993k maintenance intervals
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®© 2010 CaterpillarAll Rights Reserved
MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt
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SEBU8076-06
December 2010
Operation andMaintenance
Manual993K Wheel Loader
LWA1-Up (993K)Z9K1-Up (993K)
SAFETY.CAT.COM
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88 SEBU8076-06Maintenance SectionMaintenance Interval Schedule
i04166053
Maintenance Interval Schedule
SMCS Code: 7000
Ensure that all safety information, warnings andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.
The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, fi lters, and the replacementof components due to normal wear and aging. Failureto adhere to proper maintenance intervals andprocedures may result in diminished performance of the product and/or accelerated wear of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance. Refer to themaintenance procedure for any other exceptions thatmay change the maintenance intervals.
Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.
Note: If Cat HYDO Advanced hydraulic oils areused, the hydraulic oil change interval is extendedto 3000 hours. S·O·S services may extend the oil
change even longer. Consult your Caterpillar dealer for details.
When Required
Automatic Lubrication Grease Tank - Fill .............. 91 Axle Oil Cooler Filter - Replace ............................ 91Battery - Recycle .................................................. 93Battery or Battery Cable - Inspect/Replace .......... 93Camera - Clean .................................................... 98Circuit Breakers - Reset ........................................ 99Engine Air Filter Primary Element - Clean/
Replace ............................................................. 109Engine Air Filter Secondary Element - Replace .. 112
Ether Starting Aid Cylinder - Replace .................. 117Fuel System - Prime ........................................... 120Fuses - Replace .................................................. 125High Intensity Discharge Lamp (HID) - Replace .. 127High Pressure Screens - Clean/Replace ............ 128Oil Filter - Inspect ................................................ 144Oil Renewal System Oil - Add ............................ 145Radiator Core - Clean ......................................... 146Seat Side Rails - Adjust ...................................... 153Secondary Steering - Test .................................. 154Window Washer Reservoir - Fill .......................... 160Window Wiper - Inspect/Replace ........................ 160Windows - Clean ................................................. 160
Every 10 Service Hours or Daily
Backup Alarm - Test .............................................. 92Bucket Cutting Edges - Inspect/Replace .............. 96Bucket Tips - Inspect/Replace .............................. 97Bucket Wear Plates - Inspect/Replace ................. 98
Cooling System Coolant Level - Check .............. 102Engine Oil Level - Check ..................................... 114Fuel System Primary Filter (Water Separator) -
Check/Drain ...................................................... 121Fuel Tank Water and Sediment - Drain ............... 124Hydraulic System Oil Level (Implement) (Hydraulic
Fan) - Check ..................................................... 140Hydraulic System Oil Level (Steering) (Brake) -
Check ................................................................ 141Oil Renewal System Oil Level - Check ............... 145Rear Access Egress System Alarm - Test .......... 146Seat Belt - Inspect .............................................. 153Transmission Oil Level - Check .......................... 158
Every 50 Service Hours or Weekly
Cab Air Filter - Clean/Replace .............................. 98Steering Cylinder Bearings - Lubricate ............... 154Tire Inflation - Check ........................................... 155
Initial 250 Service Hours
Electronic Unit Injector - Inspect/Adjust .............. 109Engine Valve Lash - Check .................................. 116Engine Valve Rotators - Inspect .......................... 116Hydraulic Oil Tank Filter Element (Case Drain)
(Steer ing) (Brake) - Replace ............................. 132Hydraulic System Oil Filter (Steering Oil Cooler)
(Steering Pilot) - Replace .................................. 139Transmission Oil Filter - Replace ........................ 157
Every 250 Service Hours or Monthly
Axle Oscillation Bearings - Lubricate .................... 92Battery - Clean ...................................................... 92Belt - Inspect/Replace ........................................... 93Braking System - Test ........................................... 95Drive Shaft Spline (Center) - Lubricate ............... 108Engine Oil Sample - Obtain ................................. 114Rear Access Egress System Oil Level - Check .. 149
Initial 500 Service Hours
Rear Access Egress System Oil - Change ......... 147Seat Side Rails - Adjust ...................................... 153
Every 500 Service Hours or 3 Months
Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 102
Differential and Final Drive Oil Level - Check ..... 106Differential and Final Drive Oil Sample - Obtain .. 107Engine Crankcase Breather - Clean .................... 113Engine Oil and Filter - Change ............................ 115Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 122Fuel System Secondary Filter - Replace ............ 123
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SEBU8076-06 89Maintenance Section
Maintenance Interval Schedule
Fuel Tank Cap and Strainer - Clean ................... 124Hoses and Clamps - Inspect/Replace ................ 129Hydraulic Oil Tank Filter Element (Case Drain)
(Steering) (Brake) - Replace ............................. 132Hydraulic Oil Tank Filter Elements (Case Drain)
(Implement) (Hydraulic Fan) - Replace ............. 132
Hydraulic System Oil Filter (Implement Pilot) -Replace ............................................................. 138
Hydraulic System Oil Filter (Steering Oil Cooler)(Steering Pilot) - Replace .................................. 139
Hydraulic System Oil Sample (Implement) (HydraulicFan) - Obtain ..................................................... 141
Hydraulic System Oil Sample (Steering) (Brake) -Obtain ............................................................... 142
Hydraulic Tank Breaker Relief Valve (Implement)(Hydraulic Fan) - Clean ..................................... 143
Hydraulic Tank Breaker Relief Valve (Steering)(Brake) - Clean .................................................. 144
Rear Access Egress System Bearings -Lubricate ........................................................... 146
Rear Access Egress System Oil Sample -Obtain ............................................................... 150
Rear Access Egress System Rolling Guards -Clean ................................................................. 151
Transmission Oil Filter - Replace ........................ 157Transmission Oil Sample - Obtain ...................... 158
Every 1000 Service Hours or 6 Months
Articulation Bearings - Lubricate ........................... 90Battery Hold-Down - Tighten ................................. 93Drive Shaft Support Bearing - Lubricate ............. 109Rollover Protective Structure (ROPS) - Inspect .. 152Transmission Magnetic Screen - Clean .............. 155
Transmission Oil - Change ................................. 156
Every 2000 Service Hours or 1 Year
Brake Accumulator - Check .................................. 95Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 103Differential and Final Drive Oil - Change ............ 105Electronic Unit Injector - Inspect/Adjust .............. 109Hydraulic System Oil (Implement) (Hydraulic Fan) -
Change ............................................................. 133Hydraulic System Oil (Steering) (Brake) -
Change ............................................................. 136Rear Access Egress System Oil Filter -
Replace ............................................................. 148Refrigerant Dryer - Replace ................................ 152Ser vice Brake Wear Indicator - Check ................ 154
Every 3000 Service Hours or 2 Years
Cr ankshaft Vibration Damper - Inspect ............... 105Engine Mounts - Inspect ...................................... 114Rear Access Egress System Oil - Change ......... 147
Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 153
Every 4000 Service Hours or 2 Years
Engine Valve Lash - Check .................................. 116Engine Valve Rotators - Inspect .......................... 116
Every 5000 Service Hours or 3 Years
Alternator - Inspect ............................................... 90
Every 6000 Service Hours or 3 Years
Alternator - Inspect ............................................... 90Cooling System Coolant Extender (ELC) - Add .. 101Engine Water Pump - Inspect .............................. 117Turbocharger - Inspect ........................................ 159
Every 6000 Service Hours or 4 Years
Cooling System Water Temperature Regulator -Replace ............................................................. 104
VIMS Module Battery - Replace ......................... 159
Every 12 000 Service Hours or 6 Years
Cooling System Coolant (ELC) - Change ........... 100Fuel Lines - Replace ............................................ 118
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90 SEBU8076-06Maintenance Section
Alternator - Inspect
i02904968
Alternator - Inspect
SMCS Code: 1405-040
g01224924Illustration 90
g01445914Illustration 91
Access to the alternator is on the right side of themachine. The alternator is located on the front of the engine.
Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and for proper battery charging.
Keep the batteries fully charged.
Air temperature affects the cranking power of thebatteries. Keep the batteries warm. The engine willnot crank if the batteries are too cold. A warm enginewill not crank if the batteries are too cold.
When the engine is operated only for short periodsof time, the batteries may not fully recharge. Makesure that the alternator is properly functioning. Thealternator will charge the battery.
Consult your Caterpillar dealer for more informationabout testing the alternator.
i02520329
Articulation Bearings -Lubricate
SMCS Code: 7057-086-BD; 7065-086-BD;
7066-086-BD
Wipe off the fittings before any lubricant is applied.
g01289360Illustration 92
g01261483Illustration 93
The remote grease fitting for the upper hitch pin islocated to the right of the service center on the rightside of the machine.
g01289561Illustration 94
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SEBU8076-06 91Maintenance Section
Automatic Lubrication Grease Tank - Fill
The remote grease fitting (1) for the lower hitch pin islocated inside the service center.
Apply lubricant through the two grease fittings.
Reference: For additional information, please refer
to Operation and Maintenance Manual, “ServiceCenter”
i02520616
Automatic Lubrication GreaseTank - Fill(If Equipped)
SMCS Code: 7540-544-TNK
A pressure hazard is present. Severe personal in- jury or death can result from removing hoses or fittings that are under pressure. Relieve the pres-sure in the system before you remove hoses or fittings.
g01289565Illustration 95
There is a fast fill port (1) for the automatic lubricationsystem in the service center. Attach the proper pumpand add lubricant through the port until the systemis full.
Note: You may also use the “FULL” indicator lightin the service center in order to determine when theautomatic lubrication system is full.
Reference: For more information, refer to Operationand Maintenance Manual, “Service Center”
i02517693
Axle Oil Cooler Filter - Replace
SMCS Code: 3004-510-AOC
NOTICECare must be taken to ensure that fluids are containedduring perf ormance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
The axle oil cooler filter should be replaced when afailure occurs in the cooling system.
Note: The oil fi lters contain a 140 micron screen.
g01292902Illustration 96
There are a total of two axle oil cooler fi lters on your machine. One of the filters is located on the rear frame underneath the radiator. A second filter islocated on the front frame above the drive shaft.
1. Stop the engine.
2. The axle oil cooler filter is located inside theaccess panel on the underside of the machine.Remove the access panel.
3. Remove the oil fi lter and discard the fi lter properly.Make sure that the old seal is removed from thefilter base.
4. Install the new filter.
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92 SEBU8076-06Maintenance Section
Axle Oscillation Bearings - Lubricate
a. Apply a thin coat of oil to the seal on the newfilter.
b. Install the new fi lter hand tight until the seal of the filter contacts the base. Note the positionof the index marks on the fi lter in relation to a
fixed point on the filter base.
Note: There are rotation index marks on the oil fi lter that are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the fi lter, use therotation index marks as a guide.
c. Tighten the filter according to the instructionsthat are printed on the filter. Use the indexmarks as a guide. For non-Caterpillar filters,use the instructions that are provided with thefilter.
Note: You may want to use a Caterpillar strap
wrench, or another suitable tool in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.
5. Repeat steps 3 through 4.c for the other fi lter.
6. Install the access panel.
i02520381
Axle Oscillation Bearings -Lubricate
SMCS Code: 3268-086-BD; 3278-086-BD
Wipe off the fittings before any lubricant is applied.
g01289568Illustration 97
The remote grease fitting (1) for the axle oscillationbearing is located inside the service center. Applylubricant through the fitting.
Reference: For additional information, please refer to Operation and Maintenance Manual, “ServiceCenter”
i02472018
Backup Alarm - Test
SMCS Code: 7406-081
g01232891
Illustration 98
The backup alarm is located behind the fan guard onthe rear of the machine.
1. Turn the engine start switch key to the ON positionin order to perform the test.
2. Apply the service brake.
3. Move the transmission direction control switch tothe REVERSE position.
The backup alarm should immediately sound.
The backup alarm will continue to sound until thetransmission direction control switch is moved to theNEUTRAL position or to the FORWARD position.
i02459900
Battery - Clean
SMCS Code: 1401-070
g01227657Illustration 99
Open the battery compartments on the right side of the machine near the rear ladder.
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SEBU8076-06 93Maintenance Section
Battery - Recycle
Clean the battery terminals and the surfaces of the batteries with a clean cloth. Coat the batteryterminals with petroleum jelly. Make sure that thebattery cables are installed securely.
i00993589
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the followinglocations:
• A battery supplier
• An authorized battery collection facility
• Recycling facility
i02459960
Battery Hold-Down - Tighten
SMCS Code: 7257-527
g01227657Illustration 100
Open the battery compartments on the right side of the machine near the rear ladder.
Over time, the vibration of an operating machine cancause the battery hold-downs to loosen. To help toprevent loose batteries and the possibility of loosecable connections, tighten the eight locknuts (two per battery) to a torque of 14 ± 2 N·m (10 ± 1.5 lb ft).
i01835250
Battery or Battery Cable -Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1402-040;
1402-510
1. Turn the engine start switch key to the OFFposition. Turn all of the switches to the OFFposition.
2. Turn the battery disconnect switch to the OFFposition. Remove the key.
3. Disconnect the positive battery cable at the batterydisconnect switch. The battery disconnect switchis connected to the machine frame.
Note: Do not allow the disconnected battery cable tocontact the disconnect switch.
4. Disconnect the negative battery cable at thebattery that is connected to the battery disconnectswitch. If the machine has four 12 volt batteries,disconnect the negative battery cables of two of the batteries.
5. Make any necessary repairs or replace the battery.
6. Reconnect the negative battery cable at thebattery that is connected to the battery disconnectswitch.
7. Reconnect the positive battery cable at the batterydisconnect switch.
8. Install the key and turn the battery disconnectswitch to the ON position.
i04169829
Belt - Inspect/Replace
SMCS Code: 1397-040; 1397-510
Inspect
1. Park the machine on level ground. Lower thebucket to the ground. Move the transmissioncontrol switch to the NEUTRAL position andengage the parking brake. Shut off the engine.
