manual maintenance interval cat 416d 420d 42d 428d 430d 432d 442d backhoe loaders

8/17/2019 Manual Maintenance Interval Cat 416d 420d 42d 428d 430d 432d 442d Backhoe Loaders

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®© 2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt

http://www.heavyequipments.org/


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SEBU7821-04

June 2007

Operation andMaintenance

Manual416D, 420D, 424D, 428D, 430D, 432Dand 442D Backhoe Loaders

RXA1-Up (Machine)BKC920-Up (Machine)

BMC1060-Up (Machine)BXC1-Up (Machine)B2D1-Up (Machine)TBD1-Up (Machine)BGJ1050-Up (Machine)SMJ1-Up (Machine)BNK5900-Up (Machine)BML4800-Up (Machine)MBM1-Up (Machine)BLN10300-Up (Machine)BFP12900-Up (Machine)FDP18400-Up (Machine)WEP1-Up (Machine)TDR1-Up (Machine)

DSX1-Up (Machine)CJZ1-Up (Machine)



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128 SEBU7821-04Maintenance SectionMaintenance Interval Schedule

i02738980

Maintenance Interval Schedule

SMCS Code: 7000

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

The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, fi lters, and the replacementof components due to normal wear and aging. Failureto adhere to proper maintenance intervals andprocedures may result in diminished performance of the product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, or

calendar 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.

When Required

Battery or Battery Cable - Inspect/Replace ........ 132Bucket Cutting Edges - Inspect/Replace ............ 134Bucket Tips - Inspect/Replace ............................ 135

Cab Interior - Clean ............................................ 137Engine Air Filter Primary Element - Clean/Replace ............................................................. 145

Engine Air Filter Secondary Element - Replace .. 147Engine Compartment - Clean ............................. 148Fuel System - Prime ........................................... 153Fuses - Replace .................................................. 156Oil Filter - Inspect ................................................ 162Radiator Core - Clean ......................................... 163Window Washer Reservoir - Fill .......................... 170Window Wipers - Inspect/Replace ...................... 171Windows - Clean ................................................. 171

Every 10 Service Hours or Daily

Backhoe Boom, Stick, Bucket, and Cylinder Bearings- Lubricate ......................................................... 131

Backup Alarm - Test ............................................ 131Brake Reservoir Oil Level - Check ...................... 133Braking System - Test ......................................... 133Cooling System Coolant Level - Check .............. 140Engine Air Filter Service Indicator - Inspect ........ 147Engine Oil Level - Check .................................... 148Fuel System Water Separator - Drain ................. 155Hydraulic System Oil Level - Check ................... 160Loader Bucket, Cylinder, and Linkage Bearings -

Lubricate ........................................................... 160Seat Belt - Inspect .............................................. 164

Stabilizer and Cylinder Bearings - Lubricate ....... 165Swing Frame and Cylinder Bearings - Lubricate .. 166Tire Inflation - Check ........................................... 166Transmission Oil Level - Check .......................... 169Wheel Nut Torque - Check .................................. 170

Every 50 Service Hours or Weekly

Cab Air Filter - Clean/Replace ............................ 136Fuel Tank Water and Sediment - Drain ............... 156Parking Brake - Check/Adjust ............................. 162

Every 250 Service Hours or Monthly

Axle Breathers - Clean/Replace ......................... 130 Axle Universal Joint (Rear) - Lubricate ............... 130Belts - Inspect/Adjust/Replace ............................ 132Differential Oil Level (Front) - Check .................. 143Differential Oil Level (Rear) - Check ................... 144Engine Oil Sample - Obtain ................................ 149

Extendable Stick Pads - Inspect/Replace ........... 150Final Drive Oil Level (Front) - Check .................. 152Final Drive Oil Level (Rear) - Check ................... 152Kingpin Bearings (Rear) - Lubricate ................... 160Sideshift Stabilizer Wear Pads - Inspect ............. 165

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

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 141

Every 500 Service Hours or 3 Months

Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 140Differential Oil Sample (Front) - Obtain .............. 144Differential Oil Sample (Rear) - Obtain ............... 144Drive Shaft Spline - Lubricate ............................. 145Engine Oil and Filter - Change ........................... 149Final Drive Oil Sample (Front) - Obtain .............. 153Final Drive Oil Sample (Rear) - Obtain ............... 153Fuel System Filter and Water Separator -

Replace ............................................................. 154Hydraulic Oil Sample - Obtain ............................ 157Hydraulic System Oil Filter - Replace ................. 159Transmission Oil Filter - Replace ........................ 168Transmission Oil Sample - Obtain ...................... 169

Every 1000 Service Hours

Engine Valve Lash - Check ................................. 150

Every 1000 Service Hours or 6 Months

Differential Oil (Front) - Change .......................... 142Differential Oil (Rear) - Change .......................... 142Final Drive Oil (Front) - Change .......................... 151Final Drive Oil (Rear) - Change .......................... 152Rollover Protective Structure (ROPS) - Inspect .. 164Transmission Magnetic Screen - Clean .............. 166Transmission Oil - Change ................................. 167



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SEBU7821-04 129Maintenance Section

Maintenance Interval Schedule

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

Every 2000 Service Hours

Engine Crankcase Breather - Replace ............... 148

Every 2000 Service Hours or 1 Year

Hydraulic System Oil - Change ........................... 158

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 141

Refrigerant Dryer - Replace ................................ 164

Every 3000 Ser vice Hours or 2 Years

Cooling System Water Temperature Regulator -Clean/Replace .................................................. 141

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

Seat Belt - Replace ............................................. 165

Every 3000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 139

Every 6000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 137



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130 SEBU7821-04Maintenance Section

Axle Breathers - Clean/Replace

i01981945

Axle Breathers - Clean/Replace

SMCS Code: 3278-070-BRE; 3278-510-BRE

g00833319

Illustration 224The front axle breather is located on the top right side of thedifferential housing.

1. Clean the area around the breathers. Remove thebreather from the front axle.

Note: Do not turn the adapter when you remove thebreather.

2. Wash the breather in clean nonflammable solvent.Wipe the breather dry and check the breather for damage.

3. Install the clean breather back into the axle.Replace the breather if the breather is damaged.

Note: If the adapter is turned make sure that the slotin the adapter is parallel to the axle housing.

i01437649

Axle Universal Joint (Rear) -Lubricate(All Wheel Steer)

SMCS Code: 3251

g00753030Illustration 225


Apply lubricant to the grease fittings for the universal joints of each drive shaft to the final drives. There aretwo grease fittings for each universal joint.



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Backhoe Boom, Stick, Bucket, and Cylinder Bearings - Lubricate

i01877901

Backhoe Boom, Stick, Bucket,and Cylinder Bearings -Lubricate

SMCS Code: 6501; 6502; 6503; 6510; 6511; 6512;6513; 6533


Position the backhoe into the service position that isshown above.


Apply lubricant to the grease fitting (1) for the headend of the boom cylinder. Apply lubricant to thegrease fitting (2) for the rod end of the boom cylinder.

