment - Clean

Personal injury can result from parts and/or cov-
SMCS Code: 1000-070 ers under spring pressure.
Spring force will be released when covers are re-

NOTICE moved.
Before spraying the engine compartment with high
pressure water turn off the engine and allow the en-
Be prepared to hold spring loaded covers as the
gine to cool. Do not spray water directly on a hot fuel
bolts are loosened.
injection pump or damage may occur.
4. Remove the screws (2). Remove the plate (3).

Use a commercially available engine degreaser
in order to clean the engine compartment. Use
5. Remove the diaphragm (4) and the cap (6).
caution and minimize the water around bearings and
Remove the spring (7). Discard diaphragm (4).
electrical connections.
i02409844
Engine Crankcase Breather - Improper

can causeassembly of parts that are spring loaded
bodily injury.
Replace
To prevent possible injury, follow the established
SMCS Code: 1317-510 assembly procedure and wear protective equip-
ment.
6. Install the spring (7), the cap (6), and a new

diaphragm (4).
7. Install the plate (3). Install the screws (2).
8. Install the cover (1) on the valve mechanism cover.
9. Install a new O-ring seal (11) on the connector

(12). Install a new gasket (13) on the connector
(12). Position the connector in the valve
mechanism cover.
10. Install the setscrews (8). Tighten the setscrews to

a torque of 9 N·m (80 lb in).
11. Install the hose (10) on the connector (12). Tighten

the clamp (9) to a torque of 5 N·m (44 lb in).
g01149576
Illustration 266 i01982246
1. Loosen the clamp (9) and remove the hose (10)

from the connector (12). Engine Oil Level - Check
SMCS Code: 1302; 1318; 1326
2. Remove the setscrews (8) and remove the
connector (12) from the cylinder head. Remove NOTICE
the gasket (13). Remove the O-ring seal (11) from Do not over fill the crankcase. Engine damage can re-
the connector. Discard the gasket (13) and the sult.
O-ring seal (11).
3. Remove the cover (1) from the valve mechanism
machine.
cover (5).
SEBU7821-04 149
Maintenance Section
Engine Oil Sample - Obtain
i01982523
Engine Oil and Filter - Change

SMCS Code: 1302; 1318; 1326
Note: If
1.5% by the sulfur
weight, content
use an oil in theafuel
with TBNisof
greater than
30. With the
high sulfur fuel, change the oil and the filter element
after every 250 hours or after every month. If the
API category is CF-4 or less, change the oil and
change the filter element after every 250 hours or
after every month. Otherwise, change the oil and the
filter element after every 500 hours or after every
three months.
g01030412
Illustration 267
2. While the engine is stopped, maintain the oil level

between the “ADD” mark and the “FULL” mark on
the engine oil dipstick (2).
3. If necessary, remove the oil fi ller cap (1) and add
oil.
4. Clean the oil fi ller cap and install the oil fi ller cap.
5. Close the engine access door.
i01999134
g01030414
Engine Oil Sample - Obtain Illustration 269
The crankcase drain plug is on the right side of the

SMCS Code: 1348-008; 7542-008
oil pan.
1. Remove the crankcase drain plug and drain the

oil into a suitable container. Clean the crankcase
drain plug and replace the crankcase drain plug.
Illustration 268 g01034353

Schedule”. g01030413
Illustration 270

“General Hazard Information” for information that 2. Remove the filter element with a strap type
pertains to containing fluid spillage. wrench.
Refer to the Special Publication, SEBU6250, “S·O·S 3. Clean the fi lter mounting base with a clean cloth.
Make sure that the old filter gasket has been
removed.
150 SEBU7821-04
Maintenance Section
Engine Valve Lash - Check
4. Apply a thin fi lm of clean engine oil to the sealing i01364126

surface of the new fi lter element.
Extendable Stick Pads -
5. Install the new filter element by hand. When the Inspect/Replace
gasket contacts the filter base, tighten the filter
for an additional 3/4 turn. (If Equipped)
6. Open the engine access door on the top of the SMCS Code: 6533-040-JP; 6533-510-JP
machine.
Inspect Wear Pads
g01030412
Illustration 271
g00724233
Illustration 272
7. Remove the oil filler cap (1). Fill the crankcase
with new oil. Refer to Operation and Maintenance
Check the extendable stick for slop. Shim the
Manual, “Lubricant Viscosities” and Operation and
extendable stick pads in order to maintain an
Maintenance Manual, “Capacities (Refill)”. Clean
acceptable fit and reduce slop.
the oil fi ller cap and install the oil fi ller cap.
Note: Do not apply an excessive amount of a silicone
8. Start the engine and allow the oil to warm. Check
based lubricant. Dirt can be attracted to the lubricant
for leaks.
and dirt can cause abrasion to the pad assemblies
and wear to the pad assemblies.
9. Stop the engine and allow the oil to drain back
into the oil pan. Maintain the oil level in the
The extendable stick pads do not normally require
crosshatched region of the engine oil dipstick (2).
any lubrication. If the extendable stick becomes
Add oil, if necessary.
noisy, a small amount of a silicone based lubricant
may be applied.
10. Replace the engine access panel and close the
engine access door.
Adjustment for Top Upper Wear
i01897328 Pad
Engine Valve Lash - Check 1. Extend the extendable stick to one half of the fully
extended position.
SMCS Code: 1102-082; 1102-535; 1102; 1209-082;
1209 2. Move the stick and move the boom down against
the ground. This will take pressure off the wear
Note: A qualified service person should perform the pad.
valve lash check and/or the valve lash adjustment.
Special tools and training are required.
Refer to your machine’s Service Manual for complete

instructions.
SEBU7821-04 151
Maintenance Section
Final Drive Oil (Front) - Change
Note: Place the bucket on the ground. Apply slight

pressure toward the ground with the stick. Shim the
lower pad or replace the lower pad.
i02369952
Final Drive Oil (Front) - Change

