2010 Caterpillar

All Rights Reserved

MAINTENANCE INTERVALS
Operation and Maintenance
Manual Excerpt
SEBU8020-06
October 2010
Operation and
Maintenance
Manual
277C, 287C and 297C Multi Terrain
Loaders
JWF1-Up (277C)
MAS1-Up (287C)
GCP1-Up (297C)
SAFETY.CAT.COM
SEBU8020-06 125
Maintenance Section
Maintenance Interval Schedule
i04112628
Maintenance Interval Schedule
SMCS Code: 7000
Ensure that all safety information, warnings, and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance. All adjustments, the use of proper
lubricants, uids, lters, and the replacement of
components due to normal wear and aging are
included. Failure to adhere to proper maintenance
intervals and procedures 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 conditions
may require more frequent maintenance. Refer to the
maintenance procedure for any other exceptions that
may change the maintenance intervals.
Note: The aftertreatment system can be expected
to function properly for the useful life of the
engine (emissions durability period), as dened by
regulation. All prescribed maintenance requirements
must be followed.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
Note: If Cat HYDO Advanced hydraulic oils are used,
the hydraulic oil change interval is extended to 3000
hours. SOS services may extend the oil change
even longer. Consult your Cat dealer for details.
When Required
Aftercooler Core - Inspect/Clean ........................ 127
Aftercooler Intake Screen - Clean ....................... 128
Air Conditioner Condenser - Clean ..................... 129
Battery or Battery Cable - Inspect/Replace ........ 132
Blade Frame - Adjust .......................................... 134
Bucket Cutting Edges - Inspect/Replace ............ 140
Bucket Tips - Inspect/Replace ............................ 141
Cab Air Filter - Clean/Replace ............................ 141
Cab Interior - Clean ............................................ 142
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 149
Engine Air Filter Secondary Element - Replace .. 151
Engine Compartment - Clean ............................. 152
Fuel System Priming Pump - Operate ................ 158
Fuel Tank Cap - Clean ........................................ 158
Fuel Tank Water and Sediment - Drain ............... 159
Fuses - Replace .................................................. 159
Lower Machine Frame - Clean ........................... 168
Oil Filter - Inspect ................................................ 169
Radiator Core - Clean ......................................... 170
Track (Rubber) - Remove/Replace ..................... 176
Window Washer Reservoir - Fill .......................... 177
Window Wiper - Inspect/Replace ........................ 178
Windows - Clean ................................................. 178
Every 10 Service Hours or Daily
Air Cleaner Dust Valve - Clean/Inspect .............. 128
Axle Bearings - Lubricate .................................... 130
Backup Alarm - Test ............................................ 131
Bogie and Idler - Inspect/Replace ....................... 135
Cooling System Level - Check ............................ 147
Engine Oil Level - Check .................................... 152
Equipment Lowering Control Valve - Check ....... 155
Fuel System Primary Filter (Water Separator) -
Drain ................................................................. 157
Hydraulic System Oil Level - Check ................... 166
Lift Arm and Cylinder Linkage - Lubricate ........... 167
Quick Coupler - Clean/Inspect ............................ 169
Seat Belt - Inspect .............................................. 172
Sprocket Sleeve - Inspect ................................... 174
Tilt Cylinder Bearings and Bucket Linkage Bearings -
Lubricate ........................................................... 174
Track (Rubber) - Inspect/Adjust .......................... 175
Work Tool - Lubricate .......................................... 179
Work Tool Mounting Bracket - Inspect ................ 181
Initial 250 Service Hours
Final Drive Oil - Change ..................................... 155
Every 250 Service Hours
Final Drive Oil Level - Check .............................. 156
Every 250 Service Hours or Monthly
Belts - Inspect/Adjust/Replace ............................ 132
Every 500 Service Hours
Cooling System Coolant Sample (Level 1) -
Obtain ............................................................... 145
Final Drive Oil - Change ..................................... 155
Hydraulic System Oil Sample - Obtain ............... 166
Every 500 Service Hours or 6 Months
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 157
Hydraulic System Oil Filter - Replace ................. 165
Every 500 Service Hours or 1 Year
Engine Oil and Filter - Change ........................... 153
Hydraulic Tank Breather - Replace ..................... 167
Every 1000 Service Hours
Engine Valve Lash - Check ................................. 155
126 SEBU8020-06
Maintenance Section
Maintenance Interval Schedule
Every 1000 Service Hours or 6 Months
Rollover Protective Structure (ROPS) and Falling
Object Protective Structure (FOPS) - Inspect ... 171
Every 1000 Service Hours or 1 Year
Sprocket - Inspect ............................................... 172
Every 2000 Service Hours
Refrigerant Dryer - Replace ................................ 171
Every 2000 Service Hours or 1 Year
Fuel Injection Timing - Check ............................. 156
Hydraulic System Oil - Change ........................... 163
Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 146
Every 3000 Service Hours or 2 Years
Cooling System Water Temperature Regulator -
Replace ............................................................. 148
Every 3 Years After Date of Installation or
Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 172
Every 6000 Service Hours or 3 Years
Cooling System Coolant Extender (ELC) - Add .. 144
Every 12 000 Service Hours or 6 Years
Cooling System Coolant (ELC) - Change ........... 143
SEBU8020-06 127
Maintenance Section
Aftercooler Core - Inspect/Clean
i02555053
Aftercooler Core -
Inspect/Clean
SMCS Code: 1064-571; 1064-571-Z3
S/N: GCP1-Up
Inspect
Note: Adjust the frequency of inspection according to
the effects of the operating environment. Clean the
aftercooler core when you clean the radiator core.
The aftercooler is located behind the cab and in front
of the engine.
g01279112
Illustration 110
1. Stop the engine.
2. Clean the grill before you access the aftercooler
core.
3. Remove the pin (2) that holds the grill (1) and lift
the grill.
Note: If parts of the aftercooler system may appear
to be damaged or if parts of the aftercooler system
are repaired, a leak test is highly recommended.
Consult your Caterpillar dealer for the most current
information about the aftercooler.
Inspect the ns and tubes of the aftercooler for
damage. Some ns and tubes may be worn from
abrasive material that has passed through the
aftercooler cores. Bent ns may be opened with a
comb.
Inspect these items for good condition: welds,
mounting brackets, air lines, connections, clamps,
and seals. Make repairs, if necessary.
Clean
For air-to-air aftercoolers, use the same methods that
are used for cleaning radiators.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
NOTICE
When you are using compressed air or high pressure
water to clean the radiator ns, ensure that the air or
water is directed parallel to the ns. If the compressed
air or high pressure water is not directed parallel to the
radiator ns, the radiator ns could be bent or dam-
aged.
Pressurized air is the preferred method for removing
loose debris. Hold the nozzle approximately 6 mm
(0.25 inch) away from the ns. Slowly move the air
nozzle in a direction that is parallel with the tubes.
The air nozzle should point in the opposite direction
of the ow of the fan. This will remove debris that is
between the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud.
Use a degreaser and steam for removal of oil and
grease. Wash the core with detergent and hot water.
Thoroughly rinse the core with clean water.
After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. If there is an
extreme amount of debris, you may need to remove
the air conditioning condenser or the cover plate from
the fan housing for the aftercooler.
Close the grill and replace the retaining pin.
128 SEBU8020-06
Maintenance Section
Aftercooler Intake Screen - Clean
i02559029
Aftercooler Intake Screen -
Clean
SMCS Code: 1063-070-Z3
S/N: GCP1-Up
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Note: Pressurized air is the preferred method for
removing loose debris. Pressurized water may also
be used for cleaning. Use pressurized water in order
to soften mud. Clean the screen from both sides. The
maximum water pressure for cleaning purposes must
be less than 275 kPa (40 psi).
1. Turn off the engine.
g01281019
Illustration 111
(1) Cylinder for the lift arm
(2) Air inlet screen
(3) Hydraulic tank
(4) Electrical connectors
2. Access the screen from the right side of the
machine. Hold the nozzle approximately 6 mm
(0.25 inch) away from the screen. Ensure that the
spray nozzle is past the electrical connections.
g01281018
Illustration 112
(5) Air inlet screen
3. Access the screen from the left side of the
machine. Hold the nozzle approximately 6 mm
(0.25 inch) away from the screen.
4. If water is used to clean the screen, ensure that
the screen is dry before the engine is started. If
necessary, use compressed air to dry the screen.
i02939506
Air Cleaner Dust Valve -
Clean/Inspect
SMCS Code: 1051-571-VL
Service the air lter elements when the alert indicator
for air lter restriction lights. Refer to Operation
and Maintenance Manual, Alert Indicators for
information about the indicator.
1. Open the engine access door.
2. The air lter housing is located on the right side of
the engine compartment.
SEBU8020-06 129
Maintenance Section
Air Conditioner Condenser - Clean
g01280861
Illustration 113
3. Check the dust valve after every ten service hours
or at the end of each day. Actuate the valve by
squeezing the lips of the valve in order to remove
any accumulated debris.
i02916544
Air Conditioner Condenser -
Clean
(If Equipped)
SMCS Code: 1805-070
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
246C, 256C, 262C, 277C, 287C,
279C, and 289C
The air conditioner condenser is located behind the
engine on the frame.
Open the engine access door.
Inspect the air conditioner condenser for the following
conditions:

Damaged ns

Buildup of debris

Plugged areas
Remove any debris. Clean the condenser with low
pressure air or low pressure water. The maximum
water pressure for cleaning purposes must be less
than 275 kPa (40 psi).
272C, 297C, and 299C
The air conditioner condenser is attached to the side
of the fan housing for the aftercooler.
1. Remove the 3 bolts that retain the condenser to
the fan housing for the aftercooler.
2. Lift the core and remove the core from the
retaining lip.
3. Clean the condenser core in the opposite direction
of the air ow.
4. Reinstall the core in reverse order.
130 SEBU8020-06
Maintenance Section
Axle Bearings - Lubricate
i02418750
Axle Bearings - Lubricate
SMCS Code: 3282-086-BD
g01282148
Illustration 114
Single Level Suspension (SLS) undercarriage
(1) Front pivot (2) Rear pivot
g01284542
Illustration 115
(3) Front grease zerks (4) Rear grease zerks
SEBU8020-06 131
Maintenance Section
Backup Alarm - Test
g01282149
Illustration 116
Dual Level Suspension (DLS) undercarriage
(5) Front pivot (6) Rear pivot
g01284545
Illustration 117
(7) Front grease zerks (8) Rear grease zerks
Apply lubricant to all grease ttings.
Repeat the process for the opposite side of the
machine.
i02580453
Backup Alarm - Test
SMCS Code: 7406-081
To prevent injury, make sure that no people are
working on the machine or near the machine. To
prevent injury, keep the machine under control at all
times.
1. Get into the operator's seat. Fasten the seat belt
and pull the armrests downward.
132 SEBU8020-06
Maintenance Section
Battery or Battery Cable - Inspect/Replace
2. Start the engine.
3. Disengage the parking brake.
4. Move the joystick control to the REVERSE
position.
The backup alarm should sound immediately.
The backup alarm should continue to sound until
the joystick control is returned to the NEUTRAL
position or to the FORWARD position.
i03659214
Battery or Battery Cable -
Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1401-561;
1402-040; 1402-510
1. Turn the engine start switch to the OFF position.
Turn all switches to the OFF position.
2. The battery is located on the left side of the
machine under the cab. Raise the cab. Refer to
Operation and Maintenance Manual, Cab Tilting
for information on raising the cab.
3. Disconnect the negative battery cable at the
battery.
Note: Do not allow the disconnected battery cable to
contact the negative battery post.
4. Disconnect the negative battery cable from the
frame in order to inspect the cable.
5. Disconnect the positive battery cable at the
battery.
6. Perform the necessary repairs. Replace the
cables or the battery, as needed.
7. Connect the positive battery cable at the battery.
8. Connect the negative battery cable to the frame of
the machine.
9. Connect the negative battery cable at the battery.
10. Lower the cab. Refer to Operation and
Maintenance Manual, Cab Tilting for information
on lowering the cab.
Recycle the Battery
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:

A battery supplier

An authorized battery collection facility

Recycling facility
i02715751
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
If a new belt is installed, check the belt adjustment
after 30 minutes of operation. A belt is considered to
be used after 30 minutes of operation.
Belts
1. Stop the engine in order to inspect the belt.
2. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
g01209498
Illustration 118
3. Remove the four bolts (1) on the top of the guard.
Loosen the two bolts (2) on the bottom of the
guard.
4. Slide the guard upward from bottom bolts.
Remove the guard for the V-belt.
SEBU8020-06 133
Maintenance Section
Belts - Inspect/Adjust/Replace
g01209499
Illustration 119
5. Inspect the condition of the belt (3) and the
adjustment of the belt. The belt should deect
10 mm (0.39 inch) under a straight pull of 44 N
(10 lb). This measurement should be taken
between the alternator pulley and the crankshaft
pulley.
Note: A 144-0235 Borroughs Belt Tension
Gauge may be used to measure belt tension.
This measurement should be taken between the
alternator pulley and the crankshaft pulley. Refer to
the following table for belt tension.
Table 31
Belt Tension
Initial
Belt Tension
Used
534 22 N (120 5 lb) 400 44 N (90 10 lb)
6. Loosen the mounting bolt (4). Loosen the adjusting
locknut (5).
7. Move the alternator until the correct tension is
reached.
8. Tighten the adjusting locknut. Tighten the
mounting bolt.
9. Recheck the belt deection. If the amount of
deection is incorrect, repeat step 5 to step 8.
Air Conditioner (if equipped)
Note: If your machine is equipped with an air
conditioner, use the same procedure and the same
measurements for the belt tension.
1. Inspect the condition of the belt and the
adjustment of the belt. The belt should deect
10 mm (0.39 inch) under a straight pull of 44 N
(10 lb). This measurement should be taken
between the air conditioner compressor pulley
and the crankshaft pulley.
g01279933
Illustration 120
2. Loosen the mounting bolt (6) for the air conditioner
compressor. Loosen the adjusting locknut (7) for
the air conditioner compressor.
3. Move the air conditioner compressor until the
correct tension is reached.
Note: A hole (8) in the bracket has been provided in
order to aid with the adjustment of the tension.
4. Tighten the adjusting locknut. Tighten the
mounting bolt.
5. Recheck the belt deection. If the amount of
deection is incorrect, repeat step 2 to step 4.
Finish
1. Apply thread lock compound to the threads on
bolts (1).
134 SEBU8020-06
Maintenance Section
Blade Frame - Adjust
g01364054
Illustration 121
2. Install the guard for the V-belt (9). Ensure that the
guard is inserted between the mounting bracket
(10) and the spreader plate (11) before you tighten
the bolts (2). Tighten the bolts (2) to 15 3 Nm
(11 2 lb ft).
g01209498
Illustration 122
3. Tighten the bolts (1) to 12 3 Nm (9 2 lb ft).
Note: Start all the bolts (1) in the holes before you
start tightening the bolts. This helps align all the
holes.
4. Close the engine access door.
i02549571
Blade Frame - Adjust
SMCS Code: 6060-025-BG
Height Adjustment
g01161532
Illustration 123
(1) Height Adjustment for the Frame
(2) Adjusting Bolts
(3) Frame
The height of the frame may be adjusted in order to
compensate for the wear on the cutting edge. The
front portion of the frame needs to be lowered as the
cutting edge wears. Remove the bolts (2) and lower
the frame (3). Install the bolts. This will keep the
blade level with the ground and this will prevent the
blade from digging into the ground.
Note: In order to properly adjust the blade, the work
tool coupler needs to be vertical. The position of
the pivot point of the blade is perpendicular to the
ground. Follow this procedure in order to ensure that
the cutting edge will remain at on the ground during
operation.
SEBU8020-06 135
Maintenance Section
Bogie and Idler - Inspect/Replace
Trunnion Joint
Note: The trunnion is a dry joint. Adding grease to
the trunnion simply attracts abrasive particles. The
tightness of the joint should be monitored. Shims
should be removed when the joint becomes too
loose. This may be indicated by excessive movement
in the blade.
g01173519
Illustration 124
(A) Trunnion Joint
(B) Bolts
(C) Shims

Remove the four retaining bolts (B) and the cap.

Remove the necessary shims.

Replace the cap and bolts.

The tightening sequence is shown in illustration

124.

Torque the bolts to 530 70 Nm (391 52 lb ft).

