cat 993k manual de operacion y mantenimiento

2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU8076-06December 2010

Operation andMaintenanceManual993K Wheel LoaderLWA1-Up (993K)Z9K1-Up (993K)

SAFETY.CAT.COM

88 SEBU8076-06Maintenance SectionMaintenance Interval Schedule

i04166053

Maintenance Interval ScheduleSMCS Code: 7000

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

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

Use mileage, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance. 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. SOS services may extend the oilchange even longer. Consult your Caterpillar dealerfor details.

When Required

Automatic Lubrication Grease Tank - Fill .............. 91Axle 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 .. 112Ether 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 ................. 98Cooling 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) (HydraulicFan) - 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)(Steering) (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 ............................................................... 102Differential 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

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 ............. 132Hydraulic System Oil Filter (Implement Pilot) -Replace ............................................................. 138Hydraulic System Oil Filter (Steering Oil Cooler)(Steering Pilot) - Replace .................................. 139Hydraulic System Oil Sample (Implement) (HydraulicFan) - Obtain ..................................................... 141Hydraulic System Oil Sample (Steering) (Brake) -Obtain ............................................................... 142Hydraulic Tank Breaker Relief Valve (Implement)(Hydraulic Fan) - Clean ..................................... 143Hydraulic Tank Breaker Relief Valve (Steering)(Brake) - Clean .................................................. 144Rear Access Egress System Bearings -Lubricate ........................................................... 146Rear Access Egress System Oil Sample -Obtain ............................................................... 150Rear Access Egress System Rolling Guards -Clean ................................................................. 151Transmission 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 .............. 155Transmission 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 ................................ 152Service Brake Wear Indicator - Check ................ 154

Every 3000 Service Hours or 2 Years

Crankshaft Vibration Damper - Inspect ............... 105Engine Mounts - Inspect ...................................... 114Rear Access Egress System Oil - Change ......... 147

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

Seat Belt - Replace ............................................. 153


Engine Valve Lash - Check .................................. 116Engine Valve Rotators - Inspect .......................... 116


Alternator - Inspect ............................................... 90


Alternator - Inspect ............................................... 90Cooling System Coolant Extender (ELC) - Add .. 101Engine Water Pump - Inspect .............................. 117Turbocharger - Inspect ........................................ 159


Cooling System Water Temperature Regulator -Replace ............................................................. 104VIMS Module Battery - Replace ......................... 159

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 100Fuel Lines - Replace ............................................ 118

90 SEBU8076-06Maintenance SectionAlternator - Inspect

i02904968

Alternator - InspectSMCS Code: 1405-040

g01224924Illustration 90


Access to the alternator is on the right side of themachine. The alternator is located on the front ofthe 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 -LubricateSMCS Code: 7057-086-BD; 7065-086-BD;7066-086-BD

Wipe off the fittings before any lubricant is applied.



The remote grease fitting for the upper hitch pin islocated to the right of the service center on the rightside of the machine.



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 referto 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 orfittings that are under pressure. Relieve the pres-sure in the system before you remove hoses orfittings.


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 - ReplaceSMCS Code: 3004-510-AOC

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, CaterpillarDealer Service Tool Catalog for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

The axle oil cooler filter should be replaced when afailure occurs in the cooling system.

Note: The oil filters contain a 140 micron screen.


There are a total of two axle oil cooler filters on yourmachine. One of the filters is located on the rearframe 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 filter and discard the filter properly.Make sure that the old seal is removed from thefilter base.

4. Install the new filter.

92 SEBU8076-06Maintenance SectionAxle Oscillation Bearings - Lubricate

a. Apply a thin coat of oil to the seal on the newfilter.

b. Install the new filter hand tight until the seal ofthe 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 oil filterthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the filter, 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 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.

5. Repeat steps 3 through 4.c for the other filter.

6. Install the access panel.

i02520381

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



The remote grease fitting (1) for the axle oscillationbearing is located inside the service center. Applylubricant through the fitting.


i02472018

Backup Alarm - TestSMCS Code: 7406-081


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 - CleanSMCS Code: 1401-070


Open the battery compartments on the right side ofthe machine near the rear ladder.