Apply lubricant to the grease fitting (3) for the boompivot. There is one grease fitting on each side of themachine.


Apply lubricant to the grease fitting (9) for the headend of the stick cylinder. Apply lubricant to the greasefitting (8) for the rod end of the stick cylinder.

Apply lubricant to the grease fitting (10) for the pivotpin for the stick.

Apply lubricant to the grease fitting (7) for the headend of the bucket cylinder. Apply lubricant to thegrease fitting (6) for the rod end of the bucket cylinder.

Apply lubricant to the grease fitting (11) for the pivotpin. There is one grease fitting on each side of themachine.

Apply lubricant to the grease fitting (4) for the bucketpivot pin.

Apply lubricant to the grease fitting (5) for the link.

Apply lubricant to the grease fitting (12) for the pivotpin.

There is a total of thirteen grease fittings.

i00080741

Backup Alarm - Test

SMCS Code: 7406

Turn the engine start switch key to ON in order toperform the test.

Apply the service brake. Move the transmissiondirection control lever to REVERSE position.

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



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132 SEBU7821-04Maintenance SectionBattery or Battery Cable - Inspect/Replace

i01833495

Battery or Battery Cable -Inspect/Replace

SMCS Code: 1401

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

2. Disconnect the negative battery cable from theframe.

Note: Do not allow the disconnected battery cable tocontact the frame of the machine.

3. Disconnect the negative battery cable at thebattery.

4. Inspect the battery terminals and inspect thebattery cables. Keep the terminals clean and keepthe terminals coated with petroleum jelly.

5. Perform the necessary repairs. Replace the cableor the battery, as needed.

6. Connect the negative battery cable at the battery.

7. Connect the battery cable to the frame of themachine.

8. Install the engine start switch key.

i01981993

Belts - Inspect/Adjust/Replace

SMCS Code: 1357-025; 1357-040; 1357-510

If new belts are installed, check belt adjustmentafter 30 minutes of operation. For multiple belt driveapplications, always replace the belts in matchedsets. Replacing only one belt of a matched set willcause the new belt to carry more load because theolder belts are stretched. The additional load on thenew belt could cause the new belt to break.

1. Empty the bucket. Remove the pin that securesthe brace for the loader lift arm to the left loader liftarm. Raise the loader arm to the maximum height.

2. Position the brace for the loader lift arm over theleft lift cylinder rod with the flat end against thecylinder end.

3. Push the pin through the holes of the brace for theloader lift arm and install the cotter pin.

4. Slowly lower the loader arms until the brace for theloader lift arm contacts the top of the lift cylinder and the bosses on the loader arm.

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


6. Remove the engine access panel on the left sideof the machine.


7. Inspect the condition of the air conditioner belt andthe adjustment of the air conditioner belt. The air conditioner belt should deflect 10 mm (0.38 inch)under 110 N (25 lb) of force.

8. Loosen the adjusting locknut (1). Loosen thecompressor bracket mounting bolt (2).

9. Move the compressor until the correct belt tensionis reached.

10. Tighten the adjusting locknut (1). Tighten thecompressor bracket mounting bolt (2).

11. Recheck the belt deflection. If the amount of deflection is incorrect, repeat Step 8 to Step 10.

12. Install the engine access panel.



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Brake Reservoir Oil Level - Check


13. Remove the engine access panel on the rightside of the machine.

g01029698

Illustration 233

14. Inspect the condition of the alternator beltsand the adjustment of the alternator belts. Thealternator belts should deflect 10 mm (0.38 inch)under 110 N (25 lb) of force.

15. Loosen the mounting bolt (3). Loosen theadjusting locknut (4).

16. Move the alternator until the correct tension isreached.

17. Tighten the adjusting locknut (4). Tighten the

mounting bolt (3).

18. Recheck the belt deflection. If the amount of deflection is incorrect, repeat Step 15 to Step 17.

19. Install the engine access panel.

20. Start the engine. Raise the loader arms to themaximum height.

21. Remove the pin and replace the brace for theloader lift arm to the stored position on the loader lift arm.

22. Lower the bucket to the ground.

i01991706

Brake Reservoir Oil Level -

CheckSMCS Code: 4291-535

Open the engine access door on the top of themachine.


Maintain the oil level between the “MIN” markand “MAX” mark on the brake reservoir. Add oil, if necessary.

i02291147

Braking System - Test

SMCS Code: 4251; 4267; 7000

Service Brake Holding Ability Test

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

Test the brakes on a dry, level surface.

Fasten the seat belt before you test the brakes.

The following tests are used to determine if theservice brake is functional. These tests are notintended to measure the maximum brake holdingeffort. The brake holding effort that is required tosustain a machine at a specific engine rpm variesdepending on the machine. The variations are thedifferences in the engine setting, in the power trainef ficiency, and in the brake holding ability, etc.

1. Start the engine. Raise the bucket slightly.



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134 SEBU7821-04Maintenance SectionBucket Cutting Edges - Inspect/Replace

2. Apply the service brake. Release the parkingbrake.

3. If the machine is equipped with the standardtransmission, move the transmission speed shiftlever to THIRD gear. Move the transmission

direction control lever to FORWARD, toNEUTRAL, and back to FORWARD. If themachine is equipped with a power shifttransmission move the transmission control lever to FOURTH SPEED FORWARD, to NEUTRAL,and back to FOURTH SPEED FORWARD. Thisis done in or der to override the transmissionneutralizer for this test.

Note: Place machines that are equipped with allwheel drive into two-wheel drive mode.

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

If the machine begins to move, reduce the enginespeed immediately and engage the parking brake.

5. Reduce the engine speed to low idle. Move thetransmission to NEUTRAL. Engage the parkingbrake. Lower the bucket to the ground. Stop theengine.

NOTICE

If the machine moved while testing the brakes, contactyour Caterpillar dealer. Have the dealer inspect and,if necessary, repair the service brake before returningthe machine to operation.

Secondary Brake Holding AbilityTest


Test the brakes on a dry, level surface.

Fasten the seat belt before you test the brakes.

The following tests are used to determine if theparking brake is functional. These tests are notintended to measure the maximum brake holdingeffort. The brake holding effort that is required tosustain a machine at a specific engine rpm variesdepending on the machine. The variations are thedifferences in the engine setting, in the power trainef ficiency, and in the brake holding ability, etc.


2. Engage the parking brake.

3. If the machine is equipped with the standardtransmission, move the transmission speed shiftlever to THIRD gear. Move the transmissiondirection control lever to FORWARD, to

NEUTRAL, and back to FORWARD. If themachine is equipped with a power shifttransmission move the transmission control lever to FOURTH SPEED FORWARD, to NEUTRAL,and back to FOURTH SPEED FORWARD. Thisis done in order to override the transmissionneutralizer for this test.


Note: The parking brake indicator light should comeon and the parking brake alarm should sound.


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

5. Reduce the engine speed. Move the transmissionto NEUTRAL. Lower the bucket to the ground.Stop the engine.

NOTICEIf the machine moved while testing the brakes, contactyour Cater pillar dealer.