SMCS Code: 4050
g00635137
Illustration 273
3. Remove the bolts that secure the wear pad. Slide

the pad toward the boom. There will be enough
space in order to remove the pad. Either replace
the wear pads or stack shims behind the pad.
4. Shim the wear pad to 1 mm (0.04 inch) .
Note: In order to make adjustments to the remaining Illustration 275

g01182475
upper wear pads, refer to Disassembly and Assembly
Manual, SENR1209, “Stick, Extendable Stick,
1. Position the oil fill/drain plug at the bottom.
Extendable Stick Cylinder”. Remove the oil fi ll/drain plug and drain the oil into
a suitable container.
Adjustment for Lower Pads
2. The plug is magnetic. The plug will attract metal
1. Extend the extendable stick out until there is from the oil. Check the plug for an increased
enough clearance in order to remove the pads. amount of metal on the plug. If any abnormal
particles are found, consult your Caterpillar dealer.
Illustration 274 g00635788

g01182493
Illustration 276
2. The side pads (1) can be shimmed without moving
the stick or without moving the boom. 3. Position the plug hole at a horizontal position. Use
the line on the fi nal drive as a reference.
3. Adjust the boom and adjust the stick in order to
take pressure away from the top pad (2). Adjust 4. Add oil until the oil is level with the plug threads.
the wear pads by shimming or replacing. Shim the Refer to Operation and Maintenance Manual,
wear pads to 1 mm (0.04 inch). “Lubricant Specifications” and Operation and
Maintenance Manual, “Capacities (Refill)” for the
4. Adjust the boom and adjust the stick in order to oil.
take the pressure away from the lower pad (3).
5. Clean the plug and install the plug.
152 SEBU7821-04
Maintenance Section
Final Drive Oil (Rear) - Change
6. Repeat the procedure for the other fi nal drive. i02370034
Final Drive Oil Level (Front) -

i01995377
Check
Final Drive Oil (Rear) - Change
SMCS Code: 4050
(All Wheel Steer)
SMCS Code: 4050
g01182493
Illustration 279
g00752323 1. Position the oil fill/drain plug at a horizontal

Illustration 277
position in order to check the oil level.
1. Position the oil fill/drain plug at the bottom. 2. Remove the oil fi ll/drain plug in order to check the
Remove the oil fi ll/drain plug and drain the oil into oil level.
a suitable container.
3. The oil should be level with the bottom of the plug
threads.
4. The plug is magnetic. Check the plug for metal.

Clean the plug and install the plug.
5. Repeat the procedure for the other fi nal drive.
i01995404
Final Drive Oil Level (Rear) -

Check
g00752329
(All Wheel Steer)
Illustration 278
SMCS Code: 4050
2. Position the plug hole at a horizontal position. Use
the line on the fi nal drive as a reference.
3. Add oil until the oil is level with the plug threads.
Refer to Operation and Maintenance Manual,
“Lubricant Specifications” and Operation and
Maintenance Manual, “Capacities (Re fill)” for the
oil.
g00752329
Illustration 280
SEBU7821-04 153
Maintenance Section
Final Drive Oil Sample (Front) - Obtain
1. Position the oil fill/drain plug at a horizontal i01999152

position in order to check the oil level.
Final Drive Oil Sample (Rear)
2. Remove the oil fi ll/drain plug in order to check the - Obtain
oil level.
SMCS Code: 4050-008-RE; 7542-008
3. The oil should be level with the bottom of the plug
threads.
i02370039
Final Drive Oil Sample (Front)

- Obtain
SMCS Code: 4050-008-FR; 7542-008
g00752329
Illustration 282

Schedule”.


g01182493
Illustration 281 i01920607
Obtain the oil sample from the fi ll/drain plug. Refer to Fuel System - Prime
Special Publication, SEBU6250, “S·O·S Oil Analysis”
for information that pertains to obtaining a sample SMCS Code: 1250-548
of the engine oil. Refer to Special Publication,
S/N: RXA1-Up
PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining a sample of oil. S/N: BXC1-Up
S/N: B2D1-Up
S/N: TBD1-Up
S/N: SMJ1-Up
S/N: MBM1-Up
S/N: WEP1-Up
S/N: TDR1-Up
S/N: DSX1-Up
S/N: CJZ1-Up
Air can enter the system under the following

conditions.
• The fuel tank is drained during normal operation.

154 SEBU7821-04
Maintenance Section
Fuel System Filter and Water Separator - Replace
• The low pressur e fuel lines are disconnected. 3. Operate the lever of the fuel lift pump slowly for
approximately two minutes. If the drive cam of the
• A part of the low pressure fuel system leaks during fuel lift pump is at the point of maximum cam lift,
engine operation. the priming lever will not operate. In this situation,
the crankshaft must be turned one revolution.
If air enters the fuel system, the air must be eliminated
from the system before the engine can be started. 4. Operate the starter motor until the engine starts.
If the engine has been stopped by air in the fuel “Engine Starting”.
system, perform the following procedures:
5. If the engine runs roughly after the engine runs
• Make sure that fuel has been added to the tank. for a short period of time correctly check for air
in the fuel system. If the engine stops after the
• Make sure that the leakage problem has been engine runs for a short period of time correctly
corrected. check for air in the fuel system. If there is air in the
fuel system, check the low pressure fuel system
• Make sure that the electrical stop control is for a leak. Correct the problem and repeat Step
connected. 3 through Step 4.
• Operate the starter motor until the engine starts.

