MAINTENANCE INTERVALS

Operation and Maintenance Manual Excerpt

2010 Caterpillar All Rights Reserved

SEBU7885-12 January 2011

Operation and Maintenance Manual

994F Wheel Loader
4421-Up (Machine)

SAFETY.CAT.COM

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91 Maintenance Section Maintenance Interval Schedule

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Windows - Clean ................................................. 167

Maintenance Interval Schedule

SMCS Code: 7000 Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, uids, lters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed. Note: If Cat HYDO Advanced 10 hydraulic oil is used, the hydraulic oil change interval will change. The normal interval of 2000 hours is extended to 3000 hours. SOS services may extend the oil change even longer. Consult your Cat dealer for details.

Every 10 Service Hours or Daily

Air Tank Moisture and Sediment - Drain ............... 93 Backup Alarm - Test .............................................. 96 Bucket Cutting Edges - Inspect/Replace ............ 100 Bucket Wear Plates - Inspect/Replace ............... 103 Cooling System Coolant Level - Check .............. 109 Engine Oil Level - Check .................................... 121 Fuel Tank Water and Sediment - Drain ............... 130 Hydraulic System Oil Level (Brake Cooling) Check ................................................................ 147 Hydraulic System Oil Level (Implement) Check ................................................................ 147 Hydraulic System Oil Level (Steering, Brake) Check ................................................................ 149 Oil Renewal System Oil Level - Check ............... 152 Pump Drive (Front) Oil Level - Check ................. 157 Seat Belt - Inspect .............................................. 160 Steering Cylinder Bearings - Lubricate ............... 162 Steering Stop - Check ......................................... 162 Transmission Oil Level - Check .......................... 165

Every 50 Service Hours or Weekly

Cab Air Filter - Clean/Replace ............................ 104 Collet Pin Bolt Torque - Check ............................ 105 Tire Ination - Check ........................................... 162

Initial 250 Service Hours

Engine Valve Lash and Bridge - Check .............. 125 Engine Valve Rotators - Inspect ......................... 125

When Required
Automatic Lubrication Grease Tank - Fill .............. 94 Automatic Lubrication System Components Check .................................................................. 94 Battery - Recycle .................................................. 97 Battery or Battery Cable - Inspect/Replace .......... 98 Bucket Tips - Inspect/Replace ............................ 101 Circuit Breakers - Reset ...................................... 105 Engine Air Filter Primary Element - Clean/ Replace .............................................................. 116 Engine Air Filter Secondary Element - Replace .. 118 Engine Air Precleaner - Clean ............................. 119 Ether Starting Aid Cylinder - Replace ................. 126 Frame - Inspect ................................................... 127 Fuel System - Prime ........................................... 128 Fuses - Replace .................................................. 130 High Intensity Discharge Lamp (HID) - Replace .. 132 High Pressure Screens - Clean/Replace ............ 133 Hydraulic System Return Screen - Replace ....... 150 Oil Filter - Inspect ................................................ 152 Radiator Core - Clean ......................................... 159 Seat Side Rails - Adjust ...................................... 161 Secondary Steering - Test .................................. 161 Transmission Magnetic Screen - Clean .............. 163 Window Washer Reservoir - Fill .......................... 167 Window Wiper - Inspect/Replace ........................ 167

Every 250 Service Hours

Engine Oil Sample - Obtain ................................ 121

Every 250 Service Hours or Monthly

Alternator - Inspect ............................................... 93 Axle Oscillation Bearings - Lubricate .................... 96 Battery - Clean ...................................................... 97 Belts - Inspect/Adjust/Replace .............................. 98 Braking System - Test ........................................... 99 Differential and Final Drive Oil Level - Check ...... 114 Drive Shaft Spline (Center) - Lubricate ................ 115 Drive Shaft Support Bearing - Lubricate .............. 115 Engine Oil and Filter - Change ........................... 122 Pump Drive Shaft (Front) - Lubricate .................. 158 Pump Drive Shaft Support Bearing (Rear) Lubricate ........................................................... 158

Initial 500 Service Hours

Seat Side Rails - Adjust ...................................... 161

Initial 500 Hours (for New Systems, Relled Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) Obtain ................................................................ 110