Have the dealer inspect and, if necessary, repair theparking br akes before returning the machine to oper-ation.

i01920076

Bucket Cutting Edges -Inspect/Replace

SMCS Code: 6801

Personal injury or death can result from bucketfalling.

Block the bucket before changing bucket cuttingedges.

1. Raise the bucket. Place a block under the bucket.



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Bucket Tips - Inspect/Replace

2. Lower the bucket to the blocking.

Do not block up the bucket too high. Block upthe bucket so that the bucket is high enough toremove the cutting edges and the end bits.

3. Remove the bolts. Remove the cutting edge andthe end bits.

4. Clean the contact surfaces.

5. Use the opposite side of the cutting edge, if thisside is not worn.

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

7. Install the bolts. Tighten the bolts to the specifiedtorque.

8. Raise the bucket. Remove the blocks.

9. Lower the bucket to the ground.

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

i02420559

Bucket Tips - Inspect/Replace

SMCS Code: 6805

Personal injury or death can result from the bucketfalling.

Block the bucket before changing bucket tips.

Bucket Tips


(1) Usable(2) Replace(3) Replace

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 retainer side of the bucket to drive out the pin.

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


(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).



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136 SEBU7821-04Maintenance SectionCab Air Filter - Clean/Replace


4. Install the new bucket tip onto the adapter.

Note: The bucket tip can be rotated by 180 degrees in

order 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.


(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).

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 retainer fits snugly into the pin groove.

i01899383

Cab Air Filter - Clean/Replace

SMCS Code: 7311; 7342

Clean the Filter Element

NOTICEDo not clean the elements by bumping or tappingthem.

Inspect the elements after cleaning. Do not use anelement with damaged pleats, gaskets or seals.

When cleaning with pressure air, use 205 kPa (30 psi)maximum to prevent element damage by too much air pressure.

When cleaning with pressure water, use 280 kPa

(40 psi) maximum to prevent element damage.

Clean the filter element weekly, but clean the filter element daily when there is a reduction of air circulation.


1. Remove the filter cover that is located at thebottom of the right hand console.

2. Remove the filter element.



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Cab Interior - Clean

3. Clean the filter element with compressed air or pressure water. Direct the air or the water alongthe pleats of the element. You can also washthe element with clean water and nonsudsinghousehold detergent.

4. Rinse the filter element thoroughly with clear water.

5. Allow the filter element to air dry. Inspect theelement for damage. If the filter element isdamaged, replace the filter element.

6. Install the filter element.

7. Install the filter cover.

Clean the Precleaner (If Equipped).

g00987918

Illustration 241


1. Remove the filter cover that is located under thecab. The precleaner is located directly beneaththe air conditioner.

2. Remove the foam element.

Note: Most of the debris can be removed by strikingthe foam element against a hard surface.

3. The foam element can also be cleaned with cleanwater and nonsudsing household detergent.

4. Rinse the foam element thoroughly with clear water.

5. Allow the foam element to air dry. Inspect theelement for damage. If the foam element isdamaged, replace the foam element.

6. Install the foam element.

7. Install the filter cover.

i01404606

Cab Interior - Clean

SMCS Code: 7301-070

1. Use high pressure air in order to clean the entirecab and the main electrical box.

2. Wash off any remaining dirt and debris. Usecaution and minimize the water around electricalconnections and the cab roof.

3. Scrub the floormat, the instrument panel, thewindows, and the mirrors. Wipe the cab dry.

i01982029

Cooling System Coolant (ELC)

- Change

SMCS Code: 1353; 1395

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.

NOTICE

Mixing ELC with other products will reduce the effec-tiveness of the coolant.

This could result in damage to cooling system compo-nents.

If Caterpillar products are not available and com-mercial products must be used, make sure theyhave passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants and Caterpillar Extender.



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138 SEBU7821-04Maintenance SectionCooling System Coolant (ELC) - Change

Note: This machine is shipped with Extended LifeCoolant. Extended Life Coolant is recommended for use.

For information about the addition of Extender to your cooling system, see the Operation and Maintenance

Manual, “Cooling System Coolant Extender (ELC) - Add” or consult your Caterpillar dealer.

Flushing the Extended Life CoolantFrom the Cooling System

Some engines utilize Extended Life Coolant. See theOperation and Maintenance Manual, “MaintenanceInterval Schedule” in order to determine the serviceinterval. If a Extended Life Coolant was previouslyused, flush the cooling system with clean water. Noother cleaning agents are required.

Flushing a Standard Coolant Fromthe Cooling System

If you change the coolant of a machine to ExtendedLife Coolant from another type of coolant, use aCaterpillar cleaning agent to flush the cooling system.

After you drain the cooling system, thoroughly flushthe cooling system with clean water. All of thecleaning agent must be removed from the coolingsystem.

Changing the Coolant


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





Drain the coolant whenever the coolant is dirty or whenever foaming is observed.

The radiator cap is located under the access panelon the top of the engine compartment.

1. Open the engine access door on the top of themachine.


2. Lift the tab on the radiator cap in order to relievesystem pressure. Remove the radiator cap slowly.




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Cooling System Coolant Extender (ELC) - Add


3. Pull the drain hose for the radiator through thehole under the radiator.

g01029871

Illustration 246

4. Remove the access panel on the left side of theengine compartment. The drain valve is located inan access port of the fan shroud. Open the drainvalve. Allow the coolant to drain into a suitablecontainer.

5. Close the drain valve. Fill the system with asolution which consists of clean water and of cooling system cleaner. The concentration of thecooling system cleaner in the solution should bebetween 6 percent and 10 percent.

6. Start the engine. Run the engine for 90 minutes.Stop the engine. Drain the cleaning solution into asuitable container.

7. While the engine is stopped, flush the system withwater. Flush the system until the draining water is transparent.

8. Close the drain valve.

9. Add the coolant solution. See the following topics:

• Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”, “CoolingSystem Specifications”

• Operation and Maintenance Manual, “Capacities(Refill)”

Note: If you are using Caterpillar antifreeze, do notadd the supplemental coolant additive at this timeand/or change the element at this time.

10. Start the engine. Run the engine without theradiator cap until the thermostat opens and thecoolant level stabilizes.

11. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe.

12. Install the r adiator cap. Lower the tab on theradiator cap. Replace the radiator cap if the gasket

is damaged.

13. Stop the engine.

14. Replace the access panel. Close the access door.

i01833638

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352; 1353; 1395

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loose the cap slowly to relievethe pressure.

When a Caterpillar Extended Life Coolant isused, an extender must be added to the coolingsystem. See the Operation and MaintenanceManual, “Maintenance Interval Schedule” for theproper service interval. The amount of extender isdetermined by the cooling system capacity.

