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2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt

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SEBU8287-05

January 2011

Operation andMaintenance

Manual450E Backhoe Loader

EBL1-Up(Machine)

SAFETY.CAT.COM

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SEBU8287-05 93Maintenance Section

Maintenance Interval Schedule

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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 ofmaintenance. All adjustments, the use of properlubricants, fluids, filters, and the replacement ofcomponents due to normal wear and aging areincluded.Failure to adhere to proper maintenanceintervals and procedures may result in diminishedperformance of the product and/or accelerated wearof components.

Use mileage, fuel consumption, service hours, orcalendartime, 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 are used,the hydraulic oil change interval is extended to 3000

hours. SOS services may extend the oil changeeven longer. Consult your Cat dealer for details.

When Required

Battery or Battery Cable - Inspect/Replace .......... 96Bucket Cutting Edges - Inspect/Replace .............. 98Bucket Tips - Inspect/Replace .............................. 98Cab Interior - Clean ............................................ 102Engine Air Filter Primary Element - Clean/

Replace ............................................................. 109Engine Air Filter Secondary Element - Replace .. 110Engine Compartment - Clean .............................. 111Film (Product Identification) - Clean .................... 119

Fuses - Replace .................................................. 123OilFilter - Inspect ................................................ 128Radiator Core - Clean ......................................... 129Window Washer Reservoir - Fill .......................... 135Window Wipers - Inspect/Replace ...................... 136Windows - Clean ................................................. 136

Every 10 Service Hours or Daily

Backhoe Boom, Stick, Bucket, and Cylinder Bearings- Lubricate ........................................................... 95

Backup Alarm - Test .............................................. 96Braking System - Test ........................................... 97Cooling System Coolant Level - Check .............. 104

Engine Air Filter Service Indicator - Inspect ......... 111Engine Air Precleaner - Clean ............................. 111Engine Oil Level - Check ..................................... 112Fuel System Water Separator - Drain ................. 122Hydraulic System Oil Level - Check ................... 127Loader Bucket, Cylinder, and Linkage Bearings -

Lubricate ........................................................... 127Seat Belt - Inspect .............................................. 130Stabilizer and Cylinder Bearings - Lubricate ....... 131Swing Frame and Cylinder Bearings - Lubricate .. 132Tire Inflation - Check ........................................... 132Transmission Oil Level - Check .......................... 134Wheel Nut Torque - Check .................................. 135

Every 50 Service Hours or Weekly

Cab Filter(Fresh Air) - Clean/Inspect/Replace ... 101Cab Filter (Recirculation) - Clean/Inspect/

Replace ............................................................. 101Fuel Tank Water and Sediment - Drain ............... 122

Parking Brake - Check/Adjust ............................. 128

Every 250 Service Hours

Engine Oil Sample - Obtain ................................. 113

Every 250 Service Hours or Monthly

Axle Breathers - Clean/Replace ........................... 95Belt - Inspect/Adjust/Replace ................................ 97Differential Oil Level (Front) - Check .................. 107Differential Oil Level (Rear) - Check ................... 107Extendable Stick Pads - Inspect/Adjust ............... 114Final Drive Oil Level (Front) - Check .................. 120

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

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 105

Every 500 Service Hours or 3 Months

Brake Accumulator - Check .................................. 97Cooling System Coolant Sample (Level 1) -

Obtain ............................................................... 104Differential Oil Sample (Front) - Obtain .............. 108Differential Oil Sample (Rear) - Obtain ............... 108Drive Shaft Spline - Lubricate ............................. 108Engine Oil and Filter - Change ............................ 113Final Drive Oil Sample (Front) - Obtain .............. 120Fuel System Primary Filter (Water Separator) -

Replace ............................................................. 121Fuel System Secondary Filter - Replace ............ 121Hydraulic Oil Sample - Obtain ............................ 124Hydraulic System Oil Filter - Replace ................. 126Transmission Oil Filter - Replace ........................ 134Transmission Oil Sample - Obtain ...................... 135


Engine Valve Lash - Check .................................. 114

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94 SEBU8287-05Maintenance SectionMaintenance Interval Schedule

Every 1000 Service Hours or 6 Months

Differential Oil (Front) - Change .......................... 106DifferentialOil (Rear) - Change .......................... 106Final Drive Oil (Front) - Change .......................... 120Ride Control Accumulator - Check ..................... 130

Rollover Protective Structure (ROPS) - Inspect .. 130Transmission Magnetic Screen - Clean .............. 132Transmission Oil - Change ................................. 133


Engine Crankcase Breather - Replace ................ 112

Every 2000 Service Hours or 1 Year

Hydraulic System Oil - Change ........................... 125

Every Year

Cooling System Coolant Sample (Level 2) -

Obtain ............................................................... 105

Every 3000 Service Hours or 2 Years

Cooling System Water Temperature Regulator -Clean/Replace .................................................. 105

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

Seat Belt - Replace ............................................. 131

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 103

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 102

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Axle Breathers - Clean/Replace

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Axle Breathers - Clean/Replace

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

g01216797

Illustration 112The front axle breather is located on the top right side of the frontdifferential housing.

g01357541Illustration 113

The rear axle breather is located on the top right side of the rear

differential housing.

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

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

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

i02830830

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

SMCS Code: 6501-086-BD; 6502-086-BD;6503-086-BD; 6511-086-BD; 6512-086-BD;6533-086-BD; 7562-086-BD


Position the backhoe into the service position thatis shownabove. Lower the bucket to the ground.Relieve the hydraulic pressure.


Apply lubricant to the grease fitting (1) for the rod endof the boom cylinder.

Apply lubricant to the two remote grease fittings (2)for the head end of the boom cylinder.

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96 SEBU8287-05Maintenance SectionBackup Alarm - Test

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


Apply lubricant to the grease fitting (4) for the headend of the bucket cylinder.

Apply lubricant to the grease fitting (5) for the rod endof the stick cylinder.

Apply lubricant to the remote grease fitting (6) for thehead end of the stick cylinder.

Apply lubricant to the grease fitting (7) for the pivotpin for the stick.


Apply lubricant to the grease fitting (8) for the pivotpin.

Apply lubricant to the grease fitting (9) for the bucketpivot pin.

Apply lubricant to the grease fitting (10) for the link.

Apply lubricant to the grease fitting (11) for the rodend of the bucket cylinder.

Apply lubricant to the grease fitting (12) for the pivotpin. There is one grease fitting on each side of themachine.