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94 SEBU8076-06Maintenance SectionBelt - Inspect/Replace
g01254405Illustration 101
2. Remove the grill assembly on the right side of the machine.
g01254720
Illustration 102
3. Remove the engine access cover in order to gainaccess to the belt.
g01233393Illustration 103
4. Inspect the condition of the serpentine belt (1).The belt deflection should not be more than14 to 20 mm (0.55 to .81 inch) under 110 N (25 lb)of force. Use a 144-0235 Belt Tension Gauge inorder to measure the tension.
Note: If a new belt is installed, recheck the beltadjustment after 30 minutes of operation.
Note: This machine is equipped with a belt tensioner (2). The belt tensioner automatically adjusts the beltto the correct position.
5. Install the engine access cover.
6. Install the grill assembly.
Replace
1. Replace the belt if any of the following conditionsexist:
• Excessive cracking
• Excessive wear
• Excessive damage
2. Park the machine on level ground. Lower thebucket to the ground. Move the transmissioncontrol switch to the NEUTRAL position andengage the parking brake. Shut off the engine.
3. The battery disconnect switch is located in theservice center on the left side of the rear bumper.Turn the battery disconnect switch to the OFFposition.
4. Remove the grill assembly on the right side of
the machine.
5. Remove the engine access cover in order to gainaccess to the belt.
6. Release the tension on the serpentine belt (1).Insert a ratchet into the square hole in the belttensioner and rotate the belt tensioner in aclockwise direction.
7. Remove the belt.
8. Install a new belt.
9. When you release the tension off the belttensioner, the belt will automatically adjust the beltto the correct position. Recheck the belt tension.
10. Turn the battery disconnect switch to the ONposition.
11. Install the engine access cover.
12. Install the grill assembly.
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SEBU8076-06 95Maintenance Section
Brake Accumulator - Check
i03948191
Brake Accumulator - Check
SMCS Code: 4263-535
1. Park the machine on level ground and lower thebucket. Ensure that the area is clear of obstaclesand personnel. Block the wheels in order toprevent machine motion.
2. Move the engine start switch to the ON position.
3. Start the engine and run the engine for 1 minute inorder to increase the accumulator pressure. Thealert indicator for the brake oil pressure shouldcome on if the brake system is not at the normaloperating pressure. Release the parking brake.Stop the engine.
4. Move the engine start switch to the ON position. Allow the monitoring system to completely cyclethrough the self test. Depress the service brakepedal until the parking brake indicator comes on.This will decrease the accumulator pressure. Aminimum of five applications should be required.
5. If the parking brake indicator comes on with lessthan five applications of the service brake pedal,measure the nitrogen precharge pressure of theaccumulator.
Your Cat dealer has the appropriate tools for measur ing the precharge pressure of the brake
accumulator. Only use dry nitrogen gas for recharging.
i02060586
Braking System - Test
SMCS Code: 4251-081; 4267-081
1. Fasten the seat belt.
2. Make sure that the steering frame lock is in theunlocked position.
3. Park the machine on a hard, dry, level surface.
4. Check the area around the machine. Make surethat the machine is clear of personnel and clear of obstacles.
The following tests are used to determine whether the braking system is functional. These tests are notintended to measure the maximum brake holdingeffort. The required brake holding effort for sustaininga machine at a specific engine rpm varies from onemachine to another machine. The variations include
differences in the engine setting, the power trainef ficiency, the brake holding ability, etc.
Service Brake Holding Ability Test
Personal injury can result if the machine moveswhile testing.
If the machine begins to move during test, reducethe engine speed immediately and engage theparking brake.
This test is performed when the service brakes areengaged. If the machine begins to move, comparethe engine rpm to the engine rpm of a prior test. Thiswill indicate the amount of system deterioration.
1. Start the engine. Raise the work tool slightly. Applythe service brake. Release the parking brake.
2. Move the hydraulic lockout control to theUNLOCKED position.
3. Place the transmission in THIRD SPEED
FORWARD while the service brakes are applied.
4. Gradually increase the engine speed to high idle.The machine should not move.
5. Reduce the engine speed to low idle. Placethe transmission in neutral. Engage the parkingbrake. Lower the work tool to the ground. Stopthe engine.
If the machine moved during the test, consult your Caterpillar dealer for a brake inspection. Make anynecessary repairs before the machine is returned tooperation.
Parking Brake Holding Ability Test
Personal injury can result if the machine moveswhile testing.
If the machine begins to move, reduce the enginespeed immediately and apply the service brakepedal.
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96 SEBU8076-06Maintenance SectionBucket Cutting Edges - Inspect/Replace
This test is per formed when the parking brake isengaged. If the machine begins to move, comparethe engine rpm to the engine rpm of a prior test. Thiswill indicate the amount of system deterioration.
1. Start the engine. Raise the work tool slightly.
Engage the parking brake.
2. Move the hydraulic lockout control to theUNLOCKED position.
3. Place the transmission in THIRD SPEEDFORWARD while only the parking brake isengaged.
The parking brake indicator light should come on.
4. Gradually increase the engine speed to high idle.The machine should not move.
5. Reduce the engine speed. Place the transmissionin neutral. Lower the work tool to the ground. Stopthe engine.
If the machine moved during the test, consult your Caterpillar dealer for a brake inspection. Make anynecessary repairs before the machine is returned tooperation.
i02453840
Bucket Cutting Edges -Inspect/Replace
SMCS Code: 6801-040; 6801-510
S/N: LWA1-Up
Personal injury or death can result, if the bucket isnot blocked up. Block the bucket before changingcutting edge.
g00804790Illustration 104
Check for bolts that are missing or loose. Replaceany missing bolts and tighten any loose bolts.
Reference: For more information, refer toSpecifications, SENR3130, “Torque Specifications”or consult your Caterpillar dealer.
Inspect the cutting edges and the end bits. If wear or damage is evident, use the following procedure toreplace the components.
1. Raise the bucket and place blocking under thebucket. Lower the bucket onto the blocking.
Note: Do not block up the bucket too high. Block upthe bucket enough for removing the cutting edgesand the end bits.
2. Remove bolts (1). Remove cutting edges (2) andthe end bits.
3. Clean the contact surfaces. Inspect the cuttingedges and install the cutting edges.
If the opposite side of the cutting edge is not worn,use that side. If both sides of the cutting edge areworn, install a new cutting edge.
4. Install bolts (1). Tighten the bolts to the specifiedtorque.
5. Raise the bucket and remove the blocking. Lower the bucket to the ground.
6. After a few hours of operation, check the bolts for proper torque.
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SEBU8076-06 97Maintenance Section
Bucket Tips - Inspect/Replace
i02594942
Bucket Tips - Inspect/Replace
SMCS Code: 6805-040; 6805-510
Personal injury or death can result from the bucketfalling.
Block the bucket before changing bucket tips.
Note: In order to maximize the life of the bucket tipand the penetration of the bucket tip, the bucket tipcan be rotated.
g00101352Illustration 105
(1) Usable
(2) Removal Procedure(3) Removal Procedure
Check the bucket tips for wear. If the bucket tip has ahole, replace the bucket tip.
Removal
g01124847Illustration 106
(1) Bucket tip(2) Retainer (3) Adapter
Note: Retainer s are often damaged during theremoval process. Caterpillar recommends theinstallation of a new retainer when bucket tips arerotated or replaced.
g01175361Illustration 107
1. Use a pry bar in order to disengage retainer (2).
2. Use the pry bar in order to remove retainer (2)from bucket tip (1).
3. Remove bucket tip (1) from adapter (3) with aslight counterclockwise rotation.
4. Clean adapter (3).
Installation
1. Clean the adapter and the area around the latch,if necessary.
2. Install the new bucket tip onto the adapter with aslight clockwise rotation.
g01124736Illustration 108
3. Install the retainer. Make sure that the retainer'slatch catches under the tip pocket.
4. Make sure that the latch is properly seated bytrying to remove the bucket tip.
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98 SEBU8076-06Maintenance SectionBucket Wear Plates - Inspect/Replace
i02453827
Bucket Wear Plates -Inspect/Replace
SMCS Code: 6120-040; 6120-510
Personal injury or death can result from fallingbucket.
When working under or around the bucket or link-age, with the bucket raised, proper support mustbe provided for the bucket and/or the linkage.
g01289574Illustration 109
Before damage to the bottom of the bucket occurs,
repair damaged bucket wear plates or replacedamaged bucket wear plates.
1. Raise the bucket and block up the bucket.
2. Loosen bolts and remove wear plates.
3. Install new wear plates. Tighten the bolts to thespecified torque.
Reference: For more information, refer to Specifications, SENR3130, “TorqueSpecifications” or consult your Caterpillar dealer.
i02919930
Cab Air Filter - Clean/Replace
SMCS Code: 7342-070; 7342-510
Note: Operating conditions will influence the serviceinterval for the cab air filters. The filters must becleaned more often if the machine is being operatedin dusty conditions.
g01250863Illustration 110
1. Filter (1) is located inside the cab to the left of the operator seat. Remove the cover and thenremove filter (1).
2. Filter (2) is located inside the left hand accessdoor behind the cab. Open the access door.
3. Remove the cover and remove fi lter (2).
4. Clean the filter elements with pressure air or wash the filter elements in warm water with anonsudsing household detergent.
5. If water was used to wash the filter elements, rinsethe fi lter element in clean water and allow the filter element to air dry thoroughly.
6. Install fi lter (2) and the cover.
7. Close the access door.
8. Install fi lter (1) and the cover.
i02816405
Camera - Clean(If Equipped)
SMCS Code: 7348-070
In order to maintain suf ficient vision, keep the Work Area Vision System (WAVS) camera lens and thedisplay clean.
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SEBU8076-06 99Maintenance Section
Circuit Breakers - Reset
Display
g01223034Illustration 111
WAVS display
Use a soft, damp cloth in order to clean the display.
The display has a soft plastic surface that can beeasily damaged by an abrasive material. The displayis not sealed. Do not immerse the display withliquid.
Camera
g01223051Illustration 112
The W AVS camera is located on the rear of the machine in thecenter of the fan guard.
Use a damp cloth or water spray in order to cleanthe camera lens. The camera is a sealed unit. The
camera is not affected by high pressure spray.
The camera is equipped with an internal heater tohelp counteract the effects of condensation, snow,or ice.
Note: For more information on WAVS, refer toOperation and Maintenance Manual, SEBU8157,“Work Area Vision System”.
i02517371
Circuit Breakers - Reset
SMCS Code: 1420-529
Reset Circuit Breakers
g01258242Illustration 113
The circuit breaker reset buttons are located in thebattery compartment on the right side of the machine.
g01258243Illustration 114
Circuit Breaker Reset – Push the buttonin order to reset the circuit breaker. If theelectrical system is working properly, the
button will remain depressed. If the button does notremain depressed, check the appropriate electrical
cir cuit. Repair the electrical circuit, if necessary.
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100 SEBU8076-06Maintenance SectionCooling System Coolant (ELC) - Change
i03793929
Cooling System Coolant (ELC)- Change
SMCS Code: 1350-044-NL
Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared to
collect the fl
uid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
g01251036Illustration 115
1. The coolant drain valve (1) is located under therear of the machine. Open the drain valve. Allowthe coolant to drain into a suitable container.
2. Flush the cooling system with clean water until thedraining water is clean. Close the drain valve.
NOTICETopping off or mixing Cat ELC with other products thatdo not meet Caterpillar EC-1 specifications reducesthe effectiveness of the coolant, shortens coolant ser-vice life, and may cause premature wear to compo-
nents.
Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants. Use only Extender with Cat ELC.
Failure to follow these recommendations can result inshortened cooling system component life.
g01254759Illustration 116
3. The cooling system pressure cap is located
inside the small access door on top of the enginecompartment. Open the access door and removethe cap.
4. Add 318 L (84 US gal) of Extended Life Coolant(ELC).
5. Start the engine. Run the engine without thecooling system pressure cap until the thermostatopens and the coolant levels stabilize.
g01254784Illustration 117
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SEBU8076-06 101Maintenance Section
Cooling System Coolant Extender (ELC) - Add
6. The sight gauge is located on the left side of theengine compartment. Observe sight gauges inorder to maintain the coolant levels.
7. If the coolant level is low, add extended life coolantuntil the coolant level is visible in the sight gauge.
8. Install the cooling system pressure cap. Close theaccess door.
Fast Fill
If your machine is equipped with a deluxe servicecenter, you may drain the coolant through the fast fi llport or you may add the coolant through a fast fill port.
g01289638Illustration 118
1. Remove the dust cover (2).
2. Attach the hose to the male coupling. Use a127-9087 Nozzle for this port.
3. Drain the coolant or add the coolant, as needed.
Reference: For additional information, please refer to Operation and Maintenance Manual, “ServiceCenter”.
i03793912
Cooling System Coolant
Extender (ELC) - AddSMCS Code: 1352-544-NL
When a Caterpillar Extended Life Coolant (ELC) isused, an Extender must be added to the coolingsystem.
Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.
NOTICETopping off or mixing Cat ELC with other products thatdo not meet Caterpillar EC-1 specifications reducesthe effectiveness of the coolant, shortens coolant ser-vice life, and may cause premature wear to compo-nents.
Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants. Use only Extender with Cat ELC.
Failure to follow these recommendations can result inshortened cooling system component life.
g01254759Illustration 119
1. The cooling system pressure cap is locatedinside the small access door on top of the enginecompartment. Open the access door and removethe cap.
2. Add 2 L (0.5 US gal) of ELC Extender.
3. Start the engine. Run the engine without the
cooling system pressure cap until the thermostatopens and the coolant levels stabilize.
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102 SEBU8076-06Maintenance SectionCooling System Coolant Level - Check
g01254784Illustration 120
4. The sight gauge is located on the left side of theengine compartment. Observe sight gauges inorder to maintain the coolant levels.