Table 82

RECOMMENDED AMOUNT OF EXTENDER BYCOOLING SYSTEM CAPACITY

Cooling System Capacity Recommended Amount

of Extender

22 to 30 L (6 to 8 US gal) 0.57 L (.60 qt)

30 to 38 L (8 to 10 US gal) 0.71 L (.75 qt)

38 to 49 L (10 to 13 US gal) 0.95 L (.95 qt)

49 to 64 L (13 to 17 US gal) 1.18 L (1.25 qt)



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140 SEBU7821-04Maintenance SectionCooling System Coolant Level - Check

For additional information on the addition of extender,see Special Publication, SEBU6250, “Cat ExtendedLife Coolant (ELC) Cooling System Maintenance” or consult your Caterpillar dealer.

i01982091

Cooling System Coolant Level- Check

SMCS Code: 1350-535-FLV


Open the engine access door on the top of the hood.


1. The radiator cap is located on the top of theradiator on the left side of the machine. Lift thetab on top of the cap in order to relieve systempressure. Remove the radiator cap slowly.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the fi ller tube. If you need to addcoolant daily, check the cooling system for leaks.

3. Inspect the radiator cap seal. Replace the radiator cap seal if the radiator cap seal is damaged.

4. Install the radiator cap. Lower the tab on theradiator cap. Close the access panel.

i02436215

Cooling System CoolantSample (Level 1) - Obtain

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

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, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.

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


Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In order to receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In order to establish a pertinent history of data, perform

consistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling of the coolant:

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

• Keep the unused sampling bottles stored in plasticbags.



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Cooling System Coolant Sample (Level 2) - Obtain

• 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.

Submit the sample for Level 1 analysis.

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

dealer.

i02436220

Cooling System CoolantSample (Level 2) - Obtain

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

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, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.


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

Refer to Operation and Maintenance Manual,

“Cooling System Coolant Sample (Level 1) - Obtain”for the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.

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

i02360639

Cooling System Water

Temperature Regulator -Clean/Replace

SMCS Code: 1355; 1393

Replace the thermostat on a regular basis in order toreduce the chance of unscheduled downtime and of problems with the cooling system. Failure to replacethe engine’s thermostat on a regularly scheduledbasis could cause severe engine damage.

The thermostat should be replaced after the coolingsystem has been cleaned. Replace the thermostat

while the cooling system is completely drained or while the cooling system coolant is drained to a levelthat is below the thermostat housing.

Note: If you are only replacing the thermostat, drainthe cooling system coolant to a level that is belowthe thermostat housing.

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

1. Empty the bucket. Remove the pin that securesthe lift arm brace to the left loader lift arm. Raise

the loader arm to the maximum height.

2. Position the lift arm brace over the left lift cylinder rod with the flat end against the cylinder end.

3. Push the pin through the holes of the lift arm braceand install the cotter pin.

4. Slowly lower the loader arms until the lift armbrace contacts the top of the lift cylinder and thebosses on the loader arm.

5. Remove the engine access panel on the right sideof the machine.



17/47

142 SEBU7821-04Maintenance SectionDifferential Oil (Front) - Change


6. Loosen the hose clamp and remove the hose fromthe thermostat housing assembly.

7. Remove the bolts from the thermostat housingassembly. Remove the thermostat housingassembly.

8. Remove the gasket, the thermostat, and the sealfrom the thermostat housing assembly.

9. Install a new seal in the thermostat housingassembly. Install a new thermostat and a newgasket. Install the thermostat housing assemblyon the engine cylinder head.

The thermostats can be reused under the followingconditions.

• The thermostat is tested and the thermostatmeets test specifications.

• The thermostat is not damaged.

• The thermostat does not have excessivebuildup of deposits.

10. Install the hose. Tighten the hose clamp.

11. Refill the cooling system. Refer to SpecialPublication, “Cooling System Specifications” andOperation and Maintenance Manual, “Capacities

(Refill)”.

i02567860

Differential Oil (Front) - Change

SMCS Code: 3258


1. Remove oil drain plug (1) and drain the oil into asuitable container.

2. The drain plug is magnetic. Check the plug for metal.

3. Clean the drain plug and install the drain plug.

4. Remove oil level/fill plug (2).

5. Add oil until the oil is level with the threads for thefiller plug. Refer to Operation and Maintenance

Manual, “Lubricant Viscosities” and Operation andMaintenance Manual, “Capacities (Refill)” for oil.

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

i01982218

Differential Oil (Rear) - Change

SMCS Code: 3258

The oil change interval should be decreased to 500hours if more than 50% of the service hours is usedfor roading and loading.



18/47


Differential Oil Level (Front) - Check

Rear Axle


1. Remove the oil drain plug and drain the oil into asuitable container.



3. Remove the oil level/fill plug. Refer to SpecialPublication, “Lubricant Specifications” andOperation and Maintenance Manual, “Capacities(Refill)” for oil.

4. Add oil until the oil is level with the threads for the filler plug.

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

Rear Axle with All Wheel Steer (AWS)


1. Remove the oil drain plug and drain the oil into asuitable container.



3. Remove the oil level/fill plug. Refer toOperation and Maintenance Manual, “LubricantSpecifications” and Operation and MaintenanceManual, “Refill Capacities” for oil.

4. Add oil until the oil is level with the threads for the filler plug.

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

i02363607

Differential Oil Level (Front) -Check

SMCS Code: 3258

The oil level/fill plug is located near the middle of the front axle.



19/47

144 SEBU7821-04Maintenance SectionDifferential Oil Level (Rear) - Check


1. Remove the oil level/fill plug in order to check theoil.

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

3. Clean the oil level/fill plug and install the oillevel/fill plug.

i01355918

Differential Oil Level (Rear) -Check

SMCS Code: 3258

The oil level/fill plug is located near the middle of therear axle.


Filler plug on standard rear differential

1. Remove the oil plug in order to check the oil.

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

3. Clean the oil plug and install the oil plug.

i02363692

Differential Oil Sample (Front)- Obtain

SMCS Code: 3258-008; 7542-008


Obtain the oil sample according to the Operationand Maintenance Manual, “Maintenance IntervalSchedule”.

Refer to the Operation and Maintenance Manual,“General Hazard Information” for information thatpertains to containing fluid spillage.

Refer to the Special Publication, SEBU6250, “S·O·SOil Analysis” for more information.

i02436599

Differential Oil Sample (Rear)- Obtain

SMCS Code: 3258-008; 7542-008





20/47


Drive Shaft Spline - Lubricate



i01356061

Drive Shaft Spline - Lubricate

SMCS Code: 3253


Access the grease fittings for the drive shaft splinefrom the bottom of the machine.


Apply lubricant to the grease fitting for the drive shaftspline of the front drive shaft.


Apply lubricant to the grease fitting for the drive shaftspline of the rear drive shaft.

i02510477

Engine Air Filter PrimaryElement - Clean/Replace

SMCS Code: 1051; 1054

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

Service the air cleaner filter element when the

yellow piston on the engine air filter serviceindicator enters the red zone or the indicator reads 63.5 cm (25 inch) of water. Refer toOperation and Maintenance Manual, “Engine Air Filter Service Indicator - Inspect”.



2. Remove cover (1) for the air filter housing .



21/47

146 SEBU7821-04Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

3. Remove primary filter element (2) from the air filter housing.

4. Slide the primary filter element out of the filter base (3).

5. Clean the inside of the air filter housing.

6. Slide a clean primary air filter element into thefilter base. Install the clean filter into the air fi lter housing. Install the cover for the air fi lter housing.

Note: Refer to “Cleaning Primary Air Filter Elements”.

7. Reset the engine air fi lter service indicator.

8. Close the access door.

If the yellow piston in the indicator moves into the redzone after starting the engine or the exhaust smoke

is still black after installation of a clean primary fi lter element, install a new primary filter element. If thepiston remains in the red zone replace the secondaryelement.

Cleaning Primary Air Filter Elements

NOTICECaterpillar recommends certified air filter cleaning ser-vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and suf ficient 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 fi lter element.

Use low pressure compressed air in order to removethe dust fr om the fi lter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filter element. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage toengine components.

The primary air filter element can be used up tosix times if the element is properly cleaned andinspected. When the primary air filter element iscleaned, check for rips or tears in the fi lter material.Every two years replace the primary air fi lter elementat least one time. 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. Engine

damage could result.

Visually inspect the primary air fi lter elements beforecleaning. Inspect the air fi lter elements for damageto the seal, the gaskets, and the outer cover. Discardany damaged air filter elements.

There are two common methods that are used toclean primar y air filter elements:

• Pressurized air

• Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary air filter elements that have not been cleaned more than twotimes. Pressurized air will not remove deposits of carbon and oil. Use fi ltered, dry air with a maximumpressure of 207 kPa (30 psi).

Note: When the primary air filter elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Vacuum Cleaning

Vacuum cleaning is another method for cleaningprimary air filter elements which require 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 Filter Elements

Inspect the clean, dry primary air fi

lter element.Inspect the primary air fi lter element for tears and/or holes. If it is necessary in order to confirm the result,compare the primary air filter element to a newprimary air filter element that has the same partnumber.

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



22/47


Engine Air Filter Secondary Element - Replace

Storing Primar y 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.

Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An air flow restrictionmay result. To protect against dirt and damage, wrapthe primary air fi lter elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary air filter element into a box for storage. 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.

i01991300

Engine Air Filter SecondaryElement - Replace

SMCS Code: 1051; 1054

NOTICE Always replace the secondary filter element. Never attempt to reuse it by cleaning.

The secondary filter element should be replaced atthe time the primary element is serviced for the thirdtime. The secondary filter element should be replacedeverytime the primary element is replaced.

The secondary filter element should also be replacedif the yellow piston in the filter element indicator en-ters the red zone after installation of a clean primaryelement, or if the exhaust smoke is still black.


1. Remove the air cleaner housing cover (1).

2. Remove the primary filter element (2) from the air cleaner housing.

3. Clean the inside of the air cleaner housing (4) with

a wet rag befor e the secondary filter element (3)is removed.

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

5. Install a new secondary element.

6. Install the primary element and the air cleaner housing cover. Fasten the clips in order to securethe air cleaner housing cover.

7. Reset the fi lter element indicator.

8. Close the engine access door.

i01991054

Engine Air Filter ServiceIndicator - Inspect

SMCS Code: 1051; 1054; 7452

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


The filter service indicator is located under the engineaccess door in front of the housing for the air filter.

Start the engine. Run the engine at high idle. If theyellow piston in the fi lter service indicator enters thered zone, service the air cleaner. Stop the engine.



23/47

148 SEBU7821-04Maintenance SectionEngine Compartment - Clean

i01404793

Engine Compartment - Clean

SMCS Code: 1000-070

NOTICEBefore spraying the engine compartment with highpressure water turn off the engine and allow the en-gine to cool. Do not spray water directly on a hot fuelinjection pump or damage may occur.

Use a commercially available engine degreaser in order to clean the engine compartment. Usecaution and minimize the water around bearings andelectrical connections.

i02409844

Engine Crankcase Breather -Replace

SMCS Code: 1317-510


1. Loosen the clamp (9) and remove the hose (10)from the connector (12).

2. Remove the setscrews (8) and remove theconnector (12) from the cylinder head. Removethe gasket (13). Remove the O-ring seal (11) fromthe connector. Discard the gasket (13) and theO-ring seal (11).

3. Remove the cover (1) from the valve mechanismcover (5).

Personal injury can result from parts and/or cov-ers under spring pressure.

Spring force will be released when covers are re-moved.

Be prepared to hold spring loaded covers as thebolts are loosened.

4. Remove the screws (2). Remove the plate (3).

5. Remove the diaphragm (4) and the cap (6).Remove the spring (7). Discard diaphragm (4).

Improper assembly of parts that are spring loadedcan cause bodily injury.

To prevent possible injury, follow the establishedassembly procedure and wear protective equip-ment.

6. Install the spring (7), the cap (6), and a newdiaphragm (4).

7. Install the plate (3). Install the screws (2).

8. Install the cover (1) on the valve mechanism cover.

9. Install a new O-ring seal (11) on the connector (12). Install a new gasket (13) on the connector (12). Position the connector in the valvemechanism cover.

10. Install the setscrews (8). Tighten the setscrews toa torque of 9 N·m (80 lb in).

11. Install the hose (10) on the connector (12). Tightenthe clamp (9) to a torque of 5 N·m (44 lb in).

i01982246

Engine Oil Level - CheckSMCS Code: 1302; 1318; 1326

NOTICEDo not over fill the crankcase. Engine damage can re-sult.




24/47


Engine Oil Sample - Obtain


2. While the engine is stopped, maintain the oil levelbetween the “ADD” mark and the “FULL” mark onthe engine oil dipstick (2).

3. If necessary, remove the oil filler cap (1) and addoil.

4. Clean the oil fi ller cap and install the oil fi ller cap.

5. Close the engine access door.

i01999134

Engine Oil Sample - Obtain

SMCS Code: 1348-008; 7542-008





i01982523

Engine Oil and Filter - Change

SMCS Code: 1302; 1318; 1326

Note: If the sulfur content in the fuel is greater than1.5% by weight, use an oil with a TBN of 30. With thehigh sulfur fuel, change the oil and the filter elementafter every 250 hours or after every month. If the

API category is CF-4 or less, change the oil andchange the filter element after every 250 hours or after every month. Otherwise, change the oil and thefilter element after every 500 hours or after everythree months.


The crankcase drain plug is on the right side of theoil pan.

1. Remove the crankcase drain plug and drain theoil into a suitable container. Clean the crankcasedrain plug and replace the crankcase drain plug.


2. Remove the filter element with a strap typewrench.

3. Clean the filter mounting base with a clean cloth.Make sure that the old filter gasket has beenremoved.



25/47

150 SEBU7821-04Maintenance SectionEngine Valve Lash - Check

4. Apply a thin fi lm of clean engine oil to the sealingsurface of the new fi lter element.

5. Install the new filter element by hand. When thegasket contacts the filter base, tighten the filter for an additional 3/4 turn.