Battery - Recycle

Clean the battery terminals and the surfaces ofthe batteries with a clean cloth. Coat the batteryterminals with petroleum jelly. Make sure that thebattery cables are installed securely.

i00993589

Battery - RecycleSMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

A battery supplier

An authorized battery collection facility

Recycling facility

i02459960

Battery Hold-Down - TightenSMCS Code: 7257-527


Open the battery compartments on the right side ofthe 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 perbattery) to a torque of 14 2 Nm (10 1.5 lb ft).

i01835250

Battery or Battery Cable -Inspect/ReplaceSMCS Code: 1401-040; 1401-510; 1402-040;1402-510

1. Turn the engine start switch key to the OFFposition. Turn all of the switches to the OFFposition.

2. Turn the battery disconnect switch to the OFFposition. Remove the key.

3. Disconnect the positive battery cable at the batterydisconnect switch. The battery disconnect switchis connected to the machine frame.

Note: Do not allow the disconnected battery cable tocontact the disconnect switch.

4. Disconnect the negative battery cable at thebattery that is connected to the battery disconnectswitch. If the machine has four 12 volt batteries,disconnect the negative battery cables of two ofthe batteries.

5. Make any necessary repairs or replace the battery.

6. Reconnect the negative battery cable at thebattery that is connected to the battery disconnectswitch.

7. Reconnect the positive battery cable at the batterydisconnect switch.

8. Install the key and turn the battery disconnectswitch to the ON position.

i04169829

Belt - Inspect/ReplaceSMCS Code: 1397-040; 1397-510

Inspect1. 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.

94 SEBU8076-06Maintenance SectionBelt - Inspect/Replace


2. Remove the grill assembly on the right side ofthe machine.


3. Remove the engine access cover in order to gainaccess to the belt.


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.

Replace1. 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 ofthe 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.


Brake Accumulator - Check

i03948191

Brake Accumulator - CheckSMCS 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 formeasuring the precharge pressure of the brakeaccumulator. Only use dry nitrogen gas forrecharging.

i02060586

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

1. Fasten the seat belt.

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

3. Park the machine on a hard, dry, level surface.

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

The following tests are used to determine whetherthe braking system is functional. These tests are notintended to measure the maximum brake holdingeffort. The required brake holding effort for sustaininga machine at a specific engine rpm varies from onemachine to another machine. The variations includedifferences in the engine setting, the power trainefficiency, the brake holding ability, etc.

Service Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

If the machine begins to move during test, reducethe engine speed immediately and engage theparking brake.

This test is performed when the service brakes areengaged. If the machine begins to move, comparethe engine rpm to the engine rpm of a prior test. Thiswill indicate the amount of system deterioration.

1. Start the engine. Raise the work tool slightly. Applythe service brake. Release the parking brake.

2. Move the hydraulic lockout control to theUNLOCKED position.

3. Place the transmission in THIRD SPEEDFORWARD while the service brakes are applied.

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

5. Reduce the engine speed to low idle. Placethe transmission in neutral. Engage the parkingbrake. Lower the work tool to the ground. Stopthe engine.

If the machine moved during the test, consult yourCaterpillar dealer for a brake inspection. Make anynecessary repairs before the machine is returned tooperation.

Parking Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

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

96 SEBU8076-06Maintenance SectionBucket Cutting Edges - Inspect/Replace

This test is performed when the parking brake isengaged. If the machine begins to move, comparethe engine rpm to the engine rpm of a prior test. Thiswill indicate the amount of system deterioration.

1. Start the engine. Raise the work tool slightly.Engage the parking brake.

2. Move the hydraulic lockout control to theUNLOCKED position.

3. Place the transmission in THIRD SPEEDFORWARD while only the parking brake isengaged.

The parking brake indicator light should come on.

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

5. Reduce the engine speed. Place the transmissionin neutral. Lower the work tool to the ground. Stopthe engine.

If the machine moved during the test, consult yourCaterpillar dealer for a brake inspection. Make anynecessary repairs before the machine is returned tooperation.

i02453840

Bucket Cutting Edges -Inspect/ReplaceSMCS 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.


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

Reference: For more information, refer toSpecifications, SENR3130, Torque Specificationsor consult your Caterpillar dealer.