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Every 500 Service Hours

Cooling System Coolant Sample (Level 1) Obtain ............................................................... 109 Differential and Final Drive Oil Sample - Obtain .. 114 Hydraulic System Oil Sample (Implement) Obtain ............................................................... 149 Hydraulic System Oil Sample (Steering, Brake) Obtain ............................................................... 150 Pump Drive Oil Sample - Obtain ......................... 157 Transmission Oil Sample - Obtain ...................... 166

Engine Mounts - Inspect ..................................... 121

Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 161

Every 4000 Service Hours or 2.5 Years

Engine Valve Lash and Bridge - Check .............. 125 Engine Valve Rotators - Inspect ......................... 125

Every 500 Service Hours or 3 Months

Engine Crankcase Breather - Clean ................... 120 Fuel System Primary Filter - Clean/Inspect/ Replace ............................................................. 128 Fuel System Secondary Filter - Replace ............ 129 Fuel Tank Cap and Strainer - Clean ................... 129 Hydraulic System Oil Filter (Implement Pump Case Drain) - Replace ................................................ 143 Hydraulic System Oil Filter (Pilot) - Replace ....... 144 Hydraulic System Oil Filter (Steering Pump Case Drain) - Replace ................................................ 146 Power Train Oil Filter (Transmission, Torque Converter) - Replace ......................................... 153 Pump Drive (Front) Oil Filter - Change ............... 156

Every 5000 Service Hours or 3 Years

Starting Motor - Inspect ...................................... 162 Turbocharger - Inspect ........................................ 166

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 108 Cooling System Pressure Cap - Clean/Replace .. 111

Every 6000 Service Hours or 4 Years

VIMS Module Battery - Replace ......................... 166

Every 6000 Service Hours or 6 Years

Cooling System Water Temperature Regulator Replace .............................................................. 111 Engine Water Pump - Inspect ............................. 125

Every 1000 Service Hours or 6 Months

Battery Hold-Down - Tighten ................................. 97 Pump Drive (Front) Oil - Change ........................ 154 Rollover Protective Structure (ROPS) - Inspect .. 160 Transmission Oil - Change ................................. 163

Every 9500 Service Hours or 1 892 705 L (500 000 US gal) of Fuel
Engine Components - Replace/Install Reman .... 120

Every 1000 Service Hours or 1 Year

Hydraulic System Oil (Steering, Brake) Change ............................................................. 139

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 106

Every 2000 Service Hours or 1 Year

Air Dryer Desiccant - Replace .............................. 93 Axle Oil Cooler Screens - Clean/Replace ............. 95 Brake Accumulator - Check .................................. 99 Differential and Final Drive Oil - Change ............. 112 Hydraulic System Oil (Brake Cooling) - Change .. 134 Hydraulic System Oil (Implement) - Change ...... 136 Hydraulic System Oil Filter (Hydraulic Cooler Screen) - Clean .............................................................. 142 Hydraulic System Oil Filter (Steering Cooler Screen) (Brake Cooler Screen) - Clean .......................... 145 Hydraulic Tank Breaker Relief Valve - Clean ...... 151 Receiver Dryer (Refrigerant) - Replace .............. 159

Every 19 000 Service Hours or 3 785 410 L (1 000 000 US gal) of Fuel
Engine Components - Clean/Inspect, Rebuild/Install Reman, Install New ............................................ 119

Every Year
Cooling System Coolant Sample (Level 2) Obtain ................................................................ 110

Every 3000 Service Hours or 2 Years

Crankshaft Vibration Damper - Inspect ................ 112

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93 Maintenance Section Air Dryer Desiccant - Replace

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Air Dryer Desiccant - Replace

SMCS Code: 4285-510-DSS

Air Tank Moisture and Sediment - Drain

SMCS Code: 1466-543-M&S

Illustration 79

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Illustration 81

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The air tank is located on the right side of the cab platform. Push down on the drain valve in order to drain the moisture and the sediment from the air tank.
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Alternator - Inspect
SMCS Code: 1405-040
Illustration 80
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The air dryer is located under the cab platform on the right side of the machine. When the desiccant cartridge in the air dryer fails to absorb water, the desiccant cartridge must be rebuilt or the desiccant cartridge must be replaced. Check for moisture in the air reservoirs. If there is moisture in the air reservoirs, replace the desiccant cartridge or rebuild the desiccant cartridge. Consult your Caterpillar dealer for information about replacing the desiccant cartridge and for instructions for rebuilding the desiccant cartridge.