5. If the coolant level is low, add extended life coolantuntil the coolant level is visible in the sight gauge.
6. Install the cooling system pressure cap. Close theaccess door.
i02506874
Cooling System Coolant Level- Check
SMCS Code: 1350-535-FLV
Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.
g01254784Illustration 121
1. The sight gauge is located on the left side of theengine compartment. The coolant level should bevisible in the sight gauge.
g01254759Illustration 122
2. If the coolant level is low, extended life coolantmust be added. Open the small access door ontop of the engine compartment.
3. Remove the cooling system pressure cap.
4. Add extended life coolant until the coolant level isvisible in the sight gauge.
5. Install the pressure cap and close the access door.
i02510566
Cooling System CoolantSample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
Note: Level 1 results may indicate a need for Level 2 Analysis.
Obtain the sample of the coolant as close aspossible to the recommended sampling interval.The recommended sampling interval for Level 1Coolant Analysis is every 500 service hours. Inorder to receive the full effect of S·O·S analysis,you must establish a consistent trend of data.In order to establish a pertinent history of data,perform consistent samplings that are evenly spaced.Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Use the following guidelines for proper sampling of the coolant:
• Complete the information on the label for thesampling bottle before you begin to take thesamples.
• Keep the unused sampling bottles stored in plasticbags.
• Keep the lids on empty sampling bottles until youare ready to collect the sample.
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SEBU8076-06 103Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.
1. The machine needs to be operated in order tocirculate the coolant. Collect the sample after a
normal workday. Collect the samples from one totwo hours after the engine has been shut off.
2. Start the engine momentarily in order to circulatethe coolant again.
3. Shut off the engine.
g01254990Illustration 123
4. The sampling valve for the cooling system islocated inside the engine compartment on the leftside of the machine.
5. Do not allow dirt or other contaminants to enter the sampling bottle. Fill the sampling bottlethree-fourths from the top. Do not fill the bottlecompletely.
6. Place the sampling bottle with the completed labelinto the mailing tube.
Reference: For more information, refer to SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations” and Special Publication,PEHP6001, “How To Take A Good Oil Sample”.
i02510574
Cooling System CoolantSample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
Obtain the sample of the coolant as close aspossible to the recommended sampling interval.The recommended sampling interval for Level 2Coolant Analysis is every year. In order to receivethe full effect of S·O·S analysis, you must establisha consistent trend of data. In order to establisha pertinent history of data, perform consistentsamplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer.
Use the following guidelines for proper sampling of the coolant:
• Complete the information on the label for thesampling bottle before you begin to take thesamples.
• Keep the unused sampling bottles stored in plasticbags.
• Keep the lids on empty sampling bottles until youare ready to collect the sample.
• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.
1. The machine needs to be operated in order tocirculate the coolant. Collect the sample after anormal workday. Collect the samples from one totwo hours after the engine has been shut off.
2. Start the engine momentarily in order to circulatethe coolant again.
3. Shut off the engine.
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104 SEBU8076-06Maintenance SectionCooling System Water Temperature Regulator - Replace
g01254990Illustration 124
4. The sampling valve for the cooling system islocated inside the engine compartment on the leftside of the machine.
5. Do not allow dirt or other contaminants to enter the sampling bottle. Fill the sampling bottlethree-fourths from the top. Do not fill the bottlecompletely.
6. Place the sampling bottle with the completed labelinto the mailing tube.
Reference: For more information, refer to SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations” and Special Publication,PEHP6001, “How To Take A Good Oil Sample”.
i02510580
Cooling System Water Temperature Regulator -Replace
SMCS Code: 1355-510; 1393-010
Replace the thermostat on a regular basis in order toreduce the chance of unscheduled downtime and of problems with the cooling system.
A new thermostat should be installed after the coolingsystem has been cleaned. Install the thermostatwhile the cooling system is completely drained or while the cooling system coolant is drained to a levelthat is below the thermostat housing.
NOTICEFailure to replace the engine's thermostat on a regu-larly scheduled basis could cause severe engine dam-age.
Note: If you are only installing a new thermostat,drain the cooling system coolant to a level that isbelow the thermostat housing.
g01230293Illustration 125
1. Remove all hoses from the thermostat.
2. Remove the bolts from the thermostat housing.
3. Remove the gasket, the thermostat, and the seal.
NOTICE A used thermostat can be installed if the thermostatconforms to test specifications, and the thermostat isnot damaged. Do not install a used thermostat that hasexcessive buildup or deposits.
NOTICESince Caterpillar engines incorporate a shunt designcooling system, it is mandatory to always operate theengine with a thermostat.
Depending on load, failure to operate with a thermo-stat could result in either an overheating or an over-cooling condition.
NOTICEIf the thermostat is installed incorrectly, it will causethe engine to overheat.
4. Install a new seal in the thermostat housing. Installa new thermostat and a new gasket. Install thethermostat.
5. Install the hoses.
6. Add extended life coolant until the coolant level isvisible in the sight gauge.
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SEBU8076-06 105Maintenance Section
Crankshaft Vibration Damper - Inspect
i02517124
Crankshaft Vibration Damper - Inspect
SMCS Code: 1205-040
g01259311Illustration 126
The crankshaft vibration damper is located at therear end of the engine compartment.
Damage to the vibration damper or failure of thevibration damper will increase torsional vibrations.These vibrations will result in damage to thecrankshaft and to the other engine components. Adeteriorating vibration damper will cause excessivegear train noise at variable points in the speed range.
Caterpillar recommends replacing the vibration
damper for any of the following reasons:
• The engine has had a failure because of a brokencrankshaft.
• The S·O·S oil analysis detected a worn crankshaftfront bearing.
• The S·O·S oil analysis detected a large amount of gear train wear that is not caused by a lack of oil.
• The alignment marks on the hub and on the outer ring are not in alignment because the rubber sealhas separated.
The vibration damper can be used again if none of the above conditions are found and the damper isnot damaged.
Note: Some wobble on the outer ring of the vibrationdamper is normal.
Consult your Caterpillar dealer for more information.
i03595171
Differential and Final Drive Oil- Change
SMCS Code: 3278-044; 4050-044
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
Note: Perform this procedure on one axle at a time.
g01256594Illustration 127
1. Position the wheels so that the final drive drainplug (1) is in the lowest position. This will ensurethat the final drive filler plug (2) is in the correctposition.
Note: The final drives and the differentials are
equipped with ecology drains with internal valves.
2. Remove the final drive plug (1). Install a204-3559 Swivel Adapter into the valve. Clamp ahose to the swivel. A 19 mm (0.75 inch) pipe andhose can be used. Use a 19 mm (0.75 inch) pipewith 3/4-14 NPTF threads. Do not tighten the pipe.
3. Turn the swivel or pipe clockwise in order to openthe internal drain valve. Allow the oil to drain into asuitable container.
4. Clean the drain plug and install the drain plug.
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106 SEBU8076-06Maintenance SectionDifferential and Final Drive Oil Level - Check
5. Repeat steps 1 through 4 for the other final drive.
g01256625Illustration 128
Front axle
g01256626Illustration 129
Rear axle
6. Remove the differential drain plug (3). Install a4C-8563 Swivel into the valve. Clamp a hose tothe swivel. A 25.4 mm (1 inch) pipe and hose canbe used. Use a 25.4 mm (1 inch) pipe with 1-111/2 NPTF threads. Do not tighten the pipe.
7. Turn the swivel or pipe clockwise in order to openthe internal drain valve. Allow the oil to drain into asuitable container.
8. Clean the drain plug and install the drain plug.
9. Remove magnetic plug (4). Clean the magneticplug and install the magnetic plug.
10. Remove differential filler plug (5). .Fill thedifferential with SAE 50 oil until the oil levelreaches the bottom of the fi ller plug opening.
11. Clean the fi ller plug and install the filler plug.
12. Remove the final drive fi ller plug (2). Fill the finaldrive with SAE 50 oil until the oil level reaches thebottom of the fi ller plug opening.
13. Clean the fi ller plug and install the filler plug.
14. Repeat steps 12 through 13 for the other finaldrive.
Note: Fill each axle with 7 L (1.85 US gal) of
1U-9891 Additive.
Note: Refer to Operation and Maintenance Manual,“Lubricant Viscosities and Refill Capacities” for therefill capacity of each axle.
15. If the specified amount of oil will not fit in the finaldrives, install the final drive filler plugs. Operatethe machine on level ground for a few minutes inorder to equalize the oil level. Remove the finaldrive fi ller plugs and add the remaining oil.
16. Operate the machine for a few minutes andrecheck the oil level. The oil level should reach the
bottom of the filler plug opening.
If the oil level is higher than the fi ller plug opening,do not allow the oil to drain to the proper level.Install the filler plug.
17. Repeat this procedure for the other differentialand final drives.
i02509599
Differ ential and Final Drive OilLevel - Check
SMCS Code: 3278-535-FLV; 4050-535-FLV
Note: Perform this procedure on one axle at a time.
g01256594Illustration 130
1. Position the wheels so that the final drive drainplug (1) is in the lowest position. This will ensurethat the final drive filler plug (2) is in the correctposition.
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SEBU8076-06 107Maintenance Section
Differential and Final Drive Oil Sample - Obtain
2. Remove the final drive filler plug. The oil levelshould be at the bottom of the fi ller plug opening.If necessary, add SAE 50 oil until the oil levelreaches the bottom of the fi ller plug opening.
Note: If the oil level is higher than the filler plug
opening, do not allow the oil to drain to the proper level. Install the fi ller plug.
g01256597Illustration 131
Front axle
g01256596Illustration 132
Rear axle
3. Remove the differential filler plug. The oil levelshould be at the bottom of the fi ller plug opening.If necessary, add SAE 50 oil until the oil levelreaches the bottom of the fi ller plug opening.
Note: If the oil level is higher than the filler plugopening, do not allow the oil to drain to the proper level. Install the fi ller plug.
4. Repeat the procedure for the other differential andfinal drives.
i02510250
Differential and Final Drive OilSample - Obtain
SMCS Code: 3278-008; 4050-008; 4070-008; 7542
NOTICE Always use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
1. Operate the machine for a few minutes beforeobtaining the oil sample. This will thoroughly mixthe oil for a more accurate sample.
g01256658Illustration 133
Final Drive Filler Plug
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108 SEBU8076-06Maintenance SectionDrive Shaft Spline (Center) - Lubricate
g01256597Illustration 134
Front Differential Filler Plug
g01256596Illustration 135
Rear Differential Filler Plug
2. The differential and final drives are not equippedwith sampling valves. Obtaining an oil sample willrequire the use of a vacuum pump or equivalentin order to extract the oil from the component.Extract the oil through the filler openings on thedifferential and final drives.
Note: This procedure requires a sample for eachfinal drive and each differential. There will be atotal of three samples per axle and six samples for this procedure in total. Make sure that you properlyrecord the location of each oil sample.
Reference: For more information, refer to SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations” and Special Publication,PEHP6001, “How To Take A Good Oil Sample”.
i02519369
Drive Shaft Spline (Center) -Lubricate
SMCS Code: 3253-086-SN
NOTICETo prevent damage to the seal, articulate the machinefull right or left, before lubricating the splines.
1. Start the engine. Raise the work tool. Release theparking brake. In order to gain access to the driveshaft spline, articulate the machine to the right or to the left.
2. Lower the work tool to the ground. Engage theparking brake. Stop the engine.
g01260769Illustration 136
3. Wipe the fitting before you apply any lubricant. Apply lubricant through the fitting on the center drive shaft spline.
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110 SEBU8076-06Maintenance SectionEngine Air Filter Primary Element - Clean/Replace
NOTICEService the air filter only with the engine stopped. En-gine damage could result.
g01266330
Illustration 139
1. Open the rear access door on either side of themachine. An air fi lter element is located on bothsides of the engine compartment.
g00281967Illustration 140
2. Loosen the cover latches and remove the air cleaner cover.
Note: The latches for the air cleaner housing maysnap open when you release the latches.
3. Remove air filter element (2).
4. Clean the inside of the air filter housing.
5. Install a clean primary air fi lter element.
g01430841Illustration 141
6. Install the air cleaner cover (1) and tighten thelatches.
Note: Keep the latches for the air cleaner housingaway from the muf fler.
7. Close the access door.
8. Repeat this procedure for the air cleaner on theother side of the machine.
Cleaning the Primary Air Filter Element
NOTICECaterpillar recommends certified air filter cleaning ser-
vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and suf ficient filter life.
Observe the following guidelines if you attempt toclean the filter element:
Do not tap or strike the filter element in order to re-move dust.
Do not wash the filter element.
Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filter element. Take extreme care in order to avoid damageto the pleats.
Do not use air filters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage toengine components.
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SEBU8076-06 111Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
The primary air fi lter element can be used up to sixtimes after the element is properly cleaned. Whenthe primary air filter element is cleaned, check for rips or tears in the filter material. The primary air filter element should be replaced at least one timeper year. This replacement should be performed
regardless of the number of cleanings.
NOTICEDo not clean the air filter elements by bumping or tap-ping. This could damage the seals. Do not use ele-ments with damaged pleats, gaskets, or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.
Visually inspect the primary air fi lter element beforecleaning. Inspect the air filter element for damage tothe seal, the gaskets, and the outer cover. Discardany damaged air fi lter elements.
There are two common methods that are used toclean the primary air fi lter element:
• Pressurized air
• Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean a primary air filter element that has not been cleaned more thantwo times. Pressurized air will not remove deposits of carbon and oil. Use fi ltered, dry air with a maximumpressure of 207 kPa (30 psi).
g00281692Illustration 142
Note: When the primary air filter element is cleaned,always begin with the inside of the filter in order toforce dirt particles toward the outside.
Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the stream of air directly at the primary air fi lter element. Dirt couldbe forced further into the pleats.
Vacuum Cleaning
Vacuum cleaning is another method for cleaning aprimary air filter element which requires daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove depositsof carbon and oil.
Inspecting the Primary Air Filter Elements
g00281693Illustration 143
Inspect the clean, dry primary air fi lter element. Usea 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air filter element. Rotate the primary air filter element. Inspectthe primary air fi lter element for tears and/or holes.