There are a total of 17 grease fittings.

i00080741

Backup Alarm - Test

SMCS Code: 7406

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

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

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

i01833495

Battery or Battery Cable -Inspect/Replace

SMCS Code: 1401

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

2. Disconnect the negative battery cable from theframe.

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

3. Disconnect the negative battery cable at thebattery.

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

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

6. Connect the negative battery cable at the battery.

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

8. Install the engine start switch key.

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Belt - Inspect/Adjust/Replace

i02707745

Belt - Inspect/Adjust/Replace

SMCS Code:1397-025; 1397-040; 1397-510

Note: This engine is equipped with a belt tightenerthat automatically adjusts the belt to the correcttension.

1. Install the lift cylinder brace. Refer to Operationand Maintenance Manual, Lift Cylinder Brace -Connect and Disconnect for more information.

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

3. Inspect the belt for wear and for cracking.

4. If the belt requires replacement, perform Step 4.a

through Step 4.c.


a. Turn the belt tensioner in order to release thetension from the belt.

b. Remove the belt.

c. Install a new belt.

5. Install the engine access panel.

6. Start the engine. Raise the loader arms to the

maximum height.

7. Remove the pin and replace the brace for theloader lift arm to the stored position on the loaderlift arm.

8. Lower the bucket to the ground.

i02704944

Brake Accumulator - Check

SMCS Code: 4263-535

Hydraulic accumulator contains gas and oil underhigh pressure. Improper removal or repair proce-dures couldcause severe injury. To remove or re-pair, instructions in the service manual must befollowed. Special equipment is required for test-ing and charging.

1. Turn the engine start switch to the ON position.The alert indicator for brake oil pressure shouldilluminate if the braking system is not at normaloperating pressure.

2. Start the engine. Run the engine at half throttle fortwo minutes in order to increase the accumulatorpressure. The alert indicator for brake oil pressureshould go off.

3. Stop theengine. Apply the service brake pedaland release the service brake pedal until the alertindicator for brake oil pressure comes on. This willdecrease the accumulator pressure. A minimumof three applications of the service brake pedalare required.

Note: If your machine is equipped with the

original accumulator, replace the accumulator. If yourmachine is equipped with a replacement accumulator,recharge the accumulator at your dealer.

4. If thealert indicator illuminates before threeapplications of the brake pedal, measure theaccumulator precharge pressure. Your authorizeddealer can measure the nitrogen gas pressure inthe accumulator. Use only dry nitrogen gas forrecharging.

i03478561

Braking System - Test

SMCS Code: 4251; 4267; 7000

Service Brake Holding Ability Test

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

Test the brakes on a dry, level surface.

Fasten the seat belt before you test the brakes.

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98 SEBU8287-05Maintenance SectionBucket Cutting Edges - Inspect/Replace

The following test is used to determine if the servicebrake is functional. This test is not intended tomeasure the maximum brake holding effort. Thebrake holdingeffort that is required to sustain amachine at a specific engine rpm varies dependingon the machine. The variations are the differences in

the engine setting, in the power train efficiency, andin the brake holding ability, etc.

1. Start the engine. Raise the bucket slightly.

2. Apply the service brake. Release the parkingbrake.

3. Move the transmission control lever to THIRDSPEED FORWARD.

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

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

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

NOTICEIf the machine moved while testing the brakes, contact

your Caterpillar dealer. Have the dealer inspect and,if necessary, repair the service brake before returningthe machine to operation.

Secondary Brake Holding AbilityTest

Refer to Operation and Maintenance Manual,Parking Brake - Check/Adjust.

i01920076

Bucket Cutting Edges -Inspect/Replace

SMCS Code: 6801

Personal injury or death can result from bucketfalling.

Block the bucket before changing bucket cuttingedges.

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

2. Lower the bucket to the blocking.

Do not block up the bucket too high. Block upthe bucket so that the bucket is high enough to

remove the cutting edges and the end bits.

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

4. Clean the contact surfaces.

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

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

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

8. Raise thebucket. Remove the blocks.

9. Lower the bucket to the ground.

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

i03657242

Bucket Tips - Inspect/Replace

SMCS Code: 6805

Personal injury or death can result from the bucketfalling.

Block the bucket before changing bucket tips.

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Bucket Tips - Inspect/Replace

Bucket Tips


(1) Usable(2) Replace the tip.(3) Replace the tip.

Check the bucket tips for wear. If the bucket tip has ahole, replace the bucket tip.

1. Remove the pin from the bucket tip. The pin canbe removed by one of the following methods.

Use a hammer and a punch from the retainerside of the bucket to drive out the pin.

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


(4) Back of Pin-Master(5) Extractor

a. Place the Pin-Master on the bucket tooth.

b. Align extractor (5) with the pin.

c. Strike the Pin-Master at the back of the tool (4)and remove the pin.


(6) Retainer(7) Retaining washer(8) Adapter

2. Clean the adapter and the pin.

3. Fit retainer (6) into retaining washer (7). Installthis assembly into the groove that is in the sideof adapter (8).


4. Install the new bucket tip onto the adapter.

Note:The bucket tip can be rotated by 180 degrees inorder to allow greater penetration or less penetration.

5. Drive the pin through the bucket tip. The pin can

be installed by using one of the following methods:

From the other side of the retainer, drive thepin through the bucket tip, the adapter, and theretainer.

Use a Pin-Master. Follow Step 5.a through Step5.e for the procedure.

Note: To correctly install the pin into the retainer, thepin must be driven in from the right side of the tooth.Improper installation of the pin can result in the lossof the bucket tip.

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100 SEBU8287-05Maintenance SectionBucket Tips - Inspect/Replace


(4) Back of Pin-Master(9) Pin setter(10) Pin holder

a. Insert the pin through the bucket tooth.

b. Place the Pin-Master over the bucket tooth andlocate the pin in the hole of holder (10).

c. Strike the tool with a hammer at the back of thetool (4) in order to start the pin.

d. Slide pin holder (10) away from the pin androtate the tool slightly in order to align pin setter(9) with the pin.

e. Strike the end of the tool until the pin is fullyinserted.

6. After you drive the pin, make sure that the retainerfits snugly into the pin groove.

K-Series Tip

Removal


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 (5).

2. Use the pry bar in order to remove retainer (5)

from bucket tip (4).

3. Remove bucket tip (4) from adapter (6) with aslight counterclockwise rotation.

4. Clean adapter (6).

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.