Note: Some noise is typical and the noise does not
indicate a problem.
i03469002
Bogie and Idler -
Inspect/Replace
SMCS Code: 4159-040; 4159-510; 4192-040;
4192-510
Inspect
Clean the undercarriage before inspecting the bogies
and the idlers.
Inspect the bogies and idlers for damage and wear.
Note: Minor damage to the rubber on the bogies
and idlers is acceptable. Minor damage includes
nicks, cuts, small pieces that are missing, and
small grooves. This minor damage is normal and
acceptable. Minor damage will not adversely affect
machine performance.
The bogies and the idlers should be replaced when
the damage to the rubber wheels adversely affects
machine performance. Replace the bogies and the
idlers when the rubber is worn beyond the minimum
specications that are listed below.
Note: The hubs for the bogies and the hubs for the
idlers on the 277C, 287C and 297C contain oil. The
hubs are sealed for life. Periodically, inspect the hubs
for leaks or for excessive end play. Contact your
Caterpillar dealer if either leaks or excessive end
play is found.
136 SEBU8020-06
Maintenance Section
Bogie and Idler - Inspect/Replace
Table 32
Bogie Wheels and Idler Wheels
Wear Limits
Minimum Width Minimum Thickness
254 mm (10 inch) 15 mm (0.59 inch) 1 mm (0.04 inch)
381 mm (15 inch) 15 mm (0.59 inch) 1 mm (0.04 inch)
Loosen the Track
g01286300
Illustration 125
Use an appropriate oor jack in order to lift the
machine off the ground. Use appropriate jack stands
(1) in order to block up the machine. Raise the
machine until tracks are approximately 50 mm
(2.0 inches) (A) off the ground.
Loosen the track in order to work on the bogies and
idlers. Refer to Operation and Maintenance Manual,
Track (Rubber) - Inspect/Adjust for the procedure.
Note: The track may be removed in the illustrations
for clarity.
SEBU8020-06 137
Maintenance Section
Bogie and Idler - Inspect/Replace
Single Level Suspension
g01282884
Illustration 126
(1) Idler wheels (2) Bogie wheels
Idler wheels
g01285489
Illustration 127
(5) Outer idler wheel
(6) Bolts and washers for the wheels
(7) Inner idler wheel
1. Remove the bolts (6) and the washers for the
outer idler wheel.
2. Remove the outer idler wheel.
138 SEBU8020-06
Maintenance Section
Bogie and Idler - Inspect/Replace
g01285492
Illustration 128
(3) Front scraper plate
(4) Rear scraper plate
3. If the inner idler wheel needs to be removed, you
will need to remove the scraper plate. Remove the
bolts that hold each scraper plate.
4. If necessary, remove the bolts and the washers for
the inner idler wheel and remove the wheel.
5. Install the wheels in reverse order. Tighten the
bolts in a star pattern to a torque of 50 5 Nm
(37 3.7 lb ft). Tighten the bolts an additional 45
degrees 5 degrees in the same star pattern.
6. If necessary, install the scraper plates.
Note: The torque for the bolts for the scraper plate on
the rear idler is 120 20 Nm (89 15 lb ft). All other
torque values for the bolts for the scraper plates are
standard torque values.
Bogie wheels
g01285491
Illustration 129
(10) Scraper plate
(11) Bolts and washers for the wheels
(12) Outer bogie wheel
(13) Inner bogie wheel
1. Remove the bolts (11) and the washers for the
outer bogie wheel.
2. Remove the outer bogie wheel.
g01285490
Illustration 130
(8) Front scraper plate
(9) Rear scraper plate
3. If the inner bogie wheels need to be removed, you
will need to remove the scraper plate. Remove the
bolts that hold each scraper plate.
4. If necessary, remove the bolts and the washers for
the inner bogie wheel and remove the wheel.
5. Install the wheels in reverse order. Tighten the
bolts in a star pattern to a torque of 50 5 Nm
(37 3.7 lb ft).
SEBU8020-06 139
Maintenance Section
Bogie and Idler - Inspect/Replace
6. If necessary, install the scraper plates.
Note: All torque values for the bolts for the scraper
plates are standard torque values.
Dual Level Suspension
g01282887
Illustration 131
(1) Idler wheels (2) Bogie wheels
Idler wheels
The idler wheels are removed and installed with the
same procedure as the Single Level Suspension.
140 SEBU8020-06
Maintenance Section
Bucket Cutting Edges - Inspect/Replace
Bogie wheels
g01285573
Illustration 132
(14) Bogie wheel assembly
(15) Rubber inserts
(16) Cover plate
(17) Bolts and washers for cover plate
(18) Outer wheel bolts and washers
(19) Outer wheel
(20) Bolts for the bogie assembly
(21) Inner wheel
(22) Inner wheel bolts and washers
1. Remove the bolts (18) and the washers for the
outer bogie wheel (19).
2. Remove the outer bogie wheel.
3. Install the new wheel. Tighten the bolts in a star
pattern to a torque of 50 5 Nm (37 3.7 lb ft).
4. In order to remove the inner bogie wheels, you
must remove the bogie suspension group from
the frame. Remove the 2 bolts and 2 washers (17)
that hold the cover plate.
5. Remove the bolts (20), washers, and nuts for the
suspension group.
Note: There are 4 rubber inserts between the
two suspension groups. Retain these inserts for
installation later.
6. Remove the suspension group and the rubber
inserts from the frame.
7. Remove the bolts (22) and the washers for the
inner bogie wheel (21).
8. Install the new wheel. Tighten the bolts in a star
pattern to a torque of 50 5 Nm (37 3.7 lb ft).
9. Loosely install the bolts (20), washers, and nuts
on the suspension group.
10. Slide the suspension group onto the frame.
11. Lubricate the rubber inserts and slide the rubber
inserts into the suspension group.
12. Tighten the bolts (20) to a torque of 120 20 Nm
(89 15 lb ft).
13. Install the cover plate (16), 2 bolts, and 2 washers
(17). Tighten the bolts to a torque of 50 10 Nm
(37 7 lb ft).
14. Tighten the track to the proper tension. Refer
to Operation and Maintenance Manual, Track
(Rubber) - Inspect/Adjust for the procedure.
i01743875
Bucket Cutting Edges -
Inspect/Replace
SMCS Code: 6801-040; 6801-510
Personal injury or death can result from bucket
falling.
Block the bucket before changing bucket cutting
edges.
1. Lower the lift arms fully. Tilt back the bucket so
that the bucket cutting edge is accessible.
2. Place blocks under the raised edge of the bucket.
3. Remove the bolts. Remove the cutting edge and
the end bits.
4. Clean the contact surfaces.
5. Use the opposite side of the cutting edge, if this
side is not worn.
6. Install a new cutting edge, if both edges are worn.
7. Install the bolts.
8. Remove the blocks that are under the bucket.
9. After a few hours of operation, check the bolts for
proper torque.
SEBU8020-06 141
Maintenance Section
Bucket Tips - Inspect/Replace
i01764331
Bucket Tips - Inspect/Replace
SMCS Code: 6805-040; 6805-510
Personal injury or death can result from bucket
falling.
Block the bucket before changing bucket cutting
edges.
1. Lower the lift arms fully. Tilt back the bucket so
that the bucket tips are accessible.
2. Place blocks under the raised edge of the bucket.
3. Remove the mounting bolts. Remove the bucket
tips.
4. Clean the mounting surface.
5. Replace the bucket tips.
6. Install the bolts.
7. Remove the blocks that are under the bucket.
8. After a few hours of operation, check the bolts for
proper torque.
i02417532
Cab Air Filter - Clean/Replace
(If Equipped)
SMCS Code: 7342-070; 7342-510
Fresh Air Filter
Note: The cover for the cab air lter is located on the
left hand side of the machine behind the cab.
g01287414
Illustration 133
1. Turn the thumb screw until the thumb screw is free
from the duct. Lift up on the cover and remove
the cover.
2. Remove the air lter element from the duct and
clean the lter element with low pressure air
(maximum 207 kPa (30 psi)). Direct the air ow
up the pleats and down the pleats from the side
of the lter opposite of the air ow. Replace
the element if the element is damaged or if the
element seal is damaged. Replace the element if
the air conditioner performance is low.
Note: Do not use water for cleaning the lter.
3. Install the element. Replace the cover and tighten
the thumb screw.
142 SEBU8020-06
Maintenance Section
Cab Interior - Clean
Recirculation Filter
g01209486
Illustration 134
1. Turn the thumb screws until the thumb screws are
free from the duct. Remove the cover.
2. Remove the air lter element from the duct and
clean the lter element with low pressure air
(maximum 207 kPa (30 psi)). Direct the air ow
up the pleats and down the pleats from the side
of the lter opposite of the air ow. Replace
the element if the element is damaged or if the
element seal is damaged. Replace the element if
the air conditioner performance is low.
Note: Do not use water for cleaning the lter.
3. Install the element. Replace the cover and tighten
the thumb screws.
i02616708
Cab Interior - Clean
SMCS Code: 7301-070
The oor mat is removable. The oor mat has sides
in order to help retain the material.
g01312450
Illustration 135
Floor mat in the cab
The oor mat does not protect the foot pedal and
the pedal linkage. Debris may accumulate around
the foot pedal. The foot pedal must be kept clear of
excessive dirt and debris in order to ensure proper
activation of the pedal. Debris must be cleaned from
the area around the pedal. This can be done after
you remove the oor mat.
g01312452
Illustration 136
The drain on the left side of the machine
You can wash the oor of the cab with water. There is
a drain in the front, left corner of the oor of the cab.
SEBU8020-06 143
Maintenance Section
Cooling System Coolant (ELC) - Change
i02807909
Cooling System Coolant (ELC)
- Change
SMCS Code: 1395-044-NL
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the 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 they
have passed the Caterpillar EC-1 specication for
pre-mixed or concentrate coolants and Caterpillar
Extender.
Note: The machine was shipped from the factory with
Extended Life Coolant (ELC) in the cooling system.
For information about the addition of Extender to your
cooling system, see the Operation and Maintenance
Manual, Cooling System Coolant (ELC) Extender -
Add or consult your Caterpillar dealer.
Drain the coolant whenever the coolant is dirty or
whenever the coolant is foaming.
The radiator cap is located under the radiator guard
on the top of the engine compartment.
Allow the machine to cool before you change the
coolant.
1. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
2. Raise the radiator guard. Refer to Operation and
Maintenance Manual, Radiator Tilting.
Note: The radiator cap is located on the right side
of the radiator.
g01210063
Illustration 137
(1) Sight gauge
(2) Radiator cap
3. Slowly loosen the radiator cap (2) in order to
relieve system pressure. Remove the radiator cap.
g01279512
Illustration 138
Coolant drain
4. Locate the drain hose for the coolant system. The
drain hose is attached to the drain valve that is
shown in illustration 138.
144 SEBU8020-06
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
g01264593
Illustration 139
5. Remove the access panel under the rear of the
machine. Pull the drain hose through the access
hole.
6. Open the drain and allow the coolant to drain into
a suitable container.
7. Close the drain.
8. Push the hose back into the engine compartment.
Replace the access panel.
9. Replace the thermostat. See Operation and
Maintenance Manual, Cooling System Water
Temperature Regulator - Replace for the process
for replacing the thermostat.
10. Add the coolant solution directly to the radiator.
Do not use the coolant overow reservoir as
a ller for the coolant. Refer to Operation and
Maintenance Manual, Capacities - (Rell). Refer
to Special Publication, SEBU6250, Caterpillar
Machine Fluids Recommendations.
Note: Premix the coolant solution before lling
the cooling system. The coolant solution should
contain 50 percent coolant and 50 percent
distilled water.
Note: Add the coolant solution at a maximum rate
of ve liters per minute. This will reduce the chance
of trapping air inside the engine block. A large amount
of trapped air can cause localized heating to occur
upon start-up. Localized heating may result in engine
damage, which may lead to failure of the engine.
11. Start the engine. Run the engine without the
radiator cap until the thermostat opens and the
coolant level stabilizes. If necessary, add coolant.
Note: The sight gauge for the coolant level is located
on the left side of the radiator.
12. Check the coolant level in the sight gauge on the
radiator. Maintain the coolant level to the top of
the sight gauge with the radiator in the LOWERED
position.
13. Stop the engine. Inspect the radiator cap and the
gasket. Replace the cap if the cap or the gasket is
damaged. Install the radiator cap.
14. Pull the radiator guard downward.
15. Close the engine access door.
i02417747
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352-544-NL
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
When a Caterpillar Extended Life Coolant is used,
an extender must be added to the cooling system
periodically.
1. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
2. Tilt the radiator guard upward. Refer to Operation
and Maintenance Manual, Radiator Tilting.
SEBU8020-06 145
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
g01210063
Illustration 140
(1) Sight gauge
(2) Radiator cap
Note: The radiator cap is located on the right side
of the radiator.
3. Slowly loosen the radiator cap in order to relieve
system pressure. Remove the radiator cap.
g01279512
Illustration 141
Coolant drain
4. If necessary, drain enough coolant from the
radiator in order to allow the addition of the coolant
additive.
5. Add 0.17 L (0.18 qt) of cooling system additive.
6. Inspect the radiator cap and the gasket. If the cap
or the gasket is damaged, replace the cap. Install
the radiator cap.
Note: The sight gauge for the coolant is located on
the left side of the radiator on machines that are
equipped with the 3044 engine.
7. Check the coolant level in the sight gauge on the
radiator. Maintain the coolant level to the top of
the sight gauge with the radiator in the LOWERED
position.
8. Add the extender directly to the radiator. Do not
use the coolant overow reservoir as a ller for
the extender.
9. Tilt the radiator guard downward.
10. Close the engine access door.
For additional information on the addition of extender,
see Special Publication, SEBU6250, Caterpillar
Machine Fluids Recommendations.
i02664591
Cooling System Coolant
Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.
146 SEBU8020-06
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
g01210063
Illustration 142
Refer to the Operation and Maintenance Manual,
Access Doors and Covers for the location of the
service points.
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
Obtain the sample of the coolant from the radiator.
When the system is cool, slowly remove the radiator
cap (2).
Note: Do not take the sample from the Coolant
Overow Reservoir.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
to receive the full effect of SOS analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Use the following guidelines for proper sampling of
the coolant:

Keep the unused sampling bottles stored in plastic

bags.

Keep the lids on empty sampling bottles until you

are ready to collect the sample.

Complete the information on the label for the

sampling bottle before you begin to take the
samples.

Use a designated pump to collect the sample in

order to avoid contamination.

Obtain coolant samples directly from the coolant

tank. You should not obtain the samples from any
other location.

Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
contamination.

Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see
Special Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations or consult your Caterpillar
dealer.
i02664598
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
SEBU8020-06 147
Maintenance Section
Cooling System Level - Check
g01210063
Illustration 143
Refer to the Operation and Maintenance Manual,
Access Doors and Covers for the location of the
service points.
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
Obtain the sample of the coolant from the radiator.
When the system is cool, slowly remove the radiator
cap (2).
Note: Do not take the sample from the Coolant
Overow Reservoir.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies
for 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.
For additional information about coolant analysis, see
Special Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations or consult your Caterpillar
dealer.
i02417701
Cooling System Level - Check
SMCS Code: 1350-040-HX; 1350-535-FLV;
1382-070; 1382-510
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
1. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
2. Tilt the radiator guard upward.
g01210063
Illustration 144
(1) Sight gauge
(2) Radiator cap
3. Check the coolant level in the sight gauge (1)
on the radiator. Maintain the coolant level to the
top of the sight gauge with the radiator in the
LOWERED position. If you need to add coolant,
add the coolant directly to the radiator. Remove
the radiator cap (2) slowly in order to relieve
system pressure.
Note: The radiator cap is located on the right side
of the radiator. Inspect the cooling system hoses for
any leaks, cracks, or signs of deterioration. Replace
any damaged hoses.
4. Inspect the radiator cap and the gasket. Replace
the cap if the cap or the gasket is damaged. Install
the radiator cap.
148 SEBU8020-06
Maintenance Section
Cooling System Water Temperature Regulator - Replace
5. Tilt the radiator guard downward.
g01018341
Illustration 145
6. The coolant overow reservoir is located on the
rear door. Maintain the coolant level in the coolant
overow reservoir between the MIN and MAX
lines.
7. Close the engine access door.
i03880044
Cooling System Water
Temperature Regulator -
Replace
SMCS Code: 1355-510; 1393-010
Replace the thermostat on a regular basis in order to
reduce the chance of unscheduled downtime and of
problems with the cooling system. Failure to replace
the engine's thermostat on a regularly scheduled
basis could cause severe engine damage.
The thermostat should be replaced after the cooling
system has been cleaned. Replace the thermostat
while the cooling system is completely drained or
while the cooling system coolant is drained to a level
that is below the thermostat housing.
Caterpillar engines incorporate a shunt design
cooling system. It is mandatory to always operate the
engine with a thermostat.
1. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
2. Drain the coolant from the machine. See Operation
and Maintenance Manual, Cooling System
Coolant (ELC) - Change for the procedure to
drain the cooling system.
g01018412
Illustration 146
C2.2
g01210045
Illustration 147
C3.4
3. Loosen the hose clamp (1) and remove the hose
from the thermostat housing assembly (2).
4. Remove the two bolts (3) from the thermostat
housing assembly. Remove the thermostat
housing assembly.
5. Remove the seal and the thermostat from the
thermostat housing assembly.
6. Install a new thermostat and a new seal. Install
the thermostat housing assembly on the engine
cylinder head.
7. Install the hose. Tighten the hose clamp.
SEBU8020-06 149
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
8. Rell the cooling system. Refer to Operation and
Maintenance Manual, Capacities - (Rell). Refer
to Operation and Maintenance Manual, Cooling
System Coolant (ELC) - Change for information
about relling the cooling system. Refer to Special
Publication, SEBU6250, Caterpillar Machine
Fluid Recommendations for coolant information.
9. Close the engine access door.
i02417909
Engine Air Filter Primary
Element - Clean/Replace
SMCS Code: 1054-070-PY; 1054-510-PY
NOTICE
Never service the air cleaner when the engine is run-
ning, to avoid engine damage.
NOTICE
Caterpillar recommends certied air lter cleaning ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufcient lter life.
Observe the following guidelines if you attempt to
clean the lter element:
Do not tap or strike the lter element in order to re-
move dust.
Do not wash the lter element.
Use low pressure compressed air in order to remove
the dust from the lter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air ow up the
pleats and down the pleats from the inside of the lter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air lters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
Service the air lter elements when the alert indicator
for air lter restriction lights. Refer to Operation
and Maintenance Manual, Alert Indicators for
information about the indicator.
Clean
The primary lter element can be used up to
three times if the element is properly cleaned and
if the element is properly inspected. When the
primary lter element is cleaned, check for rips or
tears in the lter material. The primary lter element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
1. Open the engine access door.
2. The air lter housing is located on the right side of
the engine compartment.
g00101864
Illustration 148
3. Unlatch the air cleaner housing cover (1). Rotate
the cover counterclockwise and remove the cover.
4. Remove the primary lter element (2).
5. If it is appropriate, clean the primary lter element.
Use air pressure to clean the primary lter
elements. Pressurized air will not remove deposits
of carbon and oil. Use ltered, dry air with a
maximum pressure of 207 kPa (30 psi).
Note: When the primary lter elements are cleaned,
always begin with the inside in order to force dirt
particles toward the outside. Aim the hose so that the
air ows inside the element along the length of the
lter in order to help prevent damage to the paper
pleats. Do not aim the stream of air directly at the
primary lter element.
6. Inspect the cleaned, dry primary air lter element.
Use a 60 watt blue light in a dark room or in a
similar facility. Place the blue light in the primary
air lter element. Rotate the primary air lter
element. Inspect the primary air lter element for
tears and/or holes. Inspect the primary air lter
element for light that may show through the lter
material. If it is necessary in order to conrm the
result, compare the primary air lter element to a
new primary air lter element that has the same
part number.
150 SEBU8020-06
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Note: Do not use a primary air lter element that has
any tears and/or holes in the lter material. Do not
use a primary air lter element with damaged pleats,
gaskets or seals. Discard damaged primary air lter
elements.
7. Clean the inside of the air cleaner housing with a
damp cloth. Do not use compressed air to clean
the housing.
8. Install the primary lter element into the lter
housing.
9. Install the cover for the lter housing.
g01276795
Illustration 149
10. Rotate the cover clockwise and latch the cover.
Note: Make sure that the cover is properly positioned.
The arrows on the air lter cover should point upward
when the cover is in the locked position.
11. Close the engine access door.
12. Start the engine. The alert indicator for air lter
restriction should turn off. If the alert indicator
continues to light, replace the secondary air lter.
Refer to Operation and Maintenance Manual,
Engine Air Filter Secondary Element - Replace.
Replace
The primary lter element should be replaced at least
one time per year. You can clean the primary lter
up to three times.
1. Open the engine access door.
2. The air lter housing is located on the right side of
the engine compartment.
g00101864
Illustration 150
3. Unlatch the air cleaner housing cover (1). Rotate
the cover counterclockwise and remove the cover.
4. Remove the primary lter element (2).
5. Clean the inside of the air cleaner housing with a
damp cloth. Do not use compressed air to clean
the housing.
6. Install a new primary lter element into the lter
housing.
7. Install the cover for the lter housing.
g01276795
Illustration 151
8. Rotate the cover clockwise and latch the cover.
Note: Make sure that the cover is properly positioned.
The arrows on the air lter cover should point upward
when the cover is in the locked position.
9. Close the engine access door.
SEBU8020-06 151
Maintenance Section
Engine Air Filter Secondary Element - Replace
10. Start the engine. The alert indicator for air lter
restriction should turn off. If the alert indicator
continues to light, replace the secondary air lter.
Refer to Operation and Maintenance Manual,
Engine Air Filter Secondary Element - Replace.
i02417939
Engine Air Filter Secondary
Element - Replace
SMCS Code: 1054-510-SE
NOTICE
Always replace the secondary lter element. Nev-
er attempt to reuse the secondary lter element by
cleaning the element.
When the primary lter element is cleaned for the third
time, the secondary lter element should be replaced.
The secondary lter element should also be replaced
if the restricted Air Filter indicator comes on after the
installation of a clean primary lter element or if the
exhaust smoke is still black.
1. Open the engine access door.
2. The air lter housing is located on the right side of
the engine compartment.
g00101864
Illustration 152
3. Unlatch the air cleaner housing cover (1). Rotate
the cover counterclockwise and remove the cover.
4. Remove the primary lter element (2).
g00038606
Illustration 153
5. Clean the inside of the air cleaner housing with a
damp cloth. Do not use compressed air to clean
the housing.
6. Remove the secondary lter element.
7. Cover the air inlet opening.
8. Clean the inside of the air cleaner housing with a
damp cloth, if necessary. Do not use compressed
air to clean the housing.
9. Uncover the air inlet opening.
10. Install a new secondary element.
11. Install the primary element.
12. Install the cover for the lter housing.
g01276795
Illustration 154
13. Rotate the cover clockwise and latch the cover.
152 SEBU8020-06
Maintenance Section
Engine Compartment - Clean
Note: Make sure that the cover is properly positioned.
The arrows on the air lter cover should point upward
when the cover is in the locked position.
14. Close the engine access door.
i02520141
Engine Compartment - Clean
SMCS Code: 1000-070
Inspect the engine compartment for dirt buildup or
debris. Remove any dirt or debris from the engine
compartment.
1. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
g01264593
Illustration 155
2. Remove any debris or dirt from the engine
compartment. If necessary, remove the
access panel in order to clean out the engine
compartment.
Note: Use care when you clean the engine
compartment. Damage to the machine may occur.
3. Install the access panel. Close the engine access
door.
i02417992
Engine Oil Level - Check
SMCS Code: 1348-535-FLV
NOTICE
Do not overll the crankcase. Engine damage can re-
sult.
1. Stop the engine and allow the oil to drain back
into the oil pan.
g01209758
Illustration 156
(1) Oil Filler Cap
(2) Dipstick
2. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
g01277108
Illustration 157
(1) Oil level add mark
(2) Full mark
3. Maintain the oil level between the ADD (1) mark
and the FULL (2) mark on the dipstick.
SEBU8020-06 153
Maintenance Section
Engine Oil and Filter - Change
4. If oil is necessary, tilt the radiator upward. Refer
to Operation and Maintenance Manual, Radiator
Tilting.
5. Remove the oil ller cap (1) and add oil.
6. Clean the oil ller cap and install the oil ller cap.
7. Tilt the radiator downward.
8. Close the engine access door.
i02743337
Engine Oil and Filter - Change
SMCS Code: 1308-510; 1348-044
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain uids on Caterpillar
products.
Dispose of all uids according to local regulations and
mandates.
The normal oil change interval for the machine is
Every 500 Service Hours or every year when the
following conditions are met:

Use an engine oil in the Operation and Maintenance

Manual, Lubricant Viscosities.

Caterpillar lters are used.

The altitude does not exceed 2300 m (7545 ft).

Sulfur content in the fuel is between 0.05% and

0.50%.
An oil change interval of Every 250 Service Hours
or every six months is required when the following
conditions occur:

Use an engine oil in the Operation and Maintenance

Manual, Lubricant Viscosities.

The altitude exceeds 2300 m (7545 ft).

Sulfur content in the fuel is between 0.50% and

1.00%.
An oil change interval of Every 125 Service Hours is
required when the following condition occurs:

Sulfur content in the fuel is above 1.00%.