Inspect the cutting edges and the end bits. If wear ordamage 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. Lowerthe bucket to the ground.

6. After a few hours of operation, check the bolts forproper torque.


Bucket Tips - Inspect/Replace

i02594942

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

Personal injury or death can result from the bucketfalling.

Block the bucket before changing bucket tips.

Note: In order to maximize the life of the bucket tipand the penetration of the bucket tip, the bucket tipcan be rotated.


(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: Retainers are often damaged during theremoval process. Caterpillar recommends theinstallation of a new retainer when bucket tips arerotated or replaced.


1. Use a pry bar in order to disengage retainer (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).

Installation1. Clean the adapter and the area around the latch,if necessary.

2. Install the new bucket tip onto the adapter with aslight clockwise rotation.


3. Install the retainer. Make sure that the retainer'slatch catches under the tip pocket.

4. Make sure that the latch is properly seated bytrying to remove the bucket tip.

98 SEBU8076-06Maintenance SectionBucket Wear Plates - Inspect/Replace

i02453827

Bucket Wear Plates -Inspect/ReplaceSMCS Code: 6120-040; 6120-510

Personal injury or death can result from fallingbucket.

When working under or around the bucket or link-age, with the bucket raised, proper support mustbe provided for the bucket and/or the linkage.


Before damage to the bottom of the bucket occurs,repair damaged bucket wear plates or replacedamaged bucket wear plates.

1. Raise the bucket and block up the bucket.

2. Loosen bolts and remove wear plates.

3. Install new wear plates. Tighten the bolts to thespecified torque.

Reference: For more information, referto Specifications, SENR3130, TorqueSpecifications or consult your Caterpillar dealer.

i02919930

Cab Air Filter - Clean/ReplaceSMCS 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.


1. Filter (1) is located inside the cab to the left ofthe 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 filter (2).

4. Clean the filter elements with pressure air orwash the filter elements in warm water with anonsudsing household detergent.

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

6. Install filter (2) and the cover.

7. Close the access door.

8. Install filter (1) and the cover.

i02816405

Camera - Clean(If Equipped)SMCS Code: 7348-070

In order to maintain sufficient vision, keep the WorkArea Vision System (WAVS) camera lens and thedisplay clean.


Circuit Breakers - Reset

Display

g01223034Illustration 111WAVS 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


The WAVS 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. Thecamera 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 - ResetSMCS Code: 1420-529

Reset Circuit Breakers


The circuit breaker reset buttons are located in thebattery compartment on the right side of the machine.


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 electricalcircuit. Repair the electrical circuit, if necessary.

100 SEBU8076-06Maintenance SectionCooling System Coolant (ELC) - Change

i03793929

Cooling System Coolant (ELC)- ChangeSMCS 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.





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 forpre-mixed or concentrate coolants. Use only Extenderwith Cat ELC.

Failure to follow these recommendations can result inshortened cooling system component life.


3. The cooling system pressure cap is locatedinside 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.



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 FillIf your machine is equipped with a deluxe servicecenter, you may drain the coolant through the fast fillport or you may add the coolant through a fast fill port.


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 referto Operation and Maintenance Manual, ServiceCenter.

i03793912

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

When a Caterpillar Extended Life Coolant (ELC) isused, an Extender must be added to the coolingsystem.


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 forpre-mixed or concentrate coolants. Use only Extenderwith Cat ELC.

Failure to follow these recommendations can result inshortened cooling system component life.


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 thecooling system pressure cap until the thermostatopens and the coolant levels stabilize.

102 SEBU8076-06Maintenance SectionCooling System Coolant Level - Check


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- CheckSMCS Code: 1350-535-FLV



1. The sight gauge is located on the left side of theengine compartment. The coolant level should bevisible in the sight gauge.


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) - ObtainSMCS Code: 1350-008; 1395-008; 7542

Note: Level 1 results may indicate a need forLevel 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 SOS analysis,you must establish a consistent trend of data.In order to establish a pertinent history of data,perform consistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe 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.


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 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.


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 enterthe 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) - ObtainSMCS 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 SOS analysis, you must establisha consistent trend of data. In order to establisha pertinent history of data, perform consistentsamplings that are evenly spaced. Supplies forcollecting samples can be obtained from yourCaterpillar dealer.