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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Cab Filter (Fresh Air) - Clean/Inspect/Replace

i02705169

Cab Filter (Fresh Air) -Clean/Inspect/Replace

SMCS Code:7342-040; 7342-070; 7342-510

NOTICEDo not clean the elements by bumping or tappingthem.

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

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

When cleaning with pressure water, use 280 kPa

(40 psi) maximum to prevent element damage.

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


1. Openthe filter cover that is located on the rightfender.


2. Remove the filter element.

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

4. Rinse the filter element thoroughly with clearwater.

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

6. Install the filter element.

7. Install the filter cover.

i04218029

Cab Filter(Recirculation) -Clean/Inspect/Replace

SMCS Code:7342-040; 7342-070; 7342-510

The recirculation filter is located to the left of theoperators seat.


1. Remove the cover that is over the recirculationfilter. Remove the fi lter element.

2. The filter element can be cleaned by using

compressed air. Use a maximum air pressure of205 kPa (30 psi). Direct the air from the clean sidetothe dirty side.

3. Look through the filter toward a bright light. Inspectthe element for damage. Inspect the gaskets fordamage. Replace damaged filters.

4. Install the filter element.

Note:Clean the filters more often in dusty conditions.

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102 SEBU8287-05Maintenance SectionCab Interior - Clean

i01404606

Cab Interior - Clean

SMCS Code:7301-070

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

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

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

i02705616

Cooling System Coolant (ELC)

- ChangeSMCS Code: 1353; 1395

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

NOTICEMixing ELC with other products will reduce the effec-

tiveness of the coolant.

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

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

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

use.

For information about the addition of Extender to yourcooling system, see the Operation and MaintenanceManual, Cooling System Coolant Extender (ELC) -

Add or consult your Caterpillar dealer.

Flushing the Extended Life CoolantFrom the Cooling System

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

Flushing a Standard Coolant Fromthe Cooling System

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

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

Changing the Coolant


NOTICEDo notchange the coolant until you read and under-stand the material in the Cooling System Specifica-tions section.

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


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

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Cooling System Coolant Extender (ELC) - Add


3. Slowly loosen the radiator cap in order to relievesystem pressure. Remove the radiator cap slowly.

g01357599

Illustration 131

4. Open the drain valve. Drain the system into asuitable container.

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

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

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

8. Close the drain valve.

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

Special Publication, SEBU6250, CaterpillarMachine Fluids Recommendations, CoolingSystem Specifications

Operation and Maintenance Manual, Capacities(Refill)

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

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

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

12. Install the radiator cap. Lower the tab on theradiator cap. Replace the radiator cap if the gasketis damaged.

13. Stop the engine.

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

i03114912

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352; 1353; 1395

Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until radi-ator is cool. Then loosen the cap slowly to relievethe pressure.

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

Table 18

RECOMMENDED AMOUNT OF EXTENDER BYCOOLING SYSTEM CAPACITY

Cooling System Capacity Recommended Amount

of Extender

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

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

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

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

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104 SEBU8287-05Maintenance SectionCooling System Coolant Level - Check

For additionalinformation on the addition of extender,see Special Publication, SEBU6250, Cat ExtendedLife Coolant (ELC) Cooling System Maintenance orconsult your Caterpillar dealer.

i02706505

Cooling System Coolant Level- Check

SMCS Code: 1350-535-FLV


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


1. The radiator cap is located on the top of theradiator on the right side of the machine. Slowlyloosen the cap in order to relieve system pressure.Remove the radiator cap slowly.

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

3. Check the coolant level in the expansion tank.

4. Inspect the radiator cap seal. Replace the radiatorcap seal if the radiator cap seal is damaged.

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

i02706515

Cooling System CoolantSample (Level1) - Obtain

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

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

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


Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of SOS analysis, youmust establish a consistent trend of data. In orderto 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.

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Cooling System Coolant Sample (Level 2) - Obtain

Obtain coolantsamples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

Keep the lids on empty sampling bottles until youare ready to collect the sample.

Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

Never collect samples from expansion bottles.

Never collect samples from the drain for a system.

Submit thesample for Level 1 analysis.

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

dealer.

i02706518

Cooling System CoolantSample (Level 2) - Obtain

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

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.




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

Refer to Operation and Maintenance Manual,

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

Submit the sample for Level 2 analysis.

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

i02706526

Cooling System Water

Temperature Regulator -Clean/Replace

SMCS Code: 1355; 1393

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

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

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

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

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

1. Install the lift cylinder brace. Refer to Operationand Maintenance Manual, Lift Cylinder Brace -

Connect and Disconnect for more information.

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

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106 SEBU8287-05Maintenance SectionDifferential Oil (Front) - Change


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

4. Remove the bolts from the thermostat housingassembly. Remove the thermostat housingassembly.

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

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

The thermostats can be reused under the followingconditions.

The thermostat is tested and the thermostatmeets test specifications.

The thermostat is not damaged.

The thermostat does not have excessivebuildup of deposits.

7. Install the hose. Tighten the hose clamp.

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

(Refill).

i02567860

Differential Oil (Front) - Change

SMCS Code: 3258


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

2. The drain plug is magnetic. Check the plug formetal.

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

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

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

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

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

i02706610

Differential Oil (Rear) - Change

SMCS Code: 3258

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

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Differential Oil Level (Front) - Check


1. Remove the three oil drain plugs (1) and drain theoil into a suitable container.

2. Clean the drain plugs and install the drain plugs.

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

4. Add oil until the oil is level with the threads for thefiller plug. Refer to Operation and MaintenanceManual, Lubricant Viscosities and Operation andMaintenance Manual, Capacities (Refill) for oil.

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

i02363607

Differential Oil Level (Front) -Check

SMCS Code: 3258

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


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

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

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

i02575217

Differential Oil Level (Rear) -Check

SMCS Code: 3258

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


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

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

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

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108 SEBU8287-05Maintenance SectionDifferential Oil Sample (Front) - Obtain

i02363692

Differential Oil Sample (Front)- Obtain

SMCS Code:3258-008; 7542-008


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

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

Refer to the Special Publication, SEBU6250, SOSOil Analysis for more information.

i02706673

Differential Oil Sample (Rear)- Obtain

SMCS Code:3258-008; 7542-008


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

Refer to the Operation and Maintenance Manual,General Hazard Information for information thatpertains to containingfluid spillage.

