994f mantenimieto

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7885-12January 2011

Operation andMaintenanceManual994F Wheel Loader4421-Up (Machine)

SAFETY.CAT.COM

SEBU7885-12 91Maintenance Section

Maintenance Interval Schedule

i04174489

Maintenance Interval ScheduleSMCS 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, including all adjustments, the use ofproper lubricants, fluids, filters, and the replacementof components due to normal wear and aging. Failureto adhere to proper maintenance intervals andprocedures may result in diminished performance ofthe product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

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

Note: If Cat HYDO Advanced 10 hydraulic oil is used,the hydraulic oil change interval will change. Thenormal interval of 2000 hours is extended to 3000hours. S·O·S services may extend the oil changeeven longer. Consult your Cat dealer for details.

When Required

Automatic Lubrication Grease Tank - Fill .............. 94Automatic Lubrication System Components -Check .................................................................. 94Battery - Recycle .................................................. 97Battery or Battery Cable - Inspect/Replace .......... 98Bucket Tips - Inspect/Replace ............................ 101Circuit Breakers - Reset ...................................... 105Engine Air Filter Primary Element - Clean/Replace .............................................................. 116Engine Air Filter Secondary Element - Replace .. 118Engine Air Precleaner - Clean ............................. 119Ether Starting Aid Cylinder - Replace ................. 126Frame - Inspect ................................................... 127Fuel System - Prime ........................................... 128Fuses - Replace .................................................. 130High Intensity Discharge Lamp (HID) - Replace .. 132High Pressure Screens - Clean/Replace ............ 133Hydraulic System Return Screen - Replace ....... 150Oil Filter - Inspect ................................................ 152Radiator Core - Clean ......................................... 159Seat Side Rails - Adjust ...................................... 161Secondary Steering - Test .................................. 161Transmission Magnetic Screen - Clean .............. 163Window Washer Reservoir - Fill .......................... 167Window Wiper - Inspect/Replace ........................ 167

Windows - Clean ................................................. 167

Every 10 Service Hours or Daily

Air Tank Moisture and Sediment - Drain ............... 93Backup Alarm - Test .............................................. 96Bucket Cutting Edges - Inspect/Replace ............ 100Bucket Wear Plates - Inspect/Replace ............... 103Cooling System Coolant Level - Check .............. 109Engine Oil Level - Check .................................... 121Fuel Tank Water and Sediment - Drain ............... 130Hydraulic System Oil Level (Brake Cooling) -Check ................................................................ 147Hydraulic System Oil Level (Implement) -Check ................................................................ 147Hydraulic System Oil Level (Steering, Brake) -Check ................................................................ 149Oil Renewal System Oil Level - Check ............... 152Pump Drive (Front) Oil Level - Check ................. 157Seat Belt - Inspect .............................................. 160Steering Cylinder Bearings - Lubricate ............... 162Steering Stop - Check ......................................... 162Transmission Oil Level - Check .......................... 165

Every 50 Service Hours or Weekly

Cab Air Filter - Clean/Replace ............................ 104Collet Pin Bolt Torque - Check ............................ 105Tire Inflation - Check ........................................... 162

Initial 250 Service Hours

Engine Valve Lash and Bridge - Check .............. 125Engine Valve Rotators - Inspect ......................... 125

Every 250 Service Hours

Engine Oil Sample - Obtain ................................ 121

Every 250 Service Hours or Monthly

Alternator - Inspect ............................................... 93Axle Oscillation Bearings - Lubricate .................... 96Battery - Clean ...................................................... 97Belts - Inspect/Adjust/Replace .............................. 98Braking System - Test ........................................... 99Differential and Final Drive Oil Level - Check ...... 114Drive Shaft Spline (Center) - Lubricate ................ 115Drive Shaft Support Bearing - Lubricate .............. 115Engine Oil and Filter - Change ........................... 122Pump Drive Shaft (Front) - Lubricate .................. 158Pump Drive Shaft Support Bearing (Rear) -Lubricate ........................................................... 158

Initial 500 Service Hours

Seat Side Rails - Adjust ...................................... 161

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

Cooling System Coolant Sample (Level 2) -Obtain ................................................................ 110

92 SEBU7885-12Maintenance SectionMaintenance Interval Schedule

Every 500 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 109Differential and Final Drive Oil Sample - Obtain .. 114Hydraulic System Oil Sample (Implement) -Obtain ............................................................... 149Hydraulic System Oil Sample (Steering, Brake) -Obtain ............................................................... 150Pump Drive Oil Sample - Obtain ......................... 157Transmission Oil Sample - Obtain ...................... 166

Every 500 Service Hours or 3 Months

Engine Crankcase Breather - Clean ................... 120Fuel System Primary Filter - Clean/Inspect/Replace ............................................................. 128Fuel System Secondary Filter - Replace ............ 129Fuel Tank Cap and Strainer - Clean ................... 129Hydraulic System Oil Filter (Implement Pump CaseDrain) - Replace ................................................ 143Hydraulic System Oil Filter (Pilot) - Replace ....... 144Hydraulic System Oil Filter (Steering Pump CaseDrain) - Replace ................................................ 146Power Train Oil Filter (Transmission, TorqueConverter) - Replace ......................................... 153Pump Drive (Front) Oil Filter - Change ............... 156

Every 1000 Service Hours or 6 Months

Battery Hold-Down - Tighten ................................. 97Pump Drive (Front) Oil - Change ........................ 154Rollover Protective Structure (ROPS) - Inspect .. 160Transmission Oil - Change ................................. 163

Every 1000 Service Hours or 1 Year

Hydraulic System Oil (Steering, Brake) -Change ............................................................. 139

Every 2000 Service Hours or 1 Year

Air Dryer Desiccant - Replace .............................. 93Axle Oil Cooler Screens - Clean/Replace ............. 95Brake Accumulator - Check .................................. 99Differential and Final Drive Oil - Change ............. 112Hydraulic System Oil (Brake Cooling) - Change .. 134Hydraulic System Oil (Implement) - Change ...... 136Hydraulic System Oil Filter (Hydraulic Cooler Screen)- Clean .............................................................. 142Hydraulic System Oil Filter (Steering Cooler Screen)(Brake Cooler Screen) - Clean .......................... 145Hydraulic Tank Breaker Relief Valve - Clean ...... 151Receiver Dryer (Refrigerant) - Replace .............. 159

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ................................................................ 110

Every 3000 Service Hours or 2 Years

Crankshaft Vibration Damper - Inspect ................ 112

Engine Mounts - Inspect ..................................... 121

Every 3 Years After Date of Installation orEvery 5 Years After Date of Manufacture

Seat Belt - Replace ............................................. 161

Every 4000 Service Hours or 2.5 Years

Engine Valve Lash and Bridge - Check .............. 125Engine Valve Rotators - Inspect ......................... 125


Starting Motor - Inspect ...................................... 162Turbocharger - Inspect ........................................ 166


Cooling System Coolant Extender (ELC) - Add .. 108Cooling System Pressure Cap - Clean/Replace .. 111


VIMS Module Battery - Replace ......................... 166


Cooling System Water Temperature Regulator -Replace .............................................................. 111Engine Water Pump - Inspect ............................. 125

Every 9500 Service Hours or 1 892 705 L (500000 US gal) of Fuel

Engine Components - Replace/Install Reman .... 120

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 106

Every 19 000 Service Hours or 3 785 410 L (1000 000 US gal) of Fuel

Engine Components - Clean/Inspect, Rebuild/InstallReman, Install New ............................................ 119


Air Dryer Desiccant - Replace

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Air Dryer Desiccant - ReplaceSMCS Code: 4285-510-DSS

g01138821Illustration 79


The air dryer is located under the cab platform on theright side of the machine.

When the desiccant cartridge in the air dryer fails toabsorb water, the desiccant cartridge must be rebuiltor the desiccant cartridge must be replaced.

Check for moisture in the air reservoirs.

If there is moisture in the air reservoirs, replace thedesiccant cartridge or rebuild the desiccant cartridge.Consult your Caterpillar dealer for information aboutreplacing the desiccant cartridge and for instructionsfor rebuilding the desiccant cartridge.

i02339510

Air Tank Moisture andSediment - DrainSMCS Code: 1466-543-M&S


The air tank is located on the right side of the cabplatform.

Push down on the drain valve in order to drain themoisture and the sediment from the air tank.

i02118879

Alternator - InspectSMCS Code: 1405-040

Inspect the alternator for loose connections and forproper battery charging.

When the engine is operated only for short periods oftime, the batteries may not fully recharge. Make surethat the alternator is functioning properly.

Reference: Refer to Systems Operation/Testingand Adjusting, SENR1123, “3500B and 3500BHigh Displacement Engines For Caterpillar BuiltMachines”, “Electrical System” for information abouttesting the alternator.

94 SEBU7885-12Maintenance SectionAutomatic Lubrication Grease Tank - Fill

i02223981

Automatic Lubrication GreaseTank - FillSMCS Code: 7540-544-TNK



The grease tank for the automatic lubrication systemis located on the left side of the machine.

The grease tank provides lubrication for the followingitems:

• Axle oscillation bearings

• Linkage bearings

• Lift cylinder bearings

• Tilt cylinder bearings

• Steering cylinder bearings

• Articulation bearings

• Fan bearing

• Belt adjusting pulley

• Lower bucket pivot bearings

If any of the remote lines become damaged, install afitting in place of the remote line. Lubricate the itemat the fittings until the remote lines can be replaced.

The grease tank can be filled by the fast fill servicegroup. The grease tank can contain 86 kg (190 lb)of lubricant.

i02331711

Automatic Lubrication SystemComponents - CheckSMCS 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 Caterpillar dealer.


Axle Oil Cooler Screens - Clean/Replace


994F Wheel Loader

(A) A-Pin(B) B-Pin(C) C-Pin(D) D-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 for an excessive buildup of grease at eachpin joint.

Reference: For adjustment information, refer toOperation and Maintenance Manual, “Capacities(Refill), Settings of the the Injectors for theAutolube System”.

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

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

i02223943

Axle Oil Cooler Screens -Clean/ReplaceSMCS Code: 1365-070-Z3; 1365-510-Z3

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, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

Clean the screens whenever there is a failure in thebrake system.

96 SEBU7885-12Maintenance SectionAxle Oscillation Bearings - Lubricate

There is a screen for each wheel. There is a total offour screens that must be cleaned.


1. Make sure that there is no pressure in the linesfor the axle oil. Loosen the bolts on the tubeassemblies and drain the oil from the lines into asuitable container. Dispose of the oil properly.

2. Remove the tube assemblies and the screens.Clean the screens in a clean, nonflammablesolvent.

3. Install the screens, the tube assemblies, and thenew seals. Tighten the bolts.

4. Check for leaks. Make any necessary repairs.

i02274117

Axle Oscillation Bearings -LubricateSMCS Code: 3268-086-BD; 3278-086-BD

Note: The axle oscillation bearings are lubricatedby the automatic lubrication system. If any of thelubrication lines are damaged, install a fitting atthe bearing in order to lubricate the bearing. Thedamaged line must be replaced.


Machines that are not equipped with the automaticlubrication system have two remote fittings near thearticulation joint on the left side of the machine.

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

2. Apply lubricant through the two remote fittings.

i02857310

Backup Alarm - TestSMCS Code: 7406-081

Apply the service brake. Place the transmission inreverse.

Turn the engine start switch to the ON position inorder to perform the test.

The backup alarms should start to soundimmediately. The alarms will continue to sound untilthe transmission is placed into neutral or into forward.