Use the following guidelines for proper sampling ofthe 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.

104 SEBU8076-06Maintenance SectionCooling System Water Temperature Regulator - Replace


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 enterthe 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.


i02510580

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

Replace the thermostat on a regular basis in order toreduce the chance of unscheduled downtime and ofproblems 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 orwhile 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.


1. Remove all hoses from the thermostat.

2. Remove the bolts from the thermostat housing.

3. Remove the gasket, the thermostat, and the seal.

NOTICEA 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.


Crankshaft Vibration Damper - Inspect

i02517124

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040


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 vibrationdamper for any of the following reasons:

The engine has had a failure because of a brokencrankshaft.

The SOS oil analysis detected a worn crankshaftfront bearing.

The SOS oil analysis detected a large amount ofgear train wear that is not caused by a lack of oil.

The alignment marks on the hub and on the outerring are not in alignment because the rubber sealhas separated.

The vibration damper can be used again if none ofthe 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- ChangeSMCS Code: 3278-044; 4050-044




Note: Perform this procedure on one axle at a time.


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 areequipped 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.

106 SEBU8076-06Maintenance SectionDifferential and Final Drive Oil Level - Check

5. Repeat steps 1 through 4 for the other final drive.

g01256625Illustration 128Front axle

g01256626Illustration 129Rear 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 filler plug opening.

11.Clean the filler plug and install the filler plug.

12.Remove the final drive filler plug (2). Fill the finaldrive with SAE 50 oil until the oil level reaches thebottom of the filler plug opening.

13.Clean the filler 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) of1U-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 filler plugs and add the remaining oil.

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

If the oil level is higher than the filler 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

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

Note: Perform this procedure on one axle at a time.


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.


Differential and Final Drive Oil Sample - Obtain

2. Remove the final drive filler plug. The oil levelshould be at the bottom of the filler plug opening.If necessary, add SAE 50 oil until the oil levelreaches the bottom of the filler plug opening.

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

g01256597Illustration 131Front axle

g01256596Illustration 132Rear axle

3. Remove the differential filler plug. The oil levelshould be at the bottom of the filler plug opening.If necessary, add SAE 50 oil until the oil levelreaches the bottom of the filler plug opening.

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

4. Repeat the procedure for the other differential andfinal drives.

i02510250

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

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.




1. Operate the machine for a few minutes beforeobtaining the oil sample. This will thoroughly mixthe oil for a more accurate sample.

g01256658Illustration 133Final Drive Filler Plug

108 SEBU8076-06Maintenance SectionDrive Shaft Spline (Center) - Lubricate

g01256597Illustration 134Front Differential Filler Plug

g01256596Illustration 135Rear 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 forthis procedure in total. Make sure that you properlyrecord the location of each oil sample.


i02519369

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

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

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 orto the left.

2. Lower the work tool to the ground. Engage theparking brake. Stop the engine.


3. Wipe the fitting before you apply any lubricant.Apply lubricant through the fitting on the centerdrive shaft spline.


Drive Shaft Support Bearing - Lubricate

i02519546

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



There are remote fittings to the right of the servicecenter on the right side of the machine.


Note: Be sure to use 1P-0808 Multipurpose Greasein order to maximize the life of the drive shaft supportbearing.

Apply lubricant through the fitting.

i02061807

Electronic Unit Injector -Inspect/AdjustSMCS Code: 1251-025; 1251-040; 1290-025;1290-040

The Electronic Control module produces highvoltage. To prevent personal injury make sure theElectronic Control Module is not powered and theunit injector solenoids are disconnected.

NOTICEThe camshafts must be correctly timed with the crank-shaft before an adjustment of the unit injector lashis made. The timing pins must be removed from thecamshafts before the crankshaft is turned or damageto the cylinder block will be the result.

The operation of Caterpillar engines with improperadjustments of the electronic unit injector can reduceengine efficiency. This reduced efficiency could resultin excessive fuel usage and/or shortened enginecomponent life.

Adjust the electronic unit injector at the same intervalas the valve lash adjustment.

Refer to your machine's Service Manual or yourCaterpillar dealer for the complete adjustmentprocedure.

i02473339

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

Burn Hazard: Engine components may be hot dur-ing and after machine operation.

Hot components can cause serious personal in-jury. Do not contact hot components with bareskin.

To avoid personal injury, always wear eye and faceprotection when using pressurized air.

110 SEBU8076-06Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

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


1. Open the rear access door on either side of themachine. An air filter element is located on bothsides of the engine compartment.


2. Loosen the cover latches and remove the aircleaner 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 filter element.


6. Install the air cleaner cover (1) and tighten thelatches.

Note: Keep the latches for the air cleaner housingaway from the muffler.


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

Cleaning the Primary Air FilterElement

NOTICECaterpillar recommends certified air filter cleaning ser-vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

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

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


Engine Air Filter Primary Element - Clean/Replace

The primary air filter element can be used up to sixtimes after the element is properly cleaned. Whenthe primary air filter element is cleaned, check forrips or tears in the filter material. The primary airfilter element should be replaced at least one timeper year. This replacement should be performedregardless of the number of cleanings.

NOTICEDo not clean the air filter elements by bumping or tap-ping. This could damage the seals. Do not use ele-ments with damaged pleats, gaskets, or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air filter element beforecleaning. Inspect the air filter element for damage tothe seal, the gaskets, and the outer cover. Discardany damaged air filter elements.

There are two common methods that are used toclean the primary air filter element:

Pressurized air

Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean a primary airfilter element that has not been cleaned more thantwo times. Pressurized air will not remove deposits ofcarbon and oil. Use filtered, dry air with a maximumpressure of 207 kPa (30 psi).


Note:When the primary air filter element is cleaned,always begin with the inside of the filter in order toforce dirt particles toward the outside.

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the stream ofair directly at the primary air filter element. Dirt couldbe forced further into the pleats.

Vacuum Cleaning

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

Inspecting the Primary Air FilterElements


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

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

Storing Primary Air Filter Elements

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

112 SEBU8076-06Maintenance SectionEngine Air Filter Secondary Element - Replace


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

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

Date of cleaning

Number of cleanings

Store the box in a dry location.

i02473348

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

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

NOTICEAlways replace the secondary element. Do not at-tempt to reuse it by cleaning. Engine damage couldresult.

Note: Replace the secondary element when youservice the primary element for the third time. Ifa clean primary element has been installed anda warning for the air filter still occurs, replace thesecondary element. Also if the exhaust smokeremains black and a clean primary element has beeninstalled, replace the secondary element.


1. Open the rear access door on either side of themachine. An air filter element is located on bothsides of the engine compartment.

2. Remove the primary element.


3. Remove the secondary element.


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


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 forthe air cleaner housing.


9. Repeat the procedure for the other air cleaner.

i02514485

Engine Crankcase Breather -CleanSMCS 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.


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


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 oruse 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 outlethose clamp (1).

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

114 SEBU8076-06Maintenance SectionEngine Mounts - Inspect

i02164781

Engine Mounts - InspectSMCS Code: 1152-040

Caterpillar recommends checking the engine mountsfor deterioration and for proper bolt torque. This willhelp to prevent excessive engine vibration that iscaused by improper mounting.

i02481514

Engine Oil Level - CheckSMCS 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 overfill engine crankcase with oil.Either condition can cause engine damage.


1. The engine oil level gauge (2) is located below theoil filler tube (1) inside the access door on the leftside of the machine. Open the access door.


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 filler tube.

i02481560

Engine Oil Sample - ObtainSMCS 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 SOS oilanalysis at regular scheduled intervals in orderto 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 SOS Sample

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.



Engine Oil and Filter - Change


The SOS port for the engine oil is locatedunderneath the engine compartment toward the rearof the machine. The port is located to the right of theengine oil filters.

Refer to Special Publication, SEBU6250, SOS OilAnalysis for information that pertains to obtaining asample of the engine oil. Refer to Special Publication,PEHP6001, How To Take A Good Oil Sample formore information about obtaining a sample of theengine oil.

i02481135

Engine Oil and Filter - ChangeSMCS 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 suitablecontainers before opening any compartment or dis-assembling any component containing fluids.


Note: Be sure that you obtain a SOS engine oilsample before you drain the engine oil.

1. Park the machine on a level surface and engagethe parking brake. Stop the engine.


2. The drain valve (1) for the engine oil is locatedunderneath the engine compartment toward therear of the machine. Open the drain valve andallow 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 filter base.

6. Install new filters.

a. Apply a thin coat of oil to the seals on the newfilters.

b. Install the new engine oil filters hand tight untilthe seal of the engine oil filter contacts thebase. Note the position of the index marks onthe filter in relation to a fixed point on the filterbase.

Note: There are rotation index marks on the engineoil filter that are spaced 90 degrees or 1/4 of a turnaway from each other. When you tighten the engineoil filter, use the rotation index marks as a guide.


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.

116 SEBU8076-06Maintenance SectionEngine Valve Lash - Check


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 filler cap.

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


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. Ifnecessary, add oil.

12.Close the access door and stop the engine.

Fast FillIf 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.


1. Remove the dust cover (4).

2. Attach the hose to the male coupling. Use a126-7539 Nozzle for this port.

3. Drain the oil or add the oil, as needed.


i01181536

Engine Valve Lash - CheckSMCS Code: 1105-535

For the correct procedure, refer to the appropriateService Manual module for your machine's engine orconsult your Caterpillar dealer.

Note: A qualified mechanic should adjust the enginevalve lash because special tools and training arerequired.

i03952000

Engine Valve Rotators - InspectSMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to prevent being burned by hot oilor spray.


Engine Water Pump - Inspect

Caterpillar recommends replacing valve rotators thatare operating improperly. An improperly operatingvalve rotator will shorten valve life because ofaccelerated wear on the valves. Also, metal particlesfrom a damaged valve rotator could fall into thecylinder and damage to the piston head and to thecylinder head may result.


Start the engine and run the engine at low idle. Watchthe top surface of each valve rotator. Whenever aninlet valve closes or an exhaust valve closes, eachvalve rotator should turn.

If a valve rotator fails to turn, consult your Cat dealerfor service.

i02482098

Engine Water Pump - InspectSMCS Code: 1361-040


Failure of the engine water pump may cause severeengine overheating problems such as cracks in thecylinder head or piston seizure.

Visually inspect the water pump for leaks. If you findleaks, all of the seals on the water pump must bereplaced.

Note: For more information, refer to the appropriateDisassembly and Assembly manual for yourmachine'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 ofether with skin can cause personal injury.

Use ether only in well ventilated areas.

Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.

Do not store replacement ether cylinders in livingareas or in the operator's compartment.

Do not store ether cylinders in direct sunlight orat temperatures above 49 C (120 F).

Discard cylinders in a safe place. Do not punctureor burn cylinders.

Keep ether cylinders out of the reach of unautho-rized personnel.

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


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 theempty 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 cylinderretaining clamp hand tight.

5. Close the engine door.

i03898359

Fuel Lines - Replace(Low Pressure)SMCS Code: 1274




NOTICECleanliness is an important factor. The exterior of theengine should be thoroughly cleaned before the re-moval procedure. Ensure the area around the FuelManifold 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 LinesMake sure that the nonmetallic fuel lines are replacedat the engine overhaul.

SEBU8076-06 119Maintenance SectionFuel Lines - Replace

g02141035Illustration 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).

120 SEBU8076-06Maintenance SectionFuel System - Prime

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Note: Install hose clamps which have been inspectedor install new hose clamps. Refer to Specifications,SENR3130, Torque Specifications, Hose Clampsfor 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 forinformation about priming the engine with fuel.

7. Start the engine. Inspect the fuel system for leaks.

i02518810

Fuel System - PrimeSMCS 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.




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 PumpThis 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 filter.


Fuel System Primary Filter (Water Separator) - Check/Drain



Note: You can only use the priming pump whenthe engine start switch key is OFF.

1. Move the switch for the electric fuel priming pumpto the ON position. Allow the pump to run forseveral 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 theengine before additional priming.

4. Run the engine at the LOW IDLE position until theengine runs smoothly.

i02477443

Fuel System PrimaryFilter (Water Separator) -Check/DrainSMCS 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 containedduring 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, CaterpillarTools and Shop Products Guidefor tools and suppliesto collect and contain fluids in Caterpillar machines.