i01986276
1. Make sure that the electric stop control is
connected. Turn the engine start switch key to the
Fuel System Filter and Water
ON position. Separator - Replace
SMCS Code: 1261-510; 1263-510-FQ
Some fuel supplies may not meet the minimum

standard for fuel lubricity. Caterpillar recommends the
use of fuels that meet certain minimum specifications.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”.
NOTICE
It is extremely important to drain water from the water
separator daily, or every ten hours. It is also extremely
important to drain water from the fuel tank weekly, or
every 50 hours. Failure to do so could result in damage
g00724259
to the fuel system.
Illustration 283
2. Remove the access panel on the right side of the 1. Empty the bucket. Remove the pin that secures
machine. the brace for the loader lift arm to the left loader lift
2. Position the brace for the loader lift arm over the
left lift cylinder rod with the flat end against the
cylinder end.
4. Slowly lower the loader arms until the brace for the
loader lift arm contacts the top of the lift cylinder
and the bosses on the loader arm.
5. Stop the engine.

g00291786
Illustration 284
SEBU7821-04 155
Maintenance Section
Fuel System Water Separator - Drain
i01986280
Fuel System Water Separator

- Drain
SMCS Code: 1263-543; 1263

standard for fuel lubricity. Caterpillar recommends the
use of fuels that meet certain minimum specifications.
Refer to Special Publication, SEBU6250, “Caterpillar
NOTICE
Illustration 285
g00726616 It is extremely important to drain water from the water
6. Remove the access panel from the left side of important to drain water from the fuel tank weekly, or
the machine. every 50 hour s . Failure to do so could result in damage
to the fuel system.
The collar. uses a fuel filter with a push and

twistmachine
g00724316
Illustration 287
g01030464
Illustration 286 The water separator is located by the drain plug for
the engine crankcase.
7. Remove the sensor and the wire from the bottom
of the filter.
8. Remove the primary fuel fi lter that is located next

to the engine oil filter under the left side of the
machine. Rotate the locking ring counterclockwise
in order to remove the fi lter element. Discard the
filter properly.
9. Clean the fi lter element mounting base. Remove

any part of the fi lter element gasket that remains
on the fi lter element mounting base.
10. Coat the seal of the new fi lter element with clean

diesel fuel.
g01030509
Illustration 288
11. Install the new fi lter element. Rotate the locking
ring clockwise in order to fasten the filter to the 1. Loosen the drain valve on the bottom of the fuel
mounting base. filter. Allow the water and the sediment to drain
into a suitable container.
12. Install the sensor and the wire into the new fi lter.
2. Tighten the drain valve.
13. Replace the access panel.
156 SEBU7821-04
Maintenance Section
Fuel Tank Water and Sediment - Drain
3. If the engine fails to start, change the fuel filter. If i01986292
there is a power loss, change the fuel filter.
Fuses - Replace
i01986286 SMCS Code: 1417
Fuel Tank Water and Sediment
Fuses protect the electrical system from damage
- Drain that is caused by overloaded circuits. Replace the
fuse if the element separates. If the element of a new
SMCS Code: 1273-543-M&S fuse separates, check the circuit. Repair the circuit, if
necessary.
standard for fuel lubricity. Caterpillar recommends the NOTICE
use of fuels that meet certain minimum specifications. Replace the fuses with the same type and size only.
Refer to Special Publication, SEBU6250, “Caterpillar Otherwise, electrical damage can result.
If it is necessary to replace fuses frequently, an electri-
NOTICE cal problem may exist. Contact your Caterpillar dealer
It is extremely important to drain water from the water
important to drain water from the fuel tank weekly, or
every 50 hours. Failure to do so could result in damage
to the fuel system.
The fuel tank is located on the left side of the

machine.
g00724522
Illustration 290
Remove the cover on the front of the right side

console in order to access the main fuse panel.
g00832981
Illustration 289
Flip up the tab on the fuel cap. Turn the tab

counterclockwise on the fuel cap and slowly remove
the fuel tank cap(1) in order to relieve pressure.
The
rightfuel tank
corner ondrain valveof(2)
the front theisfuel
located
tank.on the lower
Remove the
fuel tank drain plug. Allow the water and sediment to
drain into a suitable container. Install the fuel tank
drain plug. Replace the fuel tank cap.
g00832506
Illustration 291
Front Floodlights (1) – 15 Amp
Auxiliar y Front Floodlights (2) – 10 Amp
Auxiliary Rear Floodlights (3) – 10 Amp
All Wheel Drive (4) – 5 Amp
SEBU7821-04 157
Maintenance Section
Hydraulic Oil Sample - Obtain
Start Relay (5) – 20 Amp Air Conditioner (6) – 10 Amp
Monitor (6) – 5 Amp Front Window Wiper (7) – 10 Amp
Transmission (7) – 10 Amp Rear Window Wiper (8) – 10 Amp
Rear Hydraulics (8) – 10 Amp Rotating Beacon (9) – 10 Amp
Bucket Positioner (9) – 5 Amp Spare (10) – 10 Amp
Starting Aid (10) – 15 Amp Rear Floodlights (11) – 15 Amp
Engine (11) – 10 Amp

i01999210
Signal Lamps (12) – 10 Amp Hydraulic Oil Sample - Obtain

Power Port (13) – 10 Amp SMCS Code: 5050-008; 7542-008
Radio (14) – 5 Amp
Key Start Switch (15) – 5 Amp
Air Seat (16) – 20 Amp
Horn (17) – 15 Amp
Spare (18) – 10 Amp
Note: Some of the main fuses are tied together with

the fuses in the headliner. For example, if all of the
lights are not functioning, check the main fuse for
the lights in the steering console. If one light is not
functioning, check the fuse in the headliner for the Illustration 293
g01030543
specific light.
Remove the cover in order to access the fuses. and Maintenance Manual, “Maintenance Interval
Schedule”.