Inspect the primary air filter element for light that mayshow through the fi lter material. If it is necessary inorder to confirm the result, compare the primary air filter element to a new primary air fi lter element thathas the same part number.
Do not use a primary air fi lter element that has anytears and/or holes in the filter material. Do not usea primary air filter element with damaged pleats,gaskets or seals. Discard damaged primary air fi lter elements.
Storing Primary Air Filter Elements
If a primary air filter element that passes inspectionwill not be used, the primary air filter element canbe stored for future use.
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112 SEBU8076-06Maintenance SectionEngine Air Filter Secondary Element - Replace
g00281694Illustration 144
Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An air flow restrictionmay result. To protect against dirt and damage, wrap
the primary air fi lter elements in Volatile CorrosionInhibited (VCI) paper.
Place the primary air filter element into a box for storage. For identification, mark the outside of thebox and mark the primary air filter element. Includethe following information:
• Date of cleaning
• Number of cleanings
Store the box in a dry location.
i02473348
Engine Air Filter SecondaryElement - Replace
SMCS Code: 1054-510-SE
NOTICEService the air filter only with the engine stopped. En-gine damage could result.
NOTICE
Always replace the secondary element. Do not at-tempt to reuse it by cleaning. Engine damage couldresult.
Note: Replace the secondary element when youservice the primary element for the third time. If a clean primary element has been installed anda warning for the air filter still occurs, replace thesecondary element. Also if the exhaust smokeremains black and a clean primary element has beeninstalled, replace the secondary element.
g01289757Illustration 145
1. Open the rear access door on either side of themachine. An air fi lter element is located on bothsides of the engine compartment.
2. Remove the primary element.
g00864077Illustration 146
3. Remove the secondary element.
g00864079Illustration 147
4. Cover the air inlet opening. Clean the inside of the air cleaner housing.
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SEBU8076-06 113Maintenance Section
Engine Crankcase Breather - Clean
5. Inspect the gasket between the air inlet pipe andthe air cleaner housing. Replace the gasket if thegasket is damaged.
6. Uncover the air inlet opening. Install a newsecondary element.
7. Install a clean primary element and the cover for the air cleaner housing.
8. Close the access door.
9. Repeat the procedure for the other air cleaner.
i02514485
Engine Crankcase Breather -Clean
SMCS Code: 1317-070
There are a total of two engine crankcase breatherson the right side of the engine. Perform this procedurefor each breather.
1. Park the machine on level ground. Lower thebucket to the ground. Move the transmissioncontrol switch to the NEUTRAL position andengage the parking brake. Shut off the engine.
g01224924Illustration 148
2. Open the upper front access door on the right side
of the machine.
g01431298Illustration 149
3. Loosen breather outlet hose clamp (1). Removethe hose from the breather cover.
4. Loosen breather inlet hose clamp (2) and removebreather (3).
5. Remove the cover from the breather.
6. Check the condition of the cover seal. If the seal isdamaged, replace the seal.
7. Wash the breather element and the cover in clean,nonflammable solvent. Shake the element dry or use air pressure.
8. Inspect the hose for damage. If necessary, replacethe hose.
9. Install the breather element in the cover.
10. Install breather (3). Tighten breather inlet hoseclamp (2).
11. Install the outlet hose and tighten breather outlet
hose clamp (1).
12. Close the upper front engine access door on theright side of the machine.
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114 SEBU8076-06Maintenance SectionEngine Mounts - Inspect
i02164781
Engine Mounts - Inspect
SMCS Code: 1152-040
Caterpillar r ecommends checking the engine mountsfor deterioration and for proper bolt torque. This willhelp to prevent excessive engine vibration that iscaused by improper mounting.
i02481514
Engine Oil Level - Check
SMCS Code: 1000-535-FLV
Hot oil and components can cause personal in- jury.
Do not allow hot oil or components to contactskin.
NOTICEDo not under fill or over fill engine crankcase with oil.Either condition can cause engine damage.
g01268005Illustration 150
1. The engine oil level gauge (2) is located below the
oil filler tube (1) inside the access door on the leftside of the machine. Open the access door.
g01239233Illustration 151
2. Check the engine oil level gauge while the engineis stopped. Maintain the engine oil level in theshaded area (A) of the engine oil level gauge.
3. If necessary, add oil through the fi ller tube.
i02481560
Engine Oil Sample - Obtain
SMCS Code: 1348-008; 7542
Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.
Obtain the Sample and the AnalysisIn addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regular scheduled intervals in order to monitor the condition of the engine and themaintenance requirements of the engine.
Each oil sample should be taken when the oil is warmand when the oil is well mixed in order to ensure thatthe sample is representative of the oil that is in thecrankcase.
Obtain the S·O·S Sample
NOTICE Always use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.
g01239458Illustration 152
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SEBU8076-06 115Maintenance Section
Engine Oil and Filter - Change
g01239460Illustration 153
The S·O·S port for the engine oil is locatedunderneath the engine compartment toward the rear of the machine. The port is located to the right of the
engine oil filters.
Refer to Special Publication, SEBU6250, “S·O·S Oil Analysis” for information that pertains to obtaining asample of the engine oil. Refer to Special Publication,PEHP6001, “How To Take A Good Oil Sample” for more information about obtaining a sample of theengine oil.
i02481135
Engine Oil and Filter - Change
SMCS Code: 1318-510
Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact skin.
NOTICECare must be taken to ensure that all fluids arecontained during performance of inspection, main-tenance, testing, adjusting and the repair of theproduct. Be prepared to collect the fluid with suitable
containers before opening any compartment or dis-assembling any component containing fluids.
Dispose of all fluids according to local regulations andmandates.
Note: Be sure that you obtain a S·O·S engine oilsample before you drain the engine oil.
1. Park the machine on a level surface and engagethe parking brake. Stop the engine.
g01239090Illustration 154
2. The drain valve (1) for the engine oil is locatedunderneath the engine compartment toward therear of the machine. Open the drain valve and
allow the oil to drain into a suitable container.
3. Close the drain valve and clean the area aroundthe drain valve.
4. The engine oil filters (2) are located underneaththe engine compartment toward the rear of themachine.
5. Remove the oil filter elements and discard thefilters properly. Make sure that the old seal isremoved from the fi lter base.
6. Install new fi lters.
a. Apply a thin coat of oil to the seals on the newfilters.
b. Install the new engine oil fi lters hand tight untilthe seal of the engine oil filter contacts thebase. Note the position of the index marks onthe fi lter in relation to a fixed point on the fi lter base.
Note: There are rotation index marks on the engineoil fi lter that are spaced 90 degrees or 1/4 of a turnaway from each other. When you tighten the engineoil filter, use the rotation index marks as a guide.
c. Tighten the filter according to the instructionsthat are printed on the filter. Use the indexmarks as a guide. For non-Caterpillar filters,use the instructions that are provided with thefilter.
Note: You may want to use a Caterpillar strapwrench, or another suitable tool in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.
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116 SEBU8076-06Maintenance SectionEngine Valve Lash - Check
g01289777Illustration 155
7. The oil filler cap (3) is located inside the accessdoor on the left side of the machine. Open theaccess door and remove the filler cap.
8. Fill the engine crankcase with 126 L (33 US gal)of clean oil.
9. Clean the filler cap and install the fi ller cap.
10. Start the engine and allow the oil to warm. Checkthe engine for leaks.
g01239233Illustration 156
11. The engine oil level gauge is located abovethe filler tube. Maintain the engine oil level inthe shaded area (A) of the oil level gauge. If necessary, add oil.
12. Close the access door and stop the engine.
Fast Fill
If your machine is equipped with a deluxe servicecenter, you may drain the engine oil through the fastfill port or you may add the engine oil through a fastfill port.
g01289781Illustration 157
1. Remove the dust cover (4).
2. Attach the hose to the male coupling. Use a
126-7539 Nozzle for this port.
3. Drain the oil or add the oil, as needed.
Reference: For additional information, please refer to Operation and Maintenance Manual, “ServiceCenter”
i01181536
Engine Valve Lash - Check
SMCS Code: 1105-535
For the correct procedure, refer to the appropriateService Manual module for your machine's engine or consult your Caterpillar dealer.
Note: A qualified mechanic should adjust the enginevalve lash because special tools and training arerequired.
i03952000
Engine Valve Rotators - Inspect
SMCS Code: 1109-040
When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to prevent being burned by hot oilor spray.
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SEBU8076-06 117Maintenance Section
Engine Water Pump - Inspect
Caterpillar recommends replacing valve rotators thatare operating improperly. An improperly operatingvalve rotator will shorten valve life because of accelerated wear on the valves. Also, metal particlesfrom a damaged valve rotator could fall into thecylinder and damage to the piston head and to the
cylinder head may result.
g00882731Illustration 158
Start the engine and run the engine at low idle. Watchthe top surface of each valve rotator. Whenever aninlet valve closes or an exhaust valve closes, eachvalve rotator should turn.
If a valve rotator fails to turn, consult your Cat dealer for service.
i02482098
Engine Water Pump - Inspect
SMCS Code: 1361-040
g01239795Illustration 159
Failure of the engine water pump may cause severeengine overheating problems such as cracks in thecylinder head or piston seizure.
Visually inspect the water pump for leaks. If you findleaks, all of the seals on the water pump must bereplaced.
Note: For more information, refer to the appropriateDisassembly and Assembly manual for your machine's engine.
i02518822
Ether Starting Aid Cylinder -Replace(If Equipped)
SMCS Code: 1456-510-CD
Ether is poisonous and flammable.
Breathing ether vapors or repeated contact of ether with skin can cause personal injury.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in livingareas or in the operator's compartment.
Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).
Discard cylinders in a safe place. Do not puncture
or burn cylinders.
Keep ether cylinders out of the reach of unautho-rized personnel.
To avoid possible injury, be sure the brakes are ap-plied and all controls are in Hold or Neutral whenstarting the engine.
g01260501Illustration 160
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118 SEBU8076-06Maintenance SectionFuel Lines - Replace
1. The ether starting aid cylinder is located insidethe engine compartment on the right side of themachine next to the air cleaner. Openthe accessdoor.
2. Loosen the cylinder retaining clamp. Unscrew the
empty ether starting aid cylinder and remove theempty ether starting aid cylinder.
3. Remove the used gasket. Install the new gasketthat is provided with each new ether starting aidcylinder.
4. Install the new ether starting aid cylinder. Tightenthe ether starting aid cylinder and the cylinder retaining clamp hand tight.
5. Close the engine door.
i03898359
Fuel Lines - Replace(Low Pressure)
SMCS Code: 1274
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
NOTICECleanliness is an important factor. The exterior of theengine should be thoroughly cleaned before the re-moval procedure. Ensure the area around the Fuel
Manifold and the Fuel Lines are thoroughly cleaned.This will prevent contaminants from entering the inter-nal mechanism. Before replacing any Fuel Lines, fol-low the instructions that are listed below. Replace theFuel Lines with the correct Fuel Lines Group.
Replace Nonmetallic Fuel Lines
Make sure that the nonmetallic fuel lines are replacedat the engine overhaul.
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SEBU8076-06 119Maintenance SectionFuel Lines - Replace
g02141035
Illustration 161Top view of engine
Note: The following procedures were written for onlyspecific fuel lines that need replacing. Only removethe fuel lines and clamps that need replacement.
Removal Procedure
1. Turn the fuel supply to the OFF position.
2. Turn the battery disconnect switch to the OFFposition.
3. Remove the rear two low-pressure fuel lines (1).
4. Remove the front two low-pressure fuel lines (2).
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120 SEBU8076-06Maintenance SectionFuel System - Prime
Installation Procedure
NOTICEKeep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: Install hose clamps which have been inspectedor install new hose clamps. Refer to Specifications,SENR3130, “Torque Specifications”, “Hose Clamps”for information about selecting and installing theproper hose clamps.
1. Install the rear two low-pressure fuel lines (1) withnew hoses.
2. Install the front two low-pressure fuel lines (2) withnew hoses.
Note: Make sure that the hoses do not contact nearbycomponents. Excessive contact with other surfaceswill produce chafing that could lead to a leak.
3. Carefully inspect the engine for any spilled fuel.Make sure that no fuel remains on or close to theengine.
4. Turn the battery disconnect switch to the ONposition.
5. Turn the fuel supply to the ON position.
Note: Fuel must be added to the fuel system aheadof the fuel filter.
6. Refill the fuel system. Refer to this Operation andMaintenance Manual, “Fuel System - Prime” for information about priming the engine with fuel.
7. Start the engine. Inspect the fuel system for leaks.
i02518810
Fuel System - Prime
SMCS Code: 1250-548
Personal injury or death may result from failure toadhere to the following procedures.
Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.
Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
If the engine does not start, air may be trapped in thefuel lines to the engine. Use the following procedurein order to purge air from the fuel lines.
Electric Fuel Priming Pump
This machine is equipped with an electric fuel primingpump. The switch for the pump is located inside theaccess doors on the front of the engine compartmentto the right of the primary fuel fi lter.
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SEBU8076-06 121Maintenance Section
Fuel System Primary Filter (Water Separator) - Check/Drain
g01258157Illustration 162
g01289805Illustration 163
Note: You can only use the priming pump when
the engine start switch key is OFF.
1. Move the switch for the electric fuel priming pumpto the ON position. Allow the pump to run for several seconds.
2. Return the switch for the electric fuel primingpump to the OFF position.
3. Start the engine. If the engine does not start,or if the engine continues to misfire or smoke,additional priming may be necessary. The electricfuel priming pump will only operate if the enginestart switch key is in the OFF position. Shut off the
engine before additional priming.
4. Run the engine at the LOW IDLE position until theengine runs smoothly.
i02477443
Fuel System PrimaryFilter (Water Separator) -Check/Drain
SMCS Code: 1263-535; 1263-543
Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.
NOTICECare must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-ing, adjusting, and repair of the machine. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide”for tools and suppliesto collect and contain fluids in Caterpillar machines.
Dispose of all fluids according to local regulations.
g01258157Illustration 164
1. The fuel fi lter is located inside the access doorson the front of the engine compartment. Open theaccess doors.
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122 SEBU8076-06Maintenance SectionFuel System Primary Filter (Water Separator) Element - Replace
g01289812Illustration 165
2. Extend the drain hose (1) into a suitable container.The drain (2) is located under the primary fuelfilter/water separator.
3. Open the drain. Allow the fluid to drain into thecontainer.
4. After the separator is completely drained, closethe drain by hand pressure only. Dispose of thedrained fluid in a safe place.
5. Close the access doors.
i02477629
Fuel System Primary Filter
(Water Separator) Element -Replace
SMCS Code: 1260-510; 1263-510-FQ
Personal injury can result from air pressure.
Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.
Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.
Personal injury or death can result from engineoverspeed.
If the engine overspeeds, it can cause injury or parts damage.
Be prepared to stop the engine by closing the air off to the air inlets or by manually pushing down-ward on the governor shutdown rod.
Personal injury or death can result from a fire.
Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.
Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.
NOTICEDo not fill fuel filter with fuel before installing the fuelfilter. Contaminated fuel causes accelerated wear tofuel system parts.
Note: In order to reduce contamination in the
system, do not remove the primary fuel fi lter and thesecondary fuel fi lter simultaneously. Perform theseoperations separately.
Note: After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to bepurged from the high pressure fuel lines before anyservice or repair is performed on the engine fuel lines.
g01258157Illustration 166
1. Open the access door on the front of the enginecompartment.
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SEBU8076-06 123Maintenance Section
Fuel System Secondary Filter - Replace
2. Turn the fuel supply valve (if equipped) to the OFFposition before you perform this maintenance.
3. Place a suitable container under the water separator in order to catch any fuel that mightspill. Clean up any spilled fuel. Clean the outside
of the water separator.
g01289897Illustration 167
4. Install a suitable tube onto the drain (1). Open thedrain. Allow the fluid to drain into the container.Remove the tube.
5. Tighten the drain by hand pressure only.
6. Unscrew the bowl (2) from the primary filter (3).
7. Use a Caterpillar strap wrench in order to removethe fi lter. Discard the old seals and the canister in
a safe place.
8. Clean the bowl.
9. Install a new filter.
a. Apply a thin coat of oil to the seal on the newfilter.
b. Install a new filter hand tight until the seal of the filter contacts the base. Note the positionof the index marks on the filter in relation to afixed point on the filter base.
Note: There are rotation index marks on the filter that are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the fi lter, use therotation index marks as a guide.
c. Tighten the fi lter according to the instructionsthat are printed on the filter. Use the indexmarks as a guide. For non-Caterpillar filters,use the instructions that are provided with thefilter.
Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.
10. Screw the bowl onto the primary filter.
11. Turn the fuel supply valve (if equipped) to the ONposition af ter you perform this maintenance.
12. Close the access doors.
13. Be sure to dispose of the fuel in a safe place.
14. Prime the f uel system. Refer to Operation andMaintenance Manual, “Fuel System - Prime” for more information.
15. Close the access door.
i02477755
Fuel System Secondary Filter -Replace
SMCS Code: 1261-510-SE
g01258157Illustration 168
1. Open the access doors on the front of the enginecompartment.
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124 SEBU8076-06Maintenance SectionFuel Tank Cap and Strainer - Clean
g01237484Illustration 169
2. Remove both fuel filters. Dispose of the usedfilters properly.
3. Clean the fi lter mounting base. Ensure that all of the used gasket is completely removed from thefilter mounting base.
4. Install new filters.
a. Apply a thin coat of oil to the seal on the newfilter.
b. Install the new fi lter hand tight until the seal of the filter contacts the base. Note the positionof the index marks on the fi lter in relation to afixed point on the filter base.
Note: There are rotation index marks on the filter that are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the fi lter, use therotation index marks as a guide.
c. Tighten the filter according to the instructionsthat are printed on the filter. Use the indexmarks as a guide. For non-Caterpillar filters,use the instructions that are provided with thefilter.
Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for final
installation. Make sure that the installation tool doesnot damage the filter.
5. Prime the fuel system.
6. Start the engine and check the fuel filters for leaks.
7. Close the access doors.
i02453628
Fuel Tank Cap and Strainer -Clean
SMCS Code: 1273-070-Z2; 1273-070-STR
g01224431Illustration 170
The fuel tank cap is located under the access door on the left side of the cab platform.
1. Remove the fuel tank cap.
2. Remove the strainer from the fi ller opening.
3. Wash the fuel tank cap and the strainer in a clean,nonflammable solvent.
4. Install the strainer into the fi ller opening.
5. Install the fuel tank cap.
i02453536
Fuel Tank Water and Sediment- Drain
SMCS Code: 1273-543-M&S
g01224392Illustration 171
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SEBU8076-06 125Maintenance Section
Fuses - Replace
The drain valve is located on the bottom of the fueltank on the right side of the machine.
g01111712Illustration 172
1. Open the drain valves. Allow the water and the
sediment to drain into a suitable container.
2. Close the drain valves.
i02541347
Fuses - Replace
SMCS Code: 1417-510
g01272838Illustration 173
The fuse panel is located inside the access door onthe right side door of the cab.
Note: There are three films for reference on theinside of the access door.
Fuses
Fuses – Fuses protect the electricalsystem from damage that is caused byoverloaded electrical circuits. Replace
a fuse if the element separates. If the fuse of
a particular electrical system requires frequentreplacement, check the electrical circuit. Repair theelectrical circuit, if necessary.
NOTICE Always replace fuses with the same type and capacityfuse that was removed. Otherwise, electrical damagecould result.
NOTICEIf it is necessary to replace fuses frequently, an elec-trical problem may exist.
Contact your Caterpillar dealer.
g01272842Illustration 174
Beacon Light and Heated Mirrors(6) –15 Amp
Front Work Light (7) – 15 Amp
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126 SEBU8076-06Maintenance SectionFuses - Replace
Front Work Light (8) – 10 Amp
Front HID Work Lights(9) – 10 Amp
Front Windshield Wiper and Rear Windshield Wiper (10) – 10 Amp
Side Window Wipers (11) – 10 Amp
Hydraulic Electronic Control (12) – 10 Amp
Engine Electronic Control Module andTransmission Electronic Control Module(13) – 10 Amp
Vital Information Management System(14) – 10 Amp
Electronic Display and Product Link(15) – 10 Amp
Heated Seat (21) – 15 Amp
Rear Work Lights (22) – 10 Amp
Rear Work Lights (23) – 10 Amp
Rear HID Work Lights (24) – 10 Amp
Power Receptacle (25) – 10 Amp
Circulation Fan (26) – 15 Amp
Service Connector(27) – 10 Amp
Spare (28) – 10 Amp
Spare (29) – 15 Amp
Spare (30) – 20 Amp
Horn (31) – 10 Amp
Power Receptacle (32) – 15 Amp
Working Light (33) – 10 Amp
Spare (34) – 10 Amp
Air Filter (35) – 15 Amp
Rear Access Egress System (36) – 15 Amp
Spare (37) – 10 Amp
Spare (38) – 10 Amp
Spare (39) – 10 Amp
Spare (40) – 10 Amp
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SEBU8076-06 127Maintenance Section
High Intensity Discharge Lamp (HID) - Replace
Power Receptacle (41) – 15 Amp
Hydraulic Electronic Control (42) – 10 Amp
Transmission Electronic Control Module(43) – 15 Amp
Engine Electronic Control Module (44) –15 Amp
Vital Information Management System(45) – 10 Amp
Electronic Display and Product Link(46) – 10 Amp
Spare (47) – 20 Amp
Spare (48) – 15 Amp
Spare (49) – 10 Amp
Spare (50) – 10 Amp
Relays
Front Work Lights (1) – 24 Volt
Front HID Work Lights (2) – 24 Volt
Rear Access Egress System (3) – 24 Volt
Rear Access Egress System (4) – 24 Volt
Rear Access Egress System (5) – 24 Volt
Spare (16) – 24 Volt
Spare (17) – 24 Volt
Rear HID Work Lights (18) – 24 Volt
Air Filter (19) – 24 Volt
Instrument Panel Illumination(20) – 24Volt
i02245859
High Intensity Discharge Lamp(HID) - Replace(If Equipped)
SMCS Code: 1434-510
HID lamps operate at very high voltages. To avoidelectrical shock and personal injury, disconnectpower before servicing HID lamps.
HID bulbs become very hot during operation.Before servicing, remove power from lamp for atleast five minutes to ensure lamp is cool.
NOTICE Although HID bulb materials may change over time,HID bulbs produced at the time of the printing of thismanual contain mercury. When disposing of this com-ponent, or any waste that contains mercury, pleaseuse caution and comply with any applicable laws.
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128 SEBU8076-06Maintenance SectionHigh Pressure Screens - Clean/Replace
1. Remove the electrical power from the highintensity discharge lamp (HID). The electricalpower must be removed from the HID lamp for at least five minutes, in order to ensure that thebulb is cool.
2. Disassemble the housing for the HID lamp in order to have access to the bulb.
Note: On some HID lamps, the bulb is an integralpart of the lens assembly. The bulb is not removedseparately from the lens assembly. Replace theentire lens assembly on these HID lamps.
3. Remove the bulb from the HID lamp.
4. Install the replacement bulb in the HID lamp.
If the bulb is an integral part of the lens assembly,install the replacement lens assembly in the HID
lamp.
Note: In order to avoid failure to the bulb that ispremature, avoid touching the bulb's surface withyour bare hands. Clean any fingerprints from the bulbwith alcohol prior to operation.
5. Reassemble the housing for the HID lamp. Ensurethat any printing on the lens is oriented correctlywith respect to the HID lamp's mounting positionon the machine.
6. Reattach the electrical power to the HID lamp.
7. Check the HID lamp for proper operation.
Note: Consult your Caterpillar dealer for additionalinformation on HID lamps.
i02576101
High Pressure Screens -Clean/Replace(If Equipped)
SMCS Code: 5068-070-Z3; 5068-510-Z3
There are a total of 7 hydraulic screens on your machine. If the system becomes contaminated or if amajor failure occurs, clean the screens. If a screen isdamaged, replace the screen.
g01293144Illustration 175
There are two screens that are located inside theaccess panel on the underside of the rear bumper.
g01431637
Illustration 176
There is a screen that is located inside the accessdoor directly behind the cab.
g01293146Illustration 177
There is a screen that is located in the compartmentto the right of the cab.
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SEBU8076-06 129Maintenance Section
Hoses and Clamps - Inspect/Replace
g01293148Illustration 178
There is a screen that is located behind the fuel tank.
g01293147Illustration 179
There are two screens that are located inside theaccess panel on the front of the front frame.
1. Stop the engine.
2. Remove the drain plug at the bottom of the fi lter housing. Allow the oil to drain into a suitablecontainer.
3. Use a strap type wrench to remove the filter housing.
4. Remove the high pressure screens from the fi lter
housing.
5. Clean the screen, the drain plug, the filter housing, and the fi lter housing base with a clean,nonflammable solvent. Allow the components todry.
6. Install the screen and the drain plug in the filter housing.
7. Install the fi lter housing on the filter housing base.
8. Start the engine. Make sure that the parking brakeis engaged.
9. Operate the steering, the brakes, and theattachment in order to circulate the oil. Check thehigh pressure screens for leaks.
10. Stop the engine.
i03898378
Hoses and Clamps -Inspect/Replace
SMCS Code: 1000; 7554-040; 7554-510
Inspect the Hoses and the Clamps
The nonmetallic hoses and the clamps must beinspected periodically in order to ensure safeoperation and continuous operation of the enginefuel system. Take proper safety precautions beforeinspecting or replacing hoses and clamps.
Note: Always use a board or cardboard when theengine components are checked for leaks. Leakingfluid that is under pressure can cause serious injuryor possible death, including leaks that are the sizeof a pin hole. Refer to Operation and MaintenanceManual, “General Hazard Information” for moreinformation.
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130 SEBU8076-06Maintenance SectionHoses and Clamps - Inspect/Replace
Nonmetallic Fuel Lines
g02141367Illustration 180
(1) R ear low -pressure fuel l ines (2) Front low -pressure fuel l ines
Inspect hoses (1) and (2) of the engine fuel systemfor leaks that are caused by the following conditions.
Replace any non-metallic fuel line (hose) whichexhibits any of the following conditions.
• Hoses which are cracked
• Hoses which are soft
• Outer covering that is chafed or cut
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Hoses which exhibit signs of leakage which are notthe result of loose couplings or clamps
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SEBU8076-06 131Maintenance Section
Hoses and Clamps - Inspect/Replace
Failure to replace a non-metallic fuel line (hose)which exhibits any of the above conditions mayresult in a hazardous situation.
Inspect all clamps for the following conditions.Replace any clamp which exhibits signs of any of the
following conditions.
• Cracking
• Looseness
• Damage
Inspect all couplings for leaks. Replace any couplingwhich exhibits signs of leaks.
Each installation application can be different. Thedifferences depend on the following factors:
• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of thefittings
Due to extreme temperature changes, the hose willheat set. Heat setting causes hose clamps to loosen.The loose clamp can result in leaks. A constanttorque hose clamp will help to prevent loose hoseclamps.
Replace hoses that are cracked or soft. Replacehoses that show signs of leakage. Replace hosesthat show signs of damage. Replace hose clampsthat are cracked or damaged. Tighten or replacehose clamps which are loose.
Replace the Hoses and the Clamps
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” or refer to Special Pub-lication, PECJ0003, “Caterpillar Shop Supplies andTools Catalog” for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
Nonmetallic Fuel Lines
Personal injury can result from removing hoses or fittings in a pressure system.
Failure to relieve pressure can cause personal in- jury.
Do not disconnect or remove hoses or fittings un-til all pressure in the system has been relieved.
NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over any dis-connected fuel system components.
Replace the non-metallic fuel lines in a set.