Dispose of all fluids according to local regulations.


1. The fuel filter is located inside the access doorson the front of the engine compartment. Open theaccess doors.

122 SEBU8076-06Maintenance SectionFuel System Primary Filter (Water Separator) Element - Replace


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 -ReplaceSMCS 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 orparts damage.

Be prepared to stop the engine by closing the airoff 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 thesystem, do not remove the primary fuel filter and thesecondary fuel filter simultaneously. Perform theseoperations separately.

Note: After the engine has stopped, you must wait for60 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.


1. Open the access door on the front of the enginecompartment.


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 waterseparator in order to catch any fuel that mightspill. Clean up any spilled fuel. Clean the outsideof the water separator.


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 filter. Discard the old seals and the canister ina safe place.

8. Clean the bowl.

9. Install a new filter.


b. Install a new filter hand tight until the seal ofthe 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 filterthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the filter, use therotation index marks as a guide.


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 after you perform this maintenance.

12.Close the access doors.

13.Be sure to dispose of the fuel in a safe place.

14.Prime the fuel system. Refer to Operation andMaintenance Manual, Fuel System - Prime formore information.

15.Close the access door.

i02477755

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


1. Open the access doors on the front of the enginecompartment.

124 SEBU8076-06Maintenance SectionFuel Tank Cap and Strainer - Clean


2. Remove both fuel filters. Dispose of the usedfilters properly.

3. Clean the filter mounting base. Ensure that all ofthe used gasket is completely removed from thefilter mounting base.

4. Install new filters.


b. Install the new filter hand tight until the seal ofthe 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 filterthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the filter, use therotation index marks as a guide.


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.

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 -CleanSMCS Code: 1273-070-Z2; 1273-070-STR


The fuel tank cap is located under the access dooron the left side of the cab platform.

1. Remove the fuel tank cap.

2. Remove the strainer from the filler opening.

3. Wash the fuel tank cap and the strainer in a clean,nonflammable solvent.

4. Install the strainer into the filler opening.

5. Install the fuel tank cap.

i02453536

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



Fuses - Replace

The drain valve is located on the bottom of the fueltank on the right side of the machine.


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

2. Close the drain valves.

i02541347

Fuses - ReplaceSMCS Code: 1417-510


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.

FusesFuses Fuses protect the electricalsystem from damage that is caused byoverloaded electrical circuits. Replace

a fuse if the element separates. If the fuse ofa particular electrical system requires frequentreplacement, check the electrical circuit. Repair theelectrical circuit, if necessary.

NOTICEAlways 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.


Beacon Light and Heated Mirrors(6) 15 Amp

Front Work Light (7) 15 Amp

126 SEBU8076-06Maintenance SectionFuses - Replace

Front Work Light (8) 10 Amp

Front HID Work Lights(9) 10 Amp

Front Windshield Wiper and RearWindshield Wiper (10) 10 Amp

Side Window Wipers (11) 10 Amp

Hydraulic Electronic Control (12) 10Amp

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


Working Light (33) 10 Amp

Spare (34) 10 Amp

Air Filter (35) 15 Amp

Rear Access Egress System (36) 15Amp

Spare (37) 10 Amp

Spare (38) 10 Amp

Spare (39) 10 Amp

Spare (40) 10 Amp


High Intensity Discharge Lamp (HID) - Replace


Hydraulic Electronic Control (42) 10Amp

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

RelaysFront Work Lights (1) 24 Volt

Front HID Work Lights (2) 24 Volt

Rear Access Egress System (3) 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.

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

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 forat least five minutes, in order to ensure that thebulb is cool.

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

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

3. Remove the bulb from the HID lamp.

4. Install the replacement bulb in the HID lamp.

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

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 yourmachine. If the system becomes contaminated or if amajor failure occurs, clean the screens. If a screen isdamaged, replace the screen.


There are two screens that are located inside theaccess panel on the underside of the rear bumper.

cat 993k manual de operacion y mantenimiento

Documents

oil filter

maintenance procedures

frequent maintenance

oil renewal system oil

hydraulic oil change

engine oil level check

consecutive interval

previous interval