Inspect the alternator for loose connections and for proper battery charging. When the engine is operated only for short periods of time, the batteries may not fully recharge. Make sure that the alternator is functioning properly. Reference: Refer to Systems Operation/Testing and Adjusting, SENR1123, 3500B and 3500B High Displacement Engines For Caterpillar Built Machines, Electrical System for information about testing the alternator.

94 Maintenance Section Automatic Lubrication Grease Tank - Fill

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Automatic Lubrication Grease Tank - Fill

SMCS Code: 7540-544-TNK

If any of the remote lines become damaged, install a tting in place of the remote line. Lubricate the item at the ttings until the remote lines can be replaced. The grease tank can be lled by the fast ll service group. The grease tank can contain 86 kg (190 lb) of lubricant.
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Automatic Lubrication System Components - Check

SMCS Code: 7540-535

Illustration 82

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A pressure hazard is present. Severe personal injury or death can result from removing hoses or ttings that are under pressure. Relieve the pressure in the system before you remove hoses or ttings. Reference: Before any service work is performed on the lubrication system, refer to Special Instructions, REHS1394 or consult your Caterpillar dealer.

Illustration 83

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The grease tank for the automatic lubrication system is located on the left side of the machine. The grease tank provides lubrication for the following items:

Axle oscillation bearings Linkage bearings Lift cylinder bearings Tilt cylinder bearings Steering cylinder bearings Articulation bearings Fan bearing Belt adjusting pulley Lower bucket pivot bearings

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95 Maintenance Section Axle Oil Cooler Screens - Clean/Replace

Illustration 84 994F Wheel Loader (A) A-Pin (B) B-Pin (C) C-Pin (D) D-Pin (E) E-Pin (F) F-Pin (G) G-Pin (H) Pin for upper articulation joint (J) Pin for lower articulation joint (K) K-Pin (L) Steering cylinder pins (X) Trunnions (Y) Y-Pin

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1. Remove any buildup of grease. Check that each pin joint is receiving a fresh supply of grease. Reference: If a fresh supply of grease is not present, refer to Special Instructions, REHS1394 for system troubleshooting procedures. 2. Check for an excessive buildup of grease at each pin joint. Reference: For adjustment information, refer to Operation and Maintenance Manual, Capacities (Rell), Settings of the the Injectors for the Autolube System. 3. Check the grease level at the top vent port of the reservoir. Reference: For lling procedures, refer to Operation and Maintenance Manual, Automatic Lubrication Grease Tank - Fill.

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Axle Oil Cooler Screens Clean/Replace

SMCS Code: 1365-070-Z3; 1365-510-Z3 NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Clean the screens whenever there is a failure in the brake system.

96 Maintenance Section Axle Oscillation Bearings - Lubricate

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There is a screen for each wheel. There is a total of four screens that must be cleaned.

Machines that are not equipped with the automatic lubrication system have two remote ttings near the articulation joint on the left side of the machine. 1. Wipe off the ttings before any lubricant is applied. 2. Apply lubricant through the two remote ttings.
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Backup Alarm - Test

SMCS Code: 7406-081 Apply the service brake. Place the transmission in reverse.
Illustration 85
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1. Make sure that there is no pressure in the lines for the axle oil. Loosen the bolts on the tube assemblies and drain the oil from the lines into a suitable container. Dispose of the oil properly. 2. Remove the tube assemblies and the screens. Clean the screens in a clean, nonammable solvent. 3. Install the screens, the tube assemblies, and the new seals. Tighten the bolts. 4. Check for leaks. Make any necessary repairs.
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Turn the engine start switch to the ON position in order to perform the test. The backup alarms should start to sound immediately. The alarms will continue to sound until the transmission is placed into neutral or into forward.

Axle Oscillation Bearings Lubricate

SMCS Code: 3268-086-BD; 3278-086-BD Note: The axle oscillation bearings are lubricated by the automatic lubrication system. If any of the lubrication lines are damaged, install a tting at the bearing in order to lubricate the bearing. The damaged line must be replaced.

Illustration 87

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The backup alarms are located behind the fan guard on the rear of the machine.

Illustration 86

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97 Maintenance Section Battery - Clean

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Battery - