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2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt

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SEBU8075-11

January 2012

Operation andMaintenance

Manual992K Wheel Loader

H4C1-Up(Machine)

SAFETY.CAT.COM

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SEBU8075-11 93Maintenance Section

Maintenance Interval Schedule

i04749293

Maintenance Interval Schedule

SMCS Code: 7000

Ensure that all safety information, warnings, andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance. All adjustments, the use of properlubricants, fluids, filters, and the replacement ofcomponents due to normal wear and aging areincluded.Failure to adhere to proper maintenanceintervals and procedures may result in diminishedperformance of the product and/or accelerated wearof components.

Use mileage, fuel consumption, service hours, orcalendartime, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance. Refer to themaintenance procedure for any other exceptions thatmay change the maintenance intervals.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

Note:If Cat HYDO Advanced hydraulic oils are used,the hydraulic oil change interval is extended to 3000

hours. SOS services may extend the oil changeeven longer. Consult your Cat dealer for details.

When Required

Automatic Lubrication Grease Tank - Fill .............. 96Automatic Lubrication System Components -

Check .................................................................. 96Axle Oil Cooler Filter - Replace .......................... 100Battery - Recycle ................................................ 101Battery or Battery Cable - Inspect/Replace ........ 102Camera - Clean .................................................. 109CaseDrain Oil Filters - Replace ......................... 109Circuit Breakers - Reset ....................................... 110

Engine Air Filter Primary Element - Clean/Replace ............................................................. 120

Engine Air Filter Secondary Element - Replace .. 123Ether Starting Aid Cylinder - Replace ................. 128Fuel System - Prime ........................................... 128Fuses - Replace .................................................. 132High Intensity Discharge Lamp (HID) - Replace .. 134High Pressure Screens - Clean/Replace ............ 134Oil Filter - Inspect ................................................ 148Oil Renewal System Oil - Add ............................ 149Radiator Core - Clean ......................................... 149Seat Side Rails - Adjust ...................................... 152Secondary Steering - Test .................................. 152Transmission Magnetic Screen - Clean .............. 155

Window Washer Reservoir - Fill .......................... 159Window Wiper - Inspect/Replace ........................ 159Windows - Clean ................................................. 159

Every 10 Service Hours or Daily

Backup Alarm - Test ............................................ 101Bucket Cutting Edges - Inspect/Replace ............ 105Bucket Linkage and Loader Cylinder Bearings -

Lubricate ........................................................... 105Bucket Stops - Inspect ........................................ 106Bucket Tips - Inspect/Replace ............................ 106Bucket Wear Plates - Inspect/Replace ............... 108Cooling System Coolant Level - Check ............... 113Engine Oil Level - Check .................................... 124Fuel System Primary Filter (Water Separator) -

Check/Drain ...................................................... 129Hydraulic System Oil Level (Implement) (Hydraulic

Fan) - Check ..................................................... 146HydraulicSystem Oil Level (Steering) (Brake) -

Check ................................................................ 146Oil Renewal System Oil Level - Check ............... 149Seat Belt- Inspect .............................................. 151Transmission Oil Level - Check .......................... 157

Every 50 Service Hours or Weekly

Cab Air Filter - Clean/Replace ............................ 108Fuel Tank Water and Sediment - Drain ............... 132Tire Inflation - Check ........................................... 154

Initial 250 Service Hours

Hydraulic System Oil Filter (Hydraulic Fan Return) -

Replace ............................................................. 143Hydraulic System Oil Filter (Implement Pilot) -Replace ............................................................. 144

Hydraulic System Oil Filter (Steering Pilot) -Replace ............................................................. 145

Transmission Oil Filter - Replace ........................ 157

Every 250 Service Hours or Monthly

AxleOscillation Bearings - Lubricate .................. 101Battery - Clean .................................................... 101Belt - Inspect/Adjust/Replace .............................. 102Braking System - Test ......................................... 104Drive Shaft Spline (Center) - Lubricate ................ 119

Engine Oil Sample - Obtain ................................ 125Steering Cylinder Bearings - Lubricate ............... 154

Initial 500 Service Hours

Electronic Unit Injector - Inspect/Adjust .............. 120Engine Valve Lash - Check ................................. 127Engine Valve Rotators - Inspect ......................... 127Seat Side Rails - Adjust ...................................... 152

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94 SEBU8075-11Maintenance SectionMaintenance Interval Schedule

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ................................................................ 115

Every 500 Service Hours or 3 Months


Differential and Final Drive Oil Level - Check ...... 117Differential and Final Drive Oil Sample - Obtain .. 118Engine Crankcase Breather - Clean ................... 124Engine Oil and Filter - Change ........................... 125Fuel SystemPrimary Filter - Clean/Replace ....... 130Fuel System Secondary Filter - Replace ............ 131Fuel Tank Cap and Strainer - Clean ................... 132Hoses and Clamps - Inspect/Replace ................ 135Hydraulic System Oil Filter (Hydraulic Fan Return) -

Replace ............................................................. 143

Hydraulic System Oil Filter (Implement Pilot) -Replace ............................................................. 144Hydraulic System Oil Filter (Steering Pilot) -

Replace ............................................................. 145Hydraulic System Oil Sample (Implement) (Hydraulic

Fan) - Obtain ..................................................... 147Hydraulic System Oil Sample (Steering) (Brake) -

Obtain ............................................................... 147Transmission Oil Filter - Replace ........................ 157Transmission Oil Sample - Obtain ...................... 158

Every 1000 Service Hours or 6 Months

Articulation Bearings - Lubricate ........................... 95

Battery Hold-Down - Tighten ............................... 102Drive Shaft Support Bearing - Lubricate ............. 120Rollover Protective Structure (ROPS) - Inspect .. 151Transmission Oil - Change ................................. 155

Every 2000 Service Hours or 1 Year

Axle Breaker Relief Valve - Clean ......................... 99Brake Accumulator - Check ................................ 103Differential and Final Drive Oil - Change ............. 116Hydraulic System Oil (Implement) (Hydraulic Fan) -

Change ............................................................. 138Hydraulic System Oil (Steering) (Brake) -

Change ............................................................. 140

Hydraulic Tank Breaker Relief Valve - Clean ...... 148Refrigerant Dryer - Replace ................................ 150Service Brake Wear Indicator - Check ................ 153

Every Year


Every 3000 Service Hours

Electronic Unit Injector - Inspect/Adjust .............. 120Engine Valve Lash - Check ................................. 127Engine Valve Rotators - Inspect ......................... 127

Every 3000 Service Hours or 2 Years

Crankshaft Vibration Damper - Inspect ................ 116Engine Mounts- Inspect ..................................... 124

Every 3 Years

Seat Belt - Replace ............................................. 152


Alternator- Inspect ............................................... 95Turbocharger - Inspect ........................................ 158


Cooling System Coolant Extender (ELC) - Add ... 112Engine Water Pump - Inspect ............................. 127

Every 6000Service Hours or 4 Years

Cooling System Water Temperature Regulator -Replace .............................................................. 115

Every 7500 Service Hours or 757 000 L(200 000 US gal) of Fuel

Engine Components - Rebuild/Install Reman ..... 124

Every 12 000 Service Hours or 6 Years

CoolingSystem Coolant (ELC) - Change ............ 111

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Alternator - Inspect

i02904968

Alternator - Inspect

SMCS Code:1405-040

g01224924Illustration 85


Access to the alternator is on the right side of themachine. The alternator is located on the front ofthe engine.

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and for proper battery charging.

Keep the batteries fully charged.

Air temperature affects the cranking power of thebatteries. Keep the batteries warm. The engine willnot crank if the batteries are too cold. A warm enginewill not crank if the batteries are too cold.

When the engine is operated only for short periodsof time, the batteries may not fully recharge. Makesure that the alternator is properly functioning. Thealternator will charge the battery.

Consult your Caterpillar dealer for more informationabout testing the alternator.

i02597645

Articulation Bearings -Lubricate

SMCS Code: 7057-086-BD; 7065-086-BD;

7066-086-BD


1. The fitting for the lower hitch pin is located at thelower bearing. The fitting can be accessed fromthe right side of the machine. Wipe off the fittingbefore any lubricant is applied.

2. Apply lubricant through the fitting.


3. The remote fitting for the upper hitch pin is located

near the articulation joint on the right side of themachine. Wipe off the fitting before any lubricantis applied.

4. Apply lubricant through the remote fitting.

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96 SEBU8075-11Maintenance Section

Automatic Lubrication Grease Tank - Fill

i02216552

Automatic Lubrication GreaseTank - Fill(If Equipped)

SMCS Code:7540-544-TNK

A pressure hazard is present. Severe personal in-jury or death can result from removing hoses orfittings that are under pressure. Relieve the pres-sure in the system before you remove hoses orfittings.

The Centro-Matic Lubrication

SystemReference:Before any service work is performed onthe lubrication system, refer to Special Instructions,REHS1394 or consult your Caterpillar dealer.

Bulk Fill

1. In order to fi ll the reservoir, remove the lower andupper plugs from the side of the reservoir.

2. Attach the appropriate pump to the lower inlet.

3. Fill the reservoir until visual indicator on the lid

of the tank indicates FULL or until the greaseappears at the top vent port.

Reference: For the correct type of grease, referto Operation and Maintenance Manual, LubricantViscosities.

4. Remove the pump and replace both plugs.

The Quicklub Lubrication System

Reference:Before any service work is performed onthelubrication system, refer to Special Instructions,

REHS1396 or consult your Caterpillar dealer.

Filling the Reservoir

1. Fill the reservoir through the grease fitting. Thegreasefitting is located at the base of the reservoir.

Reference: For the correct type of grease, refertoOperation and Maintenance Manual, LubricantViscosities.

2. Refill the reservoir when the grease reaches theMIN mark on the reservoir.

3. Fill the reservoir to the MAX mark on thereservoir.

Priming the System

After the reservoir has been filled with the

recommendedlubricant, loosen the fitting to thesupply line. Operate the pump until lubricant flowsfrom the outlet. Then, tighten fitting.

i04164902

Automatic Lubrication SystemComponents - Check(If Equipped)

SMCS Code: 7540-535

A pressure hazard is present. Severe personal in-jury or death can result from removing hoses orfittings that are under pressure. Relieve the pres-sure in the system before you remove hoses orfittings.

Reference:Before any service work is performed onthe lubrication system, refer to Special Instructions,REHS1394 or consult your Cat dealer.

Autolube systems need to be adjusted before being

put into use to ensure each joint gets the appropriateamount of grease. Different applications requirefrequency, volume, and proportioning adjustmentsfrom the recommended or factory settings.

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Automatic Lubrication System Components - Check


(A) A-Pin(B) B-Pin(C) C-Pin(E) E-Pin

(F) F-Pin(G) G-Pin(H) Pin for Upper Articulation Joint(J) Pin for Lower Articulation Joint

(K) K-Pin(L) Steering Cylinder Pins(X) Trunnions(Y) Y-Pin

1. Remove any buildup of grease. Check that eachpin joint is receiving a fresh supply of grease.

Reference: If a fresh supply of grease is notpresent, refer to Special Instructions, REHS1394for system troubleshooting procedures.

2. Check the grease level at the top vent port of thereservoir.

Reference: For filling procedures, refer toOperation and Maintenance Manual, AutomaticLubrication Grease Tank - Fill.

Settings of the Injectors for theAutolube System

The controller of the autolube system is preset fromthe factory. The lubrication is dispensed at 15 minuteintervals, and all of the injectors are preset at the full

flow setting. There may be an excessive buildup ofgrease around some of the joints. As a result, thegrease reservoir may need filling more frequently.The injectors for selected joints can be adjusted inorder to reduce the flow of grease without adverselyaffecting the life of the pin. The injectors are set bythe factory at the full flow setting. This setting isequivalent to 8 turns open. When the injectors areadjusted, the injectors shouldfirst be closed. Then,the injectors should be opened by the number ofspecified turns. The recommended settings for theinjectors at each pin location are listed in Table 17.

Table 17

Pins Qty (Injectors) Settings (Turns)

A 0

B 2

C 2

8

E 3 5

F 2 2

G 1 8

H 1

J 12

K 0 8

L 4 2

X 2 8

Y 0 8

Note: By using the above settings, the buildup ofgrease will be reduced. The interval between refillsof the reservoir will be extended to approximately250 hours. Grease levels in the reservoir must bechecked in order to ensure an uninterrupted flow.

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Automatic Lubrication System Components - Check

Timer Operation

Autolube systems must be adjusted before being putinto use to ensure each joint gets the appropriateamount of grease. Different applications requirefrequency, volume, and proportioning adjustments

from the recommended or factory settings.

Autolube settings must be monitored and adjustedas needed to account for changes in application,temperature, grease type, and NLGI grade.


(6) Access plug

Remove access plug (6) on the front of the pump inorder to access the timer control. The timer controlgroup consists of the following:

Manual lubrication switch

OFF timer rotary switch

ON timer rotary switch

Power ON LED

Pump ON LED


Timer control

(7) OFF timer switch(8) ON timer switch(9) Power ON LED.(10) Pump motor ON LED(11) Push button for manual lubrication

OFF timer switch (7) can be adjusted to 15 values.See Table 1 for the time interval for each value.

ON timer switch (8) can be adjusted to 15 values.See Table 1 for the time interval for each value.

LED (9) is marked battery. This LED will illuminatewhen power is sent to the pump control.

LED (10) is marked motor. This LED will illuminatewhen the pump is pumping lubricant.

Press push button (11) for 2 seconds. This processwill initiate a manual lubrication cycle.

The OFF position of the timer begins accumulatingtime when the ignition switch closes. When the OFFposition of the timer reaches the preset value, thepump will turn ON. The pump remains activated for

the time period that is preset on the ON timer.

When the ignition is turned OFF, the used time issaved for an unlimited duration.

Turn the ignition to the ON position. The automaticlubrication operation will finish the cycle time.

Note: Do not use the zero setting that is located onthe timer switches.

Note: The factory setting for the OFF position is 4(16 minutes). The factory setting for the ON positionis 2 (4 minutes).

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Axle Breaker Relief Valve - Clean

Table 18

OFF TIMERotarySwitchSetting

IntervalBetween

Cycles

ON TIMERotarySwitchSetting

Cycle Timeof thePump

0 0 minutes 0 0 minutes1 4 minutes 1 2 minutes

2 8 minutes 2 4 minutes








A 40 minutes A 20 minutes

B 44 minutes B 22 minutes

C 48 minutes C 24 minutes

D 52 minutes D 26 minutes

E 56 minutes E 28 minutes

F 60 minutes F 30 minutes

Note: If the Lincoln 94824 Pump or theprinted circuit board are replaced in the field,contact Lincoln Technical Service Department at

314-679-4200 ext. 4782 for instructions on specialjumper pin setting for timer operation prior toinstallation and start up.

i03247100

Axle Breaker Relief Valve -Clean

SMCS Code: 5118-070-ZX

There is a breaker relief valve on both axles. Thefront axle breaker relief valve is located inside the

front frame above the axle housing.


Front axle breaker relief valve

The access door for the rear axle breaker relief valveis located behind the cab in the middle of the cab

platform.


Rear axle breaker relief valve location


Rear axle breaker relief valve

1. Open the access door in order to access the rearaxle breaker relief valve.

2. Push the top of the breaker relief valve in orderto relieve any pressure.

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Axle Oil Cooler Filter - Replace

3. Remove the breaker relief valve.

4. Clean the breaker relief valve in a clean,nonflammable solvent. Dry the breaker relief valvethoroughly by shaking or by using compressed air.

5. Install the breaker relief valve.

6. Close the access door.

7. Repeat steps 2 through 5 for the front axle breakerrelief valve.

i04401714

Axle Oil Cooler Filter - Replace

SMCS Code:3004-510-AOC

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopeningany compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, Dealer Ser-vice Tool Catalog for tools and supplies suitable tocollect and contain fluids on Cat products.

Dispose of all fluids according to local regulations andmandates.

The axle oil coolerfi lter should be replaced when afailure occurs in the axles.

Note:The oil fi lters contain a 140 micron screen.


The axle oil cooler filters are located under theengine compartment. There is an access area on theunderside of the machine.


1. Stop the engine.

2. Push the button on the top of each axle breaker

relief valve in order to relieve any pressure.

Note: Refer to Operation and Maintenance Manual,Axle Breaker Relief Valve - Clean for the axlebreaker relief valve locations.

3. Remove the oil fi lter and discard the fi lter properly.Make sure that the old seal is removed from thefilter base.

4. Clean the filter mounting base and apply a thincoat of oil to the seal on the new fi lter.

5. Install the new filter hand tight until the seal of the

filter contacts the base. Note the position of theindex marks on the filter in relation to a fixed pointon the filter base.

Note: There are rotation index marks on the filterthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the fi lter, use therotation index marks as a guide.

6. Tighten the filter according to the instructionsthat are printed on the fi lter. Use the index marksas a guide. For non-Caterpillarfilters, use theinstructions that are provided with the fi lter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the fi lter.

7. Repeat the above steps for the remaining oil fi lter.

8. Start the engine and operate the machine for afew minutes.

9. Stop the engine. Inspect the filters for leaks. Makeany necessary repairs.

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Axle Oscillation Bearings - Lubricate

i02598561

Axle Oscillation Bearings -Lubricate

SMCS Code:3268-086-BD; 3278-086-BD

The two grease fittings for the axle oscillationbearings are located near the articulation joint on theleft side ofthe machine.


1. Wipe off the fittings before any lubricant is applied.

2. Apply lubricant through the twofittings until greaseis visible around the bearings.

3. Check that grease is visible around the bearingsin order to ensure the properfill.

i04488529

Backup Alarm - Test

SMCS Code:7406-081


The backup alarms are located behind the fan guardon the rear of the machine.

1. Turn the enginestart switch key to the ON positionin order to perform the test.

2. Apply the service brake.

3. Move the transmission direction control switch to

the REVERSE position.

The backup alarms should immediately sound.The backup alarms will continue to sound until thetransmission direction control switch is moved to theNEUTRAL position or to the FORWARD position.

i02533066

Battery - Clean

SMCS Code: 1401-070


Open the battery compartment on the right rearcorner of the cab platform.

Clean the battery terminals and the surfaces ofthe batteries with a clean cloth. Coat the batteryterminals with petroleum jelly. Make sure that thebattery cables are installed securely.

i00993589

Battery - Recycle

SMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

A battery supplier

An authorized battery collection facility

Recycling facility

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102 SEBU8075-11Maintenance SectionBattery Hold-Down - Tighten

i02533077

Battery Hold-Down - Tighten

SMCS Code:7257-527

g01267286

Illustration 100

Open the battery compartment on the right rearcorner of the cab platform.

Over time, the vibration of an operating machine cancause the battery hold-downs to loosen. To help toprevent loose batteries and the possibility of loosecable connections, tighten the eight locknuts (two perbattery) to a torque of 14 2 Nm (10 1.5 lb ft).

i01835250

Battery or Battery Cable -Inspect/Replace

SMCS Code: 1401-040; 1401-510; 1402-040;1402-510

1. Turn the engine start switch key to the OFFposition. Turn all of the switches to the OFFposition.

2. Turn the battery disconnect switch to the OFFposition. Remove the key.

3. Disconnect the positive battery cable at the battery

disconnect switch. The battery disconnect switchis connected to the machine frame.

Note: Do not allow the disconnected battery cable tocontact the disconnect switch.

4. Disconnect the negative battery cable at thebattery that is connected to the battery disconnectswitch. If the machine has four 12 volt batteries,disconnect the negative battery cables of two ofthe batteries.

5. Make any necessary repairs or replace the battery.

6. Reconnect the negative battery cable at thebattery that is connected to the battery disconnectswitch.

7. Reconnect the positive battery cable at the batterydisconnect switch.

8. Install the key and turn the battery disconnectswitch to the ON position.

i04170030

Belt - Inspect/Adjust/Replace

SMCS Code: 1397-025; 1397-040; 1397-510

Inspect

1. Park the machine on level ground. Lower the

bucket tothe ground. Move the transmissioncontrol switch to the NEUTRAL position andengage the parking brake. Shut off the engine.


2. Open the grill assembly on the right side of themachine.


3. Remove the engine access covers in order to gainaccess to the belt.

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Brake Accumulator - Check


4. Inspect the condition of the serpentine belt (1).The belt deflection should not be more than14 to 20 mm (0.55 to .81 inch) under 110 N (25 lb)

of force. Use a 144-0235Belt Tension Gauge inorder to measure the tension.

Note: If a new belt is installed, recheck the beltadjustment after 30 minutes of operation.

Note: This machine is equipped with a belt tensioner(2). The belt tensioner automatically adjusts the beltto the correct position.

5. Install the engine access covers.

6. Close the grill assembly.

Replace

1. Replace the belt if any of the following conditionsexist:

Excessive cracking

Excessive wear

Excessive damage

2. Park the machine on level ground. Lower thebucket to the ground. Move the transmissioncontrol switch to the NEUTRAL position andengage the parking brake. Shut off the engine.

3. The battery disconnect switch is located on thecontrol panel on the left side of the rear bumper.Turn the battery disconnect switch to the OFFposition.

4. Open the grill assembly on the right side of themachine.

5. Remove the engine access covers in order to gainaccess to the belt.

6. Release the tension on the serpentine belt (1).Insert a ratchet into the square hole in the belttensioner and rotate the belt tensioner in aclockwise direction.

7. Remove the belt.

8. Install a new belt.

9. When you release the tension off the belttensioner, the belt will automatically adjust to thecorrect position. Recheck the belt tension.

10. Turn the battery disconnect switch to the ONposition.

11. Install the engine access covers.

12. Close the grill assembly.

i04402685

Brake Accumulator - Check

SMCS Code: 4263-535

Hydraulic accumulator contains gas and oil underhigh pressure. Improper removal or repair proce-dures could cause severe injury. To remove or re-pair, instructions in the service manual must befollowed. Special equipment is required for test-

ing and charging.

1. Park the machine on level ground and lower thebucket. Ensure that the area is clear of obstaclesand personnel. Block the wheels in order toprevent machine motion.

2. Move the engine start switch to the ON position.

3. Start the engine and run the engine for 1 minute inorder to increase the accumulator pressure. Thealert indicator for the brake oil pressure shouldcome on if the brake system is not at the normal

operating pressure. Release the parking brake.Stop the engine.

4. Move the engine start switch to the ON position.Allow the monitoring system to completely cyclethrough the self test. Depress the service brakepedal until the parking brake indicator comes on.This will decrease the accumulator pressure. Aminimum offive applications should be required.

5. If the parking brake indicator comes on with lessthan five applications of the service brake pedal,measure the nitrogen precharge pressure of theaccumulator.