Refer to the results of the SOS oil analysis in
order to determine if the oil change interval should
be decreased. Consult your Caterpillar Dealer for
detailed information regarding the optimum oil
change interval.
1. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
2. Tilt the radiator upward. Refer to Operation and
Maintenance Manual, Radiator Tilting.
Note: The crankcase drain is located on the right
side of the oil pan.
g01264593
Illustration 158
3. Remove the access panel that is located below
the drain plug. Remove the drain plug and allow
the oil to drain into a suitable container. Install the
drain plug and install the access panel.
154 SEBU8020-06
Maintenance Section
Engine Oil and Filter - Change
g01209695
Illustration 159
4. Remove the lter element with a 187-2718 Filter
Wrench. Refer to Operation and Maintenance
Manual, Oil Filter - Inspect in order to inspect
the used lter for debris.
5. Apply a thin lm of clean engine oil to the sealing
surface of the new lter element.
6. Install a new engine oil lter hand tight until the
seal of the engine oil lter contacts the base. Note
the position of the index marks on the lter in
relation to a xed point on the lter base.
Note: There are rotation index marks on the engine
oil lter that are spaced 90 degrees or 1/4 of a turn
away from each other. When you tighten the engine
oil lter, use the rotation index marks as a guide.
7. Tighten the lter according to the instructions
that are printed on the lter. Use the index marks
as a guide. For non-Caterpillar lters, use the
instructions that are provided with the lter.
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn
the lter to the amount that is required for nal
installation. Make sure that the installation tool does
not damage the lter.
g01209758
Illustration 160
(1) Oil Filler Cap
(2) Dipstick
8. Remove the oil ller cap (1). Fill the crankcase
with new oil. Refer to Operation and Maintenance
Manual, Lubricant Viscosities and Operation
and Maintenance Manual, Rell Capacities for
information about the oil. Clean the oil ller plug
and install the oil ller plug.
9. Start the engine and allow the oil to warm. Check
for leaks.
g01277108
Illustration 161
(1) Oil level add mark
(2) Full mark
10. Stop the engine and allow the oil to drain back
into the oil pan. Fill the crankcase to the FULL
mark (2) on the dipstick. Do not exceed the
FULL mark on the dipstick. Add oil or drain
oil if it is necessary.
11. Tilt the radiator downward.
12. Close the engine access door.
SEBU8020-06 155
Maintenance Section
Engine Valve Lash - Check
i01020861
Engine Valve Lash - Check
SMCS Code: 1105-025
Refer to the Service Manual for the complete
adjustment procedure for the engine valve lash.
A qualied mechanic should adjust the engine valve
lash and the fuel injector timing because special tools
and training are required.
i02808037
Equipment Lowering Control
Valve - Check
SMCS Code: 5147-MA
Personal injury or death can result from a work
tool falling.
Keep personnel away from the front of the ma-
chine when lowering the work tool.
Before lowering any equipment, clear the area
around the equipment of all personnel.
1. Lower arms to the fully lowered position. Turn the
keyswitch to the OFF position.
2. Slide the seat forward. Slide the left hand armrest
forward.
g01400888
Illustration 162
3. Pull up on the red handle in order to fully actuate
the valve.
4. Push the red handle to the original position.
Ensure that the handle is fully seated.
i02939717
Final Drive Oil - Change
SMCS Code: 4050-044-OC
g01291697
Illustration 163
(1) Oil ll/drain plug
(2) Oil check plug
1. Position one nal drive so that the oil ll/drain plug
(1) is at the bottom.
Note: Refer to Operation and Maintenance Manual,
General Hazard Information for information on
containing uid spillage.
2. Use an 8 mm (5/16 inch) allen wrench. Remove
the oil plugs (1) and (2). Allow the oil to drain into
a suitable container.
3. Check the drained oil for metal chips or for
particles. If there are any chips or particles, consult
your Caterpillar dealer.
Note: Dispose of drained uids according to local
regulations.
4. Clean the plugs and inspect the plugs. Replace a
worn plug or a damaged plug.
5. Position the nal drive so that the oil ll/drain plug
(1) is at the top.
156 SEBU8020-06
Maintenance Section
Final Drive Oil Level - Check
6. Add oil through the opening for the oil ll/drain
plug (1) that is now at the top.
7. Fill the nal drive to the bottom of the opening
for the oil plug (2). Refer to Operation and
Maintenance Manual, Lubricant Viscosities and
Operation and Maintenance Manual, Capacities
(Rell).
8. Install the oil plugs. Tighten the oil plugs to a
torque of 27 1 Nm (20 0.7 lb ft).
9. Perform Step 1 to Step 8 on the other nal drive.
10. Completely remove any oil that has spilled.
11. Start the engine and allow the nal drives to
operate through several cycles.
12. Stop the engine.
13. Check the oil level.
14. Maintain the oil level to the bottom of the opening
for the oil check plug (2).
i02939714
Final Drive Oil Level - Check
SMCS Code: 4050-535-FLV
g01457026
Illustration 164
(1) Oil ll/drain plug
(2) Oil check plug
1. Position one nal drive so that the oil ll/drain plug
(1) is at the top.
Note: Refer to Operation and Maintenance Manual,
General Hazard Information for information on
Containing Fluid Spillage.
2. Use an 8 mm (5/16 inch) allen wrench. Remove
the oil check plug (2).
3. Check the oil level. The oil should be near the
bottom of the opening for the oil check plug (2).
4. Add oil through the opening for the oil ll/drain
plug (1), if necessary.
Note: Overlling the nal drive will cause the seals on
the travel motor to allow hydraulic oil or water to enter
the nal drive. This may contaminate the nal drive.
5. Clean the oil plugs.
6. Install the oil plugs. Tighten the oil plugs to a
torque of 27 1 Nm (20 0.7 lb ft).
7. Repeat the procedure for the other nal drive.
i00916186
Fuel Injection Timing - Check
SMCS Code: 1251-531
Note: The correct fuel timing specication is
found on the Engine Information Plate. Fuel
timing specications may vary for different engine
applications and/or for different power ratings.
A qualied mechanic should adjust the fuel injection
timing because special tools and training are
required.
Refer to the Service Manual for the complete
adjustment procedure for the fuel injection timing.
Refer to your Caterpillar dealer for the complete
adjustment procedure for the fuel injection timing.
SEBU8020-06 157
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain
i02520136
Fuel System Primary Filter
(Water Separator) - Drain
SMCS Code: 1263-543
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain uids on Caterpillar
products.
Dispose of all uids according to local regulations and
mandates.
The fuel system water separator is located in the left
side of the engine compartment.
1. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
g01264527
Illustration 165
The Fuel Filter/Water Separator is located on the left side of the
engine compartment.
2. Insert the drain hose (3) into a suitable container.
Loosen the drain valve on the bottom of the water
separator.
3. Tighten the drain valve by hand. Do not tighten
the drain valve with a tool. Damage to the valve or
to the seals may occur.
4. Close the engine access door.
5. Dispose of the water and sediment according to
local regulations.
i02520124
Fuel System Primary Filter
(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain uids on Caterpillar
products.
Dispose of all uids according to local regulations and
mandates.
Note: This unit has a dual purpose. The element
serves as a water separator and a fuel lter.
1. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
158 SEBU8020-06
Maintenance Section
Fuel System Priming Pump - Operate
g01264527
Illustration 166
The Fuel Filter/Water Separator is located on the left side of the
engine compartment.
2. Open the drain on the fuel lter/water separator
(3). Allow the water and fuel to drain into a suitable
container.
3. Close the drain valve by hand. Do not tighten the
drain valve with a tool. Damage to the valve or
to the seals may occur.
4. Support the fuel lter/water separator and rotate
the locking ring (1) counterclockwise. Remove the
fuel lter/water separator.
5. Rotate the locking ring (2) counterclockwise.
Remove the bowl assembly.
6. Clean the mounting base for the fuel lter/water
separator.
7. Clean the bowl assembly for the fuel/water
separator.
8. Install the bowl assembly onto the new fuel/water
separator and rotate the locking ring clockwise.
9. Install the new fuel lter/water separator onto the
mounting base. Rotate the locking ring clockwise
in order to fasten the fuel lter/water separator to
the mounting base.
10. Prime the fuel system in order to ll the fuel
lter/water separator with fuel. Refer to Operation
and Maintenance Manual, Fuel System Priming
Pump - Operate.
11. Close the engine access door.
i02418180
Fuel System Priming Pump -
Operate
SMCS Code: 1258-548
This machine is equipped with a fuel transfer pump
that is electric. Two examples that may cause the fuel
system to lose prime are listed here:

The machine runs completely out of fuel.

The Fuel System Filter/Water Separator Element

is replaced.
Follow the steps below in order to prime the fuel
system.
1. Ensure that the engine start switch is in the OFF
position. Turn the engine start switch to the ON
position.
Note: Do not start the engine. This operation only
starts the fuel pump.
2. Locate the Primary Fuel Filter. This is located in
the left side of the engine compartment.
3. Examine the clear bowl. The bowl must be
completely full of fuel. If the bowl is not full of fuel,
repeat Steps 1 and 2.
4. Attempt to start the engine. If the engine starts
and the engine runs rough or the engine misres,
operate the engine at low idle until the engine
runs smoothly.
Note: If the engine fails to start or if the engine
continues to misre or smoke, stop the engine and
repeat the procedure. If the problem persists after
repeating the procedure, consult your Caterpillar
dealer.
i01819309
Fuel Tank Cap - Clean
SMCS Code: 1273-070-Z2
1. Remove the fuel cap.
SEBU8020-06 159
Maintenance Section
Fuel Tank Water and Sediment - Drain
g00104238
Illustration 167
2. Inspect the cap. Replace the cap if the cap is
damaged.
3. Wash the fuel cap in a clean, nonammable
solvent and dry the fuel cap.
4. Put a light coating of fuel on the cap gasket.
5. Install the fuel cap.
i02418544
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain uids on Caterpillar
products.
Dispose of all uids according to local regulations and
mandates.
Note: Drain the water and the sediment from the fuel
tank when the tank is almost empty.
1. Slowly remove the fuel tank cap in order to allow
the tank to vent while you drain the tank.
g01209601
Illustration 168
2. The fuel tank drain plug is located on the bottom
of the fuel tank in the engine compartment on the
right side of the machine. Remove the plug.
3. Allow the water and the sediment to drain into a
suitable container.
4. Install the fuel tank drain plug.
Note: Apply 5P-3413 Pipe Sealant to the threads on
the drain plug.
5. Install the fuel tank cap.
i02417559
Fuses - Replace
SMCS Code: 1417-510; 1417; 7528
Fuses
Fuses Fuses protect the electrical system from
damage that is caused by overloaded circuits.
Replace the fuse if the element separates. If the
element of a new fuse separates, check the circuit.
Repair the circuit, if necessary.
NOTICE
Replace 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
160 SEBU8020-06
Maintenance Section
Fuses - Replace
g01287527
Illustration 169
The fuse panel is located behind the seat on the right
side.
g01210555
Illustration 170
Remove the cover in order to access the fuse panel.
g01262480
Illustration 171
The following is a list of the fuses in the panel:
1 Spare
2 Wiper
3 Front Work Lights and Beacon
4 Right Joystick
5 12 volt power socket
6 Radio
7 Solenoid for the Compressor
8 Air Conditioner
SEBU8020-06 161
Maintenance Section
Fuses - Replace
9 Left Joystick
10 Cold Start
11 Rear Work Lights
12 Backup Alarm and Brake Lights
13 HVAC Blower Fan
14 Spare
15 Headlights
16 Hydraulic Solenoid
17 Fuel Shutoff and Secondary Engine
Shutoff
18 Hydraulic Quick Coupler
19 Hydraulic Solenoid
20 Spare
Solenoids
21 Auxiliary Electrical Control AUX6(C1)
22 Auxiliary Electrical Control AUX5(C2)
23 Secondary Auxiliary Electrical Control
(C+)
24 Secondary Auxiliary Electrical Control
(C)
25 Auxiliary Electrical Control AUX7
26 Stop Lamp
27 Backup Alarm
28 Fuel Shutoff
29 Self-Level and Ride Control
30 Glow Plugs
162 SEBU8020-06
Maintenance Section
Fuses - Replace
Main Fuse
g01279310
Illustration 172
(21) Battery
(22) Main fuse
The main fuse (22) is located behind the battery (21)
on the left side of the machine under the cab. This is
a 105 amp fuse. You must disconnect the negative
battery cable before you replace this fuse.
Fuse panel behind cab
There is an additional fuse panel behind the cab on
the right side of the machine.
g01279419
Illustration 173
(23) First Pair
(24) Second Pair
(25) Third Pair
This panel has 6 fuses. In order to change these
fuses, push up on the locking tab on the fuse cover.
Pull the cover away from the back of the cab.
g01279483
Illustration 174
26 Ignition switch
27 ECM
28 Horn
29 Main power relay 1
30 Miscellaneous cab accessories
31 Main power relay 2
SEBU8020-06 163
Maintenance Section
Hydraulic System Oil - Change
i03741200
Hydraulic System Oil - Change
SMCS Code: 5095-044
Selection of the Oil Change Interval
Your machine may be able to use a 4000 hour
interval for the hydraulic oil. The hydraulic oil is in
the system that is not integral to the service brakes,
the clutches, the nal drives, or the differentials.
The standard change interval is 2000 hours. The oil
should be monitored during intervals of 500 hours.
The extended 4000 hour interval can be used if the
following criteria are met.
HYDO Advanced 10
Cat HYDO Advanced 10 is the preferred oil for use in
most Caterpillar machine hydraulic and hydrostatic
transmission systems when ambient temperature
is between 20 C (4 F) and 40 C (104 F). Cat
HYDO Advanced 10 has an SAE viscosity grade of
10W. Cat HYDO Advanced 10 has a 50% increase
in the standard oil drain interval (up to 3000 hours)
for machine hydraulic systems over second and third
choice oils when you follow the maintenance interval
schedule for oil lter changes and for oil sampling that
is stated in the Operation and Maintenance Manual.
6000 hour oil drain intervals are possible when using
SOS Services oil analysis. When you switch to Cat
HYDO Advanced 10, cross contamination with the
previous oil should be kept to less than 10%. Consult
your Cat dealer for details about the benets from
the improved performance designed into Cat HYDO
Advanced 10.
Oil Filters
Caterpillar oil lters are recommended. The interval
for changing the oil lter should be 500 hours.
Oil
The 6000 hour interval for changing the oil is specic
to HYDO Advance 10.
The 4000 hour interval for changing the oil is for the
following oil types.