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


Battery - Clean


i02235394

Battery - CleanSMCS Code: 1401-070


Open the battery compartment of the left side of thecab 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 - RecycleSMCS 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

i02235575

Battery Hold-Down - TightenSMCS Code: 7257-527


Open the battery compartment on the left side of thecab platform.


98 SEBU7885-12Maintenance SectionBattery or Battery Cable - Inspect/Replace

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 locknuts to a torque of14 ± 2 N·m (10 ± 1.5 lb ft).

i01946377

Battery or Battery Cable -Inspect/ReplaceSMCS 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 batterydisconnect 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.

i02325339

Belts - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510

Note: Always stop the engine before you inspect thebelts and before you service the belts.

Alternator Belt


1. Open the lower rear access doors on both sidesof the machine.

2. Inspect the condition of the alternator belts.

3. Check the tension of the alternator belts.

The tension of a used alternator belt with morethan 30 minutes of operation at rated speed shouldbe 489 ± 44 N (110 ± 10 lb). The tension of a newalternator belt with 30 minutes of operation or lessat rated speed should be 800 ± 22 N (180 ± 5 lb).

If the alternator belts require adjustment orreplacement, proceed to Step 4.


4. Loosen mounting bolts (1) and adjusting locknut(2).

5. Turn adjusting nut (3) until the correct belt tensionis reached.

6. Tighten adjusting locknut (3) to a torque of110 ± 10 N·m (81.1 ± 7.4 lb ft).

7. Tighten mounting bolts (1).


Brake Accumulator - Check

8. Recheck the belt tension. If the tension isincorrect, repeat the adjustment procedure.

9. Close the lower rear access doors on both sidesof the machine.

Air Conditioner Belt


1. Open the upper forward access door on the leftside of the machine.

2. Inspect the condition of the air conditioner belt.Inspect the belt for wear and for cracking.


3. If the belt requires replacement, perform thefollowing steps.

4. Turn the belt tensioner in order to release thetension from the belt.

5. Remove the belt.

6. Install a new belt.

7. Turn the belt tensioner back into the position.

8. Close the upper forward access door on the leftside of the machine.

i02113934

Brake Accumulator - CheckSMCS Code: 4263-535


1. Move the engine start switch to the ON position.The alert indicator for the brake oil pressureshould come on if the brake system is not at thenormal operating pressure.

2. Start the engine and run the engine for one minutein order to increase the accumulator pressure. Thealert indicator for the brake oil pressure shouldgo off. Stop the engine.

3. Depress the service brake pedal until the alertindicator for the brake oil pressure comes on.This will decrease the accumulator pressure. Aminimum of five applications should be required.

4. If the alert indicator for the brake oil pressurecomes on with less than five applications ofthe service brake pedal, measure the nitrogenprecharge pressure of the accumulator.

Note: Your Caterpillar dealer has the appropriatetools for measuring the precharge pressure ofthe brake accumulator. Only use dry nitrogen forrecharging.

Reference: Refer to Systems Operation/Testing andAdjusting, RENR6314, “994F Wheel Loader BrakingSystem” for additional information.

i02857312

Braking System - TestSMCS Code: 4251-081; 4267-081

1. Fasten the seat belt.

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

100 SEBU7885-12Maintenance SectionBucket Cutting Edges - Inspect/Replace

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 yourCaterpillar dealer 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 brakepedal.

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.

Note: If THIRD SPEED FORWARD is locked out,then use SECOND SPEED FORWARD.

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

i02235700

Bucket Cutting Edges -Inspect/ReplaceSMCS Code: 6801-040; 6801-510

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


Bucket Tips - Inspect/Replace


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

Reference: Refer to Specification, RENR2512,“Ground Engaging Tool Torques” for the correcttorque.

2. Inspect the cutting edges. If wear or damage isevident, use the following procedure to replacethe components.

a. Raise the bucket and place blocking under thebucket. Lower the bucket to the blocking.

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

b. Remove bolts (1). Remove cutting edge (2).

c. Clean the contact surfaces. Inspect the cuttingedge and install the cutting edge.

If the opposite side of the cutting edge is notworn, use that side. If both sides of the cuttingedge are worn, install a new cutting edge.

d. Install bolts (1). Tighten the bolts to thespecified torque.

e. Raise the bucket and remove the blocking.Lower the bucket to the ground.

f. After a few hours of operation, check the boltsfor proper torque.

i03657242

Bucket Tips - Inspect/ReplaceSMCS Code: 6805-040; 6805-510

Personal injury or death can result from the bucketfalling.

Block the bucket before changing bucket tips.

Bucket Tips


(1) Usable(2) Replace the tip.(3) Replace the tip.

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

1. Remove the pin from the bucket tip. The pin canbe removed by one of the following methods.

• Use a hammer and a punch from the retainerside of the bucket to drive out the pin.

• Use a Pin-Master. Follow Step 1.a through Step1.c for the procedure.

102 SEBU7885-12Maintenance SectionBucket Tips - Inspect/Replace

g00590670Illustration 100(4) Back of Pin-Master(5) Extractor

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

b. Align extractor (5) with the pin.

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


(6) Retainer(7) Retaining washer(8) Adapter

2. Clean the adapter and the pin.

3. Fit retainer (6) into retaining washer (7). Installthis assembly into the groove that is in the sideof adapter (8).


4. Install the new bucket tip onto the adapter.

Note: The bucket tip can be rotated by 180 degrees inorder to allow greater penetration or less penetration.

5. Drive the pin through the bucket tip. The pin canbe installed by using one of the following methods:

• From the other side of the retainer, drive thepin through the bucket tip, the adapter, and theretainer.

• Use a Pin-Master. Follow Step 5.a through Step5.e for the procedure.

Note: To correctly install the pin into the retainer, thepin must be driven in from the right side of the tooth.Improper installation of the pin can result in the lossof the bucket tip.

g00590666Illustration 103(4) Back of Pin-Master(9) Pin setter(10) Pin holder

a. Insert the pin through the bucket tooth.

b. Place the Pin-Master over the bucket tooth andlocate the pin in the hole of holder (10).


Bucket Wear Plates - Inspect/Replace

c. Strike the tool with a hammer at the back of thetool (4) in order to start the pin.

d. Slide pin holder (10) away from the pin androtate the tool slightly in order to align pin setter(9) with the pin.

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

6. After you drive the pin, make sure that the retainerfits snugly into the pin groove.

K-Series Tip

Removal


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 (5).

2. Use the pry bar in order to remove retainer (5)from bucket tip (4).

3. Remove bucket tip (4) from adapter (6) with aslight counterclockwise rotation.

4. Clean adapter (6).

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.

i02274391

Bucket Wear Plates -Inspect/ReplaceSMCS 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.

104 SEBU7885-12Maintenance SectionCab Air Filter - Clean/Replace


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”.

i02235754

Cab Air Filter - Clean/ReplaceSMCS Code: 7342-070; 7342-510

Note: The filters 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 (1) from the cover. Slide pin (2)out of the retainer. Remove fresh air filter (3).


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.

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

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

7. Install fresh air filter (3) and retainer (1). Close thecover on the outside rear of the cab.


Circuit Breakers - Reset

i02274475

Circuit Breakers - ResetSMCS Code: 1420-529

Circuit Breaker – Push the button inwardin order to reset the circuit breakers. If thesystem is functioning properly, the button

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


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



Engine Start Switch (1) – 10 amp

Engine Control Module (2) – 15 amp

Main Circuit (3) – 105 amp

Alternator (4) – 80 amp

Alternator (5) – 80 amp

i02104417

Collet Pin Bolt Torque - CheckSMCS Code: 6107-535-BC

Note: After you operate a new machine for the initial50 service hours, perform the following maintenanceprocedure. After you operate a machine with anewly installed bucket for the initial 50 service hours,perform the following maintenance procedure. Ifneither of these conditions exist, disregard thefollowing maintenance procedure.


Torque the bolts again on the collet pins for pin joints(A), (C), (E), (D), (F), and (Y).

1. Torque the bolts to 1800 ± 200 N·m(1330 ± 150 lb ft).

106 SEBU7885-12Maintenance SectionCooling System Coolant (ELC) - Change

NOTICEWhen striking the collet with a large hammer, protectthe bolt head with a spacer to prevent bolt damage.

2. Strike the collet until the bolt torque decreases to950 N·m (750 lb ft) or less.


4. Strike the collet until the bolt torque decreases to1600 N·m (1200 lb ft) or less.


i02274489

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-044-NL

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 cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure 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 Coolant Additive contains alkali.Avoid contact with skin and eyes.

NOTICEDo not change the coolant until you read and under-stand the material in the Cooling System Specifica-tions section.

NOTICEMixing Cat Extended Life Coolant (ELC) with otherproducts reduces the effectiveness of the coolantand shortens coolant life. Use only Caterpillar prod-ucts or commercial products that have passed theCaterpillar EC-1 specifications for premixed or con-centrate coolants. Use only Cat Extender with CatELC. Failure to follow these recommendations couldresult in damage to the cooling systems components.

If ELC cooling system contamination occurs, refer toOperation and Maintenance, “Extended Life Coolant(ELC)” under the topic ELC Cooling System Contam-ination.

This machine was factory filled with Cat Extended LifeCoolant.




Reference: If the coolant in the machine is changedto Extended Life Coolant from another type ofcoolant, refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations”.

If the coolant is dirty or if you observe any foamingin the cooling system, change the coolant before therecommended interval.

It is important to replace the water temperatureregulator in order to avoid any unexpected failureof the water temperature regulator. This is a goodpreventive maintenance practice that reduces thechances of unscheduled downtime. Failure to replacethe water temperature regulator on a regularlyscheduled basis could cause severe engine damage.

Note: If you are only replacing the water temperatureregulator, drain the coolant from the cooling systemso that the level of the coolant is below the housingfor the water temperature regulator.

Always operate Caterpillar engines with a watertemperature regulator because these engines have ashunt design cooling system.


Cooling System Coolant (ELC) - Change

Note: Water temperature regulators can be reusedif the water temperature regulators meet certaintest specifications. The tested water temperatureregulators must not be damaged and the tested watertemperature regulators must not have an excessivebuildup of deposits.

1. Stop the engine. Allow the radiator to coolsufficiently.



2. Open the access doors on the top of the cabplatform at the rear of the machine. Slowly removecooling system pressure caps (2) in order torelieve system pressure.



3. Open both drain valves under the rear of themachine. Allow the coolant to drain into a suitablecontainer. Dispose of the used coolant properly.

4. Flush the cooling system with clean water until thedraining water is clean. Close the drain valves.Dispose of the drained water properly.

5. Replace the water temperature regulator.

Reference: Refer to Disassembly and Assembly,SENR1126, “3500B Engines Built for CaterpillarMachines” for the correct procedure.

6. Add the coolant solution.

Reference: Refer to Operation and MaintenanceManual, “Capacities (Refill)” for the capacity of thecooling system.

7. Start the engine. Run the engine without coolingsystem pressure caps (2) until the thermostatopens and the coolant level stabilizes.

8. Start the engine. Run the engine without installingcooling system pressure caps (2) until the watertemperature regulator opens and the coolant levelstabilizes.

9. Check the coolant level. Maintain the coolantwithin the red range of sight gauges (1).

10. Install cooling system pressure caps (2).

108 SEBU7885-12Maintenance SectionCooling System Coolant Extender (ELC) - Add

i02274534

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-544-NL









When a Caterpillar Extended Life Coolant (ELC)is used, an extender must be added to the coolingsystem.

Reference: Refer toOperation and MaintenanceManual, “Maintenance Interval Schedule” for theproper service interval.