1. Stop the engine and turn off the fuel supply.
2. Turn the battery disconnect switch to the OFFposition.
3. Drain the fuel from the fuel system to a level thatis below the hose that is being replaced.
4. Remove the hose clamps.
5. Disconnect the old hose. Refer to Illustration 180.
6. Replace the old hose with a new hose.
7. Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications,SENR3130, “Torque Specifications”, “HoseClamps” for information about selecting andinstalling the proper hose clamps.
8. Carefully inspect the engine for any spilled fuel.Make sure that no fuel remains on or close to theengine.
Note: Fuel must be added to the fuel system ahead
of the fuel filter.
9. Refill the fuel system. Refer to this Operation andMaintenance Manual, “Fuel System - Prime” for information about priming the engine with fuel.
10. Start the engine. Inspect the fuel system for leaks.
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132 SEBU8076-06Maintenance SectionHydraulic Oil Tank Filter Element (Case Drain) (Steering) (Brake) - Replace
i02575180
Hydraulic Oil Tank Filter Element (Case Drain)(Steering) (Brake) - Replace
SMCS Code: 5068-510; 5091-510-US
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations andmandates.
g01237708Illustration 181
Top view
1. The access door to the hydraulic tank is locatedon the left side of the cab platform. Open theaccess door.
g01238383Illustration 182
2. Press the button on the breaker relief valve (3 ) inorder to relieve any tank pressure.
3. Clean the cover (2) and the surrounding surfacearea.
4. Remove the four bolts (1) and remove the cover (2).
5. Remove the used filter element. Be sure todispose of the used fi lter properly.
6. Install a new filter element and replace the cover.
7. Install the cover and the four bolts.
8. Close the access door.
i02594960
Hydraulic Oil Tank Filter Elements (Case Drain)(Implement) (Hydraulic Fan) -Replace
SMCS Code: 5068-510-II; 5068-510-HFN;5091-510-HFN; 5091-510-II
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
g01237676Illustration 183
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SEBU8076-06 133Maintenance Section
Hydraulic System Oil (Implement) (Hydraulic Fan) - Change
1. The access door to the hydraulic tank is locatedon top of the engine compartment toward thefront. Open the access door.
g01238142Illustration 184
2. Press the button on the breaker relief valve (3 ) inorder to relieve any tank pressure.
3. Clean the cover (2) and the surrounding surfacearea.
4. Remove the four bolts (1) and remove the cover (2).
5. There are two filters for each cover assembly.Remove the used filter elements. Be sure todispose of the used filters properly.
6. Install the new filter elements and replace the
cover.
7. Install the cover and the four bolts.
8. Repeat steps 4 through 7 for the four remainingfilters.
9. Close the access door.
i03245633
Hydraulic System Oil(Implement) (Hydraulic Fan) -Change
SMCS Code: 5056-044
Selection of the Oil Change Interval
Your machine may be able to use a 4000 hour interval for the hydraulic oil. The hydraulic oil is inthe system that is not integral to the service brakes,the clutches, the final drives, or the differentials.The standard change interval is 2000 hours. The oilshould be monitored in additional increments of 500hours. The extended 4000 hour interval can be usedif the following criteria are met.
HYDO Advanced 10
Cat HYDO Advanced 10 is the preferred oil for use inmost Caterpillar machine hydraulic and hydrostatictransmission systems when ambient temperatureis between −20 °C (−4 °F) and 40 °C (104 °F). CatHYDO Advanced 10 has an SAE viscosity grade of 10W. Cat HYDO Advanced 10 has a 50% increasein the standard oil drain interval (up to 3000 hours)for machine hydraulic systems over second and thirdchoice oils when you follow the maintenance intervalschedule for oil filter changes and for oil sampling thatis stated in the Operation and Maintenance Manual.
6000 hour oil drain intervals are possible when usingS·O·S Services oil analysis. When you switch to CatHYDO Advanced 10, cross contamination with theprevious oil should be kept to less than 10%. Consultyour Cat dealer for details about the benefits fromthe improved performance designed into Cat HYDO
Advanced 10.
Oil Filters
Caterpillar oil fi lters are recommended. The intervalfor changing the oil fi lter should be 500 hours.
Oil
The 6000 hour interval for changing the oil is specificto HYDO Advance 10.
The 4000 hour interval for changing the oil is for thefollowing oil types.
• Cat Hydraulic Oil (HYDO)
• CatTransmission/Drive Train Oil (TDTO)
• Cat TDTO-TMS
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134 SEBU8076-06Maintenance SectionHydraulic System Oil (Implement) (Hydraulic Fan) - Change
• Cat Diesel Engine Oil
• Cat Biodegradable Hydraulic Oil (HEES)
• Cat Multipurpose Tractor Oil (MTO)
• Heavy-Duty Diesel Engine Oil with a minimumzinc content of 900 parts per million (ppm)
Heavy-duty oils are identified by the followingclassifications: ECF-1, CG-4, CF, and TO-4.
Note: Industrial hydraulic oils are not recommendedfor use in Caterpillar hydraulic systems. These oilsare more likely to cause corrosion and excessivewear.
Monitoring the Condition of the Oil
The oil should be monitored during intervals of 500hours. Caterpillar's standard S·O·S Fluids Analysis or an equivalent oil sampling program should be used.
If an oil sampling program is not available, thestandar d 2000 oil change interval should be used.
Measured Data
The following information should be monitored whenyou sample the oil:
• Significant changes in wear metals should bemonitored. These metals include iron, copper,
chromium, lead, aluminum, and tin.
• The following additives should be observed for significant changes: Zinc, calcium, magnesium,and phosphorus.
• Contaminants should not be present. Thesecontaminants include fuel and antifreeze. Water content should be .5 percent or less.
• The silicon level should not exceed 15 parts per million for new oil. The particle counts should bemonitored.
• The recommended level of cleanliness for Caterpillar machines that are operated in the fieldis ISO 18/15 or cleaner. The cleanliness shouldbe monitored by particle count analysis. Thelevels of contamination should not exceed normallevels by more than two ISO codes. Action shouldbe taken in order to determine the cause of thecontamination. The system should be returned tothe original levels of contamination.
• There should not be significant changes in sodium,silicon, copper, and potassium.
• The allowable level of oxidation is 40 percent (0.12 Abs units).
• The kinematic viscosity at 100 °C (212 °F) shouldnot exceed a 2 cSt change.
Procedure for Changing theHydraulic Oil
NOTICECare must be taken to ensure that all fluids arecontained during performance of inspection, main-tenance, testing, adjusting and the repair of theproduct. Be prepared to collect the fluid with suitablecontainer s before opening any compartment or dis-assembling any component containing fluids.
Dispose of all fluids according to local regulations andmandates.
Note: Be sure that you obtain an S·O·S hydraulic oilsample before you drain the hydraulic oil.
1. Operate the machine in order to warm the oil.
2. Park the machine on level ground. Lower thework tool to the ground with a slight downwardpressure. Engage the parking brake and stop theengine.
g01237676Illustration 185
3. Open the access door on top of the enginecompartment.
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SEBU8076-06 135Maintenance Section
Hydraulic System Oil (Implement) (Hydraulic Fan) - Change
g01237678Illustration 186
4. Push the button on the top of breaker relief valve(1) in order to relieve any tank pressure.
5. Remove hydraulic tank filler cap (2). Remove thestrainer from the tube.
6. Wash the strainer and the filler cap in a clean,nonflammable solvent.
7. There is an ecology drain for the implementhydraulic tank that is located in the service center.Remove the drain plug and drain the oil. Allow theoil to drain into a suitable container.
8. Clean the drain plug and install the drain plug.
9. Install the filler strainer.
g01237715Illustration 187
10. Fill the hydraulic oil tank with 475 L (125 US gal)of clean oil. Make sure that the oil level is withinthe green range (A) on the sight gauge.
11. Start the engine and run the engine for at least tenseconds. Then, stop the engine and add hydraulicoil to the tank until the oil level is in the greenr ange (A) on the sight gauge.
12. Start the engine and run the engine at low idle.Cycle the implements so that all hydraulic systemsare filled with oil.
13. Stop the engine and top off the hydraulic tank sothat the oil level is within the green range(A) on
the sight gauge.
Note: The oil must be free of air bubbles. If air bubbles are present in the hydraulic oil, air is enteringthe hydraulic system. Inspect the hydraulic suctionline and the hose clamps.
14. If necessary, tighten any loose clamps or anyloose connections. Replace any damaged hoses.
15. Inspect the gasket on the hydraulic tank fi ller capfor damage. Replace the gasket, if necessary.Install the filler cap.
16. Stop the engine. Close the access door.
Fast Fill Port
If your machine is equipped with a deluxe servicecenter, you may add the hydraulic oil through a fastfill port.
g01432631Illustration 188
1. Remove the dust cover (3).
2. Attach the hose to the male coupling. Use a127-9088 Nozzle for this port.
3. Add the oil, as needed.
Reference: For more information, refer to Operationand Maintenance Manual, “Service Center”
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136 SEBU8076-06Maintenance SectionHydraulic System Oil (Steering) (Brake) - Change
i03245632
Hydraulic System Oil (Steering)(Brake) - Change
SMCS Code: 5056-044
Personal injury can result from hydraulic oil pres-sure and hot oil.
Hydraulic oil pressure can remain in the hydraulicsystem after the engine has been stopped. Seri-ous injury can be caused if this pressure is not re-leased before any service is done on the hydraulicsystem.
Make sure all of the attachments have been low-
ered, oil is cool before removing any componentsor lines. Remove the oilfiller cap only when the en-gine is stopped, and the filler cap is cool enoughto touch with your bare hand.
Selection of the Oil Change Interval
Your machine may be able to use a 4000 hour interval for the hydraulic oil. The hydraulic oil is inthe system that is not integral to the service brakes,the clutches, the final drives, or the differentials.The standard change interval is 2000 hours. The oilshould be monitored in additional increments of 500
hours. The extended 4000 hour interval can be usedif the following criteria are met.
HYDO Advanced 10
Cat HYDO Advanced 10 is the preferred oil for use inmost Caterpillar machine hydraulic and hydrostatictransmission systems when ambient temperatureis between −20 °C (−4 °F) and 40 °C (104 °F). CatHYDO Advanced 10 has an SAE viscosity grade of 10W. Cat HYDO Advanced 10 has a 50% increasein the standard oil drain interval (up to 3000 hours)for machine hydraulic systems over second and thirdchoice oils when you follow the maintenance interval
schedule for oil filter changes and for oil sampling thatis stated in the Operation and Maintenance Manual.6000 hour oil drain intervals are possible when usingS·O·S Services oil analysis. When you switch to CatHYDO Advanced 10, cross contamination with thepr evious oil should be kept to less than 10%. Consultyour Cat dealer for details about the benefits fromthe improved performance designed into Cat HYDO
Advanced 10.
Oil Filters
Caterpillar oil fi lters are recommended. The intervalfor changing the oil fi lter should be 500 hours.
Oil
The 6000 hour interval for changing the oil is specificto HYDO Advance 10.
The 4000 hour interval for changing the oil is for thefollowing oil types.
• Caterpillar Hydraulic Oil (HYDO)
• CaterpillarTransmission/Drive Train Oil (TDTO)
• Caterpillar TDTO (TMS)
• Caterpillar Diesel Engine Oil
• Caterpillar Biodegradable Hydraulic Oil (HEES)
• Caterpillar Multipurpose Tractor Oil (MTO)
• Heavy-Duty Diesel Engine Oil with a minimumzinc content of 900 parts per million (ppm)
Heavy-duty oils are identified by the followingclassifications: CF, CF-4, CG-4, and CH-4.
Note: Industrial hydraulic oils are not recommendedin Caterpillar hydraulic systems. These oils are morelikely to cause corrosion and excessive wear.
Monitoring the Condition of the Oil
The oil should be monitored during intervals of 500hours. Caterpillar's standard S·O·S Fluids Analysis or an equivalent oil sampling program should be used.
If an oil sampling program is not available, thestandard 2000 oil change interval should be used.
Measured Data
The following information should be monitored when
you sample the oil:
• Significant changes in wear metals should bemonitored. These metals include iron, copper,chr omium, lead, aluminum, and tin.
• The following additives should be observed for significant changes: Zinc, calcium, magnesium,and phosphorus.
• Contaminants should not be present. Thesecontaminants include fuel and antifreeze. Water content should be .5 percent or less.
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SEBU8076-06 137Maintenance Section
Hydraulic System Oil (Steering) (Brake) - Change
• The silicon level should not exceed 15 parts per million for new oil. The particle counts should bemonitored.
• The recommended level of cleanliness for Caterpillar machines that are operated in the field
is ISO 18/15 or cleaner. The cleanliness shouldbe monitored by particle count analysis. Thelevels of contamination should not exceed normallevels by more than two ISO codes. Action shouldbe taken in order to determine the cause of thecontamination. The system should be returned tothe original levels of contamination.
• There should not be significant changes in sodium,silicon, copper, and potassium.
• The allowable level of oxidation is 40 percent (0.12 Abs units).
• The kinematic viscosity at 100 °C (212 °F) shouldnot exceed a 2 cSt change.
Procedur e for Changing theHydraulic Oil
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, ad justing and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-
nent containing fl
uids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
Note: Be sure that you obtain an S·O·S hydraulic oilsample before you drain the hydraulic oil.
1. Operate the machine in order to warm the oil.
2. Park the machine on level ground. Lower the worktool to the ground and apply slight downwardpressure. Engage the parking brake and stop theengine.
g01238795Illustration 189
g01237711Illustration 190
3. The hydraulic tank is located on the left side of
the machine. Push the button on the top of thebreaker relief valve (1) in order to relieve any tankpressure.
4. Remove hydraulic tank fi ller cap (2). Remove thestrainer from the tube.
5. Wash the strainer and the filler cap in a clean,nonflammable solvent.
6. There is an ecology drain for the implementhydraulic tank that is located in the service center.Remove the drain plug and drain the oil. Allow theoil to drain into a suitable container.
7. Attach a hose to an oil drain coupling. Install theoil drain coupling into the drain plug opening inorder to open the internal drain valve. Allow the oilto drain into a suitable container.
8. Clean the drain plug and install the drain plug.
9. Install the filler strainer.
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138 SEBU8076-06Maintenance SectionHydraulic System Oil Filter (Implement Pilot) - Replace
g01237715Illustration 191
10. Fill the hydraulic oil tank with 185 L (49 US gal)of clean oil. Maintain the oil level within the greenrange (A) on the sight gauge.
11. Start the engine and run the engine for at least tenseconds. Then, stop the engine and add hydraulicoil to the tank until the oil level is within the greenrange (A) on the sight gauge.
12. Start the engine and run the engine at low idle.Operate the steering and the brakes in order tocirculate the oil.
13. Stop the engine and top off the hydraulic tank sothat the oil level is within the green range (A) onthe sight gauge.
Note: The oil must be free of air bubbles. If air bubbles are present in the hydraulic oil, air is enteringthe hydraulic system. Inspect the hydraulic suctionline and the hose clamps.
14. If necessary, tighten any loose clamps or anyloose connections. Replace any damaged hoses.
15. Inspect the gasket on the hydraulic tank fi ller capfor damage. Replace the gasket, if necessary.Install the filler cap.
Fast Fill Port
If your machine is equipped with a deluxe servicecenter, you may add the hydraulic oil through a fastfill port.
g01432447Illustration 192
1. Remove the dust cover (3).
2. Attach the hose to the male coupling. Use a
127-9088 Nozzle for this port.
3. Add the oil, as needed.
Reference: For more information, refer to Operationand Maintenance Manual, “Service Center”
i03866315
Hydraulic System Oil Filter (Implement Pilot) - Replace(Axle Oil Cooler)
SMCS Code: 5068-510-PS; 5092-510
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations andmandates.
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SEBU8076-06 139Maintenance Section
Hydraulic System Oil Filter (Steering Oil Cooler) (Steering Pilot) - Replace
g01258157Illustration 193
1. Stop the engine.
2. Turn the engine start switch key to ON.
3. Move the hydraulic control levers through all of the positions in order to release pressure.
4. Turn the engine start switch key to OFF.
5. Press the button on the breaker relief valve inorder to relieve any hydraulic tank pressure.
6. The fi lter is located inside the access door on thefront of the engine compartment. Open the accessdoors.
g01259764Illustration 194
7. Use a strap type wrench to remove the filter housing.
8. Remove the fi lter element. Dispose of the usedfilter element properly.
9. Clean the fi lter mounting base.
10. Check the condition of the seal. If the seal isdamaged, replace the seal with a new seal.
11. Insert a new filter element and install the filter housing.
12. Close the access doors.
i02594988
Hydraulic System Oil Filter
(Steering Oil Cooler) (SteeringPilot) - Replace
SMCS Code: 431F-510; 5068-510-ZH
1. Press the button on the breaker relief valve inorder to relieve any hydraulic tank pressure.
g01431637Illustration 195
2. The steering system oil fi lter is located inside thelarge access door on the cab platform behind thecab. Open the access door.
g01260043Illustration 196
3. Remove the hydraulic filter and dispose of thefilter properly. Make sure that the old filter seal isremoved from the fi lter base.
4. Apply a thin coat of oil to the seal on the new filter.
5. Install a new hydraulic filter hand tight until theseal of the filter contacts the base. Note theposition of the index marks on the fi lter in relationto a fixed point on the fi lter base.
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140 SEBU8076-06Maintenance SectionHydraulic System Oil Level (Implement) (Hydraulic Fan) - Check
Note: There are rotation index marks on the hydraulicfilter that are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the fi lter, use therotation index marks as a guide.
6. Tighten the filter according to the instructions
that are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, use theinstructions that are provided with the fi lter.
Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.
7. Close the access door.
i02594992
Hydraulic System Oil Level(Implement) (Hydraulic Fan) -Check
SMCS Code: 5056-535-FLV
g01290372Illustration 197
1. The sight gauge is located on the hydraulic tankon the left side of the machine.
g01237715Illustration 198
2. Park the machine on level ground. Lower the worktool to the ground and apply slight downwardpressure. Engage the parking brake and stop theengine.
3. Check the oil level while the engine is stopped.
Maintain the oil level within the green area (A) onthe sight gauge.
g01237676Illustration 199
4. If necessary, add oil to the hydraulic tank.Open the access door on the top of the enginecompartment.
g01237678Illustration 200
5. Push the button on top of the breaker relief valve(1) in order to relieve any tank pressure. Removethe filler cap (2) and add the oil.
6. Install the fi ller cap and close the access door.
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SEBU8076-06 141Maintenance Section
Hydraulic System Oil Level (Steering) (Brake) - Check
i02575211
Hydraulic System Oil Level(Steering) (Brake) - Check
SMCS Code: 5056-535-FLV
g01237707Illustration 201
The hydraulic tank for the steering system and for the braking system is located on the left side of themachine.
1. Park the machine on level ground. Lower the worktool to the ground and apply slight downwardpressure. Engage the parking brake and stop theengine.
g01237715Illustration 202
2. Check the oil level while the engine is stopped.Maintain the oil level within the green range (A)on the sight gauge.
g01237708Illustration 203
3. If necessary, add oil to the hydraulic tank. Openthe access door on the left side of the cab platform.
g01237711
Illustration 204
4. Push the button on the top of the breaker relief valve (1) in order to relieve any tank pressure.Remove the fi ller cap (2) and add oil.
5. Install the fi ller cap and close the access door.
i02594994
Hydraulic System Oil Sample(Implement) (Hydraulic Fan) -Obtain
SMCS Code: 5050-008; 5056-008; 7542
Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.
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142 SEBU8076-06Maintenance SectionHydraulic System Oil Sample (Steering) (Brake) - Obtain
Obtain the Sample and the Analysis
In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regular scheduled intervals in order tomonitor the condition of the hydraulic system and the
maintenance requirements of the hydraulic system.
Each oil sample should be taken when the oil is warmand when the oil is well mixed in order to ensure thatthe sample is representative of the oil in the hydraulicsystem.
Obtain the S·O·S Sample
At operating temperature, the hydraulic tank is hotand under pressure.
Hot oil and components can cause personal in- jury. Do not allow hot oil or components to contactskin.
Remove the filler cap only when the engine isstopped, and the filler cap is cool enough to touchwith your bare hand. Remove the filler cap slowlyin order to relieve pressure.
g01258157Illustration 205
1. Open the access doors on the front of the enginecompartment.
g01237651Illustration 206
2. The sampling port is below the primary fuel filter on the left side.
Reference: For information on obtaining a sample,refer to Special Publication, SEBU6250, “S·O·S Oil Analysis” and Special Publication, PEHP6001, “HowTo Take A Good Oil Sample”.
i02575239
Hydraulic System Oil Sample(Steering) (Brake) - Obtain
SMCS Code: 4250-008; 4300-008; 5050-008;5056-008; 7542
Obtain the Sample and the Analysis
In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regular scheduled intervals in order tomonitor the condition of the hydraulic system and themaintenance requirements of the hydraulic system.
Each oil sample should be taken when the oil is warmand when the oil is well mixed in order to ensure thatthe sample is representative of the oil in the hydraulicsystem.
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SEBU8076-06 143Maintenance Section
Hydraulic Tank Breaker Relief Valve (Implement) (Hydraulic Fan) - Clean
Obtain the S·O·S Sample
At operating temperature, the hydraulic tank is hot
and under pressure.
Hot oil and components can cause personal in- jury. Do not allow hot oil or components to contactskin.
Remove the filler cap only when the engine isstopped, and the filler cap is cool enough to touchwith your bare hand. Remove the filler cap slowlyin order to relieve pressure.
g01431637Illustration 207
1. Open the access door on the cab platform behind
the cab.
g01260085Illustration 208
2. The sampling port is located on the left side of the machine.
Reference: For information on obtaining a sample,refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” and Special Publication, PEHP6001, “HowTo Take A Good Oil Sample”.
i02595000
Hydraulic Tank Breaker Relief Valve (Implement) (HydraulicFan) - Clean
SMCS Code: 5118-070
g01238011Illustration 209
g01238013Illustration 210
Use the following procedure when you clean thehydraulic tank breaker relief valve:
1. Open the access door.
2. Push the button on the top of the breaker relief valve in order to relieve any tank pressure.
3. Remove the breaker relief valve.
4. Clean the breaker relief valve in a clean,nonflammable solvent. Dry the breaker relief valvethoroughly by shaking or by using compressed air.
5. Install the breaker relief valve.
6. Close the access door.
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144 SEBU8076-06Maintenance SectionHydraulic Tank Breaker Relief Valve (Steering) (Brake) - Clean
i02575243
Hydraulic Tank Breaker Relief Valve (Steering) (Brake) - Clean
SMCS Code: 5118-070
g01290367Illustration 211
g01238012Illustration 212
Use the following procedure when you clean thehydraulic tank breaker relief valve:
1. Open the access door.
2. Push the button on the top of the breaker relief valve in order to relieve any tank pressure.
3. Remove the breaker relief valve.
4. Clean the breaker relief valve in a clean,nonflammable solvent. Dry the breaker relief valvethoroughly by shaking or by using compressed air.
5. Install the breaker relief valve.
6. Close the access door.
i02106227
Oil Filter - Inspect
SMCS Code: 1308-507; 3067-507; 4295-507;431F-507; 5068-507
Inspect a Used Filter for Debris
g00100013Illustration 213
The element is shown with debris.
Use a filter cutter to cut the filter element open.Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the filter element can indicate a possiblefailur e.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals andnonferrous metals.
Ferrous metals can indicate wear on steel parts andon cast iron parts.
Nonf errous metals can indicate wear on thealuminum parts of the engine such as main bearings,rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter element. This could be caused by friction and bynor mal wear. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount
of debris is found.
Using an oil filter element that is not recommendedby Caterpillar can result in severe engine damageto engine bearings, to the crankshaft, and to other parts. This can result in larger particles in unfilteredoil. The particles could enter the lubricating systemand the particles could cause damage.
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SEBU8076-06 145Maintenance Section
Oil Renewal System Oil - Add
i02595003
Oil Renewal System Oil - Add(If Equipped)
SMCS Code: 1348-538
Park the machine on level ground. Lower theattachment to the ground. Engage the parking brakeand turn off the engine.
Note: There are two methods for adding oil to theORS.
Manual
g01298799Illustration 214
In order to fi ll the ORS manually, add oil through thefi
ller tube (1) until the sight gauge (2) indicates thatthe ORS is “FULL”.
Fast Fill
g01298806Illustration 215
In order to fi ll the ORS, attach a 126-7539 Nozzleto the male coupling (3). Fill the ORS until the sightgauge indicates that the ORS is “FULL”.
Note: You may also use the “FULL” indicator light(4) in the service center in order to determine when
the ORS is full.
Reference: For more information, refer to Operationand Maintenance Manual, “Service Center”.
i02520645
Oil Renewal System Oil Level -Check(If Equipped)
SMCS Code: 1348-535-FLV
1. Park the machine on level ground. Lower the worktool to the ground. Engage the parking brake andstop the engine.
g01261732Illustration 216
2. The oil level gauge (1) for the ORS is locatedinside the small access door to the left of the cab.
3. If the oil level is low, add SAE 10W30 oil throughthe filler tube (2) until the oil level is within theproper range.
Note: You may also use the “Low” indicator light inthe service center in order to determine when theORS is low.
Reference: For more information, refer to Operationand Maintenance Manual, “Service Center”.
Note: Keeping a daily maintenance log of all theadditions of oil is necessary for determining whether the ORS is working properly.
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SEBU8076-06 147Maintenance Section
Rear Access Egress System Oil - Change
g01433455Illustration 220
Apply lubricant through the two remote fittings (1).
Reference: For more information , refer to Operationand Maintenance Manual, “Lubricant Viscosities”
i02880062
Rear Access Egress SystemOil - Change
(If Equipped)SMCS Code: 5056-044-OLF; 7011-044-OC
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
1. Park the machine on level ground. Engage theparking brake and stop the engine.
g01433485Illustration 221
2. The oil tank for the Rear Access Egress System(RAES) is located on the left side of the machine.Open the access panel.
g01433545Illustration 222
3. Press the button on the breaker relief valve (2) inorder to relieve any tank pressure.
4. Remove the filler cap (1). Remove the strainer from the tube.
5. Wash the strainer and the filler cap in a clean,nonflammable solvent.
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148 SEBU8076-06Maintenance SectionRear Access Egress System Oil Filter - Replace
g01433547Illustration 223
6. The oil tank for the RAES is equipped with anecology drain (3). Attach a hose to an oil draincoupling. Install the oil drain coupling into thedrain plug opening in order to open the internaldrain valve. Allow the oil to drain into a suitablecontainer.
7. Clean the drain plug and install the drain plug.
8. Install the filler strainer.
9. Fill the tank with 13.2 L (3.5 US gal) of cleanSynthetic ATF oil. Maintain oil level within the sightgauge (4).
Reference: Refer to Operation and MaintenanceManual, “Lubricant Viscosities and RefillCapacities” for the correct type of oil and for thecorrect amount of oil.
10. Install filler cap (1).
i02879987
Rear Access Egress SystemOil Filter - Replace(If Equipped)
SMCS Code: 5068-510-OLF; 7011-510-FI
g01433485Illustration 224
1. The oil fi lter for the Rear Access Egress System(RAES) is located inside the access door on theleft side of the machine. Open the access door.
g01433487Illustration 225
2. Press the button on the breaker relief valve (1) inorder to relieve any tank pressure.
3. Remove the oil filter (2) and dispose of the fi lter properly. Make sure that the old filter seal isremoved from the fi lter base.
4. Apply a thin coat of oil to the seal on the new filter.
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SEBU8076-06 149Maintenance Section
Rear Access Egress System Oil Level - Check
5. Install a new oil filter hand tight until the seal of the fi lter contacts the base. Note the position of the index marks on the filter in relation to a fixedpoint on the filter base.