Caterpillar Hydraulic Oil (HYDO)

Caterpillar Transmission and Drive Train Oil

(TDTO)

Caterpillar TDTO-TMS

Caterpillar Diesel Engine Oil

Caterpillar Biodegradable Hydraulic Oils (HEES)

Caterpillar Multipurpose Tractor Oil (MTO)

Heavy-duty diesel engine oils with a minimum zinc

content of 900 ppm
If Caterpillar oils cannot be used, use heavy-duty oils
with the following classication: Caterpillar ECF-1,
API CG-4, API CF, and TO-4. These oils must have
a minimum zinc additive of 0.09 percent (900 ppm).
Note: Industrial hydraulic oils are not recommended
in Caterpillar hydraulic systems.
Monitoring the Condition of the Oil
The oil should be monitored during intervals of 500
hours. Caterpillar's standard SOS Fluids Analysis or
an equivalent oil sampling program should be used.
The current guidelines for cleanliness of the oil
should be observed. Refer to Measured Data.
If an oil sampling program is not available, the
standard 2000 oil change interval should be used.
Measured Data
The following information should be monitored
through sampling of the oil:

Signicant changes in wear metals should be

monitored. These metals include iron, copper,
chromium, lead, aluminum, and tin.

Signicant changes in the following additives

should be monitored: zinc, calcium, magnesium,
and phosphorus.

Contaminants should not be present. These

contaminants include fuel and antifreeze. Water
content should be .5 percent or less.

The silicon level should not exceed 15 parts per

million for new oil. The particle counts should be
monitored.

The recommended level of cleanliness for

Caterpillar machines that are operated in the eld
is ISO 18/15 or cleaner. The cleanliness should be
monitored by particle count analysis. The levels
of contamination should not exceed the normal
by more than two ISO codes. Action should be
taken in order to determine the cause of the
contamination. The system should be returned to
the original levels of contamination.

There should not be signicant changes in sodium,

silicon, copper, and potassium.
164 SEBU8020-06
Maintenance Section
Hydraulic System Oil - Change

The allowable level of oxidation is 40 percent (0.12

Abs units).