The amount of extender is determined by the coolingsystem capacity.

1. Stop the engine. Allow the radiator to coolsufficiently.



2. Open the access doors on the top of the cabplatform at the rear of the machine. Then, slowlyremove cooling system pressure caps (2) in orderto relieve system pressure.



Cooling System Coolant Level - Check


3. If necessary, drain enough coolant from theradiator in order to allow the addition of theExtender. The coolant drain valves are locatedat the rear of the machine under the enginecompartment. Dispose of the used coolantproperly.

4. Add 9 L (9.5 qt) of Extender to the cooling system.

5. Check the coolant level. Maintain the coolant levelwithin the red range of the sight gauges (1).

6. Check the condition of cooling system pressurecaps (2)and the seal. If there is damage or aresidue buildup on the caps, replace coolingsystem pressure caps (2).

7. Install cooling system pressure caps (2).

i02274527

Cooling System Coolant Level- CheckSMCS Code: 1350-535-FLV


The coolant level gauges are located under accessdoors on the top of the cab platform at the rear ofthe machine.


Maintain the coolant level within the red range ofsight gauges (1).

If necessary, stop the engine and allow the radiator tocool sufficiently. Then, slowly remove cooling systempressure caps (2) and add coolant.

If it is necessary to add coolant daily, check for leaks.

i02231902

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 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.

Note: Level 1 results may indicate a need forLevel 2 Analysis.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

110 SEBU7885-12Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

The cooling system is equipped with two samplingvalves.

g01125907Illustration 125The sampling valve is located on the left side of the machinebehind the bottom rear access door.

g01125909Illustration 126The sampling valve is located on the right side of the machinebehind the bottom rear access door.

Open the access doors on the right and the left of themachine. Remove the caps from the sample valves.

Attach a hose to a couple. Install the threaded end ofthe coupling into the sample valve in order to unseatthe internal drain valve.

Take a sample from each of the sample valves. Putthe caps on the valves. Close the access doors.

Submit the samples for Level 1 analysis.

Reference: For additional information about coolantanalysis, refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations” orconsult your Caterpillar dealer.

i02126353

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 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.

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

Reference: Refer to Operation and MaintenanceManual, “Cooling System Coolant Sample (Level 1)- Obtain” for the guidelines for proper sampling ofthe coolant.

Submit the sample for Level 2 analysis.

Reference: For additional information about coolantanalysis, refer toSpecial Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations” orconsult your Caterpillar dealer.


Cooling System Pressure Cap - Clean/Replace

i02339536

Cooling System Pressure Cap- Clean/ReplaceSMCS Code: 1382-070; 1382-510








1. Remove the pressure caps slowly in order torelieve the pressure.

2. Inspect the pressure caps for damage, for foreignmaterial, and for deposits.

3. Clean the pressure caps with a clean cloth orreplace the pressure caps, if necessary.

4. Install the pressure caps.

i02100387

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510; 1393-010

NOTICECaterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a ther-mostat installed.

If the thermostat is installed wrong, it will cause theengine to overheat. Inspect gaskets before assemblyand replace if worn or damaged.

Replace the water temperature regulator and theregulator housing gasket while the cooling systemis being cleaned. If you only need to replace thewater temperature regulator, drain the cooling systemcoolant to a level that is below the regulator housing.

Reference: Refer to Disassembly and Assembly,SENR1126, “3500B Engines Built for CaterpillarMachines” for the correct procedure for replacing thewater temperature regulator.

112 SEBU7885-12Maintenance SectionCrankshaft Vibration Damper - Inspect

i02274683

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040


The crankcase vibration damper is located at the rearend 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 vibrationdamper for any of the following reasons:

• The engine has had a failure because of a brokencrankshaft.

• The S·O·S oil analysis detected a worn crankshaftfront bearing.

• The S·O·S oil analysis detected a large amount ofgear train wear that is not caused by a lack of oil.

The vibration damper can be used again if none ofthe above conditions are found and the vibrationdamper is not damaged.

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

Reference: Refer to Disassembly and Assembly,SENR1126, “3500B Engines Built for CaterpillarMachines” for more information about replacing thevibration damper.

i02236207

Differential and Final Drive Oil- ChangeSMCS Code: 3278-044; 4050-044





1. Position the wheels so that the final drive drainplugs are facing downward.

2. Remove the final drive drain plugs and allow theoil to drain into a suitable container. Dispose of theused oil properly.

3. Clean the drain plugs and install the drain plugs.


Differential and Final Drive Oil - Change

g01127754Illustration 131Front Differential

g01127756Illustration 132Rear Differential

4. Remove differential drain plugs (1) and allow theoil to drain into a suitable container. Dispose of theused oil properly.

5. Clean the drain plugs and install the drain plugs.

6. Remove differential filler plugs (2). Fill thedifferentials to the bottom of the filler plugopenings.

Reference: Refer to Operation and MaintenanceManual, “Lubricant Viscosities and RefillCapacities” for the correct type of oil and for thecorrect amount of oil.

7. Clean the filler plugs and install the filler plugs.


8. Position each wheel so that the filler plugs for thefinal drives are flush with the centerline of eachwheel. Remove the filler plugs.

9. Fill the final drives to the bottom of the filler plugopenings.


10.Clean the filler plugs and install the filler plugs.

11. If the specified amount 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 in the axles.

12.Remove the final drive filler plugs and add theremaining oil.

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

Note: If the oil level is higher than the filler plugopening, do not allow the oil to drain to the properlevel. Install the filler plug.

114 SEBU7885-12Maintenance SectionDifferential and Final Drive Oil Level - Check

i02236806

Differential and Final Drive OilLevel - CheckSMCS Code: 3278-535-FLV; 4050-535-FLV


1. Position the wheels so that the filler plugs for thefinal drives are flush with the centerline of thewheels.

2. Remove the oil filler plugs. The oil level should beat the bottom of the filler plug openings. Add oil, ifnecessary.


Note: If the oil level is higher than the filler plugopenings, do not allow the oil to drain to the properlevel. Install the filler plugs.


Front Differential

g01128101Illustration 136Rear Differential

3. Remove the differential filler plugs. The oil levelshould be at the bottom of the filler plug openings.Add oil, if necessary.


Note: If the oil level is higher than the filler plugopenings, do not allow the oil to drain to the properlevel. Install the filler plug.

i02237079

Differential and Final Drive OilSample - ObtainSMCS Code: 3278-008; 4050-008; 4070-008; 7542


Front Axle


Drive Shaft Spline (Center) - Lubricate

g01128101Illustration 138Rear Axle

The axles are not equipped with sampling valves.Obtaining a sample of the differential and final driveoil will require a vacuum pump or an equivalent.Withdraw the oil through the filler opening of eachaxle.

i02274698

Drive Shaft Spline (Center) -LubricateSMCS Code: 3253-086-SN

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



Wipe off the fitting before you apply any lubricant.

Apply lubricant through the fitting on the drive shaftspline until the relief overruns.

i01298803

Drive Shaft Support Bearing -LubricateSMCS Code: 3267-086-BD



116 SEBU7885-12Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

Wipe off the fitting before any lubricant is applied.

Apply lubricant through the fitting on the right side ofthe articulation joint.

i02331730

Engine Air Filter PrimaryElement - Clean/ReplaceSMCS Code: 1054-070-PY; 1054-510-PY

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

There is a total of four engine air filters on the top ofthe cab platform. Perform this procedure for eachprimary element.


1. Remove the cover on the air filter housing.


2. Remove the primary element from the air filterhousing.


3. Clean the inside of the air filter housing.

4. Install a clean primary air filter element. For moreinformation, refer to “Cleaning the Primary AirFilter Element”.

5. Install the cover on the air filter housing.

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

Cleaning the Primary Air FilterElement

NOTICECaterpillar recommends certified air filter 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 notexceed 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 air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.


Engine Air Filter Primary Element - Clean/Replace

The primary air filter element can be used up tosix times after the element is properly cleaned andinspected. When the primary air filter element iscleaned, check for rips or tears in the filter material.The primary air filter element should be replaced atleast one time per year. This replacement should beperformed regardless of the number of cleanings.

NOTICEDo not clean the air filter 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 air filter element beforecleaning. Inspect the air filter element for damage tothe seal, the gaskets, and the outer cover. Discardany damaged air filter elements.

There are two common methods that are used toclean the primary air filter 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 filtered, dry air with a maximumpressure of 207 kPa (30 psi).


Note:When the primary air filter 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 air flows 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 air filter element. Dirt couldbe forced further into the pleats.

Vacuum Cleaning

Vacuum cleaning is another method for cleaning aprimary air filter element which requires daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuumcleaning. Vacuum cleaning will not remove depositsof carbon and oil.

Inspecting the Primary Air FilterElements


Inspect the clean, dry primary air filter element. Usea 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air filterelement. Rotate the primary air filter element. Inspectthe primary air filter element for tears and/or holes.Inspect the primary air filter element for light that mayshow through the filter material. If it is necessary inorder to confirm the result, compare the primary airfilter element to a new primary air filter element thathas the same part number.

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

Storing Primary Air Filter Elements

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

118 SEBU7885-12Maintenance SectionEngine 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, wrapthe primary air filter elements in Volatile CorrosionInhibited (VCI) paper.

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

• Date of cleaning

• Number of cleanings

Store the box in a dry location.

i02331799

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510-SE

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

NOTICEAlways 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, replace the secondaryelement if the exhaust smoke remains black afterinstallation of a clean primary element.

There is a total of four engine air filters on the top ofthe cab platform. Perform this procedure for eachsecondary element.


1. Remove the cover on the air filter housing.


2. Remove the primary element.

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



Engine Air Precleaner - Clean

3. Remove the secondary element From the aircleaner housing.

4. Cover the air inlet opening. Clean the inside ofthe air filter housing.

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

6. Install a clean primary element, a clean primaryfilter, and the cover.

i02237503

Engine Air Precleaner - CleanSMCS Code: 1055-070

NOTICEService the air cleaner only with the engine stopped.Engine damage could result.


1. Stop the engine.

2. Remove the precleaner.

3. Inspect the air inlet screen for dirt and debris.Remove the screen. Clean the screen if thescreen is dirty.

4. Inspect the precleaner tube openings. Removeany dirt and debris.

5. Clean the precleaner with compressed air or washthe precleaner in warm water. Dry all of the parts.

6. Install the precleaner screen.

7. Repeat the procedure for each precleaner. Thereis a total of four precleaners.

i02119046

Engine Components -Clean/Inspect, Rebuild/InstallReman, Install NewSMCS Code: 1000-012-IC; 1000-022-MC;1000-571-IC

Caterpillar recommends additional maintenance forthe following components on 3516B-HD Engines.Consult your Caterpillar dealer for further information.

Clean Components and InspectComponents for Reusability• Aftercooler Core

• Camshaft

• Lifters

• Connecting Rods

• Crankshaft

• Cylinder Block

• Cylinder Liners

• Damper

• Gear Train

• Pistons

• Piston Pins

• Spacer Plates

• Engine Control Module (ECM)

Rebuild Components and/or InstallRemanufactured Components• Cylinder Heads

• Fuel Transfer Pump

• Injectors

• Oil Coolers

• Oil Pump

• Scavenge Oil Pump

120 SEBU7885-12Maintenance SectionEngine Components - Replace/Install Reman

Install New Components• All Seals, Gaskets and O-rings

• Camshaft Bearings

• Fuel Pressure Regulating Valve

• Fuel Priming Pump

• Bushings for Gear Train and Bearings for GearTrain

• Main Bearings, Rod Bearings and CrankshaftThrust Bearings

• Piston Rings

• Engine Mounts

• Engine Wiring Harness

• New Software

• Crankshaft Seals

i02119051

Engine Components -Replace/Install RemanSMCS Code: 1000-022-MC

Caterpillar recommends this additional maintenancefor the following components on 3516B-HD Engines.Consult your Caterpillar dealer for further information.