Refer to the Special Publication, SEBU6250, SOSOil Analysis for more information.

i02363714

Drive Shaft Spline - Lubricate

SMCS Code: 3253

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


Applylubricant to the grease fitting for the drive shaftspline of the front drive shaft.


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

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Engine Air Filter Primary Element - Clean/Replace

i02510477

Engine Air Filter PrimaryElement - Clean/Replace

SMCS Code: 1051; 1054

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

Service the air cleanerfilter element when theyellow piston on the engine airfilter serviceindicator enters the red zone or the indicatorreads 63.5 cm (25 inch) of water. Refer toOperation and Maintenance Manual, Engine AirFilter Service Indicator - Inspect.



2. Remove cover (1) for the airfilter housing .

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

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

5. Clean the inside of the airfilter housing.

6. Slide a clean primary airfilter element into thefilter base. Install the clean filter into the airfi lterhousing. Install the cover for the airfi lter housing.

Note:Refer to Cleaning Primary Air Filter Elements.

7. Reset the engine airfi lter service indicator.

8. Close the access door.

If the yellow piston in the indicator moves into the redzone after starting the engine or the exhaust smokeis still black after installation of a clean primary filterelement, install a new primary filter element. If thepiston remains in the red zone replace the secondaryelement.

Cleaning Primary Air FilterElements

NOTICECaterpillar recommends certified airfilter 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 dustfrom 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 airfilters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary airfilter element can be used up tosix times if the element is properly cleaned andinspected. When the primary airfilter element iscleaned, check for rips or tears in the fi lter material.Every two years replace the primary airfilter elementat least one time. This replacement should beperformed regardless of the number of cleanings.

NOTICEDo not clean the airfilter 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 airfi lter elements beforecleaning. Inspect the airfi lter elements for damageto the seal, the gaskets, and the outer cover. Discardany damaged airfilter elements.

There are two common methods that are used toclean primary airfilter elements:

Pressurized air

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110 SEBU8287-05Maintenance SectionEngine Air Filter Secondary Element - Replace

Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary airfi lterelements that have not been cleaned more than two

times. Pressurized air will not remove deposits ofcarbon and oil. Use fi ltered, dry air with a maximumpressure of 207 kPa (30 psi).

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

Vacuum Cleaning

Vacuum cleaning is another method for cleaningprimary airfilter elements which require daily cleaning

because 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.Inspectthe primary airfi lter element for tears and/orholes. If it is necessary in order to confirm the result,compare the primary air filter element to a newprimary airfilter element that has the same part

number.

Do notuse a primary airfi 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 airfi lterelements.

Storing Primary Air Filter Elements

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

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

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

Date of cleaning

Number of cleanings

Store the box ina dry location.

i01991300

Engine Air Filter Secondary

Element - ReplaceSMCS Code: 1051; 1054

NOTICEAlways replace the secondary filter element. Neverattempt to reuse it by cleaning.

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

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


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

2. Remove the primary filter element (2) from the aircleaner housing.

3. Clean the inside of the air cleaner housing (4) witha wet rag before the secondary filter element (3)

is removed.

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

5. Install a new secondary element.

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

7. Reset the fi lter element indicator.

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Engine Air Filter Service Indicator - Inspect

8. Close the engine access door.

i02706745

Engine Air Filter Service

Indicator - InspectSMCS Code:1051; 1054; 7452

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


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

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

i02835415

Engine Air Precleaner - Clean

SMCS Code:1055-070


Engine Air Intake Duct

1. Inspect the bottom of the inlet duct and inspect theprecleaner tubes for dirt and debris.

Engine Air Precleaner

1. Remove the airfilter housing from the machine.

2. Remove the primary fi lter elements and removethe secondary fi lter elements in order to clean theprecleaner tubes.

3. Use pressurized air to clean the tubes. Put thetubes on a flat surface. Direct the pressurized airinto the tubes from the top. This loosens up thedirt.

4. Loosen hard deposits of dust on the precleaner

body by soaking in an appropriate cleaning agent.Then, wash the precleaner body with a spray ofwater.

5. Blow dry the precleaner body completely.

6. Install the precleaner.

7. Install the T-bolt. Hand tighten the T-bolt only.

8. Close the left engine access door.

NOTICEService the air cleaner only with the engine stopped.

Engine damage could result.

i01404793

Engine Compartment - Clean

SMCSCode: 1000-070

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

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

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112 SEBU8287-05Maintenance SectionEngine Crankcase Breather - Replace

i02409844

Engine Crankcase Breather -Replace

SMCS Code:1317-510


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

2. Remove the setscrews (8) and remove the

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

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

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

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

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

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

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

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

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

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

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

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

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

mechanism cover.

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

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

i02571470

Engine Oil Level - Check

SMCS Code:1302; 1318; 1326

NOTICEDo not overfill the crankcase. Engine damage can re-sult.



2. While the engine is stopped, maintain the oil levelin the FULL RANGE ENGINE STOPPED areaon the engine oil dipstick (2).

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Engine Oil Sample - Obtain

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

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

5. Close the engine access door.

i02708914

Engine Oil Sample - Obtain

SMCS Code:1348-008; 7542-008


Obtain a sample of the engine oil from the samplingport for the engine oil. The sampling port is located onthe engine oil filter base. Refer to Special Publication,SEBU6250, SOS Oil Analysis for information thatpertains to obtaining a sample of the engine oil.Refer to Special Publication, PEHP6001, How ToTake A Good Oil Sample for more information aboutobtaining a sample of the engine oil.

i02706770

Engine Oil and Filter - Change

SMCS Code:1302; 1318; 1326

Note: If the sulfur content in the fuel is greater than1.5% by weight, use an oil with a TBN of 30. With thehigh sulfur fuel, change the oil and the fi lter element

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


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

2. Remove the fuel filter/water separator. Refer toOperation and Maintenance Manual, Fuel SystemFilter and Water Separator - Replace.


3. Remove the filter element with a strap typewrench.

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

5. Apply a thin fi lm of clean engine oil to the sealingsurface of the new filter element.

6. Install the new oil fi lter by hand.

Instructions for the installation of the filter areprinted on the side of each Caterpillar spin-onfilter. For non-Caterpillar filters, refer to theinstallation instructions that are provided by thesupplier of the filter.