The kinematic viscosity of 100 C (212 F) oil

should not exceed a change of more than 2 cSt
from new oil.
Procedure for Changing the
Hydraulic Oil
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain uids on Caterpillar
products.
Dispose of all uids according to local regulations and
mandates.
g00956818
Illustration 175
Note: This lm is located near the hydraulic ller
cap on machines that are lled with arctic oil.
Operate the machine for a few minutes in order to
warm the hydraulic system oil.
Personal injury or death can result without releas-
ing all of the hydraulic pressure.
Release all the pressure from the hydraulic sys-
tem before any lines are disconnected.
The machine should be on level ground. Lower the
bucket to the ground and apply slight downward
pressure. Engage the parking brake and stop the
engine. Keep the armrest lowered. Turn the engine
start switch key to the ON position. Push the parking
brake switch. Move all of the joystick controls while
you press several times on each side of the auxiliary
hydraulic control (if equipped) in order to relieve
hydraulic pressure. Move the engine start switch key
to the OFF position.
g01280697
Illustration 176
(1) Hydraulic Tank Filler Cap
(2) Sight Gauge
1. Remove the hydraulic tank ller cap (1).
g01291067
Illustration 177
(1) Access panel
(2) Retaining bolts
SEBU8020-06 165
Maintenance Section
Hydraulic System Oil Filter - Replace
2. Remove the access panel in the belly guard
underneath the machine.
3. The hose is located on the right side. Pull the drain
hose through the access hole in the belly guard.
Remove the plug from the end of the drain hose.
Drain the oil into a suitable container.
4. Install the drain plug into the drain hose. Tighten
to 22 3 Nm (16 2 lb ft). Pull the drain hose
back into the machine.
5. Change the hydraulic system lter. Refer to
Operation and Maintenance Manual, Hydraulic
System Oil Filter - Change.
6. Fill the hydraulic system oil tank. Refer to
Operation and Maintenance Manual, Lubricant
Viscosities and Operation and Maintenance
Manual, Capacities (Rell).
7. Maintain the hydraulic oil level approximately in
the middle of the sight gauge (2).
Check the oil level with the loader arms in the fully
lowered position.
Note: The oil must be free of bubbles. If bubbles are
present in the oil, air is entering the hydraulic system.
Inspect the suction hoses and hose clamps.
8. Install the hydraulic tank ller cap.
i02743340
Hydraulic System Oil Filter -
Replace
SMCS Code: 5068-510
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain uids on Caterpillar
products.
Dispose of all uids according to local regulations and
mandates.
The hydraulic oil lter is located in the engine
compartment.
1. Open the engine access door. Refer to Operation
and Maintenance Manual, Access Doors and
Covers.
2. Remove the hydraulic tank ller cap.
g01209326
Illustration 178
The hydraulic lter is located on the rear door.
3. Remove the lter with a strap type wrench.
Note: Place a suitable nonconductive container
under the hydraulic oil lter. Use this container in
order to catch any oil that may spill from the lter or
the lter element mounting base.
4. Clean the lter element mounting base. Remove
any part of the lter element gasket that remains
on the lter element mounting base.
5. Apply a light coat of oil to the gasket of the new
lter element gasket.
6. Install a newlter hand tight until the seal of the
lter contacts the base. Note the position of the
index marks on the lter in relation to a xed point
on the lter base.
Note: There are rotation index marks on the lter
that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the lter, use the
rotation index marks as a guide.
7. Tighten the lter according to the instructions
that are printed on the lter. Use the index marks
as a guide. For non-Caterpillar lters, use the
instructions that are provided with the lter.
166 SEBU8020-06
Maintenance Section
Hydraulic System Oil Level - Check
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn
the lter to the amount that is required for nal
installation. Make sure that the installation tool does
not damage the lter.
8. Maintain the hydraulic oil level to the middle of the
sight gauge. Refer to Operation and Maintenance
Manual, Hydraulic System Oil Level - Check. Do
not overll the hydraulic tank.
9. Inspect the gasket on the hydraulic tank ller cap
for damage. Replace the hydraulic tank ller cap,
if necessary. Install the hydraulic tank ller cap.
10. Close the engine access door.
i02418557
Hydraulic System Oil Level -
Check
SMCS Code: 5095-535-FLV
g01306294
Illustration 179
Filler for adding hydraulic oil
g01280697
Illustration 180
(2) Sight gauge on right side of tank
1. Park the machine on level ground.
2. Lower the work tool to the ground. Turn off the
engine.
3. Wait for about ve minutes before checking the
level of the hydraulic oil.
4. Use the hydraulic oil ller on the radiator in order
to top off the hydraulic oil.
5. Maintain the oil level to the middle of the two lines
on the sight gauge. Do not overll the hydraulic
tank.
i02920120
Hydraulic System Oil Sample
- Obtain
SMCS Code: 5050-008; 7542-008
Open the rear access door. Refer to Operation and
Maintenance Manual, Access Doors and Covers for
information about the rear door.
Raise the radiator. Refer to Operation and
Maintenance Manual, Radiator Tilting for
information about the radiator.
SEBU8020-06 167
Maintenance Section
Hydraulic Tank Breather - Replace
g01280271
Illustration 181
The sampling port for the hydraulic oil is located on
the fan motor.
i02557991
Hydraulic Tank Breather -
Replace
SMCS Code: 5050-510-BRE; 5056-510-BRE
g01280304
Illustration 182
The breather for the hydraulic tank is located on the
top of the hydraulic tank.
1. Raise the cab. Refer to Operation and
Maintenance Manual, Cab Tilting for the
procedure to raise the cab.
2. Remove the breather.
3. Install the new breather and tighten to 20 3 Nm
(15 2 lb ft).
i02418559
Lift Arm and Cylinder Linkage
- Lubricate
SMCS Code: 5102-086-BD; 6107-086-BD
g01210414
Illustration 183
Radial Lift
(1) Lift Arm Pivot
(2) Lift Cylinder Rod End
(3) Head End Fitting
g01210415
Illustration 184
Vertical Lift
(1) Lift Arm Pivot
(2) Lift Cylinder Rod End
(3) Head End Fitting
(4) Link Arm
168 SEBU8020-06
Maintenance Section
Lower Machine Frame - Clean
g01210416
Illustration 185
The Link Arm is located behind the loader arm.
(5) Mounting for Link Pin
(6) Rear of Link Arm
Apply lubricant to all the grease ttings on one side.
Repeat the process for the opposite side of the
machine.
i02576463
Lower Machine Frame - Clean
SMCS Code: 7050-070
1. Tilt the cab upward. Refer to Operation and
Maintenance Manual, Cab Tilting.
g01270620
Illustration 186
This lm is located in the air duct.
NOTICE
Do not spray water or cleaning uids into the venti-
lation ducts. Cover the opening in order to prevent
foreign material or uid from entering the ventilation
ducts.
2. Seal the opening of the ventilation ducts with
plastic.
g01291067
Illustration 187
(1) Access panel
(2) Retaining bolts
3. The access panel (1) is located in the frame
underneath the machine.
4. Remove the four retaining bolts (2).
5. Slide the panel forward or slide the panel rearward.
Pull the panel downward and remove the access
panel from the machine.
SEBU8020-06 169
Maintenance Section
Oil Filter - Inspect
6. Remove any debris or dirt from the inside of the
frame.
7. Reinstall the access panel.
8. Remove the cover from the ventilation ducts.
9. Tilt the cab downward.
i02106227
Oil Filter - Inspect
SMCS Code: 1308-507; 3067-507; 5068-507
Inspect a Used Filter for Debris
g00100013
Illustration 188
The element is shown with debris.
Use a lter cutter to cut the lter element open.
Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the lter element can indicate a possible
failure.
If metals are found in the lter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the lter
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
Using an oil lter element that is not recommended
by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
i02634143
Quick Coupler - Clean/Inspect
SMCS Code: 6129-040; 6129-070
Personal injury or death can result from improp-
erly checking for a leak.
Always use a board or cardboard when checking
for a leak. Escaping air or uid under pressure,
even a pin-hole size leak, can penetrate body tis-
sue causing serious injury, and possible death.
If uid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.
Note: Do not weld on the quick coupler without
consulting your Caterpillar dealer.
1. Clean the quick coupler prior to inspection in order
to properly inspect the quick coupler.
g01322438
Illustration 189
This is the back side of the quick coupler. The lift arm and the tilt
cylinder are removed for clarity.
2. Tilt the quick coupler all the way forward in order
to clean the debris away from the pins.
3. Move the quick coupler levers. Ensure that the
levers are not bent or broken.
4. Make sure that the coupler pins extend through
the bottom of the quick coupler assembly. Check
the pins for wear and check the pins for damage.
170 SEBU8020-06
Maintenance Section
Radiator Core - Clean
5. Check the top edges of the quick coupler assembly
for wear or for damage. Check the face of the
quick coupler assembly for wear or for damage.
6. Inspect the components inside the quick coupler
for the following problems:loose bolts, oil
leaks, broken parts, missing parts, and cracked
components
7. Inspect the hydraulic lines and the hydraulic
ttings for damage or for wear. Repair any worn
components or replace any worn components.
Repair any leaking components.
8. Inspect the steel material of the quick coupler for
cracks.
Note: Perform all repairs before placing the quick
coupler back into operation.
i02575087
Radiator Core - Clean
SMCS Code: 1353-070-KO
The radiator is located at the rear of the machine
above the engine compartment.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. On models
272C and 297C, clean the aftercooler core when you
clean the radiator core.
1. Stop the engine. Open the engine access door.
Refer to Operation and Maintenance Manual,
Access Doors and Covers.
2. Tilt the radiator guard upward. Refer to Operation
and Maintenance Manual, Radiator Tilting.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
NOTICE
When you are using compressed air or high pressure
water to clean the radiator ns, ensure that the air or
water is directed parallel to the ns. If the compressed
air or high pressure water is not directed parallel to the
radiator ns, the radiator ns could be bent or dam-
aged.
Note: Pressurized air is the preferred method for
removing loose debris. Hold the nozzle approximately
6 mm (0.25 inch) away from the ns. Slowly move the
air nozzle in a direction that is parallel with the tubes.
The air nozzle should point in the opposite direction
of the ow of the fan. This will remove debris that
is between the tubes. Pressurized water may also
be used for cleaning. The maximum water pressure
for cleaning purposes must be less than 275 kPa
(40 psi). Use pressurized water in order to soften
mud. Use a degreaser and steam for removal of oil
and grease. Wash the core with detergent and hot
water. Thoroughly rinse the core with clean water.
3. Clean the radiator core from the top toward the
fan.
Note: If parts of the cooling system appear to
be damaged or if parts of the cooling system
are repaired, a leak test is highly recommended.
Consult your Caterpillar dealer for the most current
information about the cooling system.
4. After cleaning, start the engine and accelerate
the engine to high idle rpm. This will help in the
removal of debris and drying of the core. Stop the
engine. Use a light bulb behind the core in order
to inspect the core for cleanliness. Repeat the
cleaning, if necessary.
5. Inspect the ns and tubes of the radiator core
for damage. Some ns and tubes may be worn
from abrasive material that has passed through
the radiator core . Bent ns may be opened with a
comb.
NOTICE
Do not clean a rotating fan with high pressure water.
Fan blade failure can result.
6. Remove any dirt or debris from the fan, the fan
hub, the oil cooler, the radiator guard and the fan
guard.
Note: Dirt or debris on the cooling fan can cause an
imbalance.
7. Tilt the radiator guard downward.
8. Close the engine access door.
SEBU8020-06 171
Maintenance Section
Refrigerant Dryer - Replace
i01968724
Refrigerant Dryer - Replace
(If Equipped)
SMCS Code: 7322-510
Personal injury can result fromcontact with refrig-
erant.
Contact with refrigerant can cause frost bite. Keep
face 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 tting is removed.
Slowly loosen the tting. If the system is still un-
der pressure, release it slowly in a well ventilated
area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a ame contacting air con-
ditioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certied recovery and recycling cart to prop-
erly remove the refrigerant from the air condition-
ing system.
NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will en-
ter an open refrigerant system and cause corrosion
which will lead to component failure.
Refer to Service Manual, SENR5664, Air
Conditioning and Heating R-134a For All Caterpillar
Machines for the proper procedure to change the
receiver-dryer assembly and for the procedure to
reclaim the refrigerant gas.
Note: The receiver-dryer must also be replaced when
the air conditioning system is evacuated.
i02418592
Rollover Protective Structure
(ROPS) and Falling Object
Protective Structure (FOPS) -
Inspect
SMCS Code: 7323-040; 7325-040
g01280181
Illustration 190
1. Inspect the ROPS for loose bolts. Tighten the
bolts (1) to the following torque 125 20 Nm
(92 15 lb ft). Check the hinge on the cab (2).
Check the ROPS and the FOPS for damaged
bolts or missing bolts. Replace any damaged bolts
or missing bolts with original equipment parts only.
2. Operate the machine on a rough surface. Replace
the ROPS mounting supports if the ROPS
emits a noise. Replace the ROPS mounting
supports if the ROPS rattles. Refer to Operation
and Maintenance Manual, Cab Tilting for a
description of the mounting support.
Do not straighten the ROPS or the FOPS. Do
not repair the ROPS or the FOPS by welding
reinforcement plates to the ROPS or the FOPS.
Consult your Caterpillar dealer for repair of any
cracks in the ROPS or the FOPS.
Inspect the Flying Object Guard (if equipped) for
damage.
Consult your Caterpillar dealer for repair of any
cracks in the Flying Object Guard.
172 SEBU8020-06
Maintenance Section
Seat Belt - Inspect
i02429589
Seat Belt - Inspect
SMCS Code: 7327-040
Always check the condition of the seat belt and the
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
g00932801
Illustration 191
Typical example
Check the seat belt mounting hardware (1) for wear
or for damage. Replace any mounting hardware that
is worn or damaged. Make sure that the mounting
bolts are tight.
Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt.
Inspect the seat belt (3) for webbing that is worn or
frayed. Replace the seat belt if the seat belt is worn
or frayed.
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
Note: Within three years of the date of installation or
within ve years of the date of manufacture, replace
the seat belt. Replace the seat belt at the date which
occurs rst. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
the seat belt extension.
i02429594
Seat Belt - Replace
SMCS Code: 7327-510
Within three years of the date of installation or within
ve years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs rst. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
g01152685
Illustration 192
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
If your machine is equipped with a seat belt
extension, also perform this replacement procedure
for the seat belt extension.
i02708298
Sprocket - Inspect
SMCS Code: 4164-040
Note: Operating the machine in conditions that are
muddy or sandy will cause accelerated wear on the
sprocket and other undercarriage components. It is
important to clean the undercarriage of the machine
daily in order to maximize component life. Sleeves
that do not meet the minimum thickness or sleeves
that do not turn freely may cause unnecessary wear
on the drive lugs on the rubber track.
SEBU8020-06 173
Maintenance Section
Sprocket - Inspect
Remove the Sprocket
g01284748
Illustration 193
(1) Drive motor (2) Bolts and washers (3) Sprocket assembly
Note: In order to service the sprocket, the tracks must
be loosened. Refer to Operation and Maintenance
Manual, Track (Rubber) - Inspect/Adjust for the
procedure.
1. Remove the 12 bolts (2) and the 12 washers that
hold the sprocket assembly (3) to the drive motor
(1).
2. Slide the sprocket assembly off the drive motor.
Sleeves and Rings
g01282450
Illustration 194
(4) Outer ring
(5) Washers and Locknuts
(6) Outer sleeve
(7) Inner sleeve
(8) Sprocket mounting ring
(9) Middle ring
(10) Inner ring
The sprocket is equipped with two types of sleeves.

Inner Sleeves (7)

Outer sleeves (6)

