CAT M316D Maintenance

MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt © 2010 Caterpillar All Rights Reserved ® ® SEBU8017-05 December 2009 Operation and Maintenance Manual M313D, M315D, M316D, M318D, M322D, M318D MH and M322D MH Excavators W6A1-4999 (Machine) W3H1-4999 (Machine) W5M1-4999 (Machine) W8P1-4999 (Machine) W8R1-4999 (Machine) W2S1-4999 (Machine) W2T1-4999 (Machine) SAFETY.CAT.COM 312 Maintenance Section Maintenance Interval Schedule SEBU8017-05 i03788193 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, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. 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. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed. The normal oil change interval for the engine is Every 500 Service Hours or 3 Months. If the engine is operated under severe conditions, change the oil after Every 250 Service Hours or 1 Month. Severe conditions include the following factors: high temperatures, continuous high loads, and extremely dusty conditions . Refer to the results of the S·O·S oil analysis in order to determine if the oil change interval should be decreased to 250 hours. Consult your Caterpillar Dealer for detailed information regarding the optimum oil change interval. Refer to Operation and Maintenance Manual, “Hydraulic System Oil - Change” for information on a 4000 hour maintenance interval for the hydraulic system. When Required Air Conditioner/Cab Heater Filter (Recirculation) Inspect/Replace ................................................ 314 Air Precleaner - Clean ........................................ 314 Air Precleaner - Clean ........................................ 315 Battery - Recycle ................................................ 320 Battery or Battery Cable - Inspect/Replace ........ 320 Bucket Tips - Inspect/Replace ............................ 327 Bucket Tips - Inspect/Replace ............................ 331 Cab Air Filter (Fresh Air) - Clean/Replace .......... 334 Camera - Clean/Adjust ....................................... 335 Cooling System Coolant Extender (ELC) - Add .. 340 Engine Air Filter Primary Element - Clean/ Replace ............................................................. Engine Air Filter Secondary Element - Replace .. Fan Guard - Clean/Inspect ................................. Fuel System - Prime ........................................... Fuses - Replace .................................................. Hydraulic System Oil Filter (Return) - Replace ... Oil Filter - Inspect ................................................ Radiator Core - Clean ......................................... Refueling Pump Strainer - Clean ........................ Stabilizer - Clean/Inspect .................................... Window Washer Reservoir - Fill .......................... Window Wiper - Inspect/Replace ........................ Windows - Clean ................................................. 343 345 350 352 356 362 366 366 368 370 375 375 375 Every 10 Service Hours or Daily for First 100 Hours Boom and Stick Linkage - Lubricate ................... 323 Boom, Stick and Bucket Linkage - Lubricate ...... 324 Every 10 Service Hours or Daily Cooling System Coolant Level - Check .............. Engine Oil Level - Check .................................... Hydraulic System Oil Level - Check ................... Seat Belt - Inspect .............................................. 341 346 364 369 Every 10 Service Hours or Daily for Machines Used in Severe Applications Boom and Stick Linkage - Lubricate ................... 323 Boom, Stick and Bucket Linkage - Lubricate ...... 324 Initial 50 Service Hours Wheel Nut Torque - Check .................................. 374 Every 50 Service Hours or Weekly Automatic Lubrication Grease Tank - Fill ............ Boom and Stick Linkage - Lubricate ................... Boom, Stick and Bucket Linkage - Lubricate ...... Fuel System Water Separator - Drain ................. Fuel Tank Water and Sediment - Drain ............... Tire Inflation - Check ........................................... 316 323 324 354 356 373 Every 100 Service Hours or 2 Weeks Axle Oscillation Bearings - Lubricate .................. Blade Linkage - Lubricate ................................... Stabilizer Bearings - Lubricate ............................ Swing Bearing - Lubricate ................................... 319 322 370 370 Every 250 Service Hours Engine Oil Sample - Obtain ................................ 347 Every 250 Service Hours or Monthly Axle Bearings (Front) - Lubricate ........................ 316 Axle Oil Level (Front) - Check ............................. 318 Axle Oil Level (Rear) - Check ............................. 318 .......................Change ........................................................... 320 Overhead Guard ........ 337 .... Final Drive Oil Sample ...Check ..Replace .Replace ...... Final Drive Oil .Replace ............ Engine Air Filter Secondary Element ............................ Axle Oil Sample ....Change .. 369 Every 6000 Service Hours or 3 Years Every 500 Service Hours or 3 Months Cab Riser (Adjustable) Linkage ............................................... 350 Every 500 Service Hours Axle Oil Sample .................... and Converted Systems) Cooling System Coolant Sample (Level 2) Obtain ................. Final Drive Oil .............. Drive Shaft ....... Hydraulic Generator Brushes and Commutator Inspect .................... Transmission Oil .................................. 343 Engine Valve Lash ... Transmission Oil ....Obtain ............................................. Cooling System Coolant Sample (Level 1) Obtain ... Engine Air Filter Primary Element ..................... Fuel System Water Separator Element Replace .......... 317 317 351 373 Every 3000 Service Hours or 2 Years Hydraulic System Oil ........................Obtain ............... Cooling System Coolant Sample (Level 2) Obtain ... 359 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt ...................... 320 Battery Hold-Down ............................ Refilled Systems... Axle Oil (Rear) ........ 319 319 342 345 348 352 352 354 365 374 334 343 355 359 Every 1000 Service Hours Engine Valve Lash .........................Test .Inspect ...........Replace ....................................................Clean/ Replace ....Change .....................................Clean ...Change ............... Hydraulic System Oil Filter (Return) ............................. Condenser (Refrigerant) ..................Clean ................SEBU8017-05 Belts ................. Axle Oil (Rear) ........................................Change ..................................Check ... 343 343 345 359 363 364 371 Every 2000 Service Hours or 1 Year (Less than 25% Travel) Axle Oil (Front) ............................Lubricate .............................................Check .... Every 2000 Service Hours or 1 Year 317 317 351 373 Receiver Dryer (Refrigerant) ...........Change ....Change ..........Tighten ........................................................ Swing Gear ............................ Hydraulic System Oil ........................ Fuel Tank Cap and Strainer ........................................................................... Transmission Oil Level ........................... Engine Oil and Filter ............Replace ........ 366 Every 1000 Service Hours of Partial Hammer Use (50% of Service Hours) Hydraulic System Oil ........Lubricate ............Check ................... Hydraulic System Oil Sample .....Obtain .......Change ...............Lubricate . Wheel Nut Torque .......................... 359 Every 1500 Service Hours or 1 Year (Greater than 25% Travel) Axle Oil (Front) ............. Final Drive Oil Level ......Change ..............................Replace ...................................................Inspect/Adjust/Replace .Obtain ..... Engine Crankcase Breather Filter ..Change ... 368 Every 12 000 Service Hours or 6 Years Cooling System Coolant (ELC) ............... Fuel System Filter ............................ Transmission Oil Sample .... 313 Maintenance Section Maintenance Interval Schedule 321 326 336 351 374 374 Initial 500 Hours (for New Systems....Replace ....... Braking System .......................Check ....................................... Hydraulic System Oil Filter ... 350 Every 1000 Service Hours or 6 Months Battery ..........Change ....................Clean ..........Change ...Obtain ...........Change ......................... Install the air filter. as required. use a new air filter. Remove the cover from the precleaner block. Open the right front access door.314 Maintenance Section Air Conditioner/Cab Heater Filter (Recirculation) . After you clean the filter. Pull up on the air filter in order to remove the air filter. To prevent decreased performance. Clean the air filter with a maximum of 200 kPa (30 psi) pressure air. g01317127 (2) Bolt 4. Remove the scavenge hose that is attached to the box for the air filter. i03715681 Air Precleaner . Illustration 290 g01317122 (1) scavenge hose 3. 1. If the air filter is damaged or badly contaminated. 6. 1. 2. 3. Illustration 291 . Remove the three bolts below the battery compartment. Pull the box for the air filter slightly out of the battery compartment. Illustration 289 g01215821 The air filter is located in the cab behind the operator's seat.Clean SMCS Code: 1055-070-DJ NOTICE Service the engine air precleaner only with the engine stopped. Remove the screw in order to disassemble the Cyclone precleaner block. 1054-510-A/C NOTICE An air recirculation filter element plugged with dust will result in decreased performance and service life to the air conditioner or cab heater. 4. inspect the filter. 5. clean the filter element. SMCS Code: 1054-040-A/C.Inspect/Replace i03769490 Air Conditioner/Cab Heater Filter (Recirculation) Inspect/Replace SEBU8017-05 2. Engine damage could result. Attach the scavenge hose to the box for the air filter. Install the three bolts below the battery compartment.SEBU8017-05 Illustration 292 315 Maintenance Section Air Precleaner . Illustration 294 g01181961 2. Squeeze the dust valves in order to remove any dust. Close the right front access door. 10. Illustration 293 g01181958 1. 11. 3. Assemble the Cyclone precleaner block and tighten the screw. Remove the engine air precleaners and inspect the opening for dirt and debris. 4. Clean the engine air precleaner with pressure air or wash the engine air precleaner in clean warm water. Note: The following procedure is necessary only in extreme conditions. 12. . 8. if necessary. 9.Clean (If Equipped) SMCS Code: 1055-070-DJ S/N: W6A1-4999 S/N: W8P1-4999 S/N: W8R1-4999 S/N: W2S1-4999 S/N: W2T1-4999 NOTICE Service the engine air precleaner only with the engine stopped. Clean the tubes. i03731370 Air Precleaner . Install the box for the air filter into the battery compartment. Engine damage could result. Use a suitable container in order to catch the dust.Clean g01317146 7. Loosen the clamps at the bottom of the engine air precleaners. Blow dust and debris out of the Cyclone precleaner block. Illustration 296 g02003059 Autolub on Standard Wheeled Excavator Note: When adding grease to the tank. i03716048 Automatic Lubrication Grease Tank . be sure to wipe off the tank fitting and the grease gun nozzle.Fill (If Equipped) SMCS Code: 7540-544.Fill SEBU8017-05 5. 1 grease with low viscosity should be used only in cold weather conditions. Illustration 297 g01360757 i02713176 Axle Bearings (Front) Lubricate SMCS Code: 3278-086 The front axle is the axle which steers the machine. 2 grease that meets the requirements for both cold weather conditions and hot weather conditions. add grease to the grease tank. 7540-544-TNK Caterpillar recommends the use of NLGI No. For more information. Note: NLGI No. “Capacities (Refill)”. Adding grease beyond that level would allow the top cover to come off when the pump is activated. Illustration 295 Autolub on MH Machine g02002374 Wipe all grease fittings before you apply grease.316 Maintenance Section Automatic Lubrication Grease Tank . Tighten the clamps. never add the grease beyond the level approximately 2 cm (0. the grease consumption will increase. If necessary. The rear axle is the one with the gearbox. Install the engine air precleaner. Note: Any foreign materials in the grease tank could restrict the lubrication lines or damage the valves. Before adding grease to the tank. refer to Operation and Maintenance Manual.8 inch) below the top surface of the grease tank. 0 or No. The grease level should be checked before starting to work. . If used in conditions other than cold weather. Allow the oil to drain into a suitable container. If damage or wear is noticed on the O-ring seal. Note: Refer to Operation and Maintenance Manual. Refer to Operation and Maintenance Manual. Illustration 298 g01362885 A grease fitting is positioned on the top and on the bottom of the steering axle. (2) Drain Plug.Change The front axle is the axle which steers the machine. 11. replace the seal. i03715945 8. Clean filler plug (1). (1) Filler plug (2) Drain plug 1. Remove filler plug (1). Install drain plug (2). SMCS Code: 3260-044. fully turn the wheels to the left or to the right. Add oil through the filler plug opening. If damage or wear is found. Axle Oil (Front) . Remove the dirt that is around filler plug (1) and around drain plug (2). For access to the U-joints.SEBU8017-05 317 Maintenance Section Axle Oil (Front) . 