7. Install the fuel fi lter/water separator.

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114 SEBU8287-05Maintenance SectionEngine Valve Lash - Check

8. Open the engineaccess door on the top of themachine.


9. Remove the oil filler cap (1). Fill the crankcase

with new oil. Refer to Operation and MaintenanceManual, Lubricant Viscosities and Operation andMaintenance Manual, Capacities (Refill). Cleanthe oil fi ller cap and install the oil fi ller cap.

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

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

Add oil, if necessary.

12. Replace the engine access panel and close the

engine access door.

i01897328

Engine Valve Lash - Check

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

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

Refer to your machine's Service Manual for completeinstructions.

i03066310

Extendable Stick Pads -Inspect/Adjust(If Equipped)

SMCS Code: 6533-025; 6533-040

Note: The wear pads on the extendable stick areimpregnated with a lubricant. The wear pads do notrequire the application of lubricant. Do not applylubricant to the pads.

Upper Wear Pad


1. Position the machine as shown in figure 154.

2. Raise the rear of the backhoe so that tires are25.4 mm (1 inch) off of the ground.

3. Fully extend the stick. Then, retract the stick76.2mm to 101.6 mm (3 inch to 4 inch).

4. Pull stick in and position the rear bucket so thatthe bottom of the bucket and the bucket teeth areflat on the ground.

5. Fully extend the extendable stick. Lift thestabilizers off the ground.

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Extendable Stick Pads - Inspect/Adjust


6. Use a feeler gauge in order to measure the gapbetween wedge (1) and the bottom surface of theinner stick. The gap should be between 0.5 mm

(0.0197 inch) and 1.0 mm (0.0394 inch).

7. Check for clearance on the upper wear pad. If thegap between the upper wear pad and the bottomsurface of the inner stick is less than 0.5 mm(0.02 inch) proceed to Step 8, or more than 1 mm(0.04 inch) proceed to Step 9.


8. If the gap is less than 0.5 mm (0.0197 inch),perform steps 8.a through 8.i.

a. Retract the extendable stick halfway.

b. Loosen two bolts (3) that secure the upperwear pad (1) in place.

Note: Do not loosen the two bolts that are under thesetscrew.

c. Loosen set screw (2) by two turns.

d. Fully extend the stick. The upper wear padshould slide back to the stop.

e. Return the machine to the position that isshown in figure 156.

f. Turn the set screw counterclockwise in order toincrease the gap.

g. After you set the clearance, tighten bolts (3) inorder to secure the upper wear pad.

h. Measure the gap that is between the wedgeand the bottom surface of the inner stick. Ifnecessary, perform steps 8.a through 8.g.

i. When the gap is correct, apply 154-9731Thread Lock Compound to both bolts (3).

j. Torque bolts (3) to 100 20 Nm (74 15 lb ft).

k. Proceed toStep 10.

9. If the gap is more than 1.0 mm (0.0394 inch),perform steps 9.a through 9.e.

a. Loosen two bolts (3) that secure the upperwear pad (1) in place.


b. Turn set screw (2) clockwise in order todecrease the gap.

c. Tighten two bolts (3) in order to secure theupper wear pad.

d. Measure the gap that is between the wedgeand thebottom surface of the inner stick. If

necessary, perform steps 9.a through 9.c.

e. When the gap is correct, apply 154-9731Thread Lock Compound.

f. Torque bolts (3) to 100 20 Nm (74 15 lb ft).

g. Proceed to Step 10.

10. Check extension of the stick after adjusting theupper wear pad.

a. Set the stick horizontally to the ground.

b. Extend the stick and retract the stick in order tocheck for any vibrations.

c. If no vibration is evident, continue to Inspectthe Gap of the Lower Wear Pads.

d. Ifthe vibration is evident, adjust the upper wearpad to the maximum gap of 1 mm (0.04 inch).If the vibration continues contact the DealerService Network (DSN).

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116 SEBU8287-05Maintenance SectionExtendable Stick Pads - Inspect/Adjust

Note: A small amount of vertical movement ofthe outer slider is acceptable with a gap of 1 mm(0.04 inch).

Inspect the Gap of the Lower Wear

Pads


1. Remove access plate (4) and remove the twocaps for the access holes (5).


2. Position the machine. Refer to Illustration 158

3. Fully retract the extendable stick in order to allowaccess through the nose of the stick. Slightly liftthe rear of the machine.

4. At access holes (5), measure the gap between thetop of the flat wear pad that is bolted to the innerstick and the inside surface of the outer stick.

5. Check for clearance on the lower wear pad. If thegap between the lower wear pad and the bottomsurface of the outer stick is less than 0.5 mm(0.02 inch) proceed to Step 6, or more than 1 mm(0.04 inch) proceed to Step 7.

6. If the gap is less than 0.5 mm (0.0197 inch),perform the following steps:


a. Loosen the two bolts (6) that secure the lowerwear pad in place.


b. Turn set screw (7) counterclockwise by twoturns.

c. Slide the stick out 25 mm (1 inch) to 75 mm(3 inch).

Note: The lower wear pad should return against theset screw. This will create a gap between the lowerwear pad and the outer extendable stick.

Note:Ensure that the wear pad is pulled back against

the set screw. Tighten the bolts. Ensure that you canaccess the bolts after the stick has been extendedby a few inches.

d. Return the machine to the position that isshown in figure 158.

e. Measure the gap and make any neededadjustments.

f. If the gap is correct, apply 154-9731ThreadLock Compound to both bolts (6).

g. Torque the bolts (6) to 100 20 Nm

(74 15 lb ft).

7. If the gap is more than 1.0 mm (0.0394 inch),perform steps:

a. Loosen the two bolts (6) that secure the lowerwear pad in place.


b. Turn set screw (7) clockwise in order todecrease the gap.

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Extendable Stick Pads - Inspect/Adjust

c. Measure the gap and make any neededadjustments.

d. If the gap is correct, apply 154-9731ThreadLock Compound to both bolts (6).

e. Torque the bolts (6) to 100 20 Nm(74 15 lb ft).

Checking Extension of the Stick

1. Set the stick so the stick is horizontal to theground.

2. Extend and retract the extendable stick in order tocheck for any vibrations.

3. If no vibration is evident, proceed to Adjustmentof the Side Pad.

4. If the adjustment of the wedge has been performedand vibration is evident proceed to Adjustmentof the Side Pad.

Note: A small amount of vertical movement of theouter slider is acceptable with a gap of 1.0 mm(0.0394inch).

Adjustment of the Side Pad


1. Position the machine. Refer to Illustration 160.


2. Raise the rear of the backhoe and make surethat the boom nose is level with the ground. Fullyextend the stick and place the curled bucket

slightly off the ground.

3. Check for free play between the side wear padsand the inner section of the stick.

4. Check each side wear pad with the outer slider inthe following positions.

Extended 50.8 mm (2 inch) to 76.2 mm (3 inch)

Half extended

Fully extended

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118 SEBU8287-05Maintenance SectionExtendable Stick Pads - Inspect/Adjust


(8) 0.25mm (0.0098 inch)(9) No gap

5. Use a 0.25 mm (0.0098 inch) feeler gauge tocheck each side wear pad. One side should have

no gap between the inner slider and the face ofthe pad (9). The other side should have a 0.25 mm(0.0098 inch) or less gap (8). See Illustration 162.

6. Ensure that a 0.25 mm (0.0098 inch) gap ispresent at the widest part of the three checkedpositions. This will be the position of the smallestgap between the inner slider and side wear pad.Setting the 0.25 mm (0.0098 inch) gap at a narrowpoint of the inner slider may allow vibrating as thewear pads travel over the wider points of the slider.

7. If adjustment is required, perform the followingsteps:


(10) 284-3615Hex Socket Screws(11) 233-5165 Plate

a. Remove the four hex socket screws (10) and

the plate (11).

b. Apply an adequate number of shims in order tomake the side lower wear pad flush with shims.

Note: The amount of shims should be equal on bothsides within 0.5 mm (0.02 inch). The top side padand bottom side pad do not need to have an equalnumber of shims.

c. Reassemble the cover (11) and torque the hexsocket screws (10) to 50 10 Nm (37 7 lb ft).

d. Repeat steps for the remaining three additional

side pads.

e. Proceed to Step 8.

8. Check extension of the stick after adjusting theside wear pads.

a. Set the stick horizontally to the ground.

b. Extend the stick and retract the stick in order tocheck for any vibrations.

c. If adjustment is too tight, then add a 0.5 mm(0.02 inch) shim to one of the side pads and

recheck the adjustment.

Note: Choose a pad with the heaviest wear marks.

d. If adjustment is still too tight, then add a 0.5 mm(0.02 inch) shim to the corresponding pad onthe other side and recheck the adjustment.

e. If adjustment continues to be too tight, thenadd a 0.5 mm (0.02 inch) shim to the remainingwear pads.

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Film (Product Identification) - Clean

Note: Recheck for vibration before the addition ofeach shim. Do not exceed 0.5 mm (0.02 inch) ofadditional shimming at all four pads.

f. If the stick continues to vibrate, contact theDSN.

i03997106

Film (Product Identification) -Clean

SMCS Code:7405-070; 7557-070



Typical example of the Product Identification Films.

Cleaning of the Films

Make sure that all of the product identificationfilms are legible. Make sure that the recommendedprocedures are used in order to clean the productidentification films. Ensure that all the productidentification films are not damaged or missing. Cleanthe product identification films or replace the fi lms.

Hand Washing

Use a wet solution with no abrasive material thatcontains no solvents and no alcohol. Use a wetsolution with a pH value between 3 and 11. Usea soft brush, a rag, or a sponge in order to clean

the product identification films. Avoid wearing downthe surface of the product identification films withunnecessary scrubbing. Ensure that the surface ofthe productidentification fi lms is flushed with cleanwater and allow the product identification fi lms to airdry.

Power Washing

Power washing or washing with pressure may beused in order to clean product identification fi lms.However, aggressive washing can damage theproduct identification films.

Excessive pressure during power washing candamage the product identification films by forcingwater underneath the product identificationfilms. Water lessens the adhesion of the productidentification film to the product, allowing the productidentification film to lift or curl. These problems aremagnified by wind. These problems are critical forthe perforated film on windows.

To avoid lifting of the edge or other damage to theproduct identification fi lms, follow these importantsteps:

Use a spray nozzle with a wide spray pattern.

A maximum pressure of 83 bar (1200 psi)

A maximum water temperature of 50 C (120 F)

Hold the nozzle perpendicular to the productidentification film at a minimum distance of 305 mm(12 inch).

Do not direct a stream of water at a sharp angle tothe edge of the product identification fi lm.

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120 SEBU8287-05Maintenance SectionFinal Drive Oil (Front) - Change

i02369952

Final Drive Oil (Front) - Change

SMCS Code: 4050


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

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


3. Position the plug hole at a horizontal position. Use

theline on thefi

nal drive as a reference.

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

5. Clean the plug and install the plug.

6. Repeat the procedure for the otherfinal drive.

i02370034

Final Drive Oil Level (Front) -Check

SMCS Code: 4050


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

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

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

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

5. Repeat the procedure for the otherfinal drive.

i02370039

Final Drive Oil Sample (Front)- Obtain

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


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Fuel System Primary Filter (Water Separator) - Replace

Obtain the oil sample from the fill/drain plug. Refer toSpecial Publication, SEBU6250, SOS Oil Analysisfor information that pertains to obtaining a sampleof the engine oil. Refer to Special Publication,PEHP6001, How To Take A Good Oil Sample formore information about obtaining a sample of oil.

i03671548

Fuel System Primary Filter(Water Separator) - Replace

SMCS Code:1261-510; 1263-510

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

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


2. Remove the access panel from the left side of

the machine.

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


3. Open drain valve (2) and drain the fuel into asuitable container.

4. Remove sensor (3) and the wire from the bottomof the filter.

5. Remove primaryfuel fi lter (1) that is located nextto the engine oil filter under the left side of themachine. Rotate the locking ring counterclockwisein order to remove the filter element. Discard thefilter properly.

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

7. Coat the seal of the new fi lter element with cleandiesel fuel.

NOTICEDo not fill the primary fuel filter with fuel before in-stalling. The fuel would not be filtered and could becontaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.

8. Install the new fuel fi lter by hand.


9. Install the sensor and the wire into the new fi lter.

10. Use a hand priming pump to remove air from thesystem.

11. Replace the access panel.

i03664531

Fuel System Secondary Filter -Replace

SMCS Code: 1261-510-SE

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.



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122 SEBU8287-05Maintenance SectionFuel System Water Separator - Drain

Note: Replace the secondary filter in an area thathas no airborne dust or dirt. Do not expose new filtersto surfaces that are not clean.

Note: Before you replace the secondary fuel filter,the primary fuel fi lter must be replaced. Refer to the

Operation and Maintenance Manual, Fuel SystemPrimary Filter (Water Separator) - Replace.

1. Install thelift cylinder brace. Refer to Operationand Maintenance Manual, Lift Cylinder Brace -Connect and Disconnect for more information.

2. Remove the access panel from the left side ofthe machine.

3. Park the machine on a level surface. Ensure thatthe parking brake is fully engaged.


4. Use a strap wrench and remove the secondaryfuel filter. Discard the secondary fuel filter properly.

NOTICEDo not fi ll the secondary fuel filter with fuel before in-stalling. The fuel would not be filtered and could becontaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.

5. Clean the fuel filter base.

6. Coat the seal for the new secondary fuel fi lter with

clean diesel fuel prior to installation.

7. Install the new secondary fuel fi lter by hand.

Instructions for the installation of the filter areprinted on the side of each Caterpillar spin-onfilter. For non-Caterpillar filters, refer to theinstallation instructions that are provided by thesupplier of the fi lter.

8. Start the engine and check for leaks.

i02706838

Fuel System Water Separator- Drain

SMCS Code: 1263-543; 1263

Some fuel supplies may not meet the minimumstandard for fuel lubricity. Caterpillar recommends theuse of fuelsthat meet certain minimum specifications.Refer to Special Publication, SEBU6250, CaterpillarMachine Fluids Recommendations.

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

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


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

2. Tighten the drain valve.

3. If the engine fails to start, change the fuel fi lter. Ifthere is a power loss, change the fuel fi lter.

i02706870

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S

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

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Fuses - Replace

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

to the fuel system.

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


Flip up the tab on the fuel cap. Turn the tabcounterclockwise on the fuel cap and slowly removethe fuel tank cap (2) in order to relieve pressure.

The fuel tank drain valve (1) is located on the lowerright corner on the front of the fuel tank. Loosen the

fuel tank drain plug in order to drain a steady streamof liquid. Allow the water and sediment to drain intoa suitable container. Tighten the fuel tank drain plug.Replace the fuel tank cap.

i02940497

Fuses - Replace

SMCS Code: 1417

Fuses protect the electrical system from damagethat is caused by overloaded circuits. Replace thefuse if the element separates. If the element of a new

fuse separates, check the circuit. Repair the circuit, ifnecessary.

NOTICEReplace the fuses with the same type and size only.Otherwise, electrical damage can result.

If it is necessary to replace fuses frequently, an electri-cal problem may exist. Contact your Caterpillar dealer


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


Backup Alarm (1) Relay

Power Port (2) 10 Amp

Machine ECM (3) 20

Backup Alarm (4) 15 Amp

Roading Lights (5) 20 Amp

Flasher Module (6) 15 Amp

Engine Stop (7) 10 Amp

Horn and Position Lights (8) 15 Amp

Rear Window Wiper and Washer (9) 20 Amp

Laser Mast (10) 20 Amp

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124 SEBU8287-05Maintenance SectionHydraulic Oil Sample - Obtain

Rear Floodlights (11) 15 Amp

Auxiliary Rear Floodlights (12) 15 Amp

Air Seat (13) 20 Amp

Left Tail Light (14) 10 Amp

Dash Panel Lights (15) 10 Amp

Right Tail Light (16) 10 Amp

Horn (17) Relay

Tail Lights (18) Relay


Differential Lock (19) Relay

Fuel Pump (20) 15 Amp

Monitor (21) 5 Amp

Rotating Beacon (22) 15 Amp

Air Conditioner (23) 10 Amp

Auxiliary Front Floodlights (24) 15 Amp

Front Window Wiper and Washer (25) 20 Amp

Hydraulic Lockout (26) Relay

Front Floodlights (27) 15 Amp

All Wheel Drive (28) Relay

Ride Control (29) Relay

Ride Control and Hydraulic Lockout (30) 20Amp

i02830866

Hydraulic Oil Sample - Obtain

SMCS Code: 5050-008; 7542-008


Obtain a sample of the hydraulic oil from thehydraulic quick disconnect fitting that is located onthe hydraulic oil fi lter housing. The hydraulic oil fi lterhousing is located near the rear axle.

1. Turn off the engine.

Taking oil samples under a running machine maycause personal injury or death. The use of a sam-ple tube allows an oil sample to be taken while theperson is outside of the tread path of the tires. Thesample tube should be attached to thesample portwhen the machine is not running. The oil sampleshould then be taken only when the following con-ditions exist:

The machine transmission is in NEUTRAL.

The parking brake is applied.

The swing lock pin is engaged.

All implements are lowered to the ground.

The hydraulic lockout switch (if equipped) isapplied.

2. Attach a hose with a female quick disconnectfitting to the hydraulic quick disconnectfitting.

Note: Ensure that all personnel are clear of themachine before starting the engine.

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Hydraulic System Oil - Change

3. Turn the enginestart switch in order to start theengine.

4. Use the hose in order to obtain a sample of thehydraulic oil.

Note: Allow oil to pass through the hose for 10seconds before obtaining the sample in order toensure that no contaminants are in the oil sample.

5. Turn off the engine.

6. Remove the hose that was used to obtain the oilsample.

Refer to Special Publication, SEBU6250, SOS OilAnalysis for information that pertains to a sampleof the hydraulic oil. For additional information abouttaking an oil sample, refer to Special Publication,PEHP6001, How To Take A Good Oil Sample.

i03211907

Hydraulic System Oil - Change

SMCS Code: 5056

Note: The normal hydraulic oil change intervalis at every 2000 Service Hours or 1 Year. Byperforming SOS oil analysis, the hydraulicoil change interval may be extended to 4000Service Hours or 2 Years. SOS oil analysismust beperformed at every 500 Service Hours

or 3 Months in order to extend the hydraulic oilchange interval. The results from the SOS oilanalysis will determine if the hydraulic oil changeinterval may be extended. If SOS oil analysis isnot available, the hydraulic oil change intervalmustremain at every 2000 Service Hours or 1

Year . Refer to the Operation and MaintenanceManual, SOS Information.

Note: Cat HYDO Advanced 10 has a 50% increasein the standard oil drain interval for machinehydraulic systems (3000 hours versus 2000hours) over second and third choice oils - whenfollowing the maintenance interval schedule for

oilfi

lter changes and for oil sampling that isstated in the Operation and Maintenance Manualfor your particular machine. 6000 hour oil drainintervals are possible when using SOS Servicesoil analysis. Contact your Cat dealer for details.