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104 SEBU8075-11Maintenance SectionBraking System - Test

Your Cat dealerhas the appropriate tools formeasuring the precharge pressure of the brakeaccumulator. Only use dry nitrogen gas forrecharging.

i02060586

Braking System - Test

SMCS Code:4251-081; 4267-081

1. Fasten the seat belt.

2. Make sure that the steering frame lock is in theunlocked position.

3. Park the machine on a hard, dry, level surface.

4. Check the area around the machine. Make surethat the machine is clear of personnel and clear ofobstacles.

The following tests are used to determine whetherthe braking system is functional. These tests are notintended to measure the maximum brake holdingeffort. The required brake holding effort for sustaininga machine at a specific engine rpm varies from onemachine to another machine. The variations includedifferences in the engine setting, the power trainefficiency, the brake holding ability, etc.

Service Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

If the machine begins to move during test, reducethe engine speed immediately and engage theparking brake.

This test is performed when the service brakes areengaged. If the machine begins to move, comparethe engine rpm to the engine rpm of a prior test. Thiswill indicate the amount of system deterioration.

1. Start the engine. Raise the work tool slightly. Applythe service brake. Release the parking brake.

2. Move the hydraulic lockout control to theUNLOCKED position.

3. Place the transmission in THIRD SPEEDFORWARD while the service brakes are applied.

4. Gradually increase the engine speed to high idle.The machine should not move.

5. Reduce the engine speed to low idle. Placethe transmission in neutral. Engage the parkingbrake. Lower the work tool to the ground. Stopthe engine.

If the machine moved during the test, consult your

Caterpillardealer for a brake inspection. Make anynecessary repairs before the machine is returned tooperation.

Parking Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

If the machine begins to move, reduce the enginespeed immediately and apply the service brake

pedal.

This test is performed when the parking brake isengaged. If the machine begins to move, comparethe engine rpm to the engine rpm of a prior test. Thiswill indicate the amount of system deterioration.

1. Start the engine. Raise the work tool slightly.Engage the parking brake.

2. Move the hydraulic lockout control to theUNLOCKED position.

3. Place the transmission in THIRD SPEEDFORWARD while only the parking brake isengaged.

The parking brake indicator light should come on.

4. Gradually increase the engine speed to high idle.The machine should not move.

5. Reduce the engine speed. Place the transmissionin neutral. Lower the work tool to the ground. Stopthe engine.

If the machine moved during the test, consult your

Caterpillar dealer for a brake inspection. Make anynecessary repairs before the machine is returned tooperation.

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Bucket Cutting Edges - Inspect/Replace

i02453840

Bucket Cutting Edges -Inspect/Replace

SMCS Code:6801-040; 6801-510

Personal injury or death can result, if the bucket isnot blocked up. Block the bucket before changingcutting edge.


Check for bolts that are missing or loose. Replaceany missing bolts and tighten any loose bolts.

Reference: For more information, refer toSpecifications, SENR3130, Torque Specificationsor consult your Caterpillar dealer.

Inspect the cutting edges and the end bits. If wear ordamage is evident, use the following procedure toreplace the components.

1. Raise the bucket and place blocking under thebucket. Lower the bucket onto the blocking.

Note: Do not block up the bucket too high. Block upthe bucket enough for removing the cutting edgesand the end bits.

2. Remove bolts (1). Remove cutting edges (2) andthe end bits.

3. Clean the contact surfaces. Inspect the cuttingedges and install the cutting edges.

If the oppositeside of the cutting edge is not worn,use that side. If both sides of the cutting edge areworn, install a new cutting edge.

4. Install bolts (1). Tighten the bolts to the specifiedtorque.

5. Raise the bucket and remove the blocking. Lowerthe bucket to the ground.

6. After a few hours of operation, check the bolts forproper torque.

i02919686

Bucket Linkage and LoaderCylinder Bearings - Lubricate

SMCS Code: 5102-086-BD; 5104-086-BD;

6107-086-BD

Note: This procedure is for machines that are notequipped with the automatic lubrication system.


Typical example

1. Wipe off the fittings before any lubricant is applied.

2. Apply lubricant to pins (1), (2), (3), and (4) throughthe grease fittings.


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106 SEBU8075-11Maintenance SectionBucket Stops - Inspect

In order to lubricate pin (1), apply grease through theremote fitting that is located on the right side of themachine near the articulation joint.


In order to lubricate pins (3) and (4), apply greasethrough the fittings that are located on the undersideof the bucket links.

Note: Pins (5), (6), (7), and (8) do not requiregrease. Consult your Caterpillar dealer, if these pinsexperience excessive leaking, noise, or excessive

temperatures, for further information.

i03247197

Bucket Stops - Inspect

SMCS Code: 6107-040-SQ


Note: Do not use additional hydraulic force in orderto make contact with the bucket stops. Take allmeasurements at the time of initial contact in orderto prevent twisting.

1. Tilt back the bucket completely. Check for unevencontact between the bucket and rack stops (1).

Note: Cracking can occur on the boom or on thebucket if dump stop (2) on the bottom of the boomdoes not fully contact the dump stop on the bottom

of the bucket. Use the following steps to identify thisproblem.

2. Clean dump stop (2) and the dump stop on thebucket.

3. Apply a light coat of grease to the dump stop (2).The grease will help to determine the amount ofcontact that is being made when the dump stop(2) contacts the dump stop on the bucket.

4. Tilt the bucket so that dump stop (2) and the dumpstop on thebucket contact each other. Partially tiltback the bucket in order to inspect the alignment.

5. Inspect the dump stops and determine the amountof contact. If even contact is being made acrossthe dump stops, no further action is required.

Reference:If uneven contact exists, refer to SpecialInstruction, REHS0250, Boom Repair and BucketStop Alignment for instructions about repairing thebucket stops.

i02594942

BucketTips - Inspect/Replace

SMCS Code: 6805-040; 6805-510

Personal injury or death can result from the bucketfalling.

Block the bucket before changing bucket tips.

Note: In order to maximize the life of the bucket tipand the penetration of the bucket tip, the bucket tipcan be rotated.

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Bucket Tips - Inspect/Replace


(1) Usable(2) Removal Procedure(3) Removal Procedure

Check the bucket tips for wear. If the bucket tip has ahole, replace the bucket tip.

Removal


(1) Bucket tip(2) Retainer(3) Adapter

Note: Retainers are often damaged during theremoval process. Caterpillar recommends theinstallation of a new retainer when bucket tips arerotated or replaced.


1. Use a pry bar in order to disengage retainer (2).

2. Use the pry bar in order to remove retainer (2)

from bucket tip (1).

3. Remove bucket tip (1) from adapter (3) with aslight counterclockwise rotation.

4. Clean adapter (3).

Installation

1. Clean the adapter and the area around the latch,if necessary.

2. Install the new bucket tip onto the adapter with aslight clockwise rotation.


3. Install the retainer. Make sure that the retainer'slatch catches under the tip pocket.

4. Make sure that the latch is properly seated bytrying to remove the bucket tip.

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108 SEBU8075-11Maintenance SectionBucket Wear Plates - Inspect/Replace

i02453827

Bucket Wear Plates -Inspect/Replace

SMCS Code:6120-040; 6120-510

Personal injury or death can result from fallingbucket.

When working under or around the bucket or link-age, with the bucket raised, proper support mustbe provided for the bucket and/or the linkage.


Before damage to the bottom of the bucket occurs,

repair damaged bucket wear plates or replacedamaged bucket wear plates.

1. Raise the bucket and block up the bucket.

2. Loosen bolts and remove wear plates.

3. Install new wear plates. Tighten the bolts to thespecified torque.

Reference: For more information, referto Specifications, SENR3130, TorqueSpecifications or consult your Caterpillar dealer.

i03247220

Cab Air Filter - Clean/Replace

SMCS Code:7342-070; 7342-510

Note: The fi lters must be cleaned more often if themachine is being operated in dusty conditions.