g00836473
Illustration 292
Auxiliary Hydraulics (1) – 15 Amp
Spare (2) – OPEN
Ride Control (3) – 10 Amp
Left Tail Light (4) – 5 Amp
Right Tail Light (5) – 5 Amp
158 SEBU7821-04
Maintenance Section
Hydraulic System Oil - Change
i01986309
Hydraulic System Oil - Change

SMCS Code: 5056
Note: The normal

is at every hydraulic
2000 Service oil change
Hours interval
or 1 Year. By
performing S·O·S oil analysis, the hydraulic
oil change interval may be extended to 4000
Service Hours or 2 Years. S·O·S oil analysis
must be performed at every 500 Service Hours
or 3 Months in order to extend the hydraulic oil
change interval. The results from the S·O·S oil
analysis will determine if the hydraulic oil change
g00728122
interval may be extended. If S·O·S oil analysis is Illustration 295
not available, the hydraulic oil change interval
must remain at every 2000 Service Hours or 1
Year . Refer to the Operation and Maintenance
Manual, “S·O·S Information”.
Operate the machine for a few minutes in order to

warm the hydraulic system oil.
The machine should be level . Lower the bucket to

the ground and apply slight downward pressure.
Engage the parking brake and stop the engine.
The hydraulic tank filler cap is located under the

access door on the top of the engine compartment.
g00290722
1. Open the engine access door on the top of the Illustration 296
machine.
3. Remove the drain plug on the flange that is
located ona the

drain into hydraulic
suitable pump. Allow the oil to
container.
4. Clean the drain plug and replace the drain plug.

Tighten the drain plug to a torque of 90 ± 10 N·m
(66 ± 7 lb ft).
5. Change the hydraulic system filter. Refer to

Operation and Maintenance Manual, “Hydraulic
System Oil Filter - Change”.
6. Inspect the hydraulic tank breather that is located

on a hose from the over flow container. Replace
the breather, if necessary.
g01030543
Illustration 294
7. Fill the hydraulic system oil tank. Refer to
2. Remove the hydraulic tank fi ller cap. Operation and Maintenance Manual, “Lubricant
Viscosities” and Operation and Maintenance
Manual, “Capacities (Refill)”.
SEBU7821-04 159
Maintenance Section
Hydraulic System Oil Filter - Replace
2. Remove the hydr aulic tank fi ller cap that is located

under the access panel on the top of the engine
compartment.
g00724596
Illustration 297
8. Maintain the hydraulic oil level in the sight gauge

between the “MIN” mark and the “MAX” mark. Illustration 299
g00724532
Check the hydraulic

the ground oil level
and with the with in
backhoe thethe
loader on
transport 3. The hydraulic oil fi lter is located on the left side of
the machine.
position.
Note: The oil must be free of bubbles. If bubbles are

present in the oil, air is entering the hydraulic system.
Inspect the suction hoses and hose clamps.
9. Inspect the gasket on the hydraulic tank fi ller cap

for damage. Replace the gasket, if necessary.
10. Install the hydraulic tank filler cap.
11. Close the access door.
i01986704
g00290851
Hydraulic System Oil Filter - Illustration 300
Replace 4. Remove the filter element with a strap type

wrench.
SMCS Code: 5056; 5068
5. Clean the fi lter element mounting base. Remove
1. Open the engine access door on the top of the any part of the fi lter element gasket that remains
machine. on the filter element mounting base.
6. Apply a light coat of oil to the gasket of the new

filter element.
7. Install the new fi lter element by hand. When the

gasket contacts the fi lter element mounting base,
tighten the filter element for an additional three
quarters of a turn.
8. Remove the hydraulic tank breather. Replace the

old breather with a new breather.
g01030543
Illustr ation 298
160 SEBU7821-04
Maintenance Section
Hydraulic System Oil Level - Check
i00661457
Kingpin Bearings (Rear) -

Lubricate
(All Wheel Steer)
SMCS Code: 4314
g00724596
Illustration 301
9. Maintain the hydraulic oil level in the sight gauge

between the “MIN” mark and the “MAX” mark. Add
oil, if necessary.
10. Inspect the gasket on the hydraulic tank fi ller cap

for damage. Replace the gasket, if necessary.
g00291790
Illustration 303
11. Install the hydraulic tank filler cap.
Apply lubricant to the grease fi ttings for the kingpin
12. Close the access door. bearings of the rear steerable axle. There is a total of
four grease fittings.
i01352315
i01364566
Hydraulic System Oil Level -
Check Loader Bucket, Cylinder, and
Linkage Bearings - Lubricate
SMCS Code: 5056; 7479 SMCS Code: 7069; 7070; 7071
Single Tilt Machines
g00724596
Illustration 302
The sight gauge for the hydraulic tank is located on