174 SEBU8020-06
Maintenance Section
Sprocket Sleeve - Inspect
The outer sleeves (6) are free to rotate on the inner
sleeves (7). The sleeves are held in position by the
outer ring (4), the sprocket mounting ring (8), the
middle ring (9), and inner ring (10).
Note: There are many parts in the sprocket assembly.
Remove the sprocket completely from the machine
in order to work on the sprocket. Use a clean, at
surface in order to disassemble the sprocket and
assemble the sprocket.
1. Remove the 12 locknuts and washers that hold
the outer ring (4) in place.
2. Remove the ring.
3. Remove the outer sleeves and the inner sleeves.
4. Measure thickness (A) for the outer sleeves. If the
thickness of the outer sleeves measures less than
3 mm (0.12 inch), replace the sleeves. Sleeves
that do not meet the minimum thickness or sleeves
that do not turn freely may cause unnecessary
wear on the drive lugs on the rubber track.
5. When you replace the outer sleeves, rotate the
inner sleeves for 180. If the inner sleeves have
already been rotated, replace the inner sleeves.
6. Repeat steps 2 through 5 for each set of sleeves.
7. Install the sleeves and the rings.
8. Install the new locknuts. Do not reuse the
locknuts. Tighten the locknuts to a torque of
55 5 Nm (40.6 3.7 lb ft) in a star pattern. Turn
the locknuts an additional 180 5 in the star
pattern.
9. Install the sprocket on the drive motor. Tighten the
bolts to a torque of 270 40 Nm (199 30 lb ft).
Rings
The inner ring (10), the middle ring (9), the outer
ring (4), and the sprocket mounting ring (8) will wear
from the rotation of the outer sleeves. Measure the
thickness of the inner ring, the middle ring, and outer
ring. If the thickness of the rings measures less than
4.75 mm (0.19 inch), replace the ring. If the thickness
of the sprocket mounting ring measures less than
8 mm (0.32 inch), replace the sprocket mounting ring.
Track
Tighten the track to the proper tension. Refer to
Operation and Maintenance Manual, Track (Rubber)
- Inspect/Adjust for the procedure.
i02565868
Sprocket Sleeve - Inspect
SMCS Code: 4164-040-ZV
Note: Operating the machine in conditions that are
muddy or sandy will cause accelerated wear on the
sprocket and other undercarriage components. It is
important to clean the undercarriage of the machine
daily in order to maximize component life. Sleeves
that do not meet the minimum thickness or sleeves
that do not turn freely may cause unnecessary wear
on the drive lugs on the rubber track.
g01285052
Illustration 195
3 rows of outer sleeves
Check the 3 rows of outer sleeves in order to ensure
that the sleeves rotate freely. If the sleeves do not
rotate freely, refer to Operation and Maintenance
Manual, Sprocket - Inspect for information about
the inspection of the sprocket assembly.
i01878236
Tilt Cylinder Bearings and
Bucket Linkage Bearings -
Lubricate
SMCS Code: 5104-086-BD; 6107-086-BD
Wipe all of the grease ttings before you apply
lubricant.
SEBU8020-06 175
Maintenance Section
Track (Rubber) - Inspect/Adjust
g00955895
Illustration 196
Note: Lubricate the ttings with the loader lift arms in
the fully lowered position.
Apply lubricant to the grease ttings (1) for the upper
bearings for the tilt cylinders.
Apply lubricant to the grease ttings (2) for the lower
bearings for the tilt cylinders.
Apply lubricant to the grease ttings (3) for the
coupler engagement pins.
Apply lubricant to the grease tting (4) for the pivot
pin of the quick coupler assembly.
There are a total of 8 grease ttings.
i02418763
Track (Rubber) - Inspect/Adjust
SMCS Code: 4197; 4198-025; 4198-040
Periodic adjustment of the track tension is necessary
in order to avoid damage to the tracks. Maintaining
the tracks at the proper tension will maximize the
service life of the undercarriage components. The
undercarriage components include the sleeves of the
drive sprocket, the rings of the drive sprocket, the
wheels, and the track.
NOTICE
Do not overtighten the tracks. Tracks that are too tight
can cause premature failure of the tracks. Tracks that
are too tight can cause power loss and bearing fail-
ures.
Tracks that are too loose increase the possibility of
the track derailing or the drive lugs mis-feeding on the
drive sprocket. In aggressive operating conditions, oc-
casional mis-feeding is normal. If consistent mis-feed-
ing is observed, ensure that the track tension is set to
the recommended specication. If the track tension is
set to the recommended specication and mis-feed-
ing is still observed, then your application may require
a tighter track tension. Increase the track tension until
consistent mis-feeding is no longer observed.
The intervals for track tension vary depending on the
following conditions: the machine application, the op-
erator, the soil conditions, the climate, and the condi-
tion of the undercarriage components. Operators are
responsible for basic visual inspections of the track
tension on a daily basis.
Inspect
g01283123
Illustration 197
(1) Weight
(2) Straight edge
(3) Adjuster
(4) Jam nut
Place approximately 45 kg (100 lb) (1) between
the drive sprocket and the front idler wheel. Place
a straight edge (2) across the drive sprocket and
idlers. Measure the track sag between the bottom of
the straight edge and the top of the track. The track
sag should be set at 12 mm (0.5 inch). If the track
needs adjustment proceed with the following steps.
Track Adjustment
1. Loosen the jam nut (4). A 48 mm (1.875 inch)
wrench is recommended.
176 SEBU8020-06
Maintenance Section
Track (Rubber) - Remove/Replace
2. Turn the adjuster (3) in order to raise or lower the
drive sprocket. A 44 mm (1.75 inch) wrench is
recommended.
3. Tighten the jam nut to the following torque
270 40 Nm (199 30 lb ft).
4. Recheck the track tension.
Detension the track
g01286098
Illustration 198
Clean the area under the sprocket.
Note: Many operations for maintenance of the
undercarriage require the track to be loosened.
1. Remove any debris from the area under the
sprocket before you loosen the track. Trapped
material in this area may prevent the drive
sprocket from lowering fully.
2. Loosen the jam nut (4). A 48 mm (1.875 inch)
wrench is recommended.
3. Turn the adjuster (3) in order to lower the
drive sprocket. A 44 mm (1.75 inch) wrench is
recommended.
4. Lower the drive sprocket completely in order to
provide the necessary clearance for maintenance
or for removal of the track.
i02418767
Track (Rubber) -
Remove/Replace
SMCS Code: 4197; 4198-011; 4198-510
Removing the Track
1. Position the machine on rm, level ground.
2. Remove any work tool that is attached to the quick
coupler.
3. Raise the loader arms and install the brace
for the loader lift arm. Refer to Operation and
Maintenance Manual, Loader Lift Arm Brace
Operation.
g01286300
Illustration 199
4. Use an appropriate oor jack in order to lift the
machine off the ground. Use appropriate jack
stands (1) in order to block up the machine. Raise
the machine until tracks are approximately 50 mm
(2.0 inch) (A) off the ground.
5. Detension the track. Refer to Operation
and Maintenance Manual, Track (Rubber) -
Inspect/Adjust.
SEBU8020-06 177
Maintenance Section
Window Washer Reservoir - Fill
g01286297
Illustration 200
(2) Front idler wheel
6. Remove the front outboard idler wheel and the
front inboard idler wheel. Remove the mud scraper
plate. Refer to Operation and Maintenance
Manual, Bogie and Idler - Inspect/Replace for
the procedure to remove the idler wheels and the
mud scraper plate.
7. Lubricate the remaining front idler wheels and the
inside of the track in order to ease the removal
of the track.
8. Grasp the track on top of the front idlers. Pull the
track forward and pull the track away from the
frame. Slide the drive lugs past the inside front
idler wheels.
9. Lift the track off the drive sprocket and pull the
track away from the rear idler wheels.
Installing the Track
1. Slide the track onto the drive sprocket.
2. Position the rear of the track so that the drive lugs
are aligned between the rear idler wheels.
3. Pull all of the slack forward and make sure that
the drive lugs are properly meshed with the drive
sprocket. This will provide the maximum amount of
slack to aid with installation across the front idlers.
4. Lubricate the idler wheels and the inside of the
track in order to ease the installation of the track.
5. Pull the track over the front idler wheels.
6. Install the front inboard idler wheel and the front
outboard idler wheel. Install the mud scraper
plate. Refer to Operation and Maintenance
Manual, Bogie and Idler - Inspect/Replace for
the procedure to install the idler wheels and the
mud scraper plate.
7. Tension the track. Refer to Operation and
Maintenance Manual, Track (Rubber) -
Inspect/Adjust.
i02418610
Window Washer Reservoir -
Fill
(If Equipped)
SMCS Code: 7306-544-KE
NOTICE
When operating in freezing temperatures, use
Caterpillar nonfreezing window washer solvent or
equivalent. System damage can result from freezing.
g01209248
Illustration 201
The reservoir for the window washer solvent is
located inside the cab by the left footrest.
Fill the reservoir with window washer solvent.
Window washer solvent with isopropyl alcohol is
recommended.
178 SEBU8020-06
Maintenance Section
Window Wiper - Inspect/Replace
i02810705
Window Wiper -
Inspect/Replace
(If Equipped)
SMCS Code: 7305-040; 7305-510
Inspect the condition of the front window wiper blade.
Replace the window wiper blade if the window wiper
blade is worn or damaged. If the window wiper blade
streaks the window, replace the window wiper blade.
i02418633
Windows - Clean
SMCS Code: 7310-070
Rear Window and Glass Front Door
Use commercially available window cleaning
solutions in order to clean the windows.
Apply the cleaning solution liberally. Wipe the surface.
Dry the surface in order to prevent spots.
Side Windows
Use commercially available window cleaning
solutions in order to clean the windows.
The side windows of the cab can be removed for
cleaning. Refer to the following procedure in order to
remove the side windows.
g01209231
Illustration 202
1. Release the latch. Slide the front window rearward
between the circular marks (1) in the top of the
window frame. Push the window upward in the
track. Pull outward on the bottom of the window in
order to remove the window.
2. Release the latch. Slide the rear window forward
between the circular marks (1) in the top of the
window frame. Push the window upward in the
track. Pull outward on the bottom of the window in
order to remove the window.
3. Pull straight up on the bottom window in order to
remove the window from the track. Pull inward in
order to remove the window.
4. Reverse the process in order to install the
windows. Install the lower window rst. Then
install the rear window in the outer track. Install
the front window in the inner track next.
Polycarbonate Front Door and
Polycarbonate Top Window
Note: Do not wipe the window dry. Do not use
paper towels. This may scratch the nish of the
polycarbonate windows over time.
For cleaning your polycarbonate top window or
polycarbonate front door, use a soft cloth, a sponge,
or a chamois. Use any of the following cleaners:

soap and water

isopropyl alcohol

kerosene

denatured alcohol

commercially available window cleaning solutions

Apply the cleaning solution liberally. Wipe the surface.
SEBU8020-06 179
Maintenance Section
Work Tool - Lubricate
i02729220
Work Tool - Lubricate
SMCS Code: 6700-086
Multipurpose Bucket
g01280216
Illustration 203
Apply lubricant to the grease tting (1) for the pivot
pin of the apron.
Apply lubricant to the grease tting (2) for the rod end
of the multipurpose bucket cylinder.
Apply lubricant to the grease tting (3) for the head
end of the multipurpose bucket cylinder.
Repeat for the other side of the bucket.
There are six grease ttings.
Utility Grapple Bucket and Utility
Grapple Fork
g00647980
Illustration 204
Apply lubricant to the four grease ttings for the
grapples.
g00647988
Illustration 205
Apply lubricant to the two ttings for the grapple
cylinder.
There are six grease ttings.
Industrial Grapple Bucket and
Industrial Grapple Fork
g00645995
Illustration 206
Apply lubricant to the four grease ttings for the fork
cylinders.
g00646004
Illustration 207
180 SEBU8020-06
Maintenance Section
Work Tool - Lubricate
Apply lubricant to the four grease ttings for the two
forks.
There are eight grease ttings.
Grapple Rake
g01368386
Illustration 208
Apply lubricant to the four grease ttings for the
grapple cylinders.
Apply lubricant to the four grease ttings for the two
grapples.
There are eight grease ttings.
Angle Blade
g00648033
Illustration 209
Apply lubricant to the grease tting on the rod end of
the angle cylinder.
g00648037
Illustration 210
Apply lubricant to the grease tting on the horizontal
pivot point of the blade.
g00648038
Illustration 211
Apply lubricant to the grease tting on the vertical
pivot point of the blade. Repeat for opposite side of
the blade.
g00677570
Illustration 212
This is a bottom view of the angle blade.
Apply lubricant to the grease tting on the pivot point
of the cylinder.
There are ve grease ttings.
SEBU8020-06 181
Maintenance Section
Work Tool Mounting Bracket - Inspect
Dozer Blade
g01073259
Illustration 213
Apply lubricant to the grease tting on both ends of
the right hand angle cylinder (1). Repeat for opposite
side of the blade.
Apply lubricant to the grease tting on the pivot points
on each end of the tilt cylinder (2).
There are six grease ttings.
i01809997
Work Tool Mounting Bracket -
Inspect
SMCS Code: 6700-040-BK
g00925058
Illustration 214
Inspect upper angled plate (1) and ensure that the
plate is not bent or otherwise damaged. Inspect holes
(2) for wear and for damage. Inspect lower angled
plate (3) and ensure that the plate is not bent or
otherwise damaged. If any wear is suspected or any
damage is suspected, consult your Caterpillar dealer
before you use the work tool.