1. Lift the cover on the outside rear of the cab.


2. Remove retainer (2) from the cover. Remove freshair filter (1).


3. Remove the filter cover behind the seat. Removethe recirculation filter.

4. Clean the filter elements with pressure air orwash the filter elements in warm water with anonsudsing household detergent.

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Camera - Clean

5. If water was used to wash the filter elements, rinsethe fi lter elements in clean water and allow thefilter elements to air dry thoroughly.

6. Install the recirculation filter and the filter coverbehind the seat.

7. Install fresh airfilter (1) and retainer (2). Close thecover on the outside rear of the cab.

i02816405

Camera - Clean(If Equipped)

SMCS Code:7348-070

In order to maintain sufficient vision, keep the WorkArea Vision System (WAVS) camera lens and the

display clean.

Display


WAVS display

Use a soft, damp cloth in order to clean the display.The display has a soft plastic surface that can beeasily damaged by an abrasive material.The displayis not sealed. Do not immerse the display withliquid.

Camera


The WAVS camera is located on the rear of the machine in thecenter of the fan guard.

Use a damp cloth or water spray in order to cleanthe camera lens. The camera is a sealed unit. Thecamera is not affected by high pressure spray.

The camera is equipped with an internal heater tohelp counteract the effects of condensation, snow,or ice.

Note: For more information on WAVS, refer toOperation and Maintenance Manual, SEBU8157,Work Area Vision System.

i04290956

Case Drain Oil Filters - ReplaceSMCS Code: 5091-510

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, Dealer Ser-

vice Tool Catalog for tools and supplies suitable tocollect and contain fluids on Cat products.


Replace the case drain fi lters when a failure occurswithin the hydraulic system.

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110 SEBU8075-11Maintenance SectionCircuit Breakers - Reset


Three case drain fi lters are located under the access doors in thecab platform.


Left Side of Compartment

(1) Case Drain Filter (Steering)


Right Side of Compartment

(2) Case Drain Filter (Implement)(3) Case Drain Filter (Fan)

1. Stop the engine.

2. Use a strap type wrench to remove the filter.Dispose of the used fi lter properly.

3. Clean the filtermounting base. Make sure thatall of the used gasket is removed from the filtermounting base.

4. Lubricate the gasket of the new fi lter with cleanhydraulic oil.

5. Install the new filter by hand. When the gasketcontacts the filter base, tighten the filter by anadditional3/4 turn.

6. Repeat the above steps for the remaining casedrain fi lters. There are a total of three case drainfilters.

7. Start the engine and run the engine at lowidle. Operate the steering, the brakes, and theimplements.

8. Stop the engine. Inspect the filters for leaks. Make

any necessary repairs. Close all access doors.

i02534101

Circuit Breakers - Reset

SMCS Code: 1420-529

Circuit Breaker Depress the button inorder to reset the circuit breaker. If thesystem is functioning properly, the button

will remain depressed. If the button does not staydepressed, check the appropriate electrical circuit.


The circuit breakers are located under the accessdoor on the right side of the cab platform.

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Cooling System Coolant (ELC) - Change


Engine Start Switch (1) 10 amp

Alternator (2) 105 amp

Main Circuit (3) 105 amp

i02544211

Cooling System Coolant (ELC)- Change

SMCS Code: 1350-044-NL

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 relievethe pressure.


1. Open the small access door (1) on the top ofthe engine compartment. Slowly remove coolingsystem pressure cap in order to relieve systempressure.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.



2. The coolant drain valve is located under the rearof the machine. Open the drain valves. Allow thecoolant to drain into a suitable container.

3. Flush the cooling system with clean water until thedraining water is clean. Close the drain valves.

4. Replace the water temperature regulator.

Reference: Refer to Operation and Maintenance

Manual, Cooling System Water TemperatureRegulator - Replace for the correct procedure.

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112 SEBU8075-11Maintenance SectionCooling System Coolant Extender (ELC) - Add

NOTICETopping off ormixing Cat ELC with other products thatdo not meet Caterpillar EC-1 specifications reducesthe effectiveness of the coolant and shortens coolantservice life.

Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specification forpre-mixed or concentrate coolants. Use only Extenderwith Cat ELC.

Failure to follow these recommendations can result inshortened cooling system component life.

5. Add 268 L (71 US gal) of Extended Life Coolant(ELC).

6. Start the engine. Run the engine without the

cooling system pressure cap until the thermostatopens andthe coolant level stabilizes.

7. Observe sight gauge (2) in order to maintain thecoolantlevels.

8. Install the cooling system pressure cap. Close theaccess door.

Fast Fill

If your machine is equipped with a service center,you maydrain the coolant through the fast fi ll port oryou may add the coolant through a fast fi ll port.


1. Remove the dust cover (3).

2. Attach the hose to the male coupling. Use a127-9087 Nozzle for this port.

3. Drain the coolant or add the coolant, as needed.

Reference:For more information, refer to Operationand Maintenance Manual, Service Center.

i02540933

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352-544-NL

When a Caterpillar Extended Life Coolant (ELC) isused, an Extender must be added to the coolingsystem.

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 relievethe pressure.


1. The cooling system pressure cap is locatedinside the access door (1) on top of the enginecompartment. Slowly remove the cooling systempressure cap.

2. Use a coolant test kit in order to check theconcentration of the coolant.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting andrepair of the product. Be prepared to

collect thefl

uid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.



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Cooling System Coolant Level - Check


3. If necessary, drain enough coolant from theradiator in order to allow the addition of theExtender to the cooling system. The coolant drain

valve is located under the rear of the machine.

NOTICETopping off or mixing Cat ELC with other products thatdo not meet Caterpillar EC-1 specifications reducesthe effectiveness of the coolant and shortens coolantservice life.

Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specification forpre-mixed or concentrate coolants. Use only Extenderwith Cat ELC.

Failure to follow these recommendations can result in

shortened cooling system component life.

4. Add the Extender to the cooling system.

Reference: For the correct amount, refer toSpecial Publication, SEBU6250, CaterpillarMachine Fluids Recommendations or consultyour Caterpillar dealer.

5. Observe the sight gauge in order to maintain thecoolant level within the sight gauge.

6. Install the cooling system pressure cap and close

the access door.

i02540722

Cooling System Coolant Level- Check

SMCS Code: 1350-535-FLV

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is cool

enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Conditioner contains alkali. Avoidcontact with skin and eyes.


1. Observe the sight gauge in order to maintain thecoolant level within the sight gauge.

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114 SEBU8075-11Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain


2. If additional coolant is necessary, remove thecooling system pressure cap that is locatedinside the access door (1) on top of the engine

compartment.

3. Add the appropriate amount of coolant and installthe filler cap.

i02534322

Cooling System CoolantSample (Level 1) - Obtain

SMCS Code:1350-008; 1395-008; 7542

NOTICE

Always use a designated pump for oil sampling, andu s e a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: It is not necessary to obtain a CoolantSample (Level 1) if the cooling system is filledwith Cat ELC (Extended Life Coolant). Coolingsystems that are filled with Cat ELC should havea Coolant Sample (Level 2) that is obtained at

the recommended interval that is stated in theMaintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants.

Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

Cat Diesel Engine Antifreeze/Coolant (DEAC)

Commercial heavy-duty coolant




Note: Level 1 results may indicate a need for

Level 2 Analysis.



The sampling port (1) is located on the thermostathousing. Use the engine access door on the right sideof the machine in order to gain access to the port.

For additional information about coolant analysis, seeSpecial Publication, SEBU6250, Caterpillar MachineFluids Recommendations or consult your Caterpillardealer.

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Cooling System Coolant Sample (Level 2) - Obtain

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of SOS analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.

Supplies forcollecting samples can be obtained fromyour Caterpillar dealer.

Submit the sample for Level 1 Analysis.

i02049802

Cooling System CoolantSample (Level 2) - Obtain

SMCS Code:1350-008; 1395-008; 7542

Reference: Refer to Operation and Maintenance

Manual, Cooling System Coolant Sample (Level 1)- Obtain for the guidelines for proper sampling ofthe coolant.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. Suppliesfor collecting samples can be obtained from yourCaterpillar dealer.

Submit the sample for Level 2 analysis.

Reference:For additional information about coolantanalysis, refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations or

consult your Caterpillar dealer.

i03247291

Cooling System WaterTemperature Regulator -Replace

SMCS Code:1355-510; 1393-010

Replace the thermostat on a regular basis in order toreduce the chance of unscheduled downtime and of

problems with the cooling system.

A new thermostat should be installed after the coolingsystem has been cleaned. Install the thermostatwhile the cooling system is completely drained orwhile the cooling system coolant is drained to a levelthat is below the thermostat housing.

NOTICEFailure to replace the engine's thermostat on a regu-larly scheduled basis could cause severe engine dam-age.

Note: If you are only installing a new thermostat,drain the cooling system coolant to a level that isbelow the thermostat housing.


1. Remove all hoses from the thermostat.

2. Remove the bolts from the thermostat housing.

3. Remove the gasket, the thermostat, and the seal.

NOTICEA used thermostat can be installed if the thermostatconforms to test specifications, and the thermostat isnot damaged. Do not install a used thermostat that hasexcessive buildup or deposits.

NOTICESince Caterpillar engines incorporate a shunt designcooling system, it is mandatory to always operate theengine with a thermostat.

Depending on load, failure to operate with a thermo-stat could result in either an overheating or an over-cooling condition.

NOTICEIf the thermostat is installed incorrectly, it will causethe engine to overheat.

4. Install a new seal in the thermostat housing. Installa new thermostat and a new gasket.

5. Install the hoses.

6. Add extended life coolant until the coolant level isvisible in the sight gauge.

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116 SEBU8075-11Maintenance SectionCrankshaft Vibration Damper - Inspect

i02517124

Crankshaft Vibration Damper- Inspect

SMCS Code:1205-040


The crankshaft vibration damper is located at therear end of the engine compartment.

Damage to the vibration damper or failure of thevibration damper will increase torsional vibrations.These vibrations will result in damage to thecrankshaft and to the other engine components. Adeteriorating vibration damper will cause excessivegear train noise at variable points in the speed range.

Caterpillar recommends replacing the vibration

damper for any of the following reasons:

The engine has had a failure because of a brokencrankshaft.

The SOS oil analysis detected a worn crankshaftfront bearing.

The SOS oil analysis detected a large amount ofgear train wear that is not caused by a lack of oil.

The alignment marks on the hub and on the outerring are not in alignment because the rubber sealhas separated.

The vibration damper can be used again if none ofthe above conditions are found and the damper isnot damaged.

Note: Some wobble on the outer ring of the vibrationdamper is normal.

Consult your Caterpillar dealer for more information.

i03595170

Differential and Final Drive Oil- Change

SMCS Code: 3278-044; 4050-044




Note: Perform this procedure on one axle at a time.


1. Position the wheels so that the final drive drainplug (1) is in the lowest position. This will ensurethat the final drive filler plug (2) is in the correctposition.

2. Push the button on the top of each axle breaker

relief valve in order to relieve any pressure.


3. Remove the final drive plug (1) and allow the oilto drain into a suitable container.

4. Clean the drain plug and install the drain plug.

5. Repeat steps 2 through 4 for the otherfinal drive.

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Differential and Final Drive Oil Level - Check


Front axle


Rear axle

6. Remove the differential drain plug (3) and allowthe oil to drain into a suitable container.

7. Clean the drain plug and install the drain plug.

8. Remove differential filler plug (4). .Fill thedifferential with SAE 50 oil until the oil levelreaches the bottom of the fi ller plug opening.

9. Clean the fi ller plug and install the fi ller plug.

10. Remove the final drive fi ller plug (2). Fill the finaldrive with SAE 50 oil until the oil level reaches the

bottom of the fi ller plug opening.

11. Clean the fi ller plug and install the filler plug.

12. Repeat steps 10 through 11 for the other finaldrive.

Note: Fill each axle with 4.7 L (5 qt) of 1U-9891Additive.

Note: Refer to Operation and Maintenance Manual,Lubricant Viscosities and Refill Capacities for therefill capacity of each axle.

13. If the specifiedamount of oil will not fit in the finaldrives, install the final drive filler plugs. Operatethe machine on level ground for a few minutes inorder to equalize the oil level. Remove the finaldrive fi ller plugs and add the remaining oil.

14. Operate the machine for a few minutes andrecheck the oil level. The oil level should reach thebottom of the filler plug opening.

If the oil level is higher than the fi ller plug opening,do not allow the oil to drain to the proper level.Install the filler plug.

15. Repeat this procedure for the other differentialand final drives.

i02912377

Differential and Final Drive OilLevel - Check

SMCS Code:3278-535-FLV; 4050-535-FLV

Note: Perform this procedure on one axle at a time.


1. Position the wheels so that the final drive drainplug(1) is in the lowest position. This will ensurethat the final drive filler plug (2) is in the correctposition.

2. Push the button on the top of each axle breakerrelief valve in order to relieve any pressure.


3. Remove the final drive filler plug. The oil levelshould be at the bottom of the fi ller plug opening.If necessary, add SAE 50 oil until the oil levelreaches the bottom of the filler plug opening.

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118 SEBU8075-11Maintenance SectionDifferential and Final Drive Oil Sample - Obtain

Note: If the oil level is higher than the filler plugopening, drain the oil to the proper level. Install thefiller plug.


Front axle


Rear axle

4. Remove the differential filler plug. The oil levelshould be at the bottom of the fi ller plug opening.If necessary, add SAE 50 oil until the oil levelreaches the bottom of the fi ller plug opening.

Note: If the oil level is higher than the filler plugopening, drain the oil to the proper level. Install thefiller plug.

5. Repeat the procedure for the other differential andfinal drives.

i02912423

Differential and Final Drive OilSample - Obtain

SMCS Code:3278-008; 4050-008; 4070-008; 7542

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.




1. Operate the machine for a few minutes beforeobtaining the oil sample. This will thoroughly mixthe oil for a more accurate sample.


Final Drive Filler Plug

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Drive Shaft Spline (Center) - Lubricate


Front Differential Filler Plug


Rear Differential Filler Plug

2. The differential and final drives are not equippedwith sampling valves. Obtaining an oil sample willrequire the use of a vacuum pump or equivalentin order to extract the oil from the component.Extract the oil through the filler openings on thedifferential and final drives.

Note: This procedure requires a sample for eachfinal drive and each differential. There will be atotal of three samples per axle and six samples forthis procedure in total. Make sure that you properlyrecord the location of each oil sample.

Reference: For more information, refer to SpecialPublication, SEBU6250, Caterpillar MachineFluids Recommendations and Special Publication,PEHP6001, How To Take A Good Oil Sample.

i04407788

Drive Shaft Spline (Center) -Lubricate

SMCS Code: 3253-086-SN

NOTICETo prevent damage to the seal, articulate the machinefull right or left, before lubricating the splines.

1. Start the engine. Raise the work tool. Release theparking brake.

2. Articulate the machine to the left in order to accessthe drive shaft spline.

3. Lower thework tool to the ground. Stop the engineand engage the parking brake.


Note: Wipe the fitting before you apply any lubricant.

4. Apply lubricant through the fitting on the centerdrive shaft spline.

Note: Refer to this Operation and MaintenanceManual, Lubricant Viscosities for more informationon the types of grease to use.

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120 SEBU8075-11Maintenance SectionDrive Shaft Support Bearing - Lubricate

i04407849

Drive Shaft Support Bearing -Lubricate

SMCS Code: 3267-086-BD

The grease fitting can be accessed from the left sideof the machine.

Note:If necessary, articulate the machine to the rightfor easier access to the drive shaft support bearing.


Note: Wipe the fitting before you apply any lubricant.

1. Apply lubricant through the fitting on the driveshaft support bearing.

Note: Refer to this Operation and MaintenanceManual, Lubricant Viscosities for more informationon the types of grease to use.

i02061807

Electronic Unit Injector -Inspect/Adjust

SMCS Code: 1251-025; 1251-040; 1290-025;1290-040

The Electronic Control module produces highvoltage. To prevent personal injury make sure theElectronic Control Module is not powered and theunit injector solenoids are disconnected.

NOTICEThe camshaftsmust be correctly timed with the crank-shaft before an adjustment of the unit injector lashis made. The timing pins must be removed from thecamshafts before the crankshaft is turned or damage

to the cylinder block will be the result.

The operation of Caterpillar engines with improperadjustments of the electronic unit injector can reduceengine efficiency. This reduced efficiency could resultin excessive fuel usage and/or shortened enginecomponent life.

Adjust theelectronic unit injector at the same intervalas the valve lash adjustment.

Refer to your machine's Service Manual or yourCaterpillar dealer for the complete adjustment

procedure.

i02473339

Engine Air Filter PrimaryElement - Clean/Replace

SMCS Code: 1054-070-PY; 1054-510-PY

Burn Hazard: Engine components may be hot dur-ing and after machine operation.

Hot components can cause serious personal in-jury. Do not contact hot components with bareskin.

To avoid personal injury, always wear eye and faceprotection when using pressurized air.

NOTICEService the airfilter only with the engine stopped. En-

gine damage could result.

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Engine Air Filter Primary Element - Clean/Replace


1. Open the rear access door on either side of themachine. An airfi lter element is located on bothsides of the engine compartment.


2. Loosen the cover latches and remove the aircleaner cover.

Note: The latches for the air cleaner housing maysnap open when you release the latches.

3. Remove airfilter element (2).

4. Clean the inside of the airfilter housing.

5. Install a clean primary airfi lter element.


6. Install the air cleaner cover (1) and tighten thelatches.

Note: Keep the latches for the air cleaner housingaway from the muffler.


8. Repeat this procedure for the air cleaner on theother side of the machine.

Cleaning the Primary Air FilterElement

NOTICECaterpillar recommends certified airfilter cleaning ser-

vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must not

exceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use airfilters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

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122 SEBU8075-11Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

The primary airfi lter element can be used up to sixtimes after the element is properly cleaned. Whenthe primary airfilter element is cleaned, check forrips or tears in the filter material. The primary airfilter element should be replaced at least one timeper year. This replacement should be performed

regardless of the number of cleanings.

NOTICEDo not clean the airfilter elements by bumping or tap-ping. This could damage the seals. Do not use ele-ments with damaged pleats, gaskets, or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary airfi lter element beforecleaning.Inspect the airfilter element for damage tothe seal, the gaskets, and the outer cover. Discardany damaged airfi lter elements.

There are two common methods that are used toclean the primary airfi lter element:

Pressurized air

Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean a primary airfilter element that has not been cleaned more thantwo times. Pressurized air will not remove deposits ofcarbon and oil. Use fi ltered, dry air with a maximumpressure of 207 kPa (30 psi).


Note: When the primary airfilter element is cleaned,always begin with the inside of the filter in order toforce dirt particles toward the outside.

Aim the hose so that the airflows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the stream ofair directly at the primary airfi lter element. Dirt couldbe forced further into the pleats.

Vacuum Cleaning

Vacuum cleaning is another method for cleaning aprimary airfilter element which requires daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuum

cleaning. Vacuum cleaning will not remove depositsof carbon and oil.

Inspecting the Primary Air FilterElements


Inspect the clean, dry primary airfi lter element. Usea 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary airfilterelement. Rotate the primary airfilter element. Inspectthe primary airfi lter element for tears and/or holes.

Inspect the primary airfilter element for light that mayshow through the fi lter material. If it is necessary inorder to confirm the result, compare the primary airfilter element to a new primary airfi lter element thathas the same part number.

Do not use a primary airfi lter element that has anytears and/or holes in the filter material. Do not usea primary airfilter element with damaged pleats,gaskets or seals. Discard damaged primary airfi lterelements.

Storing Primary Air Filter Elements

If a primary airfilter element that passes inspectionwill not be used, the primary airfilter element canbe stored for future use.

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Engine Air Filter Secondary Element - Replace


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An airflow restrictionmay result. To protect against dirt and damage, wrap

the primary airfi lter elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary airfilter element into a box forstorage. For identification, mark the outside of thebox and mark the primary airfilter element. Includethe following information:

Date of cleaning

Number of cleanings

Store the box in a dry location.

i01693619

Engine Air Filter SecondaryElement - Replace

SMCS Code: 1054-510-SE

NOTICEService the airfilter only with the engine stopped. En-gine damage could result.

NOTICE

Always replace the secondary element. Do not at-tempt to reuse it by cleaning. Engine damage couldresult.

Note: Replace the secondary element when youservice the primary element for the third time. Ifa clean primary element has been installed anda warning for the air filter still occurs, replace thesecondary element. Also if the exhaust smokeremains black and a clean primary element has beeninstalled, replace the secondary element.

1. Remove the primary element.

Reference: Refer to Operation and MaintenanceManual, Engine Air Filter Primary Element -Clean/Replace for the correct procedure.


2. Remove the secondary element.


3. Cover the air inlet opening. Clean the inside ofthe air cleaner housing.

4. Inspect the gasket between the air inlet pipe andthe air cleaner housing. Replace the gasket if thegasket is damaged.

5. Uncover the air inlet opening. Install a newsecondary element.

6. Install a clean primary element and the cover forthe air cleaner housing.


8. Repeat the procedure for the other air cleaner.

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124 SEBU8075-11Maintenance SectionEngine Components - Rebuild/Install Reman

i02550809

Engine Components -Rebuild/Install Reman

SMCS Code: 1000-022-MC

Caterpillar recommends this additional maintenancefor the following components on C32 Engines.Consult your Caterpillar dealer for further information.

Alternator

Fuel Transfer Pump

Injectors

Turbochargers

i04408833

Engine Crankcase Breather -Clean

SMCS Code:1317-070

The engine crankcase breathers are located on eachside of the engine. Perform this procedure for eachbreather.

1. Park the machine on level ground. Lower thebucket to the ground. Move the transmissioncontrol switch to the NEUTRAL position andengage the parking brake. Shut off the engine.

2. Open the engine access door on the side of themachine.


3. Loosen breather outlet hose clamp (1). Removethe hose from the breather cover.

4. Loosen breather inlet hose clamp (2) and removebreather (3).

5. Remove the cover from the breather.

6. Check the condition of the cover seal. If the seal isdamaged, replace the seal.

7. Wash the breather element and the cover in clean,nonflammable solvent. Shake the element dry oruse air pressure.

8. Inspect the hose for damage. If necessary, replacethe hose.

9. Install the breather element in the cover.

10. Install breather (3). Tighten breather inlet hoseclamp (2).

11. Install the outlet hose and tighten breather outlethose clamp (1).

12. Close the engine access door.

13. Repeat steps 2 through 12 for the other breather.

i02164781

Engine Mounts - Inspect

SMCS Code: 1152-040

Caterpillar recommends checking the engine mountsfor deterioration and for proper bolt torque. This willhelp to prevent excessive engine vibration that iscaused by improper mounting.

i02534375

Engine Oil Level - Check

SMCS Code: 1000-535-FLV

NOTICEDo not underfill or overfill engine crankcase with oil.Either condition can cause engine damage.

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Engine Oil Sample - Obtain


1. The engine oil level gauge (2) is located insidethe engine access door on the left side of themachine. Open the access door.


2. Check the engine oil level while the engine isstopped. Maintain the engine oil level in theshaded area (A) of the engine oil level gauge.

3. If necessary, add oil through the filler tube (1).


i04409081

Engine Oil Sample - Obtain

SMCS Code:1348-008; 7542


The sampling valve for the engine oil is located on theengine oil fi lter base on the left side of the machine.

Reference:Refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations formore information about obtaining a fluid sample.

i02534690

Engine Oil and Filter - Change

SMCS Code: 1318-510

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact skin.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollectthe fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.



Note: Be sure that you obtain a SOS engine oilsample before you drain the engine oil.

1. Park the machine on a level surface and engagethe parking brake. Stop the engine.


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126 SEBU8075-11Maintenance SectionEngine Oil and Filter - Change

2. The drain valve (1) for the engine oil is locatedunderneath the engine compartment toward therear of the machine. Open the drain valve andallow the oil to drain into a suitable container.

3. Close the drain valve and clean the area around

the drain valve.


4. The engine oil filters (4) are located insidethe access door on the left side of the enginecompartment.

5. Remove the oil fi lter element and discard the fi lterproperly. Make sure that the old seal is removedfrom the filter base.

6. Install a new filter.

a. Apply a thin coat of oil to the seal on the newfilter.

b. Install the new engine oil filter hand tight untilthe seal of the engine oil filter contacts thebase. Note the position of the index marks onthe fi lter in relation to a fixed point on the filterbase.

Note: There are rotation index marks on the engineoil filter that are spaced 90 degrees or 1/4 of a turnaway from each other. When you tighten the engineoil fi lter, use the rotation index marks as a guide.

c. Tighten the fi lter according to the instructionsthat are printed on the filter. Use the indexmarks as a guide. For non-Caterpillarfilters,use the instructions that are provided with thefilter.

Note: You may want to use a Caterpillar strapwrench, or another suitable tool in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.

7. Repeat steps 5 through 6.c for the otherfi lter.

8. The oil filler cap (2) is located above the engine oilfilters. Remove the filler cap.

9. Fill the engine crankcase with 126 L (33 US gal)of clean oil.

10. Clean the fi ller cap and install the fi ller cap.

11. Start the engine and allow the oil to warm. Checkthe engine for leaks.


12. The engine oil level gauge (3) is located to the leftof the fi ller cap. Maintain the engine oil level in theshaded area (A) of the oil level gauge.

13. If necessary, add oil through the fi ller tube.

14. Close the access door and stop the engine.

Fast Fill

If your machine is equipped with a service center,you may drain the engine oil through the fast fi ll portor you may add the engine oil through a fast fi ll port.


1. Remove the dust cover (5).

2. Attach the hose to the male coupling. Use a126-7539 Nozzle for this port.

3. Drain the oil or add the oil, as needed.

Reference:For more information, refer to Operationand Maintenance Manual, Service Center.

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Engine Valve Lash - Check

i04538255

Engine Valve Lash - Check

SMCS Code: 1105-535

In order to perform the valve lash adjustment, refer toSystems Operation, Testing and Adjusting, EngineValve Lash - Inspect/Adjust.

Note: A qualified mechanic should adjust the enginevalve lash because special tools and training arerequired.

i03952000

Engine Valve Rotators - Inspect

SMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to prevent being burned by hot oilor spray.

Caterpillar recommends replacing valve rotators thatare operating improperly. An improperly operatingvalve rotator will shorten valve life because ofaccelerated wear on the valves. Also, metal particlesfrom a damaged valve rotator could fall into thecylinder and damage to the piston head and to the

cylinder head may result.


Start the engine and run the engine at low idle. Watchthe top surface of each valve rotator. Whenever aninlet valve closes or an exhaust valve closes, eachvalve rotator should turn.

If a valve rotator fails to turn, consult your Cat dealerfor service.

i02482098

Engine Water Pump - Inspect

SMCS Code: 1361-040


Failure of the engine water pump may cause severeengine overheating problems such as cracks in thecylinder head or piston seizure.

Visually inspect the water pump for leaks. If you findleaks, all of the seals on the water pump must bereplaced.

Note: For more information, refer to the appropriateDisassembly and Assembly manual for yourmachine's engine.

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128 SEBU8075-11Maintenance SectionEther Starting Aid Cylinder - Replace

i04411153

Ether Starting Aid Cylinder -Replace

SMCS Code: 1456-510-CD

Breathing ether vapors or repeated contact ofether with skin can cause personal injury. Person-al injury may occur from failure to adhere to thefollowing procedures.

Use ether only in well ventilated areas.

Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.

Do not store replacement ether cylinders in livingareas or in the operator's compartment.

Do not store ether cylinders in direct sunlight orat temperatures above 49 C (120 F).

Discard cylinders in a safe place. Do not punctureor burn cylinders.

Keep ether cylinders out of the reach of unautho-rized personnel.


1. Open the access door on the right side of themachine. The ether starting aid cylinder (1) islocated next to the hinge of the access door.

2. Loosen the cylinder retaining clamp. Unscrew theempty ether starting aid cylinder and remove theether starting aid cylinder.

1. Open engine access cover (1) on the right side ofthe machine.

2. Loosen clamp (2) and unscrew ether starting aidcylinder (3).

3. Remove the usedgasket. Install the new gasketthat is provided with the ether starting aid cylinder.Install the new ether starting aid cylinder. Tightenthe clamp.

Note: Install protective cap (4) if an ether starting aid

cylinder will not be in place.

i04411257

Fuel System - Prime

SMCS Code: 1250-548

Personal injury or death may result from failure toadhere to the following procedures.

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.

Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.

Prime the fuel system in order to purge trapped airand in order to fi ll the fuel filter.


Priming pump switch

The switch for the priming pump is located near thehinge of the engine access door on the left side ofthe machine.

Note: The engine start switch must be in the OFFposition in order to prime the fuel system.

1. Hold the priming pump switch upward in orderto activate the electric fuel priming pump. Thepriming pump will fill the engine fuel lines and thefuel filters with fuel.

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Fuel System Primary Filter (Water Separator) - Check/Drain

2. As the air is purged from the fuel system, fuelpressure will increase. Listen for the electric fuelpriming pump to come under load. Do not continuepriming the fuel system after the priming pump isunder load. Do not operate the priming pump formore than 2 minutes.

3. If the engine starts but the engine runs rough,continue to run the engine at low idle until theengine runs smoothly.

4. If the engine does not start after several attempts,consult your Cat dealer.

i04749591

Fuel System PrimaryFilter (Water Separator) -

Check/DrainSMCS Code:1263-535; 1263-543

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

NOTICE

Care must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the machine. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guidefor tools and suppliesto collect and contain fluids in Caterpillar machines.

Dispose of all fluids according to local regulations.


1. The fuel fi lter is located inside the access doorson the left side of the machine.

g02846476

Illustration 167

2. Install a suitable drain hose onto the drain. Placethe other end of the hose into a suitable container.

3. Open the drain. Allow the fluid to drain into thecontainer.

4. After the separator is drained, close the drain byhandpressure only. Dispose of the drained fluid ina safe place.

5. Close the access doors.

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130 SEBU8075-11Maintenance SectionFuel System Primary Filter - Clean/Replace

i02535268

Fuel System Primary Filter -Clean/Replace

SMCS Code:1260-070; 1260-510

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

Personal injury or death can result from engineoverspeed.

If the engine overspeeds, it can cause injury orparts damage.

Be prepared to stop the engine by closing the airoff to the air inlets or by manually pushing down-ward on the governor shutdown rod.

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.

Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.

NOTICE

Do not fill fuel filter with fuel before installing the fuelfilter. Contaminated fuel causes accelerated wear tofuel system parts.

Note: In order to reduce contaminatio

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