the left side of the machine. Move the backhoe to g00291110
Illustration 304
the transport position and lower the loader bucket
to the ground.
Apply lubricant to the grease fi ttings (1) for the frame
and for the lift arm. There is a grease fitting for each
Turn off the engine. Wait about fi ve minutes before
you check the hydraulic system oil level.
Apply lubricant to the grease fi tting (2) for the pivot
Maintain the oil level in the sight gauge between the
for the linkage of bucket positioner and lift kickout.
“MIN” mark and the “MAX” mark.
SEBU7821-04 161
Maintenance Section
Loader Bucket, Cylinder, and Linkage Bearings - Lubricate
Apply lubricant to the grease fi ttings (3) for the head Apply lubricant to the grease fittings (4) for the rod
end of the lift cylinder. There is a grease fitting for end of the tilt cylinder. There is a grease fitting for
each side of the machine. each side of the machine.
Apply lubricant to the grease fi ttings (4) for the rod Apply lubricant to the grease fittings (5) for the rod
end of the lift cylinder. There is a grease fitting for end of the lift cylinder. There is a grease fitting for
each side of the machine. each side of the machine.
Apply lubricant to the grease fi ttings (5) for the pivot Apply lubricant to the grease fi ttings (6) for the center
pin at the loader lift arm. There is a grease fi tting for pivot pin of the parallel linkage. There is a grease
each side of the machine. fitting for each side of the machine.
Apply lubricant to the grease fi ttings (6) for the pivot Apply lubricant to the grease fi ttings (7) for the head
bearings for the bucket tilt cylinder. There is a grease end of the tilt cylinder. There is a grease fitting for
fitting in each linkage (four total). each side of the machine.
Apply lubricant to the grease fi tting (7) for the rod end Apply lubricant to the grease fi ttings (8) for the frame
of the tilt cylinder. and for the lift arm. There is a grease fitting for each
Apply lubricant to the grease fi ttings (8) for the lower
pivot pins. There is a grease fi tting for each side of Apply lubricant to the grease fi ttings (9) for the frame
the machine. and for the parallel linkage. There is a grease fitting
for each side of the machine.
Apply lubricant to the grease fi ttings (9) for the upper
pivot pin. There is a grease fitting for each side of Apply lubricant to the grease fi ttings (10) for the head
the machine. end of the lift cylinder. There is a grease fitting for
each side of the machine.
There is a total of 17 grease fi ttings.
pivot pin of the parallel linkage. There is a grease
Parallel Lift Machines fitting for each side of the machine.

pivot pin of the tilt linkage. There is a grease fi tting for
There is a total of 24 grease fi ttings.
g00724847
Illustration 305

pivot pin of the quick coupler assembly. There is a
grease fi tting for each side of the machine.

pivot pin of the quick coupler assembly. There is a
grease fi tting for each side of the machine.

pivot pin of the tilt linkage. There is a grease fi tting for
162 SEBU7821-04
Maintenance Section
Oil Filter - Inspect
i02106227 i01364583
Oil Filter - Inspect Parking Brake - Check/Adjust

SMCS Code: 1318; 3067; 5068 SMCS Code: 4267
Inspect a Used Filter for Debris Check Procedure

Check the area around the machine. Make sure
obstacles.
Check the brakes on a dry, level surface.
Fasten the seat belt before you check the brakes.
The following checks are used to determine if the

parking brake is functional. These checks are not
intended to measure the maximum brake holding
effort. The brake holding effort that is required to
sustain a machine at a specific engine rpm varies
depending on the machine. The variations are the
g00100013
Illustration 306 differences in the engine setting, in the power train
The element is shown with debris. ef ficiency, and in the brake holding ability, etc.
Use a filter cutter to cut the filter element open. 1. Start the engine. Raise the bucket slightly.
Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the fi 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. g00731039
Illustration 307
Small amounts of debris may be found in the fi lter
element. This could be caused by friction and by 2. Engage the parking brake.
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount 3. If the machine is equipped with the standard
of debris is found. transmission, move the transmission speed shift
lever to THIRD gear. Move the transmission
Using an oil filter element that is not recommended direction control lever to FORWARD, to
by Caterpillar can result in severe engine damage NEUTRAL, and back to FORWARD. If the
to engine bearings, to the crankshaft, and to other machine is equipped with a power shift
parts. This can result in larger particles in un filtered transmission move the transmission control lever
oil. The particles could enter the lubricating system to FOURTH SPEED FORWARD, to NEUTRAL,
and the particles could cause damage. and back to FOURTH SPEED FORWARD. This
is done in order to override the transmission
neutralizer for this test.
Note: Place machines that are equipped with all

wheel drive into two-wheel drive mode.
SEBU7821-04 163
Maintenance Section
Radiator Core - Clean
Note: The parking brake indicator light should come If the machine moves during the parking brake test,
on and the parking brake alarm should sound. then perform the adjustment procedure again. If
you run out of adjustment on the parking brake
4. Gradually increase the engine speed to high idle. adjuster knob, refer to Systems Operation, Testing
The machine should not move. and Adjusting, SENR1259, “Parking Brake Control -
Adjust”.
i01986724
speed immediately and apply the service brake Radiator Core - Clean
pedal.
SMCS Code: 1353
5. Reduce the engine speed. Move the transmission
to NEUTRAL. Lower the blade to the ground. Stop
the engine.
If the machine
speed begins
immediately to move,
and apply reduce the engine
the service brake
pedal.
6. Reduce the engine speed. Move the transmission

to NEUTRAL. Lower the bucket to the ground.
Stop the engine.
g00725231
Illustration 309
Adjustment Procedure
If the machine moved during the test, perform the
following procedure in order to adjust the parking
brake.
1. Apply the service brakes.
g00101939
Illustration 310
NOTICE
Do not spray high pressure water into the radiator
while the engine is running.
You can use compressed air, high pressure water,

g00731041
Illustration 308 or steam to remove dust and other debris from the
radiator fi ns. However, the use of compressed air is
2. Disengage the parking brake. preferred.
3. As you view the parking brake adjuster knob from Note: If necessary, tilt the oil cooler away from the
the operator seat, turn the knob counterclockwise radiator in order to remove dust and debris between
for one quarter of a turn. the radiator and the oil cooler.
4. Repeat steps 1 to 6 in the check procedure. Note:
164 SEBU7821-04
Maintenance Section
Refrigerant Dryer - Replace
i01834322 i02429589
Refrigerant Dryer - Replace Seat Belt - Inspect

SMCS Code: 7322-510 SMCS Code: 7327-040
Reference: For
Air Conditioning the
andcorrect
Heatingprocedure, refer to
Service Manual, Always check
condition of thethe condition
seat of the seat
belt mounting belt and
hardware the
before
SENR5664 or the Disassembly and Assembly you operate the machine. Replace any parts that are
Manual for your machine. damaged or wor n before you operate the machine.
Note: A qualified mechanic should replace the

components of the refrigerant system since special
tooling and training are required.
i01364894
Rollover Protective Structure

(ROPS) - Inspect
SMCS Code: 7325
g00932801
Illustration 312
Typical example
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.
g00725241 Inspect the seat belt (3) for webbing that is worn or
Illustration 311
frayed. Replace the seat belt if the seat belt is worn
or frayed.
1. Inspect the ROPS for loose bolts or for damaged
bolts. Replace any damaged bolts or missing bolts
Consult your Caterpillar dealer for the replacement of
with original equipment parts only.
the seat belt and the mounting hardware.
Tighten the M16 bolts (1) to a torque of
Note: Within three years of the date of installation or
165 ± 30 N·m (122 ± 22 lb ft). Tighten the
within five years of the date of manufacture, replace
M24 bolts (2) to a torque of 524 ± 100 N·m
the seat belt. Replace the seat belt at the date which
(386 ± 74 lb ft).
occurs fi rst. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
Note: Apply oil to
install the bolts. all ROPS
Failure bolt oil
to apply threads
to the before you
bolt threads buckle, and the seat belt retractor.
can result in improper bolt torque.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
2. Operate the machine on a rough surface. Replace
the seat belt extension.
the ROPS mounting supports if the ROPS emits
a noise. Replace the ROPS mounting supports if
the ROPS rattles.
Do not straighten the ROPS. Do not repair the ROPS

by welding reinforcement plates to the ROPS.
Consult your Caterpillar dealer for repair of any

cracks in the ROPS.
SEBU7821-04 165
Maintenance Section
Seat Belt - Replace
i02429594 Check the stabilizers for slop. Shim the stabilizer

pads in order to maintain an acceptable fit and
Seat Belt - Replace reduce slop. Refer to the Service Manual for the
correct procedure.
SMCS Code: 7327-510
Note: Do not apply an excessive amount of a silicone
Within three
five years of years of the
the date date of installation
of manufacture, or the
replace within based lubricant. Dirt can be attracted to the lubricant
and dirt can cause abrasion to the pad assemblies
seat belt . Replace the seat belt at the date which and wear to the pad assemblies.
occurs fi rst. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt The stabilizer pads do not normally require any
buckle, and the seat belt retractor. lubrication. If the stabilizers become noisy, a small
amount of a silicone based lubricant may be applied.
i01365042
Stabilizer and Cylinder

Bearings - Lubricate
SMCS Code: 5468; 7222
g01152685
Illustration 313
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
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. g00728949
Illustration 315
Position the stabilizer, as shown.

i01437416
Sideshift Stabilizer Wear Pads Apply lubricant to the grease fitting for the head end
of the cylinder.
- Inspect
Repeat for the other stabilizer.
SMCS Code: 7222-040
There is a total of two grease fi ttings.
g00752808
Illustration 314
166 SEBU7821-04
Maintenance Section
Swing Frame and Cylinder Bearings - Lubricate
i01365047 • The weight of a r eady-to-work machine at the front

tires and at the rear tires
Swing Frame and Cylinder
Bearings - Lubricate • The rated payload
SMCS Code: 5105; 6506; 6507; 7063 • Average operating conditions

Contact your tire supplier if your machine is
experiencing tire slippage. Tire wear may cause tire
slippage.
i01365052
Transmission Magnetic Screen

- Clean
SMCS Code: 3030
1. Drain the transmission oil. Refer to Operation

and Maintenance Manual, “Transmission Oil -
Illustration 316
g00729366 Change”.
Apply lubricant to the grease fitting (1) for the top

swing pin.
Apply lubricant to the grease fi tting (2) for the bottom

swing pin.
Apply lubricant to the grease fitting (3) for the eye

of the swing cylinder. Repeat for the other swing
cylinder.
Apply lubricant to the grease fi tting (4) for the bearing

on the top of the swing cylinder. Repeat for the other
swing cylinder.
g00725296
Apply lubricant to the grease fi tting (5) for the bearing Illustration 317
on the bottom of the swing cylinder. Repeat for the Magnetic strainer cover for the standard transmission
other swing cylinder.
There is a total of eight grease fi ttings.
i02369786
Tire Inflation - Check

SMCS Code: 4203
Measure the tire pressure on each tire. Tire inflation
pressures for each application may vary. These tire
inflation pressures should be obtained from your tire
supplier.
g00725298
Illustration 318
Inflate the tires, if necessary. Refer to Operation and
Magnetic strainer cover for the power shift transmission
Maintenance Manual, “Tire In flation with Air”.
The operating pressure is based on the following 2. Remove the magnetic strainer cover.
conditions.
3. Remove the magnets from the housing.
SEBU7821-04 167
Maintenance Section
Transmission Oil - Change
4. Remove the screen from the housing.
5. Wash the tube and the screen in a clean,

nonflammable solvent.
NOTICE
Do not drop or rap the magnets against any hard ob-
jects. Replace any damaged magnets.
6. Clean the magnets with a cloth, with a stiff bristle

brush, or with pressure air.
7. Install the magnets and the tube assembly into the

magnetic screen.
g00725461
Illustration 320
8. Install the magnetic screen. Drain plug for power shift transmission
9. Clean the cover and inspect the seal. Replace the 1. Remove the transmission drain plug. Allow the
seal, if the seal is damaged. transmission oil to drain into a suitable container.
Clean the transmission drain plug and install the
10. Install the cover. Tighten the cover bolts. transmission drain plug.
11. Fill the transmission. Refer to Operation and 2. Change the transmission oil filter element.
Maintenance Manual, “Transmission Oil - Refer to Operation and Maintenance Manual,
Change”. “Transmission Oil Filter - Replace”.
3. Clean the transmission magnetic screen.