4.Change i02200350 SMCS Code: 3278-044 Axle Oil (Rear) . 7. The machine wheels may require rotation in order to access the grease fittings. 2. Install filler plug (1). 10. Clean drain plug (2). 9. Note: Refer to the Operation and Maintenance Manual. Filler plug (1) and drain plug (2) are located under the machine on the rear axle. Inspect the O-ring seal. “General Hazard Information” for information in containing fluid spillage. The rear axle is the one with the gearbox. “General Hazard Information” for information in containing fluid spillage.Change 3. Maintain the oil level to the bottom of the filler plug opening. Remove drain plug (2). 3278-044 Illustration 299 g01111561 Illustration 300 g01111566 (1) Filler Plug. . replace the O-ring seal. Note: Dispose of drained fluids according to local regulations. Operate the machine for an adequate amount of time in order to warm the oil. 5. Apply grease to these fittings at each end of the steering axle. Operate the machine for an adequate amount of time in order to warm the oil. 6. Inspect the O-ring seal. “Capacities (Refill)”. . Clean the filler plug. Inspect the O-ring seal. Remove the dirt that is around the filler plug. Install the filler plug. 4. 2. 9. 6. 2. replace the seal. The rear axle is the one with the gearbox. “Capacities (Refill)”. See Operation and Maintenance Manual.318 Maintenance Section Axle Oil Level (Front) . Add oil through the filler plug opening. Since the rear axle has a common oil circuit any oil that is added will be distributed through the entire circuit. Clean the filler plug. as needed. Illustration 301 g01103917 1. Fill the axle with oil to the bottom of the filler plug opening. If damage or wear is noticed on the O-ring seal. 3. i02181845 Axle Oil Level (Front) . Install drain plug (2). Install filler plug (1). as needed. Remove the filler plug. Remove the dirt that is around filler plug (1) and around drain plug (2). Maintain the oil level to the bottom of the filler plug opening. Remove the filler plug. The front axle is the axle which steers the machine. Drain the oil into a suitable container. 3278-535 5. SMCS Code: 3260-535-FLV. 7. 5. Inspect the O-ring seal. Add oil through the filler plug opening. Install the filler plug.Check 4. i02529374 Axle Oil Level (Rear) . Clean filler plug (1). 10. If damage or wear is noticed on the O-ring seal. If damage or wear is noticed on the O-ring seal. Clean drain plug (2). If damage or wear is noticed on the O-ring seal. Remove drain plug (2). The rear axle is the one with the gearbox. 6. 5.Check SEBU8017-05 1. Note: The rear axle housing and the final drive housing for the rear axle share the same oil circuit. Remove filler plug (1). Inspect the O-ring seal. Inspect the O-ring seal. 6. 3. replace the seal. The front axle is the axle which steers the machine. 3.Check SMCS Code: 3278-535 Illustration 302 g01103926 1. Remove the dirt that is around the filler plug. replace the seal. 2. replace the seal. 4. Note: Dispose of any used oil according to local regulations. Maintain the oil level to the bottom of the filler plug opening. 8. Refer to Special Publication. 7542 Obtain an oil sample from the front axle by removing the filler plug and taking the sample directly from the axle housing. Refer to Special Publication. “Caterpillar Machine Fluids Recommendations”. 7542 Illustration 304 g01108690 g01103917 Illustration 306 g00102405 A grease fitting is also positioned on the rear of the steer axle pin. “Caterpillar Machine Fluids Recommendations”. Apply grease to this grease fitting. 3278-008. SMCS Code: 3260-008. “How To Take A Good Oil Sample” for more information about obtaining an oil sample from the front axle housing. 3282 Illustration 303 g01103926 Wipe all the grease fittings before you apply grease. Refer to Special Publication. 3278. A grease fitting is positioned on the front of the steer axle pin. .Obtain (Front) Illustration 305 A steer axle pin is positioned at the front of the machine.Obtain (Rear) SMCS Code: 3260-008. Apply grease to this grease fitting. PEHP6001. “S·O·S Oil Analysis” for information that pertains to obtaining an oil sample from the front axle housing. 3278-008. “S·O·S Oil Analysis” for information that pertains to obtaining an oil sample from the rear axle housing. SEBU6250.SEBU8017-05 319 Maintenance Section Axle Oil Sample . PEHP6001. Refer to Special Publication. i02182213 Axle Oil Sample . i02837393 Axle Oscillation Bearings Lubricate (If Equipped) SMCS Code: 3268-086-BD. Obtain an oil sample from the rear axle by removing the filler plug and taking the sample directly from the axle housing. “How To Take A Good Oil Sample” for more information about obtaining an oil sample from the rear axle housing. SEBU6250.Obtain i02182195 Axle Oil Sample . Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes. SMCS Code: 1401-561 i00993589 Always recycle a battery. Never discard a battery.Tighten SMCS Code: 7257 Tighten the hold-downs for the battery in order to prevent the batteries from moving during machine operation.Clean SEBU8017-05 Remote Grease Fittings (If Equipped) Battery . 1402-510. Apply grease to the remote grease fittings until grease is visible around the steer axle pin.Recycle Wipe remote grease fittings before you apply grease. Sparks could cause vapors to explode. Keep the terminals clean and keep the terminals coated with petroleum jelly. 1. Do not allow jumper cable ends to contact each other or the engine. . Battery Hold-Down . Note: If the machine is equipped with a front attachment. i03731373 Battery or Battery Cable Inspect/Replace SMCS Code: 1401-510. Remove the disconnect switch key. Illustration 308 g01360649 i00934864 Battery .320 Maintenance Section Battery . Always wear protective glasses when working with batteries. Install the post cover after you coat the terminal post with petroleum jelly. the front and the rear end of the steer axle pin are lubricated by two remote grease nipples. Turn the battery disconnect switch to the OFF position. Prevent sparks near the batteries.Clean SMCS Code: 1401-070 Clean the battery surface with a clean cloth. Improper jumper cable connections can cause an explosion. Turn all switches to the OFF position. If the machine is not equipped with any front attachment. 1402-510 Personal injury can result from battery fumes or explosion. Always return used batteries to one of the following locations: • A battery supplier • An authorized battery collection facility • Recycling facility i00934872 Illustration 307 g01360647 The remote grease fittings for the steer axle pin are located next to the right oscillating axle cylinder. then only the rear end of the pin is lubricated by a remote grease nipple. Batteries give off flammable fumes that can explode. Turn the engine start switch to the OFF position. 2. 4. 1405-025. In order to remove poly V-belt (1). If equipped. 4.Inspect/Adjust/Replace SMCS Code: 1357-025. Remove pin (3) from the locking hole and gradually release automatic belt tensioner (2). Open the right rear access door. Disconnect the battery cable at the battery disconnect switch. replace the belts in belt sets. 5. 1. lock the automatic belt tensioner (2) in place by placing pin (3) into the locking hole. 1359-040. Connect the negative battery cable at the battery. Your engine is equipped with a fan drive V-belt that also drives the alternator. recheck the belt adjustment after 30 minutes of operation. 1397-025. 6. 1405-510. Replace the Poly V-Belt 1. Stop the engine. i03717240 Belts . and excessive damage. 3. 4. 1358-510. Alternator and Fan Drive Belt Inspect the Poly V-Belt Note: Do not allow the disconnected battery cable to contact the battery disconnect switch. The inclusion of an automatic belt tensioner ensures the correct belt tension during the life of the belt.SEBU8017-05 321 Maintenance Section Belts . Connect the negative battery cable at the battery that is connected to the battery disconnect switch. 1802-510 All drive belts are behind the right rear access door. 1397-510. If two belts or more are required for an application. 8.Inspect/Adjust/Replace 3. The battery disconnect switch is connected to the machine frame. . Disconnect the negative battery cable at the battery that is connected to the battery disconnect switch. 1357-510. an additional standard belt will drive the A/C compressor from an adapter pulley on the fan drive. inspect the belt for wear and for cracking. rotate automatic belt tensioner (2) open. Once automatic belt tensioner (2) has been rotated. 1361-040. Replace poly V-belt (1) if any of the following conditions exist: excessive cracking. If only one belt of a matched set is replaced. Install the disconnect switch key and turn the battery disconnect switch to the ON position. 1802-025. 7. 2. 1357-040. Inspect the condition of poly V-belt (1). Secure the access door. 1397-040. Illustration 309 g01229454 Illustration 310 g01229884 9. Replace poly V-belt (1). the new belt will carry more load. 3. The additional load on the new belt could cause the new belt to break. excessive wear. 2. If new belts are installed. 1359-510. Connect the battery cable at the battery disconnect switch. 1361-510. 1358-025. Make all of the necessary repairs or replace the battery. For maximum engine performance and maximum utilization of your engine. This is due to the fact that the older belts are stretched. Tighten bracket bolt (5) and mounting bolt (4). Blade Linkage . loosen mounting bolt (4) and bracket bolt (5). Illustration 311 g01230234 (4) Mounting bolt (5) Bracket bolt 3. apply 420 + 20 .Lubricate (If Equipped) SMCS Code: 6060-086-KL Note: Caterpillar recommends the use of 5% molybdenum grease for lubricating the blade linkage.25 lb) of force. Make sure that the bracket bolt and the mounting bolt are tightened correctly.5 .322 Maintenance Section Blade Linkage .Lubricate SEBU8017-05 Air Conditioner Belt i03717241 NOTICE An incorrectly tensioned V-belt could cause not only a decrease of the compressor performance but damage to the belt and compressor. If the belt loses tension below 325 ± 10 N (73 ± 2. Move the compressor in order to attain the correct adjustment. When you reinstall a used belt after inspection. When you install a new belt. 2. apply325 ± 10 N (73 ± 2. SEBU6250. Refer to Special Publication. Raise the access cover. If the belt tension is not correct. Illustration 312 g00103933 2. 1. Wipe all fittings before lubricating. Note: The used belt should not need to be tightened again. Lower the dozer blade. 1. Illustration 313 g00103934 .25 lb) of force. tighten the belt again.25 lb).10 N (94 + 4.2. “Lubricating Grease” for more information on the Molybdenum Grease. 4. 3. SEBU6250. Apply lubricant through the one remote grease fitting. Note: For some applications of the machine. service the boom.Lubricate 4. Note: The arrows on Illustrations 312 through 315 show grease points without grease lines.SEBU8017-05 323 Maintenance Section Boom and Stick Linkage . and the work tool linkage after Every 50 Service Hours. After the initial 100 service hours of operation. the repeated duty cycle of the front linkage may only require small angular movements of the boom or stick. Only the dozer blades on the Material Handler machines do not offer a remote grease fitting (refer to illustration 316). Refer to Special Publication. All dozer blades are equipped with a remote grease fitting. There might not be enough angular motion in order to distribute the grease between the pin and the bearing. Close the access cover (the MH dozer blade does not have a cover). . Illustration 314 g00103935 Remote Grease Pins for the Parallel Blade Illustration 317 g01063444 Remote grease pin for the parallel dozer blade Note: The remote grease nipple for the radial dozer blade is in the middle of the access cover. the stick and the work tool in order to distribute the grease within the joint assemblies. Illustration 316 g01360720 Grease Pins for the MH Blade Service a new machine after Every 10 Service Hours only within the initial 100 service hours. or the individual fittings on the MH dozer blade. The operator should operate the boom. “Caterpillar Machine Fluids Recommendations” for more information on molybdenum grease. the stick. Illustration 315 g01360718 Remote Grease Pins for the Radial Blade i02519869 Boom and Stick Linkage Lubricate SMCS Code: 6501-086. 6502-086 S/N: W8R1-4999 S/N: W2T1-4999 Caterpillar recommends the use of 5% molybdenum grease. Stick and Bucket Linkage . Refer to Special Publication. “Lubricating Grease” for more information on Molybdenum Grease. Stick and Bucket Linkage . The distribution valve is designed to give the proper amount of grease to all bearings. 