• Air Starter or Electric Starter

• Alternator

• Fuel Transfer Pump

• Injectors

• Turbochargers

• Refrigerant Compressor

• Air Compressor

i02274850

Engine Crankcase Breather -CleanSMCS Code: 1317-070

There are a total of four engine crankcase breathers(two breathers on each side of the engine). Performthis procedure for each breather.


1. Open the upper front access door on the right sideof the machine.


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

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

4. Remove the cover from the breather.

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

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


Engine Mounts - Inspect

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

8. Install the breather element in the cover.

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

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

11.Close the upper front engine access door on theright side of the machine.

12.Repeat steps 12 to 11 for the left side of themachine.

i01947006

Engine Mounts - InspectSMCS 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.

Reference: Refer to Specifications, SENR3130,“Torque Specifications” for the proper bolt torques forthe engine mounts.

i02274838

Engine Oil Level - CheckSMCS Code: 1000-535-FLV


1. Open the lower rear access door on the right sideof the machine.


2. Remove the engine oil level gauge and cleanthe gauge with a clean cloth. Reinsert the gaugecompletely and remove the gauge again. This willgive a more accurate measurement of the oil level.

3. When the engine is running at low idle, check the“LOW IDLE” side of the engine oil level gauge.Maintain the oil level between the “ADD” mark andthe “FULL” mark.

When the engine is stopped, check the “ENGINESTOPPED” side of the engine oil level gauge.Maintain the oil level between the “ADD” mark andthe “FULL” mark.

4. If necessary, remove the filler cap and add oil.

5. Make sure that the engine oil level gauge and thefiller cap are installed securely.

6. Close the lower rear access door.

i02239897

Engine Oil Sample - ObtainSMCS Code: 1348-008; 7542


122 SEBU7885-12Maintenance SectionEngine Oil and Filter - Change

The sampling valve for the engine oil is located onthe engine oil filter base on the right side of theengine compartment.

Reference: Refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations”,“S·O·S Oil Analysis” for information that pertains toobtaining a sample of the engine oil. Refer to SpecialPublication, PEHP6001, “How To Take A Good OilSample” for more information about obtaining asample of the engine oil.

i02857316

Engine Oil and Filter - ChangeSMCS Code: 1318-510

Note: Some commercial oils that meet APIspecifications may require shorter oil changeintervals. The oil change intervals are determinedby close monitoring of the oil condition and enginewear metals. Caterpillar prefers the scheduled oilsampling as the proper method of checking enginewear metals. Consult your Caterpillar dealer for thelatest oil recommendations.

Fast Fill Service Center

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

Your machine is equipped with a fast fill servicecenter for changing the engine oil. The fast fill servicecenter allows the engine oil to be changed faster thanthe conventional method.


(1) Fast Fill Service Center(2) Access Doors

1. Park the machine on a level surface. Lower thebucket to the ground and engage the parkingbrake.


2. Open the door of the fast fill service center andlocate the correct fitting. Connect an oil pump tothe fitting.

3. Turn on the oil pump and withdraw the engine oilfrom the engine crankcase. Dispose of the usedoil properly.

4. Open both lower access doors on the right side ofthe machine.


5. Use a strap type wrench in order to remove thefour used filter elements.

6. Clean the filter mounting bases with a clean cloth.Ensure that the used gaskets are completelyremoved.


Engine Oil and Filter - Change


7. Apply a thin coat of clean engine oil to the seal onthe new filter. Install a new engine oil filter handtight until the seal of the engine oil filter contactsthe base. Note the position of the index marks onthe filter 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 or a turnaway from each other. When you tighten the engineoil filter, use the rotation index marks as a guide.

8. Tighten the filter according to the instructionsthat are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, use theinstructions that are provided with the filter.

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 filter.

Note: Improper installation of the engine oil filters canresult in the loosening of the filter due to vibration,which can cause substantial engine damage.

9. Clean the end of the male coupler at the fast fillservice center. Connect an oil pump to the malecoupler. Fill the crankcase with new oil.

Reference: Refer to Operation and MaintenanceManual, “Lubricant Viscositites and RefillCapacities” for the type of lubricant and for therefill capacity.

10.Clean the end of the male coupler. Close the doorto the fast fill service center.

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

12.Check the engine oil level.

Reference: Refer to Operation and MaintenanceManual, “Engine Oil Level - Check” for the correctprocedure.

13.Close the lower access doors on the right side ofthe machine.

Conventional Method

Hot oil and components can cause personal in-jury.

Do not allow hot oil or components to contactskin.


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


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

Note: Some commercial oils that meet APIspecifications may require shorter oil changeintervals. The oil change intervals are determinedby close monitoring of the oil condition and enginewear metals. Caterpillar prefers the scheduled oilsampling as the proper method of checking enginewear metals. Consult your Caterpillar dealer for thelatest oil recommendations.

1. Run the engine for a few minutes in order to warmup the oil.


124 SEBU7885-12Maintenance SectionEngine Oil and Filter - Change

g01423856Illustration 162(1) Fast Fill Service Center(2) Access Doors

3. Open both lower access doors on the right side ofthe machine.


4. Open the drain valve on the bottom of the oil pan.Allow the oil to drain into a suitable container.Dispose of the used oil properly.

5. Close the drain valve on the bottom of the oil pan.


Note: Oil will be trapped in the filter housing bases.To avoid possible burns, remove the filters when thefilters are cool enough to touch with your bare hand.

6. Use a strap type wrench to remove four used filterelements (1). Dispose of the used filter elementsproperly.

7. Clean the filter housing bases. Make sure that allof the used gaskets are removed.


8. Apply a thin coat of clean engine oil to the seal onthe new filter. Install a new engine oil filter handtight until the seal of the engine oil filter contactsthe base. Note the position of the index marks onthe filter 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 or a turnaway from each other. When you tighten the engineoil filter, use the rotation index marks as a guide.

9. Tighten the filter according to the instructionsthat are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, use theinstructions that are provided with the filter.

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 filter.

Note: Improper installation of the engine oil filters canresult in the loosening of the filter due to vibration,which can cause substantial engine damage.

10.Remove filler cap (2) and fill the crankcase withoil.



Engine Valve Lash and Bridge - Check

11.Start the engine and operate the engine at lowidle for five minutes. Inspect the engine oil filtersfor oil leaks. Make any necessary repairs.


12.Check the oil level on the “LOW IDLE” side ofthe engine oil level gauge. Maintain the oil levelbetween the “ADD” mark and the “FULL” mark.Add oil, if necessary.

13.Close both lower access doors on the right sideof the machine.

i01947678

Engine Valve Lash and Bridge- CheckSMCS Code: 1102-535; 1121-535

Perform the first valve lash adjustment for newengines and for rebuilt engines at the first oil change.The initial wear of the valve train components and theinitial seating of the valve train components makesthis valve lash adjustment necessary.

Reference: To check the engine valve lash and thebridge, refer to Testing And Adjusting, RENR2211,“3500B Engines For Caterpillar Built Machines”.Consult your Caterpillar dealer for any additionalinformation.

i03952000

Engine Valve Rotators - InspectSMCS 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 thecylinder 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.

i02099172

Engine Water Pump - InspectSMCS 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.

Reference: Refer to Disassembly and Assembly,SENR1126, “3500B Engines for Caterpillar BuiltMachines” for additional information about the waterpump.

126 SEBU7885-12Maintenance SectionEther Starting Aid Cylinder - Replace

i02274883

Ether Starting Aid Cylinder -ReplaceSMCS Code: 1456-510-CD

Ether is poisonous and flammable.

Breathing ether vapors or repeated contact ofether with skin can cause personal injury.

Use ether only in well ventilated areas.

Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.

Do not store replacement ether cylinders in 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.

To avoid possible injury, be sure the brakes are ap-plied and all controls are in Hold or Neutral whenstarting the engine.


1. Open the upper front access door on the right sideof the machine.


Note: There are two ether cylinders.

2. Loosen the cylinder retaining clamp. Unscrew theempty ether cylinder and remove the empty ethercylinder.


3. Remove the used gasket. Install the new gasketthat is provided with the new ether cylinder.

4. Install the new ether cylinder. Tighten the ethercylinder by hand. Tighten the cylinder retainingclamp securely.

5. Close the engine access door.


Frame - Inspect

i02857319

Frame - InspectSMCS Code: 7051-040; 7054-040

g01082021Illustration 171Engine End Frame

g01082024Illustration 172Engine End Frame

g01082025Illustration 173Non-Engine End Frame

The side covers are removed for clarity.


Inspect the frames. Clean the indicated areas with awire brush.

Consult your Caterpillar dealer for repairs if cracks orany damage is found on the frames.

128 SEBU7885-12Maintenance SectionFuel System - Prime

i02233097

Fuel System - PrimeSMCS Code: 1250-548


1. Make sure that the ignition key is in the OFFposition.



3. Pull the toggle out and up. This will start the pump.The pump will shutoff when the filter elements arefull of fuel.

4. Start the engine. Look for leaks around the filterelements. If the engine will not start or the enginemisfires, more priming is necessary.

i02234284

Fuel System Primary Filter -Clean/Inspect/ReplaceSMCS Code: 1260-040; 1260-070; 1260-510


1. Open the lower rear access door on the left sideof the machine.


2. Loosen retaining bolt (1).

3. Remove filter housing (2) and the filter element.

4. Wash the filter element, the filter housing, and thefilter housing base with a clean, nonflammablesolvent.

5. Use pressure air to dry the filter element.

6. Inspect the filter housing seal. Replace the sealif the seal is damaged.

7. Inspect the filter element. If the filter element isdamaged, replace the filter element.


Fuel System Secondary Filter - Replace

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

8. Install the filter element and filter housing (2) ontothe filter housing base.

9. Tighten the retaining bolt.

10.Close the lower rear access door.

i02233286

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE




2. Use a strap type wrench to remove the fuel filters.Dispose of the used filters properly.

3. Clean the filter mounting base. Make sure that allof the used gaskets are removed.

4. Lubricate the gaskets of the new fuel filters withclean diesel fuel.

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

5. Install the new fuel filters by hand. After thegaskets contact the filter mounting base, tightenthe fuel filters by an additional 3/4 turn.

Note: There are rotation index marks on each filterat 90 degree intervals. Use these marks as a guidefor proper tightening.

6. Prime the fuel system.

Reference: Refer to Operation and MaintenanceManual, “Fuel System - Prime” for the correctprocedure.

7. Close the lower rear access door.

i02857320

Fuel Tank Cap and Strainer -CleanSMCS Code: 1273-070-STR; 1273-070-Z2


The fuel tank caps are located on the rear of themachine.

130 SEBU7885-12Maintenance SectionFuel Tank Water and Sediment - Drain


1. Lift lever (1) and turn lever (1) counterclockwiseuntil the cap stops. Lift the cap straight up in orderto remove the cap.

2. Inspect seal (2) for damage. If necessary, replacethe seal.

3. Wash the cap in clean, nonflammable solvent.

4. Remove the strainer from the filler opening.

5. Wash the strainer in a clean nonflammablesolvent.

6. Install the strainer into the filler opening.

7. Install the fuel tank cap.

i02857324

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S


The drain valves are located under each fuel tank atthe rear of the machine.


1. Open the drain valve. Allow the water and thesediment to drain into a suitable container.

2. Close the drain valve.

i02235078

Fuses - ReplaceSMCS Code: 1417-510

NOTICEReplace the fuses with the same type and size only.Otherwise, electrical damage can result.

If it is necessary to replace fuses frequently, an electri-cal problem may exist. Contact your Caterpillar dealer

Fuses – Fuses protect the electricalsystem from damage that is caused byoverloaded circuits. Replace the fuse if

the element separates. If the element of a new fuseseparates, check the circuit. Repair the circuit, ifnecessary.



Fuses - Replace


The fuse panel is located under an access door onthe left side of the cab platform.


(1) Spare – 15 amp



(4) Spare – 10

(5) Spare – 10

(6) Spare – 10

(7) ROPS HID – 15 amp

(8) Front Wipers and Rear Wipers – 15amp

(9) Front ROPS Floodlight – 15 amp

(10) Front Fender Floodlight – 10 amp

(11) Rear Radiator Floodlights – 10 amp

(12) ROPS HID – 15 amp

(13) Platform Floodlights – 10 amp

(14)Converter and Bucket Floodlights –10 amp

(15) Side Wipers – 10 amp

(16) Beacon – 10 amp

(17) Implement ECM – 10 amp

(18) Horn – 10 amp

132 SEBU7885-12Maintenance SectionHigh Intensity Discharge Lamp (HID) - Replace

(19) Engine Compartment Lamps – 10amp

(20) Prelube Primer and Stair Lamps –10 amp

(21) Product Link – 15 amp

(22) Spare – 10

(23) Spare – 10

(24) Precleaner – 10 amp

(25) Spare – 10

(26) Lighter – 10 amp

(27) Seat Air Compressor – 10 amp

(28) Fan – 15 amp

(29) Power Train Control – 10 amp

(30) Vital Information ManagementSystem – 10 amp

(31) Air Dryer – 10 amp

(32) Rear ROPS Floodlight – 10 amp

i02245859

High Intensity Discharge Lamp(HID) - Replace(If Equipped)SMCS Code: 1434-510

HID lamps operate at very high voltages. To avoidelectrical shock and personal injury, disconnectpower before servicing HID lamps.

HID bulbs become very hot during operation.Before servicing, remove power from lamp for atleast five minutes to ensure lamp is cool.

NOTICEAlthough HID bulb materials may change over time,HID bulbs produced at the time of the printing of thismanual contain mercury. When disposing of this com-ponent, or any waste that contains mercury, pleaseuse caution and comply with any applicable laws.

1. Remove the electrical power from the highintensity discharge lamp (HID). The electricalpower must be removed from the HID lamp forat least five minutes, in order to ensure that thebulb is cool.

2. Disassemble the housing for the HID lamp in orderto have access to the bulb.

Note: On some HID lamps, the bulb is an integralpart of the lens assembly. The bulb is not removedseparately from the lens assembly. Replace theentire lens assembly on these HID lamps.

3. Remove the bulb from the HID lamp.

4. Install the replacement bulb in the HID lamp.

If the bulb is an integral part of the lens assembly,install the replacement lens assembly in the HIDlamp.


High Pressure Screens - Clean/Replace

Note: In order to avoid failure to the bulb that ispremature, avoid touching the bulb's surface withyour bare hands. Clean any fingerprints from the bulbwith alcohol prior to operation.

5. Reassemble the housing for the HID lamp. Ensurethat any printing on the lens is oriented correctlywith respect to the HID lamp's mounting positionon the machine.

6. Reattach the electrical power to the HID lamp.

7. Check the HID lamp for proper operation.

Note: Consult your Caterpillar dealer for additionalinformation on HID lamps.

i02252336

High Pressure Screens -Clean/ReplaceSMCS Code: 5068-070-Z3; 5068-510-Z3


The screens are located behind the front axle from the bottom.


The screens are located at the articulated joint.


The high pressure screens for the implement pumpsare located on the front frame. Screen (1) is for therear implement pump. Screen (2) is for the frontimplement pump. Screen (3) is for the left implementpump. Clean the screens whenever an implementpump fails. Screen (4) is for the right implementpump.



The high pressure screens for the steering pumpsare located behind the cab on the platform. Openthe access door behind the cab in order to accessthe screens. Screen (5) is for the left steering pump.Screen (6) is for the right steering pump.

134 SEBU7885-12Maintenance SectionHydraulic System Oil (Brake Cooling) - Change

Clean the screens whenever a steering pump fails.

1. Remove the plug at the bottom of the filterhousing. Allow the oil to drain from the filterhousing into a suitable container.

2. Use a strap type wrench to remove the filterhousing.

3. Clean the screen, the filter housing, and the filtermounting base in a clean, nonflammable solvent.

4. Check the condition of the screen. Replace anyscreen that is damaged.

5. Check the condition of the filter housing seal.Replace any seal that is damaged.

6. Install the clean screen in the filter housing. Installthe filter housing on the filter mounting base.

7. Start the engine and run the engine at low idle.Inspect the screens for leaks.

i02857341

Hydraulic System Oil (BrakeCooling) - ChangeSMCS Code: 5056-044-BRK

Personal injury can result from hot oil.

At operating temperature, the hydraulic oil tank ishot and under pressure. Hot oil can cause burns.

Remove the fill plug only when the engine isstopped, and the fill plug is cool enough to touchwith your bare hand.





Fast Fill Service CenterYour machine is equipped with a fast fill servicecenter for changing the hydraulic oil. The fast fillservice center allows the hydraulic oil to be changedfaster than the conventional method.

1. Operate the machine in order to warm the oil.

2. Park the machine on a level ground. Lower thebucket to the ground and apply slight downwardpressure. Engage the parking brake and stop theengine.



Hydraulic System Oil (Brake Cooling) - Change


3. Open the door to the fast fill service center thatis on the right side of the machine near thearticulation joint. Locate the correct male couplerand connect an oil pump to the fitting.

4. Turn on the oil pump and withdraw the hydraulicoil from the hydraulic tank for the steering and thebrakes. Dispose of the used oil properly.

5. Turn off the oil pump. Clean the end of the malecoupler.

6. Connect the oil pump to the male coupler. Fill thehydraulic tank with new oil.

Reference: Refer to Operation and MaintenanceManual, “Lubricant Viscositites” for the type oflubricant.

Reference: Refer to Operation and MaintenanceManual, “Capacities (Refill)” for the refill capacity.

7. Clean the end of the male coupler and close thedoor to the fast fill service center.

8. Start the engine and run the engine at low idle.Operate the steering and the brakes in order tocirculate the oil.


9. Stop the engine and top off the hydraulic tank sothat the oil level is above the halfway mark onsight gauge (2).

Note: The oil must be free of air bubbles. If airbubbles are present in the hydraulic oil, air is enteringthe hydraulic system. Inspect the hydraulic suctionline and the hose clamps.

10. If necessary, tighten any loose clamps or anyloose connections. Replace any damaged hoses.

Conventional Method1. Operate the machine in order to warm the oil.

2. Park the machine on level ground. Lower thebucket to the ground and apply slight downwardpressure. Engage the parking brake and stop theengine.


136 SEBU7885-12Maintenance SectionHydraulic System Oil (Implement) - Change


3. Open the access door in the platform behind thecab. Slowly loosen filler cap (1) in order to relieveany tank pressure.

4. Remove the filler cap 1 and the filler strainer.Wash the filler cap and the filler strainer in a clean,nonflammable solvent.

5. Remove the drain plug from the bottom of thehydraulic tank.

6. Attach a hose to a pipe nipple that is long.

7. Install the pipe nipple into the drain plug openingin order to open the internal drain valve. Allow theoil to drain into a suitable container. Dispose of theused oil properly.

8. Remove the pipe nipple in order to close theinternal drain valve.

9. Clean the drain plug and install the drain plug.

10.Clean the cooling screen.

Reference: Refer to Operation and MaintenanceManual, “Hydraulic System Oil Filter (SteeringCooler Screen) (Brake Cooler Screen) - Clean” forthe correct procedure.

11. Install the filler strainer.

12. Fill the hydraulic oil tank with clean oil. Ensurethat the oil level is above the halfway mark onsight gauge (2).

Reference: Refer to Operation and MaintenanceManual, “Lubricant Viscosities” for the correct typeof hydraulic oil.

Reference: Refer to Operation and MaintenanceManual, “Capacities (Refill)” for the correct amountof hydraulic oil.

13.Start the engine and run the engine for at leastten seconds. Then, stop the engine and addhydraulic oil to the tank until the oil level is abovethe halfway mark on sight gauge (2).

14.Start the engine and run the engine at low idle.Operate the steering and the brakes in order tocirculate the oil.

15.Stop the engine and top off the hydraulic tank sothat the oil level is above the halfway mark onsight gauge (2).



17. Inspect the gasket on filler cap (1) for damage.Replace the gasket, if necessary. Install filler cap(1).

i02958014

Hydraulic System Oil(Implement) - ChangeSMCS Code: 5056-044






Hydraulic System Oil (Implement) - Change




Quick Fill/Drain ValveYour machine is equipped with a quick fill/drain valvefor changing the hydraulic oil for the implements. Thequick fill/drain valve allows the hydraulic oil to bechanged faster than the conventional method.




2. The valve is located on the right side of themachine on the front frame. Locate the correctmale coupler and connect an oil pump to thefitting.

3. Turn on the oil pump and withdraw the hydraulicoil from the hydraulic tank. Dispose of the usedoil properly.


5. Replace the oil filter.

Reference: Refer to Operation and MaintenanceManual, “Hydraulic System Oil Filter (ImplementPump Case Drain) - Replace” for the correctprocedure.




7. Clean the end of the male coupler.


8. Ensure that the oil level is visible in the top sectionof the sight gauge.

9. Start the engine. Run the engine for a few minutes.

10.Maintain the oil level within the top section of thesight gauge. Add hydraulic oil, if necessary.

Note: The oil must be free of bubbles. If bubblesare present in the oil, air is entering the hydraulicsystem. Inspect the hydraulic suction line and thehose clamps.

11.Stop the engine.

138 SEBU7885-12Maintenance SectionHydraulic System Oil (Implement) - Change

12. If necessary, tighten any hose clamps and anyhydraulic connections. Replace any damagedhoses.

Conventional MethodYour machine is equipped with a fast fill servicecenter for changing the hydraulic oil. The fast fillservice center allows the hydraulic oil to be changedfaster than the conventional method.





3. Press the breaker relief valve in order to relieveany pressure.



5. Turn on the oil pump and withdraw the hydraulicoil from the hydraulic tank. Dispose of the usedoil properly.



Reference: Refer to Operation and MaintenanceManual, “Hydraulic System Oil Filter (ImplementPump Case Drain) - Replace” for the correctprocedure.


8. Remove the filler cap. Fill the hydraulic tank withnew oil.




Hydraulic System Oil (Steering, Brake) - Change


9. Ensure that the oil level is visible in the top sectionof the sight gauge. Install the filler cap.

10.Start the engine. Run the engine for a fewminutes.

11.Maintain the oil level within the top section of thesight gauge. Add hydraulic oil, if necessary.

Note: The oil must be free of bubbles. If bubblesare present in the oil, air is entering the hydraulicsystem. Inspect the hydraulic suction line and thehose clamps.

12.Stop the engine.