7. Remove the oil filler cap (1). Fill the crankcasewith new oil. Refer to Operation and MaintenanceManual, “Lubricant Viscosities” and Operation andMaintenance Manual, “Capacities (Refill)”. Cleanthe oil fi ller cap and install the oil fi ller cap.

8. Start the engine and allow the oil to warm. Checkfor leaks.

9. Stop the engine and allow the oil to drain backinto the oil pan. Maintain the oil level in thecrosshatched region of the engine oil dipstick (2).

Add oil, if necessary.

10. Replace the engine access panel and close theengine access door.

i01897328

Engine Valve Lash - Check

SMCS Code: 1102-082; 1102-535; 1102; 1209-082;1209

Note: A qualified service person should perform thevalve lash check and/or the valve lash adjustment.Special tools and training are required.

Refer to your machine’s Service Manual for completeinstructions.

i01364126

Extendable Stick Pads -Inspect/Replace(If Equipped)

SMCS Code: 6533-040-JP; 6533-510-JP

Inspect Wear Pads


Check the extendable stick for slop. Shim theextendable stick pads in order to maintain anacceptable fit and reduce slop.

Note: Do not apply an excessive amount of a siliconebased lubricant. Dirt can be attracted to the lubricantand dirt can cause abrasion to the pad assembliesand wear to the pad assemblies.

The extendable stick pads do not normally requireany lubrication. If the extendable stick becomesnoisy, a small amount of a silicone based lubricantmay be applied.

Adjustment for Top Upper Wear Pad

1. Extend the extendable stick to one half of the fullyextended position.

2. Move the stick and move the boom down againstthe ground. This will take pressure off the wear pad.



26/47


Final Drive Oil (Front) - Change


3. Remove the bolts that secure the wear pad. Slidethe pad toward the boom. There will be enoughspace in order to remove the pad. Either replace

the wear pads or stack shims behind the pad.

4. Shim the wear pad to 1 mm (0.04 inch) .

Note: In order to make adjustments to the remainingupper wear pads, refer to Disassembly and AssemblyManual, SENR1209, “Stick, Extendable Stick,Extendable Stick Cylinder”.

Adjustment for Lower Pads

1. Extend the extendable stick out until there isenough clearance in order to remove the pads.


2. The side pads (1) can be shimmed without movingthe stick or without moving the boom.

3. Adjust the boom and adjust the stick in order totake pressure away from the top pad (2). Adjustthe wear pads by shimming or replacing. Shim thewear pads to 1 mm (0.04 inch).

4. Adjust the boom and adjust the stick in order totake the pressure away from the lower pad (3).

Note: Place the bucket on the ground. Apply slightpressure toward the ground with the stick. Shim thelower pad or replace the lower pad.

i02369952

Final Drive Oil (Front) - ChangeSMCS Code: 4050


1. Position the oil fill/drain plug at the bottom.Remove the oil fi ll/drain plug and drain the oil intoa suitable container.

2. The plug is magnetic. The plug will attract metalfrom the oil. Check the plug for an increasedamount of metal on the plug. If any abnormalparticles are found, consult your Caterpillar dealer.


3. Position the plug hole at a horizontal position. Usethe line on the final drive as a reference.

4. Add oil until the oil is level with the plug threads.Refer to Operation and Maintenance Manual,“Lubricant Specifications” and Operation andMaintenance Manual, “Capacities (Refill)” for theoil.

5. Clean the plug and install the plug.



27/47

152 SEBU7821-04Maintenance SectionFinal Drive Oil (Rear) - Change

6. Repeat the procedure for the other final drive.

i01995377

Final Drive Oil (Rear) - Change

(All Wheel Steer)SMCS Code: 4050


1. Position the oil fill/drain plug at the bottom.Remove the oil fill/drain plug and drain the oil intoa suitable container.


2. Position the plug hole at a horizontal position. Usethe line on the final drive as a reference.

3. Add oil until the oil is level with the plug threads.Refer to Operation and Maintenance Manual,“Lubricant Specifications” and Operation andMaintenance Manual, “Capacities (Refill)” for theoil.



i02370034

Final Drive Oil Level (Front) -Check

SMCS Code: 4050


1. Position the oil fill/drain plug at a horizontalposition in order to check the oil level.

2. Remove the oil fi ll/drain plug in order to check theoil level.

3. The oil should be level with the bottom of the plugthreads.

4. The plug is magnetic. Check the plug for metal.Clean the plug and install the plug.


i01995404

Final Drive Oil Level (Rear) -Check(All Wheel Steer)

SMCS Code: 4050




28/47


Final Drive Oil Sample (Front) - Obtain

1. Position the oil fill/drain plug at a horizontalposition in order to check the oil level.

2. Remove the oil fi ll/drain plug in order to check theoil level.

3. The oil should be level with the bottom of the plugthreads.



i02370039

Final Drive Oil Sample (Front)- Obtain

SMCS Code: 4050-008-FR; 7542-008


Obtain the oil sample from the fill/drain plug. Refer toSpecial Publication, SEBU6250, “S·O·S Oil Analysis”for information that pertains to obtaining a sampleof the engine oil. Refer to Special Publication,PEHP6001, “How To Take A Good Oil Sample” for more information about obtaining a sample of oil.

i01999152

Final Drive Oil Sample (Rear)- Obtain

SMCS Code: 4050-008-RE; 7542-008





i01920607

Fuel System - Prime

SMCS Code: 1250-548

S/N: RXA1-Up

S/N: BXC1-Up

S/N: B2D1-Up

S/N: TBD1-Up

S/N: SMJ1-Up

S/N: MBM1-Up

S/N: WEP1-Up

S/N: TDR1-Up

S/N: DSX1-Up

S/N: CJZ1-Up

Air can enter the system under the followingconditions.

• The fuel tank is drained during normal operation.



29/47

154 SEBU7821-04Maintenance SectionFuel System Filter and Water Separator - Replace

• The low pressur e fuel lines are disconnected.

• A part of the low pressure fuel system leaks duringengine operation.

If air enters the fuel system, the air must be eliminated

from the system before the engine can be started.

If the engine has been stopped by air in the fuelsystem, perform the following procedures:

• Make sure that fuel has been added to the tank.

• Make sure that the leakage problem has beencorrected.

• Make sure that the electrical stop control isconnected.

• Operate the starter motor until the engine starts.

1. Make sure that the electric stop control isconnected. Turn the engine start switch key to theON position.


2. Remove the access panel on the right side of themachine.


3. Operate the lever of the fuel lift pump slowly for approximately two minutes. If the drive cam of thefuel lift pump is at the point of maximum cam lift,the priming lever will not operate. In this situation,the crankshaft must be turned one revolution.

4. Operate the starter motor until the engine starts.Refer to Operation and Maintenance Manual,“Engine Starting”.

5. If the engine runs roughly after the engine runsfor a short period of time correctly check for air in the fuel system. If the engine stops after theengine runs for a short period of time correctlycheck for air in the fuel system. If there is air in thefuel system, check the low pressure fuel systemfor a leak. Correct the problem and repeat Step3 through Step 4.

i01986276

Fuel System Filter and Water Separator - Replace

SMCS Code: 1261-510; 1263-510-FQ

Some fuel supplies may not meet the minimumstandard for fuel lubricity. Caterpillar recommends theuse of fuels that meet certain minimum specifications.Refer to Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”.