i01986745
Transmission Oil - Change “Transmission Magnetic Screen - Clean”.
SMCS Code: 3030; 3080
Operate the machine for a few minutes in order to

warm the transmission oil.
The machine should be level. Lower the bucket to the

ground and apply slight downward pressure. Engage
the parking brake and stop the engine.
g00725462
Illustration 321
4. Remove the transmission breather from the top of

the transmission case. Clean the breather in clean
nonflammable solvent and allow the breather to
dry. Replace the breather.

machine.
g00725460
Illustration 319
Drain plug for standard transmission
168 SEBU7821-04
Maintenance Section
Transmission Oil Filter - Replace
i01986825
Transmission Oil Filter -

Replace
SMCS Code: 3067
g01030657
Illustration 322
6. Remove the dipstick/fill cap and fill the

transmission with transmission oil. Refer to
Operation and Maintenance Manual, “Lubricant
Viscosities” and Operation
Manual, “Capacities and Maintenance
(Re fill)”. g00724532
Illustration 323
7. Start the engine and run the engine at low idle. The transmission filter is located on the left side of
Apply the service brake. Slowly operate the the machine .
transmission controls in order to circulate the oil.
8. Move the transmission control lever to NEUTRAL

and engage the parking brake. Inspect the
transmission for leaks.
9. Maintain the transmission oil level within the

crosshatched region on the “CHECK WITH OIL
WARM” side of the dipstick when the transmission
is warm. Add transmission oil through the
transmission fi ller tube, if necessary.
Note: The transmission can be checked with cold

transmission oil. Check the oil level with the cold
oil check side of the dipstick. The engine must be
g00293355
stopped in order to do a cold oil check. Illustration 324
10. Install the dipstick/fill cap and install the engine 1. Remove the transmission oil fi lter element with a
access door. strap type wrench.
11. Stop the engine. 2. Clean the fi lter element mounting base. Remove
any part of the fi lter element gasket that remains
on the filter element mounting base.
3. Apply a light coat of oil to the gasket of the new

filter element.
4. Install the new fi lter element by hand. When the

gasket contacts the mounting base, tighten the
filter element for an additional three quarters of
a turn.
5. Start the engine and apply the service brake.

Slowly operate the transmission controls in order
to circulate the transmission oil.
SEBU7821-04 169
Maintenance Section
Transmission Oil Level - Check
6. Move the transmission control lever to NEUTRAL Note: The transmission can be checked with cold
and engage the parking brake. Inspect the filter transmission oil. Check the oil level with the cold
element for leaks. oil check side of the dipstick. The engine must be
stopped in order to do a cold oil check.
4. Clean the dipstick/ fill plug and install the dipstick/fill

plug.
i01999161
Transmission Oil Sample -

Obtain
SMCS Code: 3030-008; 7542-008
g01030657
Illustration 325
7. Maintain the transmission oil level within the

crosshatched region on the “CHECK WITH WARM
OIL” side of the dipstick when the transmission is
warm. Add transmission oil, if necessary.
8. Stop the engine.
i01986801
Transmission Oil Level - Check Illustration 327

g01030657
SMCS Code: 3030; 3080; 3081

Check the transmission oil level while the machine is and Maintenance Manual, “Maintenance Interval
on a level surface. Schedule”.
1. Open the engine access door on the top of the Refer to the Operation and Maintenance Manual,
machine. “General Hazard Information” for information that

i01986834
Wheel Bearings (Front) -

Lubricate
(Two-Wheel Drive)
SMCS Code: 4205; 4208
g01030657 Use the following procedure for both wheels.

Illustration 326
1. Raise the front wheels slightly off the ground.

2. Remove the dipstick/fill plug for the transmission.
2. Install suf ficient blocking under the frame and
3. Maintain the oil level within the crosshatched lower the machine to the blocking.
region on the “CHECK WITH OIL WARM” side of
the dipstick/fill plug when the transmission is warm 3. Remove the nuts and both wheels.
and the engine is at low idle. Add transmission
oil, if necessary.
170 SEBU7821-04
Maintenance Section
Wheel Nut Torque - Check
i01986855
Wheel Nut Torque - Check

SMCS Code: 4051; 4199; 4200
g00976070
Illustration 328
4. Remove the dust cap (1).
5. Remove bolts (2) and retaining plate (3).