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

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

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


g01289083

Illustration 178

2. Remove the hydraulic tank fi ller cap.



3. Open the drain valve that is located on thehydraulic pump. Allow the oil to drain into asuitable container.

4. Tighten the drain valve.

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126 SEBU8287-05Maintenance SectionHydraulic System Oil Filter - Replace

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

6. Inspect the hydraulic tank breather that is locatedin the breather hose on top of the hydraulic tank.

Replace the breather, if necessary.

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


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

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

position.

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

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

10. Install the hydraulic tank filler cap.


i02831278

Hydraulic System Oil Filter -Replace

SMCS Code: 5056; 5068



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


Note: The hydraulic fi lter is located next to the rearaxle.

3. Remove the filter element with a strap typewrench.

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

5. Apply a light coat of oil to the gasket of the new

filter element.

6. Install the new oil filter. Tighten the oil filter to atorque of 44.74 8 Nm (33 6 lb ft).


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

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Hydraulic System Oil Level - Check


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

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

10. Install the hydraulic tank filler cap.


i02831279

Hydraulic System Oil Level -Check

SMCS Code: 5056; 7479


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

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

Maintain the oil level in the sight gauge between theMIN mark and the MAX mark.

i02710271

Loader Bucket, Cylinder, andLinkage Bearings - Lubricate

SMCS Code: 7069; 7070; 7071


Apply lubricant to grease fittings (1) for the frame andfor the lift arm. There is a grease fitting for each sideof the machine.

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

Apply lubricant to grease fittings (3) for the rod endof the lift cylinder. There is a grease fitting for eachside of the machine.

Apply lubricant to grease fittings (4) for the pivot pinat the loader lift arm. There is a grease fitting for eachside of the machine.

Apply lubricant to grease fittings (5) for the pivotbearings for the bucket tilt cylinder. There is a greasefitting in each linkage (four total).

Apply lubricant to grease fitting (6) for the rod end ofthe tilt cylinder.

Apply lubricant to grease fittings (7) for the upperpivot pin. There is a grease fitting for each side ofthe machine.

Apply lubricant to grease fittings (8) for the lowerpivot pins. There is a grease fitting for each side ofthe machine.

Apply lubricant to grease fitting (9) for the pivot forthe linkage of bucket positioner and lift kickout.

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128 SEBU8287-05Maintenance SectionOil Filter - Inspect

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

Open the engine access door on the top of themachine.


Apply lubricant to grease fitting (11) for the pivot pointfor the lift arms.

There are a total of 18 grease fittings.

i02106227

Oil Filter - Inspect

SMCS Code:1318; 3067; 5068

Inspect a Used Filter for Debris


The element is shown with debris.

Use a filter cutter to cut the filter element open.Spread apart the pleats and inspect the element formetal and for other debris. An excessive amount ofdebris in the filter element can indicate a possiblefailure.

If metals arefound in the filter element, a magnet canbe used to differentiate between ferrous metals andnonferrous metals.

Ferrous metals can indicate wear on steel parts andon cast iron parts.

Nonferrous metals can indicate wear on thealuminum parts of the engine such as main bearings,rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filterelement. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer in order

to arrange for further analysis if an excessive amountof debrisis found.

Using an oil filter element that is not recommendedby Caterpillar can result in severe engine damageto engine bearings, to the crankshaft, and to otherparts. This can result in larger particles in unfilteredoil. Theparticles could enter the lubricating systemand the particles could cause damage.

i04218069

Parking Brake - Check/Adjust

SMCS Code: 4267

Note: The parking brake can also be referred to asthe secondary brake. The parking brake is referredto as the secondary brake when used in a stoppingapplication. The parking brake is referred to as theparking brake when used in a holding application.

Check Procedure

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

Check the brakes on a dry, level surface.

Fasten the seat belt before you check the brakes.

The following check is used to determine if theparking brake is functional. This check is not intendedto measure the maximum brake holding effort. Thebrake holding effort that is required to sustain amachine at a specific engine rpm varies dependingon the machine. The variations are the differences inthe engine setting, in the power train efficiency, andin the brake holding ability, etc.

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Radiator Core - Clean



2. Engage the parking brake.

3. If the machine is equipped with the directdrive transmission, move the transmissionspeed shift lever to THIRD gear. Move thetransmission direction control lever to FORWARD,to NEUTRAL, and back to FORWARD. Ifthe machine is equipped with a power shifttransmission move the transmission control leverto THIRD SPEED FORWARD, to NEUTRAL, andback to THIRD SPEED FORWARD. This is donein order to override the transmission neutralizerfor this test.

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

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

4. Gradually increase the engine speed to 2000 rpm.The machine should not move.

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

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

Adjustment Procedure

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

1. Apply the service brakes.

2. Disengage the parking brake.

3. As you view the parking brake adjuster knob fromthe operator seat, turn the knob clockwise for onehalf of a turn.


5. Engage the parking brake.

6. If the machine is equipped with the direct drivetransmission, move the transmission speedcontrol to THIRD gear. Move the transmissiondirection control to the FORWARD, to theNEUTRAL position and back to the FORWARDposition. If the machine is equipped with a powershift transmission, move the transmission speedcontrol tothe THIRD SPEED FORWARD position,to the NEUTRAL position and back to the THIRDSPEED FORWARD position. This is done in orderto override the transmission neutralizer.

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

8. Reduce the engine speed. Move the transmissiondirection control to the NEUTRAL position. Lowerthe bucket to the ground.

9. Stop theengine.

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

your machine.

i02514305

Radiator Core - Clean

SMCS Code: 1353


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130 SEBU8287-05Maintenance SectionRide Control Accumulator - Check


NOTICEDo not spray high pressure water into the radiatorwhile the engine is running.

You can use compressed air, high pressure water,or steam to remove dust and other debris from theradiatorfins. However, the use of compressed air ispreferred.

Note: Ifnecessary, tilt the oil cooler away from theradiator in order to remove dust and debris betweenthe radiator and the oil cooler.

Note:

i02814826

Ride Control Accumulator -Check

SMCS Code: 5077-535-R6

The ride control accumulator reduces the pitching ofthe machine. If the machine seems to be bouncingexcessively, check the charge in the ride controlaccumulator.

Note: Special tools and equipment are required totest the a

sebu8287 05 maint

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