Note: There are rotation index marks on the oil fi lter
that are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the fi lter, use therotation index marks as a guide.
6. Tighten the filter according to the instructionsthat are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, use theinstructions that are provided with the fi lter.
Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.
7. Close the access door.
i02880133
Rear Access Egress SystemOil Level - Check(If Equipped)
SMCS Code: 5056-535-FLV; 7011-535-FLV
The oil tank for the Rear Access Egress System
(RAES) is located on the left side of the machine.
g01433598Illustration 226
1. Maintain the hydraulic oil level above the sightglass.
g01433485Illustration 227
2. If necessary, add oil to the oil tank. Open theaccess door on the left side of the machine.
g01433545Illustration 228
3. Press the button on the top of the breaker relief valve (2) in order to relieve any tank pressure.Remove the fi ller cap (1) and add oil.
4. Install the fi ller cap and close the access door.
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150 SEBU8076-06Maintenance SectionRear Access Egress System Oil Sample - Obtain
i03044865
Rear Access Egress SystemOil Sample - Obtain(If Equipped)
SMCS Code: 5050-008-OLF; 5056-008-OLF; 7542
Hot oil and components can cause personal in- jury.
Do not allow hot oil or components to contactskin.
NOTICECare must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
Obtain the Sample and the Analysis
In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regular scheduled intervals in order tomonitor the condition of the hydraulic system and themaintenance requirements of the hydraulic system.
Each oil sample should be taken when the oil is warmand when the oil is well mixed in order to ensure thatthe sample is representative of the oil in the hydraulicsystem.
Obtain the S·O·S Sample
Note: The Rear Access Egress System (RAES) isnot equipped with a sampling valve. Obtaining asample of the RAES oil will require a vacuum pumpor an equivalent.
g01433485Illustration 229
1. Open the access door on the left side of themachine.
g01433545Illustration 230
2. Press the button on the breaker relief valve (2) inorder to relieve any tank pressure.
3. Remove the filler cap (1) and withdraw the oilthrough the fi ller opening.
4. Install filler cap.
Reference: For information on obtaining a sample,refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” and Special Publication, PEHP6001, “HowTo Take A Good Oil Sample”.
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SEBU8076-06 151Maintenance Section
Rear Access Egress System Rolling Guards - Clean
i02880501
Rear Access Egress SystemRolling Guards - Clean(If Equipped)
SMCS Code: 7011-070-GD; 7150-070-OLF
Personal injury can result from air pressure.
Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.
Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.
The rolling guards need to be cleaned regularly. Adjust the frequency of cleaning according to theeffects of the operating environment.
NOTICE An excess accumulation of dirt and debris may affectthe tension of the rolling guards. Improper tension maycause excessive wear to the RAES components.
After the rolling guards are cleaned, visually inspectthe rolling guards. If excessive sagging exists, adjust-ment may be needed.
Refer to System Operation/Testing and Adjusting for the proper procedure.
g01433917Illustration 231
1. Lower the Rear Access Egress System (RAES) inorder to fully extend the rolling guards (1).
2. Blow out the rolling guards with compressed air.
Move the air nozzle in a systematic pattern so thatthe air flow covers the whole guard.
3. Visually inspect the tension of the rolling guards.
Note: If excessive sagging exists, adjustment may beneeded. Refer to System Systems Operation/Testingand Adjusting for the proper procedure.
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152 SEBU8076-06Maintenance SectionRefrigerant Dryer - Replace
i02519927
Refrigerant Dryer - Replace
SMCS Code: 7322-510
Personal injury can result from contact with refrig-erant.
Contact with refrigerant can cause frost bite. Keepface and hands away to help prevent injury.
Protective goggles must always be worn when re-frigerant lines are opened, even if the gauges in-dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilatedarea.
Personal injury or death can result from inhalingrefrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through alit cigarette or other smoking method or inhalingfumes released from a flame contacting air con-ditioner refrigerant gas, can cause bodily harm or death.
Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to prop-erly remove the refrigerant from the air condition-ing system.
NOTICEIf the refrigerant system has been open to the outsideair (without being plugged) for more than 30 minutes,the receiver-dryer must be replaced. Moisture will en-ter an open refrigerant system and cause corrosionwhich will lead to component failure.
g01261210Illustration 232
The refrigerant dryer is located behind the rear cover of the cab.
Refer to Service Manual, SENR5664, “Air Conditioning and Heating System with R-134aRefrigerant for All Caterpillar Machines” for the proper procedure to change the receiver-dryer assemblyand for the procedure to reclaim the refrigerant gas.
i02510283
Rollover Protective Structure(ROPS) - Inspect
SMCS Code: 7325-040
NOTICEDo not attempt to straighten the ROPS structure. Donot repair the ROPS by welding reinforcement platesto the structure.
If there are any cracks in the welds, in the castings, or in any metal section of the ROPS, consult your Cater-
pillar dealer for repairs.
There are access covers near the base of the ROPS.Remove the access covers from both sides of therollover protective structure (ROPS).
Inspect the ROPS for damage and for bolts that areloose or damaged. Use original equipment parts onlyto replace bolts that are damaged or missing. Tightenthe mounting bolts to a torque of 1600 ± 200 N·m(1200 ± 150 lb ft).
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SEBU8076-06 153Maintenance Section
Seat Belt - Inspect
Note: Apply oil to all bolt threads before installation.Failure to apply oil can result in improper bolt torque.
i02429589
Seat Belt - Inspect
SMCS Code: 7327-040
Always check the condition of the seat belt and thecondition of the seat belt mounting hardware beforeyou operate the machine. Replace any parts that aredamaged or worn before you operate the machine.
g00932801Illustration 233
Typical example
Check the seat belt mounting hardware (1) for wear or for damage. Replace any mounting hardware that
is wor n or damaged. Make sure that the mountingbolts are tight.
Check buckle (2) for wear or for damage. If the buckleis worn or damaged, replace the seat belt.
Inspect the seat belt (3) for webbing that is worn or frayed. Replace the seat belt if the seat belt is wornor frayed.
Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware.
Note: Within three years of the date of installation or
within five years of the date of manufacture, replacethe seat belt. Replace the seat belt at the date whichoccurs first. A date label for determining the age of the seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.
If your machine is equipped with a seat beltextension, also perform this inspection procedure for the seat belt extension.
i02429594
Seat Belt - Replace
SMCS Code: 7327-510
Within three years of the date of installation or withinfive years of the date of manufacture, replace theseat belt . Replace the seat belt at the date whichoccurs first. A date label for determining the age of the seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.
g01152685Illustration 234
(1) Date of installation (retractor)(2) Date of installation (buckle)(3) Date of manufacture (tag) (fully extended web)(4) Date of manufacture (underside) (buckle)
Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware.
If your machine is equipped with a seat beltextension, also perform this replacement procedurefor the seat belt extension.
i01547608
Seat Side Rails - Adjust
SMCS Code: 7312-025
g00804394Illustration 235
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154 SEBU8076-06Maintenance SectionSecondary Steering - Test
Caterpillar recommends adjusting the side rails after the initial 500 hours of machine operation. After theinitial 500 service hours, perform this procedurewhen it is necessary.
Reference: Refer to Service Manual, SENR6615,
“Contour Ser ies Seat” for the adjustment procedure.
i03694709
Secondary Steering - Test
SMCS Code: 4300-081-SE; 4300-081-SST;4324-081; 4324
The service brake must be checked in order to en-sure proper operation before you test the supple-
mental steering system.
Personal injury, death, or property damage couldoccur if the supplemental steering system is test-ed and the service brake is not operational.
Test the service brake before you test the supple-mental steering system.
Perform the following procedure if your machine isequipped with a ground driven supplemental steeringand if the procedure is required by local regulations.
Ensur e that there are no hazards in the test area. Thetest area must be unobstructed and level. Operatethe machine in second gear.
Ensure that all air tanks and accumulators areproperly charged. Ensure that there is no load in thework tool. Position the machine with the bucket or thework tool in the carry position with the machine inneutral. Release the parking brake. Apply the servicebrakes and put the engine at low idle. Ensure that Thearea around the machine is clear of personnel. Shiftthe transmission to second gear forward and slowlyrelease the service brakes. Moderately increase theengine speed to high idle. Shift the transmission to
neutral. Turn the ignition to the OFF position. Allowthe machine to coast.
While the machine is in motion, turn the machine tothe left and to the right. If the machine responds tothe steering input, the supplemental steering systemis operating. Stop the machine with the servicebr akes. Apply the parking brake. The machine canthen be returned to normal operation.
If there is no response to the steering input, thesupplemental steering system is not operating. Stopthe machine immediately. Repair the supplementalsteering system before returning the machine toservice.
i02197967
Service Brake Wear Indicator -Check
SMCS Code: 4255-535-IND
Reference: For information about checking theservice brake wear indicator, refer to Testing and
Adjusting, “Braking System” for the machine that isbeing serviced or consult your Caterpillar dealer.
i02516944
Steering Cylinder Bearings -Lubricate
SMCS Code: 4303-086-BD
There are two locations for lubricating the steeringcylinders.
g01289360Illustration 236
g01259174Illustration 237
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SEBU8076-06 155Maintenance SectionTire Inflation - Check
There are remote fittings to the right of the servicecenter on the right side of the machine. These fittingsare for the rod end of the steering cylinders.
g01290395Illustration 238
There is a grease fitting (1) inside the servicecenter. This fitting is for the head end of the steeringcylinders.
Wipe off the fittings before any lubricant is applied.
Apply lubricant through the two fittings.
Reference: For more information, refer to Operationand Maintenance Manual, “Service Center”.
i02305841
Tire Infl
ation - CheckSMCS Code: 4203-535-AI
g01160201Illustration 239
Always obtain proper tire inflation pressures andmaintenance recommendations for the tires on your machine from your tire supplier. Measure the tirepressure on each tire.
Inflate the tires with nitrogen , if necessary.
Reference: Ref er to the “Tire Inflation Information”section of the Operation and Maintenance Manualfor more information.
i02512909
Transmission Magnetic Screen- Clean
SMCS Code: 3030-070-MGS; 3159-070-MGS
g01257508Illustration 240
The transmission magnetic screen is located on theleft side of the transmission.
g00110013Illustration 241
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156 SEBU8076-06Maintenance SectionTransmission Oil - Change
1. Park the machine on level ground. Lower theattachment to the ground and apply slightdownward pressure. Engage the parking brakeand stop the engine.
2. Remove covers (1) and seals (2).
3. Remove screen tube assemblies (3) and suctionscreens (4).
4. Wash the screen tube assemblies and the suctionscreens in clean, nonflammable solvent. Allow thecomponents to dry.
5. Install screen tube assemblies (3) and suctionscreens (4).
6. Inspect seals (2) for damage. Replace the seals, if necessary.
7. Install seals (2) and covers (1).
i02508980
Transmission Oil - Change
SMCS Code: 3030-044
NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations andmandates.
1. Operate the machine in order to warm the oil.
2. Park the machine on level ground. Lower theattachment to the ground and apply slightdownward pressure. Engage the parking brakeand stop the engine.
g01255943Illustration 242
3. The transmission drain plug is located on thebottom of the transmission case and the plug isaccessible from the underside of the machine.
Remove the transmission drain plug and allow theoil to drain into a suitable container.
4. Clean the drain plug and install the drain plug.
g01432003Illustration 243
5. The access door for the transmission oil fi ller capis located on the cab platform to the right of thecab. Open the access door.
6. Remove the fi ller cap and add 170 L (45 US gal)of transmission oil.
7. Clean the fi ller cap and install the fi ller cap.
8. Close the access door.
9. Start and run the engine at low idle. Inspect thetransmission for leaks.
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SEBU8076-06 159Maintenance Section
Turbocharger - Inspect
g01432003Illustration 249
The sampling ports for the transmission are locatedbehind the cab on the right side of the cab platform.
There is a sampling port at the base of each of thetwo filter assemblies. Either port may be used toobtain a sample.
Reference: For more information, refer to SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations” and Special Publication,PEHP6001, “How To Take A Good Oil Sample”.
i02453220
Turbocharger - Inspect
SMCS Code: 1052-040
If the turbocharger fails during engine operation,severe damage to the turbocharger compressor wheel and to the entire engine can result.
Turbocharger bearing failures can cause largequantities of oil to enter the intake system and the
exhaust system. Loss of engine oil can result inserious engine damage.
Do not continue to operate the engine when aturbocharger bearing failure is accompanied bya significant loss of engine performance. Enginesmoke and speeding up of the engine with no loadare characteristics of a loss of engine performance.
i02018740
VIMS Module Battery - Replace
SMCS Code: 7601-510-B11
g01043143Illustration 250
(1) Plate
A lithium battery is contained inside the main moduleof the VIMS. The internal battery prevents the lossof stored information. An example of the storedinformation is the payload data. The internal batteryalso retains the time and the date.
If power is removed from the main module of theVIMS, the internal battery will begin to retain thestored data. Power is removed from the main moduleof the VIMS when the battery disconnect switch isin the OFF position. The internal battery retains the
time and the date when the engine start switch is inthe OFF position. This will occur regardless of theposition of the battery disconnect switch.
Note: To prevent the loss of stored information,replace the internal battery at the service interval. If the ambient temperature is continuously in the rangeof 0 to −40°C (32 to −40°F), cut the service intervalin half.
Note: If the Vital Information Management System(VIMS) detects a failed battery, a fault code willindicate that the battery needs a replacement. If power is removed from the main module of the VIMS
during this fault code, loss of the stored data canoccur within several hours. The lithium battery failsquickly. When the fault code is present, immediatelydownload the stored data. Then replace the internalbattery without turning off the engine start switch or the battery disconnect switch.
Note: If ECM BKUP BATT ERR is displayed in themessage area of the VIMS, do NOT turn the enginestart switch to the OFF position. Go to Step 3.
1. Stop the machine and turn off the engine. Leavethe battery disconnect switch in the ON position.
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