g00729576
Illustration 329
6. Pull the hub assembly (4) until the cone and roller
assembly come out of the hub assembly. Then, Check the torque on new wheels or repaired wheels
pull off the hub all the way. after every ten service hours until the speci fied torque
is maintained.
7. Clean all of the parts in clean, nonflammable
solvent and allow the parts to air dry. Do not use The nut and the stud should be clean and dry for
pressure air. reassembly. Apply one drop of lubricating oil to the
stud before installing the nut onto the stud.
8. Inspect the roller assemblies for heat discoloration
and for wear. Inspect the seals for damage. Torque the nuts to 460 ± 60 N·m (339 ± 44 lb ft). Use
Replace any damaged parts. a star pattern when you torque the nuts.
9. Make sure that the grease gets packed between Check the nuts on all four wheels.
the rollers and the cage on both bearings.
i01990919
Force the grease through the bearing from the
large end of the rollers. Window Washer Reservoir -
10. Pack a 6 mm (0.25 inch) layer of grease between Fill
the bearing assemblies in the hub. Do not pack
the hub fully with grease. SMCS Code: 7306-544
11. Apply a 6 mm (0.25 inch) thick fi lm of grease on NOTICE

the spindle surface. When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing
12. Install the hub, the bearings, the washer, the nut window washer solvent.
and the wheel.
13. While you turn the wheel, tighten bolt (2) until a
slight drag is noticed.
14. All bearing surfaces must make contact. The

wheel should turn freely within 0.025 to 0.25 mm
(0.001 to 0.010 inch) end play.
15. Install the dust cap.
SEBU7821-04 171
Maintenance Section
Window Wipers - Inspect/Replace
i01077829
Windows - Clean
SMCS Code: 7310; 7340
S/N: RXA1-Up
S/N: BKC920-Up
S/N: BMC1060-Up
S/N: BXC1-Up
S/N: B2D1-Up
g01031223 S/N: TBD1-Up
Illustration 330
S/N: BGJ1050-Up
The washer fluid bottle is located in the engine
compartment. S/N: SMJ1-Up
S/N: BNK5900-Up
1. Open the engine access door.
S/N: BML4800-Up
2. Remove the fi ller cap.
S/N: MBM1-Up
3. Fill the washer fluid bottle with washer fluid
through the filler opening. S/N: BLN10300-Up
S/N: FDP18400-Up
4. Replace the filler cap.
S/N: WEP1-Up
5. Close the engine access door.
S/N: TDR1-Up
i01437556 S/N: DSX1-Up
Window Wipers - S/N: CJZ1-Up
Inspect/Replace Use commercially available window cleaning
solutions in order to clean the windows. Clean the
SMCS Code: 7305
outside of the windows from the ground, unless
handholds are available.
Inspect the condition of the wiper blades. Replace
the wiper blades if the wiper blades are worn or
damaged or if streaking occurs.
g00566124
Illustration 331
Typical example
Use a pole with a squeegee in order to reach the high

areas of the window.
172 SEBU7821-04
Maintenance Section
Windows - Clean
Cleaning Methods
Aircraft Windshield Cleaner
Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with a
clean soft cloth.
Soap and Water

Use a clean sponge or a soft cloth. Wash the windows
with a mild soap or with a mild detergent. Also
use plenty of lukewarm water. Rinse the windows
thoroughly. Dry the windows with a moist chamois or
with a moist cellulose sponge.
Stubborn Dirt and Grease
Wash the windows with a good grade of naphtha, of

isopropyl alcohol, or of Butyl Cellosolve. Then, wash
the windows with soap and with water.

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i02738980 Stabilizer and Cylinder Bearings - Lubricate ....... 165

Ensure that are

When Required Cooling System Coolant Sample (Level 2) -

Wheel Bearings (Front) - Lubricate ..................... 169

Every 2000 Service Hours

Every 2000 Service Hours or 1 Year

Every 3000 Ser vice Hours or 2 Years

Every 3 Years After Date of Installation or

Every 3000 Service Hours or 3 Years

Every 6000 Service Hours or 6 Years

Axle Breathers - Clean/Replace Axle Universal Joint (Rear) -

Note: Do not turn the adapter when you remove the

2. Wash the breather in clean non ﬂammable solvent.

Note: If the adapter is turned make sure that the slot

Apply lubricant to the grease ﬁ ttings for the universal

Backhoe Boom, Stick, Bucket,

Apply lubricant to the grease ﬁ tting (9) for the head

Apply lubricant to the grease ﬁtting (10) for the pivot

Apply lubricant to the grease ﬁ tting (4) for the bucket

Apply lubricant to the grease ﬁ tting (5) for the link.

Apply lubricant to the grease ﬁtting (12) for the pivot

There is a total of thirteen grease ﬁ ttings.

The backup alarm should immediately sound.

i01833495 5. Stop the engine in order to inspect the belts.

Battery or Battery Cable -

1. Turn the engine start switch to the OFF position.

2. Disconnect the negative battery cable from the

Note: Do not allow the disconnected battery cable to

5. Perform the necessary repairs. Replace the cable

6. Connect the negative battery cable at the battery.

7. Connect the battery cable to the frame of the

8. Install the engine start switch key.

22. Lower the bucket to the ground.

Brake Reservoir Oil Level -

Open the engine access door on the top of the

13. Remove the engine access panel on the right

Maintain the oil level between the “MIN” mark

If the machine begins to move, reduce the engine

Have the dealer inspect and, if necessary, repair the

The following tests are used to determine if the

3. Remove the bolts. Remove the cutting edge and

6. Install a new cutting edge, if both edges are worn.

7. Install the bolts. Tighten the bolts to the speci ﬁed

8. Raise the bucket. Remove the blocks.

9. Lower the bucket to the ground.

10. After a few hours of operation, check the bolts

a. Place the Pin-Master on the bucket tooth.

c. Strike the Pin-Master at the back of the tool (4)

Block the bucket before changing bucket tips.

2. Clean the adapter and the pin.

c. Strike the tool with a hammer at the back of the

d. Slide pin holder (10) away from the pin and

e. Strike the end of the tool until the pin is fully

Clean the ﬁlter element weekly, but clean the ﬁlter

1. Use high pressure air in order to clean the entire

2. Wash off any remaining dirt and debris. Use

3. Scrub the ﬂoormat, the instrument panel, the