2. service the boom. Illustration 318 g01109002 Note: If the machine is operated under severe conditions that might cause abrasive material to enter the bearings.324 Maintenance Section Boom. g01109000 1. Apply a slight downward pressure on the work tool.Lubricate SEBU8017-05 Note: If the machine is operated under severe conditions that might cause abrasive material to enter the bearings. Apply lubricant through fittings (2). Use Steps 1. Apply lubricant through fitting (1). If the distribution valve will not accept grease. Lower the boom and the work tool to the ground.c to ensure proper lubrication: a. 6513-086 S/N: W6A1-4999 b. 6502-086. Service a new machine after Every 10 Service Hours only within the initial 100 service hours. SEBU6250. service the linkage after Every 10 Service Hours. Note: This fitting supplies grease to all other bearings except the bearings on the stick end through a distribution valve. one of the lines is blocked. S/N: W3H1-4999 c. i02863963 Boom. Wipe all fittings before you apply lubricant. Wipe all fittings before you apply lubricant. Open the access door for the engine compartment on the right side of the machine. . Apply grease through the grease fitting. Illustration 319 (2) Fittings After the initial 100 service hours of operation. and the work tool linkage after Every 50 Service Hours. the stick. stick and bucket control linkage. S/N: W8P1-4999 S/N: W5M1-4999 S/N: W2S1-4999 Note: Caterpillar recommends the use of 5% molybdenum grease for lubricating the boom. (1) Fitting 2. service the linkage after Every 10 Service Hours. 3. 1.Lubricate (If Equipped) SMCS Code: 6501-086.a through 1. The valve is designed to give the proper amount of grease to all bearings. If the valve will not accept grease. Apply lubricant through the grease fittings. a.Lubricate Illustration 321 g01066936 Illustration 322 g01426604 g00794926 3. c. one of the lines is blocked. Apply a slight downward pressure on the work tool.d to ensure proper lubrication. Ditch Cleaning Bucket (If Equipped) 1.SEBU8017-05 Illustration 320 325 Maintenance Section Boom. Lower the boom and the work tool to the ground. d. Stick and Bucket Linkage . Lower the boom and the stick to ground level. Apply grease through the grease fitting. Use Steps 3.a through 3. 4. Note: This fitting supplies grease to all linkage bearings from the frame to the nose of the boom. Wipe all fittings before you apply lubricant. Apply lubricant through the lowest grease fitting that is located in the engine compartment. Apply grease through the grease fitting while the boom is raised and the work tool is suspended. 5. Illustration 323 g01066935 . b. Test SEBU8017-05 2. Apply lubricant through the grease fittings. Start the engine. Illustration 326 g01215873 The soft switch panel is located on the right console. level surface. 2. Make sure the area is clear of personnel and obstructions before testing the brakes. Fasten the seat belt before moving the machine. The following test determines if the service brakes are functional. Personal injury can result from a sudden stop during brake test. Keep the engine speed at low idle. (3) Parking brake control (4) Transmission control 4. This test is not intended to measure the maximum brake holding effort. . Test the service brakes on a dry. These differences are caused by differences in the following factors: • Engine setting • Power train efficiency • Brake holding ability • Other factors Illustration 324 g01072199 2. Depress service brake pedal (1). Slightly raise all work tools. The maximum brake holding effort that is required to hold a machine stationary at a certain engine rpm varies between machines. Wipe the remote grease fittings (1) before you apply lubricant.326 Maintenance Section Braking System . Release the parking brake by pushing down on the button for the parking brake control (3).Test Illustration 325 SMCS Code: 4250-081 Service Brake Holding Ability Test g01361688 (1) Service brake pedal (2) Travel speed pedal 1. Make sure that the area around the machine is clear of personnel and of obstacles. If the machine begins to move during the test. 3. i03731386 Braking System . Apply lubricant through the remote grease fittings (1) until grease is visible around pins and bearings. Fasten the seat belt before you test the brakes. Offset Boom (If Equipped) 1. engage the parking brake immediately. depress the front of travel speed pedal (2) to the FORWARD position. 4. Block the bucket before changing bucket tips or side cutters. Move the engine start switch key to the ON position. the bucket tip can be rotated. Engage parking brake (3). The machine should not move. S/N: W2S1-4999 NOTICE If the machine moved while testing the service brakes. 6. Without releasing the service brake pedal. turn the engine start switch to the ON position. S/N: W5M1-4999 Personal injury or death can result from bucket falling. Illustration 327 Acceptable wear g01055179 . Have the dealer inspect and. S/N: W8P1-4999 9. the monitor will display a “BRAKE PRESSURE LOW” warning. 5. 6. consult your Caterpillar dealer.Inspect/Replace (Drive-through System) SMCS Code: 6805-040. repair the service brakes before returning the machine to operation. The first LED light will illuminate. 2. Run the engine for 30 seconds in order to increase the accumulator pressure. Note: In order to maximize the life of the bucket tip and the penetration of the bucket tip. Start the engine.Inspect/Replace i03450548 Bucket Tips . While the engine is stopped.SEBU8017-05 5. 3. S/N: W3H1-4999 8. Release the travel speed pedal. If the warning message on the monitor comes on. Lower all the work tools to the ground. Testing the Brake Accumulator Bucket Tips 1. 327 Maintenance Section Bucket Tips . Stop the engine. Stop the engine. contact your Caterpillar dealer. 6805-510 S/N: W6A1-4999 7. Apply the service brakes for two times. if necessary. Push the button for the transmission control (4) once in order to select FIRST GEAR. The warning message on the monitor should turn off. If the accumulator is not at normal operating pressure. This is the end of the test of the service brakes. g01498093 Proper location for installing the retainer 3.Inspect/Replace Illustration 328 SEBU8017-05 g01055196 Illustration 330 g01054386 Replace this bucket tip. wear protective glasses when striking a retainer pin. Removal Procedure 2. can fly out and cause injury to nearby people. when struck with force. The retainer can be removed from the top of the bucket tip or from the bottom of the bucket tip. 2. Install the new bucket tip or the rotated bucket tip onto the adapter with a slight clockwise rotation. If the bucket tip has a hole. The retainer can be installed from the top of the bucket tip or from the bottom of the bucket tip. 1. Use a hammer and a punch in order to drive out the retainer. To avoid injury to your eyes. Internal view Check the bucket tips for wear. . Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced. Installation Procedure Make sure the area is clear of people when driving retainer pins. Remove the bucket tip from the adapter with a slight counterclockwise rotation. 1. Clean the adapter. Use a hammer and a 1 inch X 1 inch X 8 inch steel bar stock in order to drive retainer (2) into adapter (3). if necessary.328 Maintenance Section Bucket Tips . Illustration 331 Illustration 329 g01053737 (1) Bucket tip (2) Retainer (3) Adapter Note: Retainers are often damaged during the removal process. replace the bucket tip. Retainer pin. 4. Hand tighten the bolts. 3. as needed. Note: Certain bolts may require thread compound.Inspect/Replace Side Cutters (If Equipped) Illustration 332 g01492733 Internal View Illustration 334 The latch of the retainer is properly seated in the recess of the bucket tip. Illustration 335 g01389435 (4) Side cutter Note: Some side cutters may be rotated for additional wear.SEBU8017-05 329 Maintenance Section Bucket Tips . The retainer is properly seated if the retainer can be moved slightly by the technician's hand. 2. Remove any burrs or protrusions on the mating surfaces. adjust the retainer. Remove the mounting bolts and the side cutters. Bucket with side cutters g01092808 (A) Side cutters 1. . Install the side cutter. Illustration 333 g01054753 A properly installed retainer does not extend beyond the ear of the bucket tip. The ends of the retainer should not extend beyond the ear of the bucket tip. Clean the mounting surface of the side plate on the bucket and of the side cutter. 4. If the retainer cannot be moved. pin (11). Put retainer (9) in side plate (8). Install the shims between the side plate and the side protector on the opposite side of the retainer. replace the pin and/or the retainer. 3. Make sure that there is not a gap between the side plate on the bucket and the shear ledge on the side cutter. retainer (9) and side plate (8) before installation.330 Maintenance Section Bucket Tips .0 mm (0. Align two pin holes of the new protector and the side plate. 6.0 inch) Shear ledge on a side cutter 5. replace the protector. Side Protectors (If Equipped) Inspect the wear of the side protector. Note: If the pin and/or the retainer are worn. 1. Shims may be required in order to decrease the lateral clearance which will decrease movement.04 inch). Illustration 337 g01389452 . Hit pin (11) from the retainer side of the bucket in order to remove side protector (10) from side plate (8).Inspect/Replace Illustration 336 SEBU8017-05 g01389433 Section B-B From Illustration 335 (4) (5) (6) (7) Illustration 338 g01389453 (8) Side plate (9) Retainer (10) Side protector (11) Pin Side cutter Side plate on a bucket 0. Clean side protector (10). Hit the pin from the side of the bucket without the retainer. When too much wear is present. 2. 4. Note: Lateral clearance between the side plate and the side protector should not exceed 1 mm (0. Torque the mounting bolts to the correct specification. Align extractor (5) with the pin. Bucket Tips b. Fit retainer assembly (6) into the counterbore that is in the side of adapter (7).Inspect/Replace i03574842 Bucket Tips . Illustration 340 g01577993 (4) Back of Pin-Master (5) Extractor a. • Use a Pin-Master. Follow Step 1. If the bucket tip has a hole. The pin. Place the Pin-Master on the bucket tip. Illustration 341 g01577913 (6) Retainer assembly (7) Adapter 2. Make sure that the face of the retainer assembly with the marking “OUTSIDE” is visible. 1.SEBU8017-05 331 Maintenance Section Bucket Tips .a through Step 1. . The pin can be removed by one of the following methods. Note: Discard the old pin and the retainer assembly.c for the procedure. 6805-510 S/N: W6A1-4999 S/N: W3H1-4999 S/N: W5M1-4999 S/N: W8P1-4999 S/N: W2S1-4999 Block the bucket before changing the bucket teeth. When you change tips. c. 3. Illustration 339 g01577934 (1) Usable tip (2) Replaceable bucket tip (3) Overworn tip Check the bucket tips for wear. wear a protective face shield when striking the pin. Remove the pin from the bucket tip. use a new pin and a new retainer assembly. can fly out and cause injury to nearby personnel. Refer to the appropriate parts manual for your machine. replace the bucket tip.Inspect/Replace SMCS Code: 6805-040. To prevent possible injury to the eyes. Strike the Pin-Master at the back of the tool (4) and remove the pin. • Use a hammer and a punch from the retainer side of the bucket to drive out the pin. Clean the adapter and the pin. when struck. Strike the Pin-Master with a hammer at the back of the tool (4) in order to insert the pin. Illustration 343 (8) Pin a. d. Illustration 345 g01209159 Final assembly of pin into bucket tip e. the retainer assembly. Install the new bucket tip onto the adapter. c. If wear is present on the tips. Follow Step 5. Check the tips often. g01578233 . Insert pin (8) through the bucket tip.a through Step 5. and the adapter. Place the Pin-Master over the bucket tips so that the pin will fit into the counterbore of the pin holder (9). You may also move the tips from the outside teeth to the inside teeth.Inspect/Replace Illustration 342 SEBU8017-05 g00101359 4.e for the procedure. Slide pin holder (9) away from the pin and rotate the tool slightly in order to align pin setter (10) with the pin. Strike the end of the tool until the pin is fully inserted. Note: The bucket tips can be rotated by 180 degrees in order to allow the tip to wear evenly. rotate the tips. 5. The outside teeth generate the most wear. • From the same side of the retainer.332 Maintenance Section Bucket Tips . Drive the pin through the bucket tip. • Use a Pin-Master. drive the pin through the bucket tip. The pin can be installed by using one of the following methods: Illustration 344 g01578342 b. SEBU8017-05 333 Maintenance Section Bucket Tips - Inspect/Replace Side Cutters Note: Certain bolts may require thread compound. 4. Hand tighten the bolts. 5. Make sure that there is not a gap between the side plate on the bucket and the shear ledge on the side cutter. 6. Torque the mounting bolts to the correct specification. Side Protectors (If Equipped) Inspect the wear of the side protector. When too much wear is present, replace the protector. Illustration 346 g01579693 Bucket With Side Cutters 1. Remove the mounting bolts and the side cutters (11). 2. Clean the mounting surface of the side plate on the bucket and of the side cutter. Remove any burrs or protrusions on the mating surfaces. Illustration 347 g01579713 (12) Shear ledge on a side cutter (13) Side plate on a bucket (B) 0.0 mm (0.0 inch) Note: Some side cutters may be rotated for additional wear. 3. Install the side cutter. Illustration 348 g01592996 Illustration 349 g01903678 (14) (15) (16) (17) (18) Side plate Retainer Side protector Pin Shim 334 Maintenance Section Cab Air Filter (Fresh Air) - Clean/Replace SEBU8017-05 1. Hit pin (17) from the side of the bucket without the retainer in order to remove side protector (16) from side plate (14). 