NOTICEIt is extremely important to drain water from the water separator daily, or every ten hours. It is also extremelyimportant to drain water from the fuel tank weekly, or every 50 hours. Failure to do so could result in damageto the fuel system.





5. Stop the engine.



30/47


Fuel System Water Separator - Drain


6. Remove the access panel from the left side of the machine.

The machine uses a fuel filter with a push andtwist collar.


7. Remove the sensor and the wire from the bottomof the filter.

8. Remove the primary fuel fi lter that is located nextto the engine oil filter under the left side of themachine. Rotate the locking ring counterclockwisein order to remove the fi lter element. Discard thefilter properly.

9. Clean the fi lter element mounting base. Removeany part of the fi lter element gasket that remainson the fi lter element mounting base.

10. Coat the seal of the new filter element with cleandiesel fuel.

11. Install the new fi lter element. Rotate the lockingring clockwise in order to fasten the filter to themounting base.

12. Install the sensor and the wire into the new filter.

13. Replace the access panel.

i01986280

Fuel System Water Separator - Drain

SMCS Code: 1263-543; 1263


NOTICEIt is extremely important to drain water from the water separator daily, or every ten hours. It is also extremelyimportant to drain water from the fuel tank weekly, or every 50 hour s. Failure to do so could result in damageto the fuel system.


The water separator is located by the drain plug for the engine crankcase.


1. Loosen the drain valve on the bottom of the fuelfilter. Allow the water and the sediment to draininto a suitable container.

2. Tighten the drain valve.



31/47

156 SEBU7821-04Maintenance SectionFuel Tank Water and Sediment - Drain

3. If the engine fails to start, change the fuel filter. If there is a power loss, change the fuel filter.

i01986286

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S


NOTICEIt is extremely important to drain water from the water separator daily, or every ten hours. It is also extremely

important to drain water from the fuel tank weekly, or every 50 hours. Failure to do so could result in damageto the fuel system.

The fuel tank is located on the left side of themachine.


Flip up the tab on the fuel cap. Turn the tabcounterclockwise on the fuel cap and slowly removethe fuel tank cap(1) in order to relieve pressure.

The fuel tank drain valve (2) is located on the lower right corner on the front of the fuel tank. Remove thefuel tank drain plug. Allow the water and sediment todrain into a suitable container. Install the fuel tankdrain plug. Replace the fuel tank cap.

i01986292

Fuses - Replace

SMCS Code: 1417

Fuses protect the electrical system from damagethat is caused by overloaded circuits. Replace thefuse if the element separates. If the element of a newfuse separates, check the circuit. Repair the circuit, if necessary.

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

g00724522

Illustration 290

Remove the cover on the front of the right sideconsole in order to access the main fuse panel.


Front Floodlights (1) – 15 Amp

Auxiliar y Front Floodlights (2) – 10 Amp

Auxiliary Rear Floodlights (3) – 10 Amp

All Wheel Drive (4) – 5 Amp



32/47


Hydraulic Oil Sample - Obtain

Start Relay (5) – 20 Amp

Monitor (6) – 5 Amp

Transmission (7) – 10 Amp

Rear Hydraulics (8) – 10 Amp

Bucket Positioner (9) – 5 Amp

Starting Aid (10) – 15 Amp

Engine (11) – 10 Amp

Signal Lamps (12) – 10 Amp

Power Port (13) – 10 Amp

Radio (14) – 5 Amp

Key Start Switch (15) – 5 Amp

Air Seat (16) – 20 Amp

Horn (17) – 15 Amp

Spare (18) – 10 Amp

Note: Some of the main fuses are tied together withthe fuses in the headliner. For example, if all of thelights are not functioning, check the main fuse for the lights in the steering console. If one light is notfunctioning, check the fuse in the headliner for thespecific light.

Remove the cover in order to access the fuses.


Auxiliary Hydraulics (1) – 15 Amp

Spare (2) – OPEN

Ride Control (3) – 10 Amp

Left Tail Light (4) – 5 Amp

Right Tail Light (5) – 5 Amp

Air Conditioner (6) – 10 Amp

Front Window Wiper (7) – 10 Amp

Rear Window Wiper (8) – 10 Amp

Rotating Beacon (9) – 10 Amp

Spare (10) – 10 Amp

Rear Floodlights (11) – 15 Amp

i01999210

Hydraulic Oil Sample - Obtain

SMCS Code: 5050-008; 7542-008







33/47

158 SEBU7821-04Maintenance SectionHydraulic System Oil - Change

i01986309

Hydraulic System Oil - Change

SMCS Code: 5056

Note: The normal hydraulic oil change intervalis at every 2000 Service Hours or 1 Year. Byperforming S·O·S oil analysis, the hydraulicoil change interval may be extended to 4000Service Hours or 2 Years. S·O·S oil analysismust be performed at every 500 Service Hoursor 3 Months in order to extend the hydraulic oilchange interval. The results from the S·O·S oilanalysis will determine if the hydraulic oil changeinterval may be extended. If S·O·S oil analysis isnot available, the hydraulic oil change intervalmust remain at every 2000 Service Hours or 1

Year . Refer to the Operation and MaintenanceManual, “S·O·S Information”.

Operate the machine for a few minutes in order towarm the hydraulic system oil.

The machine should be level . Lower the bucket tothe ground and apply slight downward pressure.Engage the parking brake and stop the engine.

The hydraulic tank filler cap is located under theaccess door on the top of the engine compartment.


g01030543

Illustration 294

2. Remove the hydraulic tank fi ller cap.



3. Remove the drain plug on the flange that is

located on the hydraulic pump. Allow the oil todrain into a suitable container.

4. Clean the drain plug and replace the drain plug.Tighten the drain plug to a torque of 90 ± 10 N·m(66 ± 7 lb ft).

5. Change the hydraulic system filter. Refer toOperation and Maintenance Manual, “HydraulicSystem Oil Filter - Change”.

6. Inspect the hydraulic tank breather that is locatedon a hose from the over flow container. Replacethe breather, if necessary.

7. Fill the hydraulic system oil tank. Refer toOperation and Maintenance Manual, “LubricantViscosities” and Operation and MaintenanceManual, “Capacities (Refill)”.



34/47


Hydraulic System Oil Filter - Replace


8. Maintain the hydraulic oil level in the sight gaugebetween the “MIN” mark and the “MAX” mark.

Check the hydraulic oil level with the loader onthe ground and with the backhoe in the transportposition.

Note: The oil must be free of bubbles. If bubbles arepresent in the oil, air is entering the hydraulic system.Inspect the suction hoses and hose clamps.

9. Inspect the gasket on the hydraulic tank fi ller capfor damage. Replace the gasket, if necessary.

10. Install the hydraulic tank filler cap.


i01986704

Hydraulic System Oil Filter -Replace

SMCS Code: 5056; 5068


g01030543Illustr ation 298

2. Remove the hydr aulic tank filler cap that is locatedunder the access panel on the top of the enginecompartment.


3. The hydraulic oil fi lter is located on the left side of the machine.


4. Remove the filter element with a strap typewrench.

5. Clean the fi lter element mounting base. Removeany part of the fi lter element gasket that remainson the filter element mounting base.

6. Apply a light coat of oil to the gasket of the newfilter element.

7. Install the new fi lter element by hand. When thegasket contacts the fi lter element mounting base,tighten the filter element for an additional threequarters of a turn.

8. Remove the hydraulic tank breather. Replace theold breather with a new breather.



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160 SEBU7821-04Maintenance SectionHydraulic System Oil Level - Check


9. Maintain the hydraulic oil level in the sight gaugebetween the “MIN” mark and the “MAX” mark. Addoil, if necessary.

10. Inspect the gasket on the hydraulic tank fi ller capfor damage. Replace the gasket, if necessary.

11. Install the hydraulic tank filler cap.


i01352315

Hydraulic System Oil Level -Check

SMCS Code: 5056; 7479


The sight gauge for the hydraulic tank is located onthe left side of the machine. Move the backhoe tothe transport position and lower the loader bucketto the ground.

Turn off the engine. Wait about five minutes beforeyou check the hydraulic system oil level.

Maintain the oil level in the sight gauge between the“MIN” mark and the “MAX” mark.

i00661457

Kingpin Bearings (Rear) -Lubricate(All Wheel Steer)

SMCS Code: 4314


Apply lubricant to the grease fittings for the kingpinbearings of the rear steerable axle. There is a total of four grease fittings.

i01364566

Loader Bucket, Cylinder, andLinkage Bearings - Lubricate

SMCS Code: 7069; 7070; 7071

Single Tilt Machines


Apply lubricant to the grease fittings (1) for the frameand for the lift arm. There is a grease fitting for eachside of the machine.

Apply lubricant to the grease fitting (2) for the pivotfor the linkage of bucket positioner and lift kickout.



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Loader Bucket, Cylinder, and Linkage Bearings - Lubricate

Apply lubricant to the grease fittings (3) for the headend of the lift cylinder. There is a grease fitting for each side of the machine.

Apply lubricant to the grease fittings (4) for the rodend of the lift cylinder. There is a grease fitting for

each side of the machine.

Apply lubricant to the grease fittings (5) for the pivotpin at the loader lift arm. There is a grease fitting for each side of the machine.

Apply lubricant to the grease fittings (6) for the pivotbearings for the bucket tilt cylinder. There is a greasefitting in each linkage (four total).

Apply lubricant to the grease fitting (7) for the rod endof the tilt cylinder.

Apply lubricant to the grease fittings (8) for the lower

pivot pins. There is a grease fitting for each side of the machine.

Apply lubricant to the grease fittings (9) for the upper pivot pin. There is a grease fitting for each side of the machine.

There is a total of 17 grease fittings.

Parallel Lift Machines


Apply lubricant to the grease fittings (1) for the lower pivot pin of the quick coupler assembly. There is agrease fitting for each side of the machine.

Apply lubricant to the grease fittings (2) for the upper pivot pin of the quick coupler assembly. There is agrease fitting for each side of the machine.

Apply lubricant to the grease fittings (3) for the upper pivot pin of the tilt linkage. There is a grease fitting for each side of the machine.

Apply lubricant to the grease fittings (4) for the rodend of the tilt cylinder. There is a grease fitting for each side of the machine.

Apply lubricant to the grease fittings (5) for the rodend of the lift cylinder. There is a grease fitting for


Apply lubricant to the grease fittings (6) for the center pivot pin of the parallel linkage. There is a greasefitting for each side of the machine.

Apply lubricant to the grease fittings (7) for the headend of the tilt cylinder. There is a grease fitting for each side of the machine.

Apply lubricant to the grease fittings (8) for the frameand for the lift arm. There is a grease fitting for eachside of the machine.

Apply lubricant to the grease fittings (9) for the frameand for the parallel linkage. There is a grease fittingfor each side of the machine.

Apply lubricant to the grease fittings (10) for the headend of the lift cylinder. There is a grease fitting for each side of the machine.

Apply lubricant to the grease fittings (11) for the lower pivot pin of the parallel linkage. There is a greasefitting for each side of the machine.

Apply lubricant to the grease fittings (12) for the lower pivot pin of the tilt linkage. There is a grease fitting for


There is a total of 24 grease fittings.



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162 SEBU7821-04Maintenance SectionOil Filter - Inspect

i02106227

Oil Filter - Inspect

SMCS Code: 1318; 3067; 5068

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 for metal and for other debris. An excessive amount of debris in the filter element can indicate a possiblefailure.

If metals are found in the fi lter element, a magnet canbe used to differentiate between ferrous metals and

nonferrous 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 fi lter element. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer in order to 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 other parts. This can result in larger particles in unfilteredoil. The particles could enter the lubricating systemand the particles could cause damage.

i01364583

Parking Brake - Check/Adjust

SMCS Code: 4267

Check Procedure


Check the brakes on a dry, level surface.

Fasten the seat belt before you check the brakes.

The following checks are used to determine if theparking brake is functional. These checks are notintended to measure the maximum brake holdingeffort. The brake holding effort that is required to

sustain a machine at a specific engine rpm variesdepending on the machine. The variations are thedifferences in the engine setting, in the power trainef ficiency, and in the brake holding ability, etc.



2. Engage the parking brake.

3. If the machine is equipped with the standardtransmission, move the transmission speed shiftlever to THIRD gear. Move the transmissiondirection control lever to FORWARD, toNEUTRAL, and back to FORWARD. If themachine is equipped with a power shifttransmission move the transmission control lever to FOURTH SPEED FORWARD, to NEUTRAL,and back to FOURTH SPEED FORWARD. Thisis done in order to override the transmissionneutralizer for this test.




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Radiator Core - Clean

Note: The parking brake indicator light should comeon and the parking brake alarm should sound.



5. Reduce the engine speed. Move the transmissionto NEUTRAL. Lower the blade to the ground. Stopthe engine.


6. Reduce the engine speed. Move the transmissionto NEUTRAL. Lower the bucket to the ground.Stop the engine.

Adjustment Procedure

If the machine moved during the test, perform thefollowing procedure in order to adjust the parkingbrake.

1. Apply the service brakes.


2. Disengage the parking brake.

3. As you view the parking brake adjuster knob fromthe operator seat, turn the knob counterclockwisefor one quarter of a turn.

4. Repeat steps 1 to 6 in the check procedure.

If the machine moves during the parking brake test,then perform the adjustment procedure again. If you run out of adjustment on the parking brakeadjuster knob, refer to Systems Operation, Testingand Adjusting, SENR1259, “Parking Brake Control -

Adjust”.

i01986724

Radiator Core - Clean

SMCS Code: 1353



NOTICEDo not

manual maintenance interval cat 416d 420d 42d 428d 430d 432d 442d backhoe loaders

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