13. If necessary, tighten any hose clamps and anyhydraulic connections. Replace any damagedhoses.

i02857347

Hydraulic SystemOil (Steering,Brake) - ChangeSMCS Code: 5056-044-US








Fast Fill Service CenterYour machine is equipped with a fast fill servicecenter for changing the hydraulic oil. The fast fillservice center allows the hydraulic oil to be changedfaster than the conventional method.




140 SEBU7885-12Maintenance SectionHydraulic System Oil (Steering, Brake) - Change



4. Turn on the oil pump and withdraw the hydraulicoil from the hydraulic tank for the steering and thebrakes. Dispose of the used oil properly.



Reference: Refer to Operation and MaintenanceManual, “Hydraulic System Oil Filter (Steering andBraking) - Replace” for the correct procedure.







10.Stop the engine and top off the hydraulic tank sothat the oil level is above the “ADD” mark on thesight gauge.






Hydraulic System Oil (Steering, Brake) - Change



(1) Breaker Relief Valve(2) Filler Cap

3. Open the access door in the platform behind thecab. Press the button on the breaker relief valve inorder to relieve any tank pressure.

4. Remove the filler cap and the filler strainer. Washthe filler cap and the filler strainer in a clean,nonflammable solvent.


5. Remove the drain plug from the bottom of thehydraulic tank.

6. Attach a hose to a pipe nipple that is long.

7. Install the pipe nipple into the drain plug openingin order to open the internal drain valve. Allow theoil to drain into a suitable container. Dispose of theused oil properly.

8. Remove the pipe nipple in order to close theinternal drain valve.


10.Replace the oil filter.

Reference: Refer to Operation and MaintenanceManual, “Hydraulic System Oil Filter (Steering andBraking) - Replace” for the correct procedure.

11. Install the filler strainer.

12. Fill the hydraulic oil tank with clean oil. Ensurethat the oil level is above the “ADD COLD” markon sight gauge (2).

Reference: Refer to Operation and MaintenanceManual, “Lubricant Viscosities” for the correct typeof hydraulic oil.

Reference: Refer to Operation and MaintenanceManual, “Capacities (Refill)” for the correct amountof hydraulic oil.

13.Start the engine and run the engine for at least tenseconds. Then, stop the engine and add hydraulicoil to the tank until the oil level is above the “ADD”mark on the sight gauge.

14.Start the engine and run the engine at low idle.Operate the steering and the brakes in order tocirculate the oil.

142 SEBU7885-12Maintenance SectionHydraulic System Oil Filter (Hydraulic Cooler Screen) - Clean


15.Stop the engine and top off the hydraulic tank sothat the oil level is above the “ADD” mark on thesight gauge.



17. Inspect the gasket on filler cap for damage.Replace the gasket, if necessary. Install filler cap.

i02857349

Hydraulic System Oil Filter(Hydraulic Cooler Screen) -CleanSMCS Code: 5068-070-Z3











Hydraulic System Oil Filter (Implement Pump Case Drain) - Replace


3. The breaker relief valve is located on the platformon the front frame.


4. Press the breaker relief valve in order to releasethe pressure in the hydraulic system.


5. Open the access door in the platform in front ofthe engine air cleaners.


6. Unscrew the nut and remove the cover from thefilter housing.

7. Clean the screen in a nonflammable solvent.


9. Install the clean screen in the filter housing. Placethe cover on the filter housing and screw the nuton the filter housing.

10.Start the engine and run the engine at low idle.Operate the implements in order to circulate theoil.

11. Inspect the screens for leaks.

12.Close the access door in the platform in front ofthe engine air cleaners.

i02341095

Hydraulic System Oil Filter(Implement Pump Case Drain)- ReplaceSMCS Code: 5068-510; 5091-510-II



144 SEBU7885-12Maintenance SectionHydraulic System Oil Filter (Pilot) - Replace



3. Press the breaker relief valve in order to relieveany tank pressure.

4. Open the access door in front of the cab on theplatform.


5. Remove the filter housing from the housing base.Dispose of the used filter element properly.

6. Clean the filter housing and clean the filtermounting base with a clean, nonflammablesolvent.

7. Install the new filter element into the filter housing.Inspect the filter housing seal. Replace the sealif the seal is damaged.

8. Install the filter housing into the filter mountingbase.

9. Repeat steps 5 to 8 for each of the filter elements.

10.Close the access door.

11.Start the engine. Run the engine at low idle andcheck for leaks in the hydraulic system.

12.Check the hydraulic oil level.

Reference: Refer to Operation and MaintenanceManual, “Hydraulic System Oil (Implement) -Check” for the correct procedure.

13.Stop the engine.

i02349138

Hydraulic System Oil Filter(Pilot) - ReplaceSMCS Code: 5092-510


The oil filter is located on the left side of the machine.



Hydraulic System Oil Filter (Steering Cooler Screen) (Brake Cooler Screen) - Clean


2. Remove the filter housing from the housing base.Dispose of the used filter element properly.

3. Clean the filter housing and clean the filtermounting base with a clean, nonflammablesolvent.

4. Install the new filter element into the filter housing.Inspect the filter housing seal. Replace the sealif the seal is damaged.

5. Install the filter housing into the filter mountingbase.

6. Start the engine and run the engine at low idle.

7. Inspect the pilot system for leaks. Stop the engineand make any necessary repairs.

i02857350

Hydraulic System Oil Filter(Steering Cooler Screen)(Brake Cooler Screen) - CleanSMCS Code: 4295-070; 431F-070-Z3













4. Slowly loosen filler cap (2) in order to relieve anytank pressure.

146 SEBU7885-12Maintenance SectionHydraulic System Oil Filter (Steering Pump Case Drain) - Replace

5. Unscrew the nut and remove the cover from filterhousing (1).

6. Clean the screen in a nonflammable solvent.


8. Install the clean screen in the filter housing. Placethe cover on the filter housing and screw the nuton the filter housing.


10. Inspect the screens for leaks.

11.Close the access door in the platform in front ofthe engine air cleaners.

i02857351

Hydraulic System Oil Filter(Steering Pump Case Drain) -ReplaceSMCS Code: 5068-510-US; 5091-510-ZH

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








3. Slowly remove the filler cap in order to relieve anytank pressure.

4. Open the access door in the platform behind thecab.


5. Use a strap type wrench to remove the filters.Dispose of the used filters properly.


Hydraulic System Oil Level (Brake Cooling) - Check

6. Clean the filter mounting bases. Make sure that allof the used gaskets are removed from the filtermounting bases.

7. Lubricate the gaskets of the new filters with cleanhydraulic oil.

8. Install the new filters by hand. When the gasketcontacts the filter base, tighten the filter by anadditional 3/4 turn.

9. Install the filler cap.

10.Close the access doors.

i02857353

Hydraulic System Oil Level(Brake Cooling) - CheckSMCS Code: 5056-535-BRK; 5056-535-FLV


The access doors for the hydraulic tank (steering andbraking cooling system) are located on the platformin front of the engine air cleaners.


Maintain the oil level above the halfway mark of sightgauge (2). If necessary, remove filler cap (1) and addhydraulic oil.


The hydraulic tank can also be filled from the fast fillservice center.

i02857356

Hydraulic System Oil Level(Implement) - CheckSMCS Code: 5056-535-FLV


148 SEBU7885-12Maintenance SectionHydraulic System Oil Level (Implement) - Check


The sight gauge for the hydraulic oil level is locatedin the articulation joint on the right side of the frontframe.

Maintain the oil level in the center section of the sightgauge.


If necessary, press the button on breaker relief valve(2) in order to relieve any tank pressure. Removefiller cap (1) and add hydraulic oil.


The hydraulic tank can also be filled from the fast fillservice center.


Hydraulic System Oil Level (Steering, Brake) - Check

i02857357

Hydraulic System Oil Level(Steering, Brake) - CheckSMCS Code: 5056-535-US; 5056-535-FLV


The access doors for the hydraulic tank (steeringsystem and braking system) are located on theplatform in front of the engine air cleaners. The sightgauge for the hydraulic oil is located on the left sideof the machine on the side of the platform.


Maintain the oil level between the top of sight gaugeand the “ADD COLD” mark. If necessary, removefiller cap (1) and add hydraulic oil.


The hydraulic tank can also be filled from the fastfill service center that is located on the right side ofthe machine.

i02857378

Hydraulic System Oil Sample(Implement) - ObtainSMCS Code: 5050-008; 5056-008; 7542


The sampling valve is located at the front of the cabplatform. Take off the front access panel in order toaccess the sampling valve.

150 SEBU7885-12Maintenance SectionHydraulic System Oil Sample (Steering, Brake) - Obtain

i04025996

Hydraulic System Oil Sample(Steering, Brake) - ObtainSMCS Code: 5050-008; 5056-008; 7542




2. Remove filler cap (1).

3. Obtain an oil sample.

4. Replace the cap. Close the access door.

i02857360

Hydraulic System ReturnScreen - ReplaceSMCS Code: 5068-510-Z3

The screen should be cleaned especially when oneof the following situations have occurred:

• Failure of the Implement Pump

• Failure of the Brake Pump

• Failure of the Steering

• Cleaning of the Hydraulic Tank

• PCR (Engine Overhaul)

1. Park the machine on a level surface. Lower thework tool to the ground. Engage the parking brake.

2. Turn the engine start switch key to ON.

3. Move the hydraulic control levers through all ofthe positions in order to release pressure.

4. Turn the engine start switch key to OFF.

At operating temperature, the hydraulic tank is hotand under pressure.

Hot oil and components can cause personal in-jury. Do not allow hot oil or components to contactskin.

Before removing the filler cap, press the valve re-lief button on the hydraulic tank in order to relievethe tank pressure.

Remove the filler cap only when the engine isstopped and the filler cap is cool enough to touchwith your bare hand. Remove the filler cap slowlyin order to relieve any remaining pressure.



Hydraulic Tank Breaker Relief Valve - Clean

g01458779Illustration 241(1) Breaker Relief Valve(2) Filler Cap

5. Press the button on the breaker relief valve inorder to relieve any tank pressure.

6. Drain the hydraulic oil tank.

Reference: For the correct procedure, refer toOperation and Maintenance Manual, “HydraulicSystem Oil (Steering, Brake) - Change”.

7. Disconnect the drain lines.

8. Remove the hydraulic tank.

9. Remove all of the bolts around the tank. Separatethe tank.



10.Remove the screens. Clean the screens witha clean, nonflammable solvent. If the screenscannot be cleaned then replace the screens.

11. Inspect all of the O-ring seals. If a seal isdamaged, replace the seal.

12.Replace return screens.

13.Bolt the hydraulic tank together.

14. Install the hydraulic tank.

15.Assemble the drain lines.

16. Fill the hydraulic tank.

Reference: For the correct procedure, refer toOperation and Maintenance Manual, “HydraulicSystem Oil (Steering, Brake) - Change”.

i02265629

Hydraulic Tank Breaker ReliefValve - CleanSMCS Code: 5118-070


152 SEBU7885-12Maintenance SectionOil Filter - Inspect


The breaker relief valve is located on the platformon the front frame.

1. Press the breaker relief valve in order to releasethe pressure in the hydraulic system.

2. Remove the breaker relief valve.

3. Clean the breaker relief valve in a clean,nonflammable solvent. Shake the breaker reliefvalve dry or use compressed air.

4. Install the breaker relief valve.

i02106227

Oil Filter - InspectSMCS Code: 1308-507; 3067-507; 4295-507;431F-507; 5068-507

Inspect a Used Filter for Debris


The element is shown with debris.

Use a filter cutter to cut the filter element open.Spread apart the pleats and inspect the element formetal and for other debris. An excessive amount ofdebris in the filter element can indicate a possiblefailure.

If metals are found in the filter element, a magnet canbe used to differentiate between ferrous metals andnonferrous metals.

Ferrous metals can indicate wear on steel parts andon cast iron parts.

Nonferrous metals can indicate wear on thealuminum parts of the engine such as main bearings,rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filterelement. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer in orderto arrange for further analysis if an excessive amountof debris is found.

Using an oil filter element that is not recommendedby Caterpillar can result in severe engine damageto engine bearings, to the crankshaft, and to otherparts. This can result in larger particles in unfilteredoil. The particles could enter the lubricating systemand the particles could cause damage.

i02067046

Oil Renewal System Oil Level -Check(If Equipped)SMCS Code: 1348-535-FLV

1. Park the machine on level ground. Lower the worktool to the ground. Engage the parking brake andstop the engine.

2. Check the oil level of the makeup oil tank.

Reference: If the oil level of the makeup oiltank does not decrease daily, refer to SystemsOperation, RENR8160, “Troubleshooting” orcontact your Caterpillar dealer.

Note: Keeping a daily maintenance log of all theadditions of oil is necessary for determining whetherthe ORS is working properly.


Power Train Oil Filter (Transmission, Torque Converter) - Replace

i02335628

Power Train Oil Filter(Transmission, TorqueConverter) - ReplaceSMCS Code: 3004-510; 3067-510







2. Park the machine on level ground. Lower thebucket to the ground and apply slight downwardpressure. Engage the parking brake. Stop theengine.


3. Open the access panel that is located behind thecab.


4. Remove the drain plugs from the filter housings.Allow the oil to drain into a suitable container.Dispose of the used oil properly.

Note: The majority of the oil will not drain until theseal around the lid has been broken.

5. Unscrew the bolts on the lids.

6. Remove the lids. The filters are attached to thelids. Unscrew the nuts and slide off the filters.Dispose of the used filter elements properly.

7. Clean the filter housings, the drain plugs, and thefilter mounting bases with a clean, nonflammablesolvent.

8. Inspect the filter housing seals. Replace the sealsif the seals are damaged.

9. Place new filters on the rods that are attachedto the lids. Screw on the nuts. Tighten the nutfor the high pressure filter to a torque of 15 N·m(11.1 lb ft). Tighten the nut for the low pressurefilter to a torque of 30 N·m (22.1 lb ft). Replacethe lids on the filter housing. Screw the bolts ontothe lids.

10. Install the drain plugs in the filter housings.

11.Start the engine. Apply the service brake. Onlyuse the right brake pedal.

12.Slowly operate the STIC transmission directioncontrol switch in order to circulate the oil.

13.Move the STIC transmission direction controlswitch to the NEUTRAL position. Engage theparking brake. Inspect the entire transmissionsystem for leaks.

14.Check the transmission oil level.

154 SEBU7885-12Maintenance SectionPump Drive (Front) Oil - Change

Reference: Refer to Operation and MaintenanceManual, “Transmission Oil Level - Check” for thecorrect procedure.

15.Close the access panel that is located behindthe cab.

i02946576

Pump Drive (Front) Oil -ChangeSMCS Code: 3108-044






Crushing Hazard. Connect the steering frame lockbetween front and rear frames before servicing themachine in the articulation area. Disconnect thesteering frame lock and secure it in the stored po-sition before resuming operation. Failure to do socould result in serious injury or death.

Note: Refer to Operation and Maintenance Manual,“Steering frame Lock” for the correct procedure.

Quick Drain ValveYour machine is equipped with a quick drain valvefor draining the pump drive oil. The quick drain valveallows the pump drive oil to be drained faster thanthe conventional method.





3. Turn on the oil pump and withdraw the oil from thetank. Dispose of the used oil properly.

4. Completely drain the front pump drive.



Pump Drive (Front) Oil - Change

Conventional Drain


The pump drive is located inside the front frame nearthe articulation joint.

1. Park the machine on level ground. Lower thebucket to the ground. Engage the parking brakeand stop the engine.

g01460741Illustration 252(1) Dipstick(2) Drain Plug

2. Remove drain plug (2) from the pump drivehousing. Allow the oil to drain into a suitablecontainer. Dispose of the used oil properly.

3. Completely drain the front pump drive.


Procedure for RefillReference: Please refer to Technical InformationBulletin, TIBU5143 for more information aboutthe Front Pump Drive. Refer to Operation andMaintenance Manual, “Capacities (Refill)” for thecorrect amount of oil. Refer to Operation andMaintenance Manual, “Lubricant Viscosities” for thecorrect type of oil.


1. Open the access panel on the platform in front ofthe cab. Remove the dipstick (1) from the pumpdrive housing.

2. Fill the pump drive with half of the correct amountof oil.

3. Purge any air from the drain line. Collect any oilthat is removed from the system.

4. Run the machine for 3 to 5 minutes.

5. Add any oil that was collected back into thesystem and continue to fill the system to thecorrect amount of oil according to the table.

156 SEBU7885-12Maintenance SectionPump Drive (Front) Oil Filter - Change


6. While the engine is stopped, make sure that the oillevel is between the “ADD” and “FULL” marks onthe “ENGINE STOPPED” side of the dipstick (1).

7. Clean the dipstick and install the dipstick.

i02249398

Pump Drive (Front) Oil Filter -ChangeSMCS Code: 3108-510-FI







The filter for the front pump drive is located at thefront of the cab platform. Take off the front accesspanel in order to access the filter.


1. Use a strap type wrench to remove the filter.Dispose of the used filter properly.

2. Clean the filter mounting base. Make sure thatall of the used gasket is removed from the filtermounting base.

3. Lubricate the gasket of the new filter element withclean hydraulic oil.

4. Install the new filter by hand. After the gasketcontacts the filter mounting base, tighten the filterby an additional 3/4 turn.

5. Start the engine and run the engine at low idle.Inspect the system for leaks.

6. Stop the engine. Make any necessary repairs.


Pump Drive (Front) Oil Level - Check

i02778946

Pump Drive (Front) Oil Level -CheckSMCS Code: 3108-535-FLV


The front pump drive is located inside the front framenear the articulation joint.



While the engine is stopped, make sure that the oillevel is between the “ADD” and “FULL” marks on the“ENGINE STOPPED” side of the dipstick (1).

1. Remove the dipstick (1) and add oil through thefiller tube.

Reference: Refer to Operation and MaintenanceManual, “Lubricant Viscosities” for the correct typeof oil.

2. Install the dipstick (1).

i02857380

Pump Drive Oil Sample -ObtainSMCS Code: 3108-008; 7542


The sampling valve for the pump drive is located atthe front of the cab platform. Take off the front accesspanel in order to access the sampling valve.

Reference: Refer to Special Publication, PEHP6001,“How To Take A Good Oil Sample” for moreinformation about obtaining a sample of the pumpdrive oil.

158 SEBU7885-12Maintenance SectionPump Drive Shaft (Front) - Lubricate

i02857361

Pump Drive Shaft (Front) -LubricateSMCS Code: 3108-086-D6



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

2. Apply lubricant through fitting for the slip joint onthe pump drive shaft.

i02857363

Pump Drive Shaft SupportBearing (Rear) - LubricateSMCS Code: 3108-086-D6; 3267-086-BD



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

2. Apply lubricant through one fitting on the right sideof the articulation joint.

SEBU7885-12 159Maintenance SectionRadiator Core - Clean

i02857366

Radiator Core - CleanSMCS Code: 1353-070-KO



Compressed air, high pressure water, or steam canbe used to remove dust and other debris from theradiator core. However, the use of compressed airis preferred.

Reference: Refer to Special Publication, SEBD0518,“Know Your Cooling System” for the completeprocedure for cleaning the radiator core.

i02723802

Receiver Dryer (Refrigerant) -ReplaceSMCS Code: 7322-510

Personal injury can result from contact with refrig-erant.

Contact with refrigerant can cause frost bite. Keepface and hands away to help prevent injury.

Protective goggles must always be worn when re-frigerant lines are opened, even if the gauges in-dicate the system is empty of refrigerant.

Always use precaution when a fitting is removed.Slowly loosen the fitting. If the system is still un-der pressure, release it slowly in a well ventilatedarea.

Personal injury or death can result from inhalingrefrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through alit cigarette or other smoking method or inhalingfumes released from a flame contacting air con-ditioner refrigerant gas, can cause bodily harm ordeath.

Do not smoke when servicing air conditioners orwherever refrigerant gas may be present.

Use a certified recovery and recycling cart to prop-erly remove the refrigerant from the air condition-ing system.

NOTICEIf the refrigerant system has been open to the outsideair (without being plugged) for more than 30 minutes,the receiver-dryer must be replaced. Moisture will en-ter an open refrigerant system and cause corrosionwhich will lead to component failure.

Refer to Service Manual, SENR5664, “AirConditioning and Heating System with R-134aRefrigerant for All Caterpillar Machines” for the properprocedure to change the receiver-dryer assemblyand for the procedure to reclaim the refrigerant gas.

160 SEBU7885-12Maintenance SectionRollover Protective Structure (ROPS) - Inspect

i02337495

Rollover Protective Structure(ROPS) - InspectSMCS Code: 7325-040

NOTICEDo not attempt to straighten the ROPS structure. Donot repair the ROPS by welding reinforcement platesto the structure.

If there are any cracks in the welds, in the castings, orin any metal section of the ROPS, consult your Cater-pillar dealer for repairs.



1. Remove the access covers from both sides of theRollover Protective Structure (ROPS).

2. Inspect the ROPS for bolts that are damaged,loose, or missing. Use only original equipmentparts for bolts that are damaged or missing.Tighten the bolts to a torque of 1600 ± 200 N·m(1200 ± 150 lb ft).

Note: Apply oil to the bolt threads before you installthe bolt. Failure to apply oil can result in improperbolt torque.

3. Install the access covers.

i02429589

Seat Belt - InspectSMCS Code: 7327-040

Always check the condition of the seat belt and thecondition of the seat belt mounting hardware beforeyou operate the machine. Replace any parts that aredamaged or worn before you operate the machine.

g00932801Illustration 269Typical example

Check the seat belt mounting hardware (1) for wearor for damage. Replace any mounting hardware thatis worn or damaged. Make sure that the mountingbolts are tight.

Check buckle (2) for wear or for damage. If the buckleis worn or damaged, replace the seat belt.

Inspect the seat belt (3) for webbing that is worn orfrayed. Replace the seat belt if the seat belt is wornor frayed.

Consult your Caterpillar dealer for the replacement ofthe seat belt and the mounting hardware.

Note:Within three years of the date of installation orwithin five years of the date of manufacture, replacethe seat belt. Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

If your machine is equipped with a seat beltextension, also perform this inspection procedure forthe seat belt extension.

SEBU7885-12 161Maintenance SectionSeat Belt - Replace

i02429594

Seat Belt - ReplaceSMCS Code: 7327-510

Within three years of the date of installation or withinfive years of the date of manufacture, replace theseat belt . Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

g01152685Illustration 270(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 ofthe seat belt and the mounting hardware.

If your machine is equipped with a seat beltextension, also perform this replacement procedurefor the seat belt extension.

i01547608

Seat Side Rails - AdjustSMCS Code: 7312-025


Caterpillar recommends adjusting the side rails afterthe initial 500 hours of machine operation. After theinitial 500 service hours, perform this procedurewhen it is necessary.

Reference: Refer to Service Manual, SENR6615,“Contour Series Seat” for the adjustment procedure.

i03694709

Secondary Steering - TestSMCS Code: 4300-081-SE; 4300-081-SST;4324-081; 4324

The service brake must be checked in order to en-sure proper operation before you test the supple-mental steering system.

Personal injury, death, or property damage couldoccur if the supplemental steering system is test-ed and the service brake is not operational.

Test the service brake before you test the supple-mental steering system.

Perform the following procedure if your machine isequipped with a ground driven supplemental steeringand if the procedure is required by local regulations.

Ensure that there are no hazards in the test area. Thetest area must be unobstructed and level. Operatethe machine in second gear.

Ensure that all air tanks and accumulators areproperly charged. Ensure that there is no load in thework tool. Position the machine with the bucket or thework tool in the carry position with the machine inneutral. Release the parking brake. Apply the servicebrakes and put the engine at low idle. Ensure that Thearea around the machine is clear of personnel. Shiftthe transmission to second gear forward and slowlyrelease the service brakes. Moderately increase theengine speed to high idle. Shift the transmission toneutral. Turn the ignition to the OFF position. Allowthe machine to coast.

While the machine is in motion, turn the machine tothe left and to the right. If the machine responds tothe steering input, the supplemental steering systemis operating. Stop the machine with the servicebrakes. Apply the parking brake. The machine canthen be returned to normal operation.

162 SEBU7885-12Maintenance SectionStarting Motor - Inspect

If there is no response to the steering input, thesupplemental steering system is not operating. Stopthe machine immediately. Repair the supplementalsteering system before returning the machine toservice.

i02119057

Starting Motor - InspectSMCS Code: 1451-040; 1453-040

Caterpillar recommends a scheduled inspection ofthe starting system.

Check the starting motor and the battery chargerfor proper operation. Check for loose electricalconnections

Reference: Refer to Systems Operation/Testingand Adjusting, SENR1123, “3500B and 3500BHigh Displacement Engines For Caterpillar BuiltMachines”, “Electric Starting System” for informationabout testing the starting system.

i02857368

Steering Cylinder Bearings -LubricateSMCS Code: 4303-086-BD

The steering cylinder bearings are lubricated by theautomatic lubrication system. If any of the lubricationlines are damaged, install a fitting at the bearingand lubricate the bearing. The damaged line mustbe replaced.


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

Note: There are a total of four fittings.

2. Apply lubricant through the fitting for the rod end ofeach steering cylinder. Apply lubricant through thefitting for the head end of each steering cylinder.

i02246969

Steering Stop - CheckSMCS Code: 4330-535-SQ


Check for contact between the steering stops. If thesteering stops have been contacting each other, thesteering neutralizer valve needs to be adjusted.

Adjusting the steering system should be done by aqualified Caterpiller product support representative.

Reference: Refer to Testing and Adjusting,RENR6325, “994F Steering System”, “SteeringNeutralizer Valve - Adjust” for the correct procedure.

i02243191

Tire Inflation - CheckSMCS Code: 4203-535-AI


Measure the tire pressure on each tire. Inflate thetires, if necessary.


Transmission Magnetic Screen - Clean

Reference: Refer to Operation and MaintenanceManual, “Tire Inflation Information” for moreinformation or consult your Caterpillar dealer.

i02337526

Transmission Magnetic Screen- CleanSMCS Code: 3030-070-MGS; 3159-070-MGS

Clean the transmission magnetic screens if thetransmission oil pump fails or the transmission isdisassembled. Drain the transmission oil before youremove the transmission magnetic screen.

Reference: Refer to Operation and MaintenanceManual, “Transmission Oil - Change” for theprocedure to drain the transmission oil.


The two transmission magnetic screens are locatedin the transmission case at the center of the machine.



2. Remove cover assemblies (1) and seals (2).

3. Remove screen tube assemblies (3) and suctionscreens (4).

4. Wash the screen tube assemblies and the suctionscreens in a clean, nonflammable solvent. Allowthe components to air dry.

5. Install screen tube assemblies (3) and suctionscreens (4).

6. Inspect seals (2). Replace the seals, if necessary.

7. Install seals (2) and cover assemblies (1).

i02857369

Transmission Oil - ChangeSMCS Code: 3030-044






Fast Fill Service CenterYour machine is equipped with a fast fill servicecenter for changing the transmission oil. The fastfill service center allows the transmission oil to bechanged faster than the conventional method.

164 SEBU7885-12Maintenance SectionTransmission Oil - Change





3. Turn on the oil pump and withdraw thetransmission oil from the transfer gear case.Dispose of the used oil properly.


5. Connect the oil pump to the male coupler. Fill thetransfer gear case with new oil.




7. Start the engine. Cycle the transmission controlin order to warm the oil. Check the transmissionfor oil leaks.

8. Check the transmission oil level in sight gauge (1).

Reference: Refer to Operation and MaintenanceManual, “Transmission Oil Level - Check” for thecorrect procedure.


2. Park the machine on level ground. Lower thebucket to the ground and apply slight downwardpressure. Engage the parking brake. Stop theengine.


3. The drain valve for the transmission oil tank islocated on the bottom of the transmission casenear the center of the machine. Open the drainvalve and allow the oil to drain into a suitablecontainer. Dispose of the used oil properly.

4. Change the filter element.

Reference: Refer to Operation and MaintenanceManual, “Power Train Oil Filter (Transmissionand Torque Converter) - Replace” for the correctprocedure.

5. Clean the transmission magnetic screen.

Reference: Refer to Operation and MaintenanceManual, “Transmission Magnetic Screen - Clean”for the correct procedure.

6. Close the drain valve for the transmission oil tank.


Transmission Oil Level - Check



7. The transmission oil filler tube is located behindthe cab. Remove filler cap (1) and fill thetransmission with oil.

Reference: Refer to Operation and MaintenanceManual, “Lubricant Viscosities” for the correct typeof oil.

Reference: Refer to Operation and MaintenanceManual, “Capacities (Refill)” for the correct amountof oil.

8. Clean the filler cap and install the filler cap.

9. Remove transmission breather (2). Wash thebreather in a clean, nonflammable solvent. Allowthe breather to dry or use air pressure to dry thebreather. Install the transmission breather.

10.Start and run the engine at low idle. Inspect thetransmission for leaks.

11.Slowly operate the STIC transmission directioncontrol switch in order to circulate the oil.

12.Move the STIC transmission direction controlswitch to the NEUTRAL position. Engage theparking brake. Inspect the entire transmissionsystem for leaks.


13.Check the transmission oil level in the sightgauge on the right side of the articulation joint.Maintain the oil level between the marks on theoil level sight gauge. If necessary, remove thetransmission oil filler cap and add oil.

i02337511

Transmission Oil Level - CheckSMCS Code: 3030-535-FLV


The transmission sight gauge is located on the rightside of the machine in the articulation joint. While theengine is running at low idle, maintain the oil levelbetween the marks on the sight gauge.

166 SEBU7885-12Maintenance SectionTransmission Oil Sample - Obtain


If necessary, remove transmission oil filler cap (1)and add oil.

i02334728

Transmission Oil Sample -ObtainSMCS Code: 3080-008; 7542


The sampling valve is located behind the cab. Lift theaccess panel in order to obtain the samples.


Obtain the sample for the torque converter from port(1). Obtain the sample for the transmission from port(2). Close the access panel once the samples havebeen obtained.

Reference: Refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations”,“S·O·S Oil Analysis” for information that pertains toobtaining a sample of the transmission oil.

Reference: Refer to Special Publication, PEHP6001,“How To Take A Good Oil Sample” for moreinformation about obtaining a sample of the pumpdrive oil.

i02119071

Turbocharger - InspectSMCS Code: 1052-040

If the turbocharger fails during engine operation,severe damage to the turbocharger compressorwheel and to the entire engine can result.

Turbocharger bearing failures can cause largequantities of oil to enter the intake system and theexhaust system. Loss of engine oil can result inserious engine damage.

Do not continue to operate the engine when aturbocharger bearing failure is accompanied bya significant loss of engine performance. Enginesmoke and speeding up of the engine with no loadare characteristics of a loss of engine performance.

Reference: For additional information aboutinspecting the turbocharger, refer to SystemOperation, SENR1123, “3500B and 3500B HighDisplacement Engines For Caterpillar Built Machines”, “Air and Inlet Exhaust System”.

i02093570

VIMS Module Battery - ReplaceSMCS Code: 7601-510-B11

A lithium battery is contained inside the main moduleof the VIMS. The internal battery prevents the lossof stored information. An example of the storedinformation is the payload data. The internal batteryalso retains the time and the date.


Window Washer Reservoir - Fill

If power is removed from the main module of theVIMS, the internal battery will begin to retain thestored data. Power is removed from the main moduleof the VIMS when the battery disconnect switch isin the OFF position. The internal battery retains thetime and the date when the engine start switch is inthe OFF position. This will occur regardless of theposition of the battery disconnect switch.

Note: To prevent the loss of stored information,replace the internal battery at the service interval. Ifthe ambient temperature is continuously in the rangeof 0 to −40°C (32 to −40°F), cut the service intervalin half.

Note: If the Vital Information Management System(VIMS) detects a failed battery, a fault code willindicate that the battery needs a replacement. Ifpower is removed from the main module of the VIMSduring this fault code, loss of the stored data canoccur within several hours. The lithium battery failsquickly. When the fault code is present, immediatelydownload the stored data. Then replace the internalbattery without turning off the engine start switch orthe battery disconnect switch.

Note: If ECM BKUP BATT ERR is displayed in themessage area of the VIMS, do NOT turn the enginestart switch to the OFF position. Go to Step 3.

1. Stop the machine and turn off the engine. Leavethe battery disconnect switch in the ON position.

2. Turn the engine start switch to the ON position orturn the keyswitch for the VIMS to the ON position.

3. Use the service tool for the VIMS to download allof the stored information. The service tool for theVIMS is not part of the machine. Failure to performthis step may result in the loss of stored data.

4. Leave the engine start switch in the ON positionor leave the keyswitch for the VIMS in the ONposition. Leave the battery disconnect switch inthe ON position.

Note: If these switches remain in the ON positionduring replacement, the date and the time of day areless likely to require programming.

5. Remove the battery from the back of the VIMSmodule.

Note: Do not allow dirt or water into the opening.Keep the area clean.

6. Install a new internal battery. Be careful to alignthe pins of the new battery with the sockets.

7. Check the O-ring seal. Tighten securely againstthe housing.

8. The real time clock format in the main module ispowered by this battery. A dead battery will causethe date to be lost and a dead battery will causethe time to be lost. After the battery has beenreplaced, the date will default to “01/01/00”. Also,the time will default to “00:00:00”. If necessary, usethe service tool for the VIMS to set the time andthe date. Refer to Service Manual, SENR6059,“Vital Information Management System (VIMS)”for additional information.

i02275845

Window Washer Reservoir -FillSMCS Code: 7306-544

NOTICEWhen operating in freezing temperatures, useCaterpillar nonfreezing window washer solvent orequivalent. System damage can result from freezing.

The window washer reservoir is located behind thecab on the right side. Remove the cap and fill thereservoir with window washer solvent.

i01258249

Window Wiper -Inspect/ReplaceSMCS Code: 7305-040; 7305-510

Inspect the condition of the wiper blades. Replacethe wiper blades if the wiper blades are worn ordamaged or if streaking occurs.

i01391802

Windows - CleanSMCS Code: 7310-070

Use commercially available window cleaningsolutions in order to clean the windows. Use a cleancloth or a squeegee to clean the windows from thecab platform.

994f mantenimieto

Documents

frequent maintenance

maintenance procedures

hydraulic oil change

consecutive interval

previous interval

thenormal interval

oil filter

service hours