2. Clean side protector (16), pin (17), retainer (15) and side plate (14) before installation. Note: Lateral clearance between the side plate and the side protector should not exceed 1 mm (0.04 inch). Shims (18) may be required in order to decrease the lateral clearance which will decrease movement. Install the shims (18) between the side plate and the side protector on the opposite side of the retainer. Illustration 351 3. Put retainer (15) in side plate (14). 4. Align two pin holes of the new protector and the side plate. Hit the pin from the retainer side of the bucket. Note: If the pin and/or the retainer are worn, replace the pin and/or the retainer. i02520019 Cab Air Filter (Fresh Air) Clean/Replace g01261373 (2) Filter cover (3) Air filter 2. Remove air filter (3) from filter cover (2). 3. Clean the air filter with a maximum of 200 kPa (30 psi) pressure air. 4. After you clean the air filter, inspect the air filter. If the air filter is damaged or badly contaminated, use a new air filter. 5. Install the air filter and the filter cover. Note: Make sure that the arrow on top of the air filter is facing forward. SMCS Code: 7342-070; 7342-510 i01871602 Cab Riser (Adjustable) Linkage - Lubricate (If Equipped) SMCS Code: 7260-086-KL S/N: W8R1-4999 S/N: W2T1-4999 Illustration 350 g01261325 (1) Wing bolt (2) Filter cover The cab air filter is behind the cab. 1. Loosen wing bolt (1) and open filter cover (2). Service the linkage after Every 500 Service Hours while the cab is in the lowered position. 1. Wipe all fittings before you apply lubricant. SEBU8017-05 Illustration 352 335 Maintenance Section Camera - Clean/Adjust g00349372 2. Apply lubricant through fittings (1) and (2) on both sides of the linkage. Illustration 355 g00353312 5. Apply lubricant through fittings (5) on the right side of the linkage. i03126933 Camera - Clean/Adjust SMCS Code: 7348 Illustration 353 g00352012 3. Apply lubricant through fitting (3) on each side of the linkage. Failure to use an appropriate external ladder or an appropriate platform for direct access to the rear view camera could result in slipping and falling which could result in personal injury or death. Be sure to use an appropriate external ladder or an appropriate platform for direct access to the rear view camera. The machine's counterweight and the engine hood are not approved as a maintenance platforms. Unexpected machine movement can cause injury or death. In order to avoid possible machine movement, move the hydraulic lockout control to the LOCKED position and attach a Special Instruction, SEHS7332, “Do Not Operate” or similar warning tag to the hydraulic lockout control. Illustration 354 g00349232 4. Apply lubricant through fittings (4) on the left side of the linkage. When maintenance or servicing of the rear view camera is required follow these steps. 1. Park the machine on a level surface. 2. Place the work tool on the level surface. 3. Move the hydraulic lockout control to the Locked position. Repair the fins if found defective. 5.5 ± 0. clean condenser with a brush.Clean SEBU8017-05 4.4 lb in). 4. Open the right rear access door.05 N·m (4 ± 0. Illustration 357 g01598214 (3) Bolt 1. clean the camera lens before you operate the machine. Secure the access door. 1. Remove the 2 bolts (2) in order to remove the cover (1). To prevent damage or bending of the fins. Adjust the area of the visibility of the camera so that a 1. Adjust the Area of Visibility If the camera displays an undesired view. adjust the area of the visibility.336 Maintenance Section Condenser (Refrigerant) . (1) Cover (2) Bolt i02617968 Condenser (Refrigerant) Clean SMCS Code: 1805-070 NOTICE If excessively dirty.5 m (5 ft 11 inch) tall obstacle which is 1 m (3 ft) behind the counterweight can be seen. Tighten the 2 bolts (2) to a torque of 55 ± 10 N·m (40 ± 7 lb ft) in order to fix the cover (1). do not use a stiff brush. Tighten the 2 bolts (3) to a torque of 0. . Illustration 358 g01598234 3. Turn the battery disconnect switch to theOFF position and remove the battery disconnect switch key. 2. Unfasten the 2 bolts (3). Clean Camera Lens If necessary. Illustration 356 g01598213 5. Turn the engine start switch to the OFF position and remove the engine start switch key. Use a soft cloth for cleaning. Loosen bolts (1) in order to release the condenser. if necessary. Open the right front access door. 7. Note: Open the condenser in order to clean both sides of the condenser. and secure the condenser with the bolts (1). Swing the condenser back into position. 5. “Caterpillar Machine Fluids Recommendations”. i02709297 Cooling System Coolant (ELC) . Pull the door latch for the right front access door. Swing the condenser open. Illustration 361 g01217574 a. The door latch is located in the engine compartment. Close the access doors. NOTICE Do not change the coolant until you read and understand the cooling system information in Special Publication. 6. Inspect the condenser for debris. Clean the condenser.Change g01217572 Door latch for the right front access door 2. 3.Change SMCS Code: 1350-044 Illustration 360 g01217573 4. . Failure to do so could result in damage to the cooling system components.SEBU8017-05 Illustration 359 337 Maintenance Section Cooling System Coolant (ELC) . This will unlatch the right front access door. SEBU6250. b. Use clean water to wash off all dust and dirt from the condenser. Secure the access door. Open the right rear access door. 1. Allow the engine to cool before removing the filler cap or the pressure cap. Remove the pressure cap. Bodily injury can occur from unexpected contact with open cab doors on machines equipped with a fixed cab riser. This could result in damage to cooling system components. Secure the access door. see Special Publication. To avoid injury. Secure the access door. This machine was filled with Extended Life Coolant at the factory. 4. In order to open the top access door for the engine compartment. Illustration 363 g01217622 3. Illustration 362 Steam or hot coolant can cause severe burns. g01311235 2.338 Maintenance Section Cooling System Coolant (ELC) . Slowly loosen the pressure cap in order to relieve the system pressure. drain the coolant before the recommended interval. SEBU6250. close the cab door before climbing onto the rear of the machine. Open the left front access door. make sure they have passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants and Caterpillar Extender. “Caterpillar Machine Fluids Recommendations”. If the coolant in the machine is changed to Extended Life Coolant from another type of coolant. If the coolant is dirty or if you observe any foaming in the cooling system. Secure the access door. the quick locks should be turned 90 degrees counter clockwise. . If Caterpillar products are not available and commercial products must be used.Change SEBU8017-05 NOTICE Mixing ELC with other products will reduce the effectiveness of the coolant. Do not loosen the filler cap or the pressure cap on a hot engine. 14. Note: Refer to the Operation and Maintenance Manual. Install the access cover under the rear center part of the upper frame. . Close the drain valves. The access cover is held by two bolts. “General Hazard Information” for information in containing fluid spillage. There is a cover under the engine compartment. and allow the coolant to drain into a suitable container. 11. 8. Note: The maximum fill rate is 6-7 L/min (1. 12.SEBU8017-05 339 Maintenance Section Cooling System Coolant (ELC) . 16. A drain valve is located at the side of the cylinder block. Add the Extended Life Coolant. 15. “Capacities (Refill)” for the capacity of the cooling system. Open the drain valves. Note: Dispose of drained fluids according to local regulations. 9.Change Illustration 366 g01311237 Drain valve Illustration 364 g01217623 Drain valve 5. Use two bolts to secure the access cover. Flush the cooling system with clean water until the draining water is clean.9 US gpm). Illustration 365 g00903010 6. 13. Remove the cover in order to expose the drain valve. 10. Refer to the Operation and Maintenance Manual. Attach suitable hoses to the drain valves. Remove the access cover in order to expose the drain valve.6-1. Open this drain valve in order to allow coolant to drain from the internal passages in the cylinder block. Install the drain plug on the engine cylinder block. 7. Stop the engine. Open the pressure cap slowly and carefully. The second drain valve is located under the center of the rear frame. Close the pressure cap and run the engine at speed dial 1 for 2 to 5 minutes. Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. . “Caterpillar Machine Fluids Recommendations” for all the cooling system requirements. 18. Illustration 368 g01217625 2. Bodily injury can occur from unexpected contact with open cab doors on machines equipped with a fixed cab riser. Use an coolant conditioner test kit to check the concentration of the coolant. close the cab door before climbing onto the rear of the machine. 19.Add SMCS Code: 1352. 1395 Note: This machine was filled with Caterpillar Extended Life Coolant at the factory. SEBU6250. To avoid injury. Use only Caterpillar Extender with Extended Life Coolant. i02617987 Cooling System Coolant Extender (ELC) . Failure to follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed.Add SEBU8017-05 NOTICE Use only Caterpillar products or commercial products that have passed Caterpillar EC-1 specification for pre-mixed or concentrated coolants. Allow the machine to cool down. Close the pressure cap and run the engine until the temperature reaches its normal operating temperature. Fill up the coolant as required to main coolant level at the center of the expansion tank gauge. Secure the access door. Illustration 367 g01217624 17. Fill up coolant if required. When Caterpillar Extended Life Coolant (ELC) is used. 20. Open the top access door for the engine compartment by turning the quick locks counterclockwise for 90 degrees. Close all access doors and secure all doors. 1353. Secure the access door. See Special Publication.340 Maintenance Section Cooling System Coolant Extender (ELC) . Open the left front access door. 1. Caterpillar Extender must be added to the cooling system. Check coolant level again. g01217624 4. Close all access doors. Note: Refer to Operation and Maintenance Manual. close the cab door before climbing onto the rear of the machine. Pull the door latch for the right front access door. . Refer to Operation and Maintenance Manual. Open the right front access door. Secure the access door. open the left front access door. Secure the access door. 4. refer to Operation and Maintenance Manual. The door latch is located in the engine compartment. Add the proper amount of Caterpillar ELC Extender to the cooling system. Illustration 371 i02618000 Cooling System Coolant Level . “Cooling System Coolant (ELC) .Check g01217622 3. “Extended Life Coolant (ELC)” for the proper quantity. Illustration 370 g01217572 Door latch for the right front access door 2. Remove the pressure cap. If this is necessary. “Capacities (Refill)” and Operation and Maintenance Manual. If additional coolant is needed. 6. Note: Dispose of drained fluids according to local regulations.SEBU8017-05 Illustration 369 341 Maintenance Section Cooling System Coolant Level . 7. You may be required to drain enough coolant from the radiator in order to allow the addition of the Caterpillar ELC Extender. Install the pressure cap.Change” for the location of the radiator drain valves. 3. Close the cover over the pressure cap. Slowly loosen the pressure cap in order to relieve the system pressure.Check SMCS Code: 1350-535 1. Replace the pressure cap if the gasket is damaged. 5. Bodily injury can occur from unexpected contact with open cab doors on machines equipped with a fixed cab riser. To avoid injury. Secure the access door. Maintain the coolant level to the center of the sight gauge. “General Hazard Information” on containing fluid spillage. This will unlatch the right front access door. Open the right rear access door. 5. 10.342 Maintenance Section Cooling System Coolant Sample (Level 1) . 1395-554. 8. If you must add coolant daily. adjusting and repair of the product. Illustration 373 g01217622 Note: Level 1 results may indicate a need for Level 2 Analysis. Install the pressure cap. i03717304 Cooling System Coolant Sample (Level 1) . Refer to Special Publication. Close all access doors. Remove the pressure cap.Clean”. testing. 7542-008. 12. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.Obtain SEBU8017-05 11. 1395-008. NENG2500. 7. Close the top access door for the engine compartment. Add the coolant. 13. Dispose of all fluids according to local regulations and mandates. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. SMCS Code: 1350-008. Open the top access door for the engine compartment by turning the quick locks by 90 degrees counterclockwise. check the coolant system for leaks. g00544510 . See Operation and Maintenance Manual. as needed. Slowly loosen the pressure cap in order to relieve the system pressure. Inspect the pressure cap and the cap seal for the following defects: • Damage • Deposits • Foreign material Clean the pressure cap with a clean cloth or replace the pressure cap if the pressure cap is damaged. “Radiator Core . Clean the radiator core. maintenance. Inspect the radiator core for debris. Secure the access door. 9. Illustration 374 A typical example is shown.Obtain Illustration 372 g01217625 6. 7542 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. see Special Publication. • Never collect samples from expansion bottles. Submit the sample for Level 1 analysis. stop the engine and wait until the cooling system components are cool. perform consistent samplings that are evenly spaced. 1395-554. Supplies for collecting samples can be obtained from your Caterpillar dealer. Submit the sample for Level 2 analysis. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Supplies for collecting samples can be obtained from your Caterpillar dealer. refer to Special Publication. 7542 Reference: Refer to Operation and Maintenance Manual. “Cooling System Coolant Sample (Level 1) . 1395-008.Lubricate SMCS Code: 3253-086 Use the following guidelines for proper sampling of the coolant: • Complete the information on the label for the sampling bottle before you begin to take the samples. For additional information about coolant analysis. i02049802 Cooling System Coolant Sample (Level 2) . “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer. SEBU6250. Reference: For additional information about coolant analysis. “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer. i03717306 Engine Air Filter Primary Element . • Obtain coolant samples directly from the coolant sample port.Obtain Pressurized System: Hot coolant can cause serious burns. Obtain the sample of the coolant as close as possible to the recommended sampling interval. you must establish a consistent trend of data. are ready to collect the sample. • Keep the lids on empty sampling bottles until you Illustration 375 • Place the sample in the mailing tube immediately The grease fittings are located below the center of the machine. when possible. To open the cooling system filler cap.Obtain” for the guidelines for proper sampling of the coolant. There is a total of four grease fittings per drive shaft. after obtaining the sample in order to avoid contamination. In order to establish a pertinent history of data.Clean/Replace SMCS Code: 1054-070. i03717305 Drive Shaft . SEBU6250. • Keep the unused sampling bottles stored in plastic bags. In order to receive the full effect of S·O·S analysis. AIR FILTER PLUGGED . Obtain the sample of the coolant as close as possible to the recommended sampling interval.Obtain g00102443 Apply grease to the fitting on the universal joint at both ends of the drive shaft.SEBU8017-05 343 Maintenance Section Cooling System Coolant Sample (Level 2) . This machine is equipped with a two-piece drive shaft. 1054-510 Table 184 SMCS Code: 1350-008. Replace a damaged primary element with a clean primary element. Pull up on handle (4) in order to remove primary filter element (3). Inspect the primary element. A primary filter element may be cleaned for a maximum of five times. 4. 8. Also replace the primary element if the primary element has been used for two years. If the primary element is not damaged. A primary element may be cleaned for a maximum of five times. If you use pressurized air.Replace”. the gaskets. Open four latches (1) in order to unlock cover (2). Illustration 376 g01217976 (1) Latch (2) Cover 2. 1. In order to access the filter elements. discard the element. 7. Also replace the primary element if the primary element has been used for two years. Clean cover (2). 3. Do not use filter elements with damaged pleats. clean the primary element. or the seals are damaged. See Operation and Maintenance Manual. use a maximum air pressure of 205 kPa (30 psi). Illustration 377 g02003304 (3) Primary filter element (4) Handle 5. If the pleats. The secondary filter element should also be replaced when the primary filter element is replaced. Remove the cover. Do not wash the filter elements. or seals. open the right front access door. 6. “Engine Air Filter Secondary Element . .Clean/Replace SEBU8017-05 Service the air filter if the “AIR FILTER PLUGGED” warning appears on the monitor. Clean the inside of the air cleaner housing. NOTICE Do not clean the filter elements by bumping or tapping them. Stop the engine. The filter elements can be cleaned with pressurized air.344 Maintenance Section Engine Air Filter Primary Element . gaskets. The secondary filter element should also be replaced if the restricted Air Filter indicator comes on after the installation of a clean primary filter element or if the exhaust smoke is still black. Secure the access door. Store the elements in a clean.Replace 1. Lower the handle in order to secure the new primary filter in the air cleaner housing. 13. 2. 5. Clean the inside of the air cleaner housing. 4. dry location. Pull up on the secondary filter element in order to remove the secondary filter element. When the primary filter element is replaced.SEBU8017-05 345 Maintenance Section Engine Air Filter Secondary Element . Uncover the air inlet opening. 10. Illustration 379 g01229520 12.Replace SMCS Code: 1054-510 NOTICE Always replace the secondary filter element. i03027620 Engine Crankcase Breather Filter . Close the access door. Do not use a filter if the pleats. . allow the engine and the components to cool. Inspect the filter elements after you clean the filter elements. Close four latches (1) in order to lock cover (2) in place. 3. Remove the cover and the primary filter element. See Operation and Maintenance Manual.Clean/Replace” for the necessary steps. direct the air along the pleats. 1317-510-FI. i02618005 Engine Air Filter Secondary Element . Install a clean primary filter element. Cover the air inlet opening. 1317 1. 11. 14. See the Operation and Maintenance Manual. When you clean the inside pleats and the outside pleats. Install cover (2). Hot engine components can cause injury from burns. Never attempt to reuse the secondary filter element by cleaning the element. 15. Cover the clean filter elements. “Engine Air Filter Primary Element Clean/Replace”. Illustration 378 g02003305 9. “Engine Air Filter Primary Element . Before performing maintenance on the engine.Replace SMCS Code: 1317-510. the gaskets or the seals are damaged. Open the engine access door that is located on the top of the machine. Install a new secondary filter element. Install the primary filter element and the cover. the secondary filter element should be replaced. 346 Maintenance Section Engine Oil Level . 1. 5. You may need to use a Caterpillar strap wrench or another suitable tool in order to tighten the filter. Note: Index marks on the filter are separated by 90 degrees or 1/4 of a rotation. Illustration 382 (S/N: W3H1-UP. Check the engine oil level while the machine is parked on a level surface and the engine has been stopped for a minimum of 10 minutes. Do not damage the filter with the installation tool. NOTICE Do not overfill the crankcase. Dispose of the used filter according to local regulations. Illustration 381 g00102462 4. Apply a thin coat of oil to the gasket of the new filter seal. Open the right rear access door. Close all access covers. Note: If you install a filter that has not been provided by Caterpillar. Remove all of the remaining filter gasket from the housing. Note the position of the index marks on the filter relative to a fixed point on the filter base. Tilting the filter will allow oil to run out of the filter. “Oil Filter Inspect”. Note: Maintain the vertical position of the filter until you can dispose of the filter and oil properly. Clean the housing base for the filter. Remove the filter with a strap type wrench.Check SEBU8017-05 6.Check SMCS Code: 1000-535 Illustration 380 g01532096 2. Secure the access door. Engine damage can result. See Operation and Maintenance Manual. Use the rotation index marks as a guide. 7. use the instructions that were provided with the filter. Use the instructions that are printed on the filter in order to tighten the filter. W5M1-UP) g01262193 . Rotate the filter until the filter seal contacts the base. i02522182 Engine Oil Level . 3. Place the new filter onto the base. Close the right rear access door. 7542 3. The reduction of lubricating characteristics of the oil causes bearing damage. 1348-008. 8. “Lubricant Viscosities” for information on recommended engine oil. 9. SM. operating the engine could cause the crankshaft to dip into the oil. Note: Refer to Operation and Maintenance Manual. 6. Remove the dipstick again.SEBU8017-05 347 Maintenance Section Engine Oil Sample . Remove dipstick (1) in order to measure the oil level. 2. 1318.Obtain 5. Replace the oil regardless of the time interval. Before performing maintenance on the engine. 7. 7542-008.Obtain SMCS Code: 1000-008. Install the oil filler plug. 1000. “General Hazard Information” for information on containing fluid spillage. add oil. Note: If the oil level is above the “FULL RANGE” mark. 1348-554. Bearing damage leads to loss of engine power. Clean oil filler plug (2). Remove the oil from dipstick (1). 4. Hot engine components can cause injury from burns. Add oil. i02522209 Engine Oil Sample . Oil which is badly contaminated or badly deteriorated should be replaced early. if necessary. Maintain the oil level below the “FULL RANGE” mark on the dipstick and above the “ADD” on the dipstick. If the oil level is low. W8R1-UP. W2S1-UP. 7542-554-OC. This could lead to excessively high oil temperatures. 1348-554-SM. allow the engine and the components to cool. W5M1-UP) Illustration 384 g00102290 g01262213 . Illustration 385 (S/N: W3H1-UP. 7000. Illustration 383 g01217627 (S/N: W6A1-UP. Excessively high oil temperatures can reduce the lubricating characteristics of the oil. 1300. W8P1-UP. Insert dipstick (1). W2T1-UP) Note: Refer to Operation and Maintenance Manual. Remove oil filler plug (2) in order to add oil. Secure the access door. 3. Lower the work tools to the ground.Change Illustration 386 SEBU8017-05 g01217628 (S/N: W6A1-UP. Engage the parking brake. “Caterpillar Machine Fluids Recommendations”. W2S1-UP. PEHP6001. W8R1-UP. Remove oil filler plug (1). W8R1-UP. 5. W5M1-UP) i03731387 Engine Oil and Filter . W8P1-UP. . As the oil cools. SEBU6250. “S·O·S Oil Analysis” for information that pertains to obtaining a sample of the engine oil. W2S1-UP. W8P1-UP. W2T1-UP) Obtain a sample of the engine oil from the engine oil sampling valve that is located on the engine oil filter housing. Refer to Special Publication. the waste particles will settle to the bottom of the crankcase. Open the right rear access door. This allows waste particles that are suspended in the oil to drain. Stop the engine. Note: Drain the crankcase while the oil is warm.Change SMCS Code: 1318-510 1. Refer to Special Publication. 4. Illustration 387 g01262675 (S/N: W3H1-UP. W2T1-UP) 6. Illustration 388 g01262688 (S/N: W6A1-UP. Park the machine on a level surface.348 Maintenance Section Engine Oil and Filter . The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with the new oil. 2. “How To Take A Good Oil Sample” for more information about obtaining a sample of the engine oil. 9. Clean the housing base for the filter. 10. W8P1-UP. W8R1-UP.Inspect”. W5M1-UP) g01262681 g00102462 11. See Operation and Maintenance Manual. Remove all of the old filter gasket.Change g01262686 (3) Crankcase drain valve Illustration 391 g01217630 (S/N: W6A1-UP. Allow the oil to drain into a suitable container. Note: Maintain the vertical position of the filter until you can dispose of the filter and oil properly. Open crankcase drain valve (3). Remove used oil filter (4). “General Hazard Information” for information in containing fluid spillage. Before performing maintenance on the engine.SEBU8017-05 Illustration 389 349 Maintenance Section Engine Oil and Filter . Note: Refer to the Operation and Maintenance Manual. W2T1-UP) 7. allow the engine and the components to cool. Tilting the filter will allow oil to run out of the filter. Close crankcase drain valve (3). Illustration 392 Illustration 390 (S/N: W3H1-UP. Hot engine components can cause injury from burns. Remove the cover under crankcase drain valve (3). . “Oil Filter . W2S1-UP. Apply a thin coat of engine oil to the gasket of the new filter. Note: Dispose of drained fluids according to local regulations. 8. Use the index marks as a guide. . Run the engine at low idle for two minutes. Stop the engine.Check SMCS Code: 1102-082. Fill the crankcase with new oil. Lift the fan guard in order to inspect the fan and the radiator grill for dirt accumulation or debris accumulation. S/N: W2S1-4999 Illustration 394 g01177535 1. 1105-535. Tighten the filter according to the instructions that are printed on the filter.350 Maintenance Section Engine Valve Lash . Wait for ten minutes in order to allow the oil to drain back into the crankcase. Clean filler plug (1). i02357513 Fan Guard . 20. 7527 Refer to Engine Systems Operation/Testing and Adjusting in order to perform the complete procedure for the valve lash adjustment. 17.Clean/Inspect (If Equipped) SMCS Code: 1360 S/N: W6A1-4999 14. 1209-535. 1121-535. S/N: W2T1-4999 16. clean the fan or the radiator grill. Install the cover under crankcase drain valve (3). “Capacities (Refill)”. Maintain the oil level between the “ADD” mark and “FULL” mark on dipstick (2). Note the position of the index marks on the filter in relation to a fixed point on the filter base. i01747875 Engine Valve Lash . 1102. Install the engine oil filter hand tight until the gasket of the engine oil filter contact the filter base. NOTICE Do not overfill the crankcase. S/N: W8R1-4999 15. Engine damage can result. If there is debris on the fan or the radiator grill. 2. Use the rotation index marks as a guide for tightening the oil filter. Start the engine. Note: Do not use a strap wrench on the filter. 1105-025. 1209-082. 12. Illustration 393 NOTICE Inspect the fan motor and the fan shaft for any obstructions. 19.Check SEBU8017-05 Note: Every new oil filter has rotation index marks that are spaced at increments of 1/4 turn. Failure to remove any debris from the fan motor or the fan shaft could result in damage to the machine. 13. S/N: W8P1-4999 Note: Refer to the Operation and Maintenance Manual. Check the oil level. g00102420 18. 1209. Close the right rear access door. Check for oil leaks. 1102-535. Install filler plug (1). Turn the hub until the opening of the fill/drain plug is horizontal. “Capacities (Refill)”. Note: Refer to Operation and Maintenance Manual. “General Hazard Information” for information on containing fluid spillage. 4. 3. 6. Install the fill/drain plug. 2. See Operation and Maintenance Manual. Drain the oil into a suitable container. 5. Turn the hub until the opening of the fill/drain plug is horizontal. 6. Remove the fill/drain plug. 4. 5. Fill the final drive with lubricant to the bottom of the opening of the fill/drain plug. Install the O-ring seal.Check SMCS Code: 4050-044-FLV SMCS Code: 4050-535-FLV Illustration 395 g00102722 1. if necessary. . 1. Note: Dispose of used oil according to local regulations. Repeat Steps 1 through 6 for the remaining three axle hubs. replace the seal. 7. 7. Install the O-ring seal. Repeat Steps 1 through 7 for the remaining three axle hubs. Remove the dirt that is around the fill/drain plug. If damage or wear is noticed on the O-ring seal. Remove the dirt that is around the fill/drain plug. Install the fill/drain plug. 3. “Lubricant Viscosities”.Change Final Drive Oil Level . Add oil. replace the seal. as shown. Fill the final drive with lubricant to the bottom of the opening of the fill/drain plug.Change i01827771 i02437239 Final Drive Oil . “General Hazard Information” for information on containing fluid spillage. Remove the fill/drain plug.SEBU8017-05 351 Maintenance Section Final Drive Oil . Turn the hub until the fill/drain plug is at the lowest position. See Operation and Maintenance Manual. Inspect the O-ring seal. Illustration 396 g00311043 Note: Refer to Operation and Maintenance Manual. Inspect the O-ring seal. If damage or wear is noticed on the O-ring seal. 2. 8. Illustration 397 g00311043 Obtain an oil sample of the final drive oil by removing the filler plug and taking the sample directly from the final drive housing. i03731390 Fuel System Filter . 4. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. “How To Take A Good Oil Sample” for more information about obtaining an oil sample from the final drive housing. 4050-SM. . continue to run the engine at low idle. W8R1-UP. SEBU6250. 6. PEHP6001. Check the fuel system for leaks. 5. Press the button and release. Do not smoke while working on the fuel system. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Open the right rear access door. 7542 Illustration 399 g01217631 (S/N: W6A1-UP. If the engine does not start. i02618303 Fuel System . Secure the access door. Stop the engine. W2S1-UP. W8P1-UP. Refer to Special Publication. Illustration 398 (S/N: W3H1-UP. If the engine starts but the engine runs rough. Note: Do not fill the fuel filter with fuel before installing the filter on the machine. Touching the fuel injection lines could cause the fuel injection lines to break. or the engine emits smoke.352 Maintenance Section Final Drive Oil Sample .Obtain SMCS Code: 4011-008. 7542-008. W2T1-UP) 2.Obtain SEBU8017-05 i01905883 Final Drive Oil Sample .Prime SMCS Code: 1250-548 1. Refer to Special Publication. W5M1-UP) g01262710 Clean up all leaked or spilled fuel. Repeat this process approximately 10 times to 15 times. NOTICE Do not touch the high pressure fuel injection lines. Run the engine at low idle until the engine runs properly.Replace SMCS Code: 1261-510 Personal injury or death can result from a fire. Crank the engine. 3. or the engine misfires. 4050-008. Close the right rear access door. “S·O·S Oil Analysis” for information that pertains to obtaining an oil sample from the final drive housing. then prime the engine again. Touching the fuel injection lines could cause the fuel injection lines to break. The valve is closed when the lever is horizontal. NOTICE Do not touch the high pressure fuel injection lines. “General Hazard Information” for information in Containing Fluid Spillage. g01217824 (S/N: W6A1-UP. Note: Refer to Operation and Maintenance Manual. Open the fuel supply valve. Illustration 401 (S/N: W3H1-UP. Open the right rear access door. 4. Refer to Operation and Maintenance Manual. “Fuel System . W2T1-UP) 3. 5. W8P1-UP.Prime” for the engine starting procedure to be used after servicing the fuel system. W5M1-UP) g01262965 Note: Do not fill the fuel filter with fuel before installing the filter on the machine. W8R1-UP. Secure the access door. Close the fuel supply valve. Install the new filter by hand. Remove the fuel filter. 6. Close the right rear access door. W2S1-UP. Illustration 400 g01215468 2. Clean the base for the filter housing. Dirt or debris might enter the system which could cause damage to the fuel injection equipment.Replace NOTICE Do not pre-fill new fuel filters during fuel filter changes. 7. 8. NOTICE Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. Illustration 402 1. . Engine damage can result.SEBU8017-05 353 Maintenance Section Fuel System Filter . Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. Personal injury or death can result from a fire. “General Hazard Information” for information in Containing Fluid Spillage. Do not smoke while working on the fuel system. The drain valve is located on the bottom of the water separator and bowl. Open the right rear access door. Turn the drain valve counterclockwise in order to open. Secure the access door. Illustration 404 g01215468 2. Illustration 403 g01262996 2.354 Maintenance Section Fuel System Water Separator . Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Open the right rear access door. Note: Refer to Operation and Maintenance Manual. Drain the water and the sediment into a suitable container. Engine damage can result.Drain Note: Drained fluids should always be disposed of according to local regulations.Replace SMCS Code: 1263-510-FQ. Clean up all leaked or spilled fuel. 1. 3. SMCS Code: 1263 i03734080 Personal injury or death can result from a fire. 1263 Clean up all leaked or spilled fuel. 1.Drain SEBU8017-05 i02709634 Fuel System Water Separator . The valve is closed when the lever is horizontal. 4. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. Do not smoke while working on the fuel system. NOTICE Do not pre-fill new fuel filters during fuel filter changes. Secure the access door. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. 5. . Close the right rear access door. Close the fuel supply valve. Fuel System Water Separator Element . Close the drain valve. 3. 1.SEBU8017-05 355 Maintenance Section Fuel Tank Cap and Strainer . Replace the seal if the seal is damaged. Hold bowl (3). Close the left front access door. Install the fuel tank cap. Illustration 405 g01263129 3. Remove the fuel tank cap and the fuel fill screen. Clean the inside surfaces of the filter base and of bowl (4). “General Hazard Information” for information in Containing Fluid Spillage. Install bowl (4). Drain the water and the sediment into a suitable container. i01606934 Fuel Tank Cap and Strainer Clean SMCS Code: 1273-070-STR Personal injury or death can result from a fire. Note: Do not start the engine until all service to the fuel system is complete. Do not smoke while working on the fuel system. Note: Obey all local regulations when you discard drained fluids and filters. 6. To avoid injury. Open the fuel supply valve. replace the bowl. 10. 4. Secure the access door. close the cab door before climbing onto the rear of the machine. If damage is found. Remove fuel filter/water separator (2). 8. “Fuel System . 11. 12. The drain valve is located at the bottom of the fuel filter/water separator. refer to Operation and Maintenance Manual. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. Close drain valve (4). 13. Wash the fuel fill screen and wash the fuel tank cap in a clean. Clean up all leaked or spilled fuel. nonflammable solvent. Open the left front access door.Prime”. Close the right rear access door. For instructions about priming the fuel system. Install a new fuel filter/water separator by hand. Discard fuel filter/water separator (2). 7.Clean 14. Bodily injury can occur from unexpected contact with open cab doors on machines equipped with a fixed cab riser. Remove bowl (3) from the fuel filter/water separator. 2. 5. 9. 5. Inspect the seal for damage. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Inspect the O-ring on the bowl (4). Note: Refer to the Operation and Maintenance Manual. Inspect the bowl (4). Tighten the collar in order to secure the filter element. . 4. Replace the seal if the O-ring seal is worn or damaged. 6. Turn drain valve (4) counterclockwise in order to open. Drain SMCS Code: 1273-543 Personal injury or death can result from a fire. Machine Security System. Clean up all leaked or spilled fuel. an electrical problem may exist. Travel Alarm Relay and Auto Lubrication Relay – 5 Amp (4) Low Beam and High Beam Relays – 15 Amp (5) Turn Signals – 5 Amp NOTICE If it is necessary to replace fuses frequently. Monitor. Contact your Caterpillar dealer. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. g01983398 (1) Soft Switch Panel. i03688014 Fuses . Install a drain hose onto the drain valve in order to drain the water and the sediment. Left Fuse Panel – (+24V Ignition) Fuses – Fuses protect the electrical system from damage that is caused by overloaded circuits. 3. 2. 1.Replace SMCS Code: 1417-510 Illustration 406 The fuse panel is located behind the operator seat in the cab. Service Connector – 5 Amp (2) Hydraulic Lockout Control. Remove the drain hose. Change a fuse if the element separates. (9) Rotating Beacons and 24 Volt Plug at the Rear of the Cab – 10 Amp . Product Link. If the element of a new fuse separates.356 Maintenance Section Fuel Tank Water and Sediment . Otherwise. Install the cap. electrical damage could result. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. The amperage for each fuse is included with each circuit. Drain the water and the sediment into a suitable container. check the circuit and/or repair the circuit.Drain SEBU8017-05 i01546211 Fuel Tank Water and Sediment . Working Lights for the Rear of the Cab Working Lights Front Relays and Travel Alarm – 5 Amp (3)24V Sensors. Do not smoke while working on the fuel system. NOTICE Always replace fuses with the same type and capacity fuse that was removed. (6) Brake Lights – 5 Amp (7) Working Lights for the Front of the Cab – 15 Amp (8) Working Lights for the Boom – 15 Amp The following list identifies the circuits that are protected by each fuse. Remove the cap that is on the bottom of the fuel tank drain valve. Replace (34) Cab Heater and Air Conditioner – 15 Amp (35) Spare – 30 Amp (36) Spare – 10 Amp (37) Spare – 10 Amp (38) Spare – 15 Amp (39) Spare – 15 Amp (40) Spare – 20 Amp (15) Electric Fuel Pump – 15 Amp (16) 12. Dome Light – 15 Amp Illustration 407 (41) Boom Lights – Relay (42) Front Cab Lights .SEBU8017-05 (10) Individual Stabilizers. 12V Radio) – 5 Amp (18) 15 kW Generator Control 2 – 30 Amp (19) Spare – 5 Amp (20) Spare – 5 Amp Right Fuse Panel – (+24V Battery) (21) Electronic Machine Controller (Master) and Hydraulic Lockout Control Relay – 20 Amp (22) Electronic Machine Controller (Slave) and Product Link – 20 Amp (23) Monitor – 5 Amp (24) Engine Start Switch and Main Power Relay – 5 Amp (25) Warning Lights (Hazards) – 10 Amp (26) Position Light Relays – 5 Amp (27) Left Side Position Lights and 24 Volt Plug (Front Socket) – 10 Amp (28) Right Side Position Lights. Cab Socket 12V15A. Automatic Lubrication and Reverse Fan – 10 Amp 357 Maintenance Section Fuses . Switch Locating Lights and License Plate Lights – 10 Amp (29) Left Side Low Beams – 5 Amp (30) Right Side Low Beams – 5 Amp (31) Left Side High Beams – 5 Amp (32) Right Side High Beams – 5 Amp (33) Converter (Rear Camera. 12V Radio).Relay – Relay (43) Horn – Relay (44) Hydraulic Lockout – Relay (45) Brake Lights – Relay (46) Travel Alarm – Relay g02013973 . 15 kW Generator Control 1 – 15 Amp (17) Converter (Rear Camera. Cab Socket 12V5A. Dozer Blade and Material Handler Dozer Front Blade – 5 Amp (11) Horn. Cigar Lighter.5 kW Generator. Wiper Motor and Window Washer Pump – 15 Amp (12) Air Suspension Seat and Deluxe Seat – 15 Amp (13) Heater Fan and Air Conditioner – 10 Amp (14) Mirror Heater. Glow Plug (56) – 60 Amp Alternator (49) – 80 Amp Starter Relay (57) – 60 Amp Main Power (50) – 80 Amp Spare (58) – 80 Amp Glow Plug (51) – 60 Amp Main Power (59) – 80 Amp Starter Relay (52) – 60 Amp Electronic Control Module (60) – 30 Amp Electronic Control Module (53) – 30 Amp Spare (54) – 80 Amp .Replace SEBU8017-05 (48) Automatic Lubrication – Relay Additional Fuses for 4 Cylinder Engine Additional Fuses for 6 Cylinder Engine Fuses for the Main Power. and for the Thermal Starting Aid Illustration 409 g01433101 These fuses are located behind the right rear access door.Relay – Relay Fuses for the Main Power. and for the Thermal Starting Aid (47) Window Wiper Cut Off . Alternator (55) – 80 Amp Illustration 408 g01229562 These fuses are located behind the right rear access door.358 Maintenance Section Fuses . for the Alternator. for the Alternator. 79 inch) in length. Machines that are used in severe conditions must use the interval in the Maintenance Interval Schedule. The interval for S·O·S monitoring is every 500 hours. Operate the machine for an adequate period of time in order to warm the oil.Inspect SMCS Code: 1404-040-BQ S/N: W8R1-4999 S/N: W2T1-4999 Machines with hammers are not included in the 4000 service hour or 2 year maintenance interval. Drain the Oil 1.SEBU8017-05 359 Maintenance Section Hydraulic Generator Brushes and Commutator . 2. Machines that are used in severe conditions are not included in the 6000 service hour or 3 year maintenance interval. The generator is located on the rear right corner of the upper structure above the hydraulic tank. A 4000 service hour or 2 year maintenance interval for hydraulic oil (change) is available.Change SMCS Code: 5056-044 Cat HYDO Oil Change Interval The standard Cat HYDO oil change interval is every 2000 service hours or 1 year. Cat HYDO Advanced 10 Oil Change Interval The standard Cat HYDO Advanced 10 oil change interval is every 3000 service hours or 18 months. Engage the parking brake. Machines that are used in severe conditions must use the interval in the Maintenance Interval Schedule. A 6000 service hour or 3 year maintenance interval for hydraulic oil (change) is available. The interval for S·O·S monitoring is every 500 hours. The extended interval requires S·O·S monitoring of the hydraulic oil. Remove the access cover in order to gain access to the brushes on the generator. i03738740 Machines with hammers are not included in the 6000 service hour or 3 year maintenance interval. 3. The extended interval requires S·O·S monitoring of the hydraulic oil. Hydraulic System Oil . Machines with hammers must use the intervals that are listed in the Maintenance Interval Schedule. Machines with hammers must use the intervals that are listed in the Maintenance Interval Schedule. Note: The brushes should be no shorter than a length of 20 mm (0. 2. 3.79 inch).Inspect i02618010 Hydraulic Generator Brushes and Commutator . Illustration 411 g01362926 . The maintenance interval for the hydraulic oil filter is not changed. Machines that are used in severe conditions are not included in the 4000 service hour or 2 year maintenance interval. The maintenance interval for the hydraulic oil filter is not changed. The brushes should be replaced in order to prevent any damage to the generator if the brushes are less than 20 mm (0. Inspect the brushes for wear and the ability to move in the brush holder. Illustration 410 g00987570 1. Park the machine on a level surface. as shown.360 Maintenance Section Hydraulic System Oil . Install a drain hose in order to drain the hydraulic tank. “General Hazard Information” for information in containing fluid spillage. “Hydraulic System Pressure . Refer to Testing and Adjusting.Change SEBU8017-05 Note: In order to loosen the breather.Release”. a clip must be attached to the breather. Stop the engine. 8. Remove the cap at the bottom of the drain valve. The clip is located in the literature compartment with the machines Operation and Maintenance Manual. Close the drain valve and remove the drain hose. Slowly loosen the breather in order to relieve system pressure. Install the cap at the drain valve. Tighten the breather in Step 7. 4. Secure the access door. 6. 7. Illustration 412 g01404462 Illustration 415 Illustration 413 g01362927 g00803527 The drain valve is under the middle of the machine. Open the drain valve. 10. Refer to the following topics in order to service the hydraulic system filters: Illustration 414 g01217959 . 11. Open the left front access door. Place the machine in the service position. 9. 5. Note: Refer to Operation and Maintenance Manual. Service the Hydraulic System Filters Note: The pressure must be removed from the hydraulic oil system before the filter can be serviced. Allow the oil to drain into a suitable container. Note: Dispose of drained fluids according to local regulations. Fill the Hydraulic Tank Illustration 417 g01362926 Illustration 418 g01404462 4. 6. Place the machine in the service position. The pump may cavitate or the machine may move in jerks for several seconds. “Hydraulic Note: Air may become trapped in the hydraulic system. as shown. “Hydraulic System Oil Filter . Operate the control levers in order to allow the hydraulic oil to circulate through all hydraulic circuits. 3.Release” for instructions on releasing the air. Fill the hydraulic oil tank. Inspect the O-ring seal. 2. “Capacities (Refill)”.Replace (Return In-line Filter)” • Operation and Maintenance Manual. Stop the engine. System Oil Filter . Install the filler plug.Replace (Pilot Filter)” • Operation and Maintenance Manual.Replace (Hydraulic Swing Circuit Filter)” • Operation and Maintenance Manual. Replace the O-ring seal if the seal is worn or damaged. “Hydraulic System Oil Filter .Replace (Return Filter)” Note: All machines have all these filters. “Hydraulic System Oil Filter . Operate the engine at idling speed for a few minutes. Illustration 419 g01362927 5. Remove the filler plug from the hydraulic tank. Clean the filler plug. Start the engine. If these symptoms continue then air is trapped in the hydraulic system. 7. “Hydraulic System Oil Filter . “Hydraulic System Pressure . Illustration 416 g01217962 1. Refer to Testing and Adjusting. See Operation and Maintenance Manual. 8. .SEBU8017-05 361 Maintenance Section Hydraulic System Oil .Change • Operation and Maintenance Manual.Replace (Hydraulic Demand Fan In-Line Filter)” • Operation and Maintenance Manual. and between the center ring and the top ring for a machine at normal operating temperature. 9.Release”. . 10. Maintain the oil level between the bottom ring and the center ring for a cold machine. The sight gauge contains three red rings for level markers. Hydraulic System Oil Filter (Return) . Illustration 422 g01969938 Typical example of the sight gauge when the hydraulic oil is warm.Replace Illustration 420 SEBU8017-05 g01217964 The sight gauge is located in the engine compartment on the right side of the machine.Replace (In-line Filters) SMCS Code: 5068-510-RJ Note: The pressure must be removed from the hydraulic oil system before the filter can be serviced. i03737701 Illustration 421 g01969937 Typical example of the sight gauge when the hydraulic oil is cold. “Hydraulic System Pressure . Close all access doors.362 Maintenance Section Hydraulic System Oil Filter (Return) . Refer to Testing and Adjusting. Illustration 424 g00804053 In-line filter (3) is positioned at the front of hydraulic tank (2). replace the cover seal. Install new in-line filters. 1. Inspect the cover seal. 2. Clean the holders. 2. “Hydraulic System Pressure . 6. Connect the hydraulic lines. 3. Install a new filter element. Separate the hydraulic lines at in-line filter (1) and at in-line filter (3).Replace 5. 4.SEBU8017-05 363 Maintenance Section Hydraulic System Oil Filter (Return) . .Release”. If damage or wear is found. i02437695 Hydraulic System Oil Filter (Return) . Clean filter cover (2). Remove filter cover (2). Install four lock washers and nuts (1). Inspect the O-ring seals of the holders. Discard the filter. 3. If damage or wear is found. Refer to Testing and Adjusting. Discard the filter element. Remove the in-line filter from the holders. Remove the filter element. Note: Dispose of used filter elements according to local regulations. 5. 4. Note: Dispose of used filters according to local regulations. Illustration 425 g01217968 (1) Nuts (2) Filter cover 1. replace the O-ring seals. Install filter cover (2). Install the in-line filters into the holders. Illustration 423 g00804045 In-line filter (1) is positioned at the right rear of hydraulic tank (2). Remove four nuts (1) and lock washers.Replace SMCS Code: 5068-510-RJ Note: The pressure must be removed from the hydraulic oil system before the filter can be serviced. Install the filter housing. Remove the filter housing. Place the machine in the service position. 3. Refer to Testing and Adjusting. i03668728 Hydraulic System Oil Level Check SMCS Code: 5050-535 1. “Hydraulic System Pressure . Clean the filter housing.Replace SEBU8017-05 i01983461 Hydraulic System Oil Filter Replace (Pilot Filter) 2. Illustration 427 1. Park the machine on ground that is stable and level. SMCS Code: 5068-510 Note: The pressure must be removed from the hydraulic oil system before the filter can be serviced.364 Maintenance Section Hydraulic System Oil Filter . 4. Install a new filter element in the filter housing. 5. Discard the filter element. Illustration 426 g00804473 The pilot filter is located under the cab of the machine. Note: Dispose of used filter elements according to local regulations.Release”. g00804075 Illustration 428 g01362926 Illustration 429 g01404462 . Remove the filter element. 7. “How To Take A Good Oil Sample” for more information about obtaining a sample of the hydraulic oil. .SEBU8017-05 365 Maintenance Section Hydraulic System Oil Sample . Refer to the illustrations 428. Stop the engine and remove the key. Refer to Special Publication. 9. and between the center ring and the top ring for a machine at normal operating temperature. 3. Open the right rear access cover that is located in the engine compartment on the right side of the machine. Refer to Special Publication. Maintain the oil level between the bottom ring and the center ring for a cold machine. and 430 in order to make sure that the stabilizers and the dozer blade (if equipped) are in the fully raised position. PEHP6001. please read the introduction “Fill the hydraulic tank”. Wait for 5 minutes in order to allow the hydraulic oil to stabilize before checking hydraulic oil level. 6. 5.Obtain SMCS Code: 5050-008. 429. “S·O·S Oil Analysis” or contact your dealer for information that pertains to obtaining a sample of the hydraulic oil. and 430 in order to place the machine in the service position. Illustration 432 g01217962 Obtain a sample of the hydraulic oil from the hydraulic tank opening. Engage the parking brake. Refer to the illustrations 428. i03668700 Hydraulic System Oil Sample . SEBU6250. 4. Illustration 431 g00803536 Note: The glass gauge contains three rings for level markers. 7542-008 Illustration 430 g01362927 2. Close the right rear access door. 429. If the level is low.Obtain 8. Consult your Caterpillar dealer for repair of cracks in any metal section of the overhead guard. 2. If metals are found in the filter element. Use original equipment parts only. 5068-507 Inspect a Used Filter for Debris SMCS Code: 7159-040 Illustration 434 Illustration 433 g00102876 g00100013 The element is shown with debris. a magnet can be used to differentiate between ferrous metals and nonferrous metals.Inspect SEBU8017-05 i02106227 Oil Filter . i03667941 Radiator Core . An excessive amount of debris in the filter element can indicate a possible failure. or turbocharger bearings. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings. and to other parts. If the overhead guard rattles during machine operation or if the overhead guard makes noises during machine operation. Consult your Caterpillar dealer for repair of cracks in the welds on the overhead guard. Use a filter cutter to cut the filter element open. Small amounts of debris may be found in the filter element. • Make sure that the radiator fan comes to a complete stop before you open the radiator access door. This could be caused by friction and by normal wear.Inspect (If Equipped) SMCS Code: 1308-507. . to the crankshaft. Note: Apply oil to all the bolt threads before you install the bolts. Do not repair the overhead guard by welding reinforcement plates to the overhead guard.Inspect i00699883 Overhead Guard . Tighten the bolts. Failure to oil the threads can cause improper bolt torque. Inspect the overhead guard for any bolts that are loose or damaged.Clean SMCS Code: 1353-070 Note: Observe the following guidelines when you perform the procedure: • Park the machine on a level surface. replace the mounting supports for the overhead guard. Spread apart the pleats and inspect the element for metal and for other debris. rod bearings. The particles could enter the lubricating system and the particles could cause damage. Replace bolts that are damaged or missing. 1.366 Maintenance Section Oil Filter . Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings. This can result in larger particles in unfiltered oil. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. Ferrous metals can indicate wear on steel parts and on cast iron parts. • Stop the engine before you perform the procedure. Illustration 436 g01311495 2. . 5. Close the radiator access door and tighten bolts (1). compressed air is preferred. “Know Your Cooling System” for more information on cleaning the radiator fins. SEBD0518. Check the radiator fins for debris.SEBU8017-05 Illustration 435 367 Maintenance Section Radiator Core .Clean g01968803 1. High pressure water can be used and steam can also be used. Remove foreign material from the radiator fins. Loosen bolts (1) on the radiator access door. 4. Note: In order to remove dust from a radiator and debris from a radiator. Open the radiator access door and secure the access door. Refer to Special Publication. Illustration 437 g00820764 3. “Air Conditioning and Heating System with R-134a Refrigerant for All Caterpillar Machines” for the proper procedure to change the receiver-dryer assembly and for the procedure to reclaim the refrigerant gas. the receiver-dryer must be replaced. Open the tool box on the left side of the machine. 7322-710 i02618651 Refueling Pump Strainer Clean (If Equipped) SMCS Code: 1295-070-STR Personal injury can result from contact with refrigerant. Slowly loosen the fitting. 4. Close the tool box. SENR5664. Dry the screen. Always use precaution when a fitting is removed. If the system is still under pressure. “General Hazard Information” for information in containing fluid spillage. 1. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas. Wash screen (2) in a clean. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system. even if the gauges indicate the system is empty of refrigerant. Contact with refrigerant can cause frost bite. nonflammable solvent. . Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Remove screen (1) from coupling (2). Personal injury or death can result from inhaling refrigerant through a lit cigarette. release it slowly in a well ventilated area. can cause bodily harm or death. Install the screen to coupling (2).368 Maintenance Section Receiver Dryer (Refrigerant) . Note: Refer to Operation and Maintenance Manual. NOTICE If the refrigerant system has been open to the outside air (without being plugged) for more than 30 minutes. Protective goggles must always be worn when refrigerant lines are opened. Keep face and hands away to help prevent injury. 5. Illustration 439 g01311513 (1) Screen (2) Coupling 2. Moisture will enter an open refrigerant system and cause corrosion which will lead to component failure. Illustration 438 g01263831 A typical example is located in the figure above. Refer to Service Manual. 3.Replace SEBU8017-05 i02723802 Receiver Dryer (Refrigerant) Replace SMCS Code: 7322-510. Replace SMCS Code: 7327-040 SMCS Code: 7327-510 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine. Check buckle (2) for wear or for damage. Note: Within three years of the date of installation or within five years of the date of manufacture. and the seat belt retractor. and the seat belt retractor. Illustration 441 (1) (2) (3) (4) g01152685 Date of installation (retractor) Date of installation (buckle) Date of manufacture (tag) (fully extended web) Date of manufacture (underside) (buckle) Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware.Inspect i02429589 i02429594 Seat Belt . Replace the seat belt at the date which occurs first. Make sure that the mounting bolts are tight. the seat belt buckle. If your machine is equipped with a seat belt extension. If your machine is equipped with a seat belt extension. Within three years of the date of installation or within five years of the date of manufacture. . replace the seat belt .SEBU8017-05 369 Maintenance Section Seat Belt . A date label for determining the age of the seat belt is attached to the seat belt. the seat belt buckle. Inspect the seat belt (3) for webbing that is worn or frayed. Replace any mounting hardware that is worn or damaged. also perform this inspection procedure for the seat belt extension. replace the seat belt. A date label for determining the age of the seat belt is attached to the seat belt. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. If the buckle is worn or damaged.Inspect Seat Belt . Replace the seat belt at the date which occurs first. Replace the seat belt if the seat belt is worn or frayed. replace the seat belt. Replace any parts that are damaged or worn before you operate the machine. Illustration 440 g00932801 Typical example Check the seat belt mounting hardware (1) for wear or for damage. also perform this replacement procedure for the seat belt extension. Clean/Inspect (If Equipped) SMCS Code: 7222-040. 2. i01829671 Swing Bearing .Clean/Inspect SEBU8017-05 i03731388 Stabilizer .Lubricate (If Equipped) SMCS Code: 7222-086-BD. Illustration 444 g00797153 Apply grease to the two upper grease fittings that are located in the engine compartment. Apply lubricant to one fitting that is on the pin for the stabilizer arm. Illustration 442 g01060126 1. Note: Perform the following procedure for each stabilizer. 7222 Wipe all fittings before you apply the grease. clean the stabilizer cylinder and that area around the stabilizer cylinder. Apply lubricant to the fitting on the pin at the head end of the stabilizer cylinder. 7222-070 Illustration 443 g00102409 Apply lubricant to the one fitting that is on the pin for the stabilizer pad.370 Maintenance Section Stabilizer . . Apply lubricant to the fitting that is on the rod end of the stabilizer cylinder. If there is dirt on the stabilizer cylinder.Lubricate SMCS Code: 7063-086 i00699946 Stabilizer Bearings . Lift the stabilizer cover in order to inspect the stabilizer cylinder for dirt accumulation. SEBU8017-05 371 Maintenance Section Swing Gear . Note: The lubrication requirements may exceed these recommendations for some severe applications. especially under the cold weather conditions. additional greasing is not required. The swing gear should be checked after a long period of stationary. thereby accelerating grease deterioration. Recommended Amount of Grease per Service (Grams) 100 Total Amount of Grease to be applied (Grams) 400 400 400 Per Machine Operating Hours 400 250 135 80 30 Grease deterioration can cause damage to the pinion gear of the swing drive and swing internal gear. Inspect the grease. Every two weeks Once a week Once every 10 service hours When the amount of grease in the compartment becomes too large. Not enough grease will result in poor gear lubrication.Lubricate SMCS Code: 7063-086 Table 185 Recommended Lubrication and Service Period Based on the Load Factor Swing Drive Actuation/Load Factor Recommended Greasing Frequency NOTICE Improper lubrication can cause damage to machine components. Reduce the amount of grease that is applied to the bearing if the grease overflows excessively on the outer bearing seal. Remove the inspection cover that is located near the boom base. Requirements for the swing bearing lubrication increase with frequency of the swing and higher load factors. Low (<30%) Medium (30 . The lubrication frequency may increase in some severe applications. the agitation loss becomes large.Lubricate Apply an appropriate amount of grease according to the severity of the application.40%) High (>40%) To avoid damage. When the new grease is overflowed. . Reducing grease to the bearing seal will avoid damage to the bearing seal. i03167110 Swing Gear . Check the collar of grease for overflow. make sure that the proper amount of grease is applied to the swing drive. Illustration 445 g01426848 1. Remove grease. Remove cover (3) and gasket (4). . 3. Smeared or waveless areas as shown in Illustration 448 are evidence for a lack of grease. Illustration 449 g00309463 (5) Plug (6) O-ring seal 6. inspect the O-ring seal (6). Too little grease will result in poor lubrication of the swing gear.372 Maintenance Section Swing Gear . Illustration 447 g01624697 Waves of grease from rotating pinion are present.Lubricate Illustration 446 (1) (2) (3) (4) SEBU8017-05 g00290391 Bolts Bumper springs Cover Gasket Illustration 448 g01624721 VisibleWaveless area indicates lack of grease. Replace the gasket if damage is evident. Too much grease will result in the deterioration of the grease because of excessive movement of the grease. change the grease. Check for contamination and for discolored grease. If the grease is contaminated or if the grease is discolored with water. Replace the O-ring seal if damage is evident. Remove bolts (1) and bumper springs (2). Inspect gasket (4). 4. 2. as needed. Check the level of grease. 5. When you reinstall plug (5). as needed. Note: Add grease. as shown in illustration447. from the rotating swing drive pinion are present along the entire swing gear. The grease should be evenly distributed on the floor of the pan. Remove plug (5) in order to allow the water to drain. The level of grease is correct when waves of grease. Illustration 450 g00102393 Measure the air pressure on each tire. See Operation and Maintenance Manual. Fill the gearbox with oil to the bottom of the filler plug opening. 3. cover (3). i02837406 Transmission Oil . 8. Install drain plug (2). For more information. 4. Note: Dispose of any used oils according to local regulations. inflate the tires. Consult your Caterpillar dealer for the correct load rating and for the correct operating pressures. See Operation and Maintenance Manual. Repeat Step 4 to Step 7 twelve times. refer to Operation and Maintenance Manual. bumper springs (2) and bolts (1). . Turn the upper structure by 1/12 of a turn. Add grease. Lower the work tool to the ground. If damage or wear is noticed on the O-ring seal. Inspect the O-ring seal.SEBU8017-05 373 Maintenance Section Tire Inflation .Check Illustration 451 SMCS Code: 4203-535-PX.Check 7. 8. 2. 9. 1. Remove drain plug (2). 9. 10. replace the seal. “Tire Inflation Information”. 4203-535-AI g00102674 (1) Filler plug (2) Drain plug Operate the machine for an adequate amount of time in order to warm the oil. Remove filler plug (1). 6. 7. as needed. Install filler plug (1). “Capacities (Refill)”. Drain the oil into a suitable container. The grease fitting is used only under towing conditions for activating and deactivating the parking brake manually. replace the seal. “Towing Information”. Clean drain plug (2). Clean filler plug (1). If damage or wear is noticed on the O-ring seal. 5. Inspect the O-ring seal. Raise the boom. If necessary. Install gasket (4).Change SMCS Code: 3080-044 Note: Do not grease the transmission. i00735307 Tire Inflation . This is the same angle as the angle between the hours of an analog clock. Remove the dirt that is around filler plug (1) and around drain plug (2). If necessary. . Clean filler plug (1). Clean the dirt and debris from filler plug (1). SEBU6250. “How To Take A Good Oil Sample” for more information about obtaining an oil sample from the transmission housing. 2. Check the oil level. 4. i01871854 Transmission Oil Sample Obtain SMCS Code: 3030-008.374 Maintenance Section Transmission Oil Level . If damage or wear is noticed on the O-ring seal. Refer to Special Publication. PEHP6001. tighten the wheel nuts. 7542 Illustration 453 Illustration 452 g00655082 (1) Filler plug 1. “S·O·S Oil Analysis” for information that pertains to obtaining an oil sample from the transmission housing. For more information. 3080. i02525605 Wheel Nut Torque . Illustration 454 g00102965 Check the torque on all wheel nuts on each of the four wheels. “Towing Information”. The oil level should be at the bottom of the opening for filler plug (1).Check SMCS Code: 4210-535 5. 7542-008. Inspect the O-ring seal. Refer to Special Publication. g00947765 Obtain an oil sample from the transmission by removing the filler plug and taking the sample directly from the transmission housing.Check SEBU8017-05 i03667882 Transmission Oil Level . 3.Check SMCS Code: 3080-535-FLV Note: Do not grease the transmission. The torque needs to be 450 ± 50 N·m (332 ± 37 lb ft). replace the seal. Remove filler plug (1). Install filler plug (1). The grease fitting is used only under towing conditions for activating and deactivating the parking brake manually. refer to Operation and Maintenance Manual. If necessary. 6. fill the gearbox with oil to the bottom of the opening for filler plug (1). “Caterpillar Machine Fluids Recommendations”. Then. of isopropyl alcohol. Soap and Water Use a clean sponge or a soft cloth. Stubborn Dirt and Grease i01258249 Window Wiper Inspect/Replace SMCS Code: 7305-040. use Caterpillar or any commercially available nonfreezing window washer solvent. wash the windows with soap and with water. Cleaning Methods Aircraft Windshield Cleaner Apply the cleaner with a soft cloth. Bodily injury can occur from unexpected contact with open cab doors on machines equipped with a fixed cab riser. close the cab door before climbing onto the rear of the machine. Open the top access cover. 7305-510 Inspect the condition of the wiper blades.Clean SMCS Code: 7306-544-KE Use commercially available window cleaning solutions in order to clean the windows. Illustration 456 g00566124 Typical example Use a pole with a squeegee in order to reach the high areas of the window. unless handholds are available. Close all access doors. SMCS Code: 7310-070. . Secure the access door. 7340-070 1. NOTICE When operating in freezing temperatures. Rinse the windows thoroughly. Wipe off the cleaner with a clean soft cloth. Rub the window with moderate pressure until all the dirt is removed. Allow the cleaner to dry. To avoid injury. 2. Fill the fluid reservoir through the filler opening on the top of the reservoir. Also use plenty of lukewarm water.SEBU8017-05 375 Maintenance Section Window Washer Reservoir . Open the left front access door. or of Butyl Cellosolve. Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs. Dry the windows with a moist chamois or with a moist cellulose sponge. Clean the outside of the windows from the ground. Wash the windows with a good grade of naphtha. Illustration 455 g01217973 Typical location 3. Wash the windows with a mild soap or with a mild detergent.Fill i02437701 i01077829 Window Washer Reservoir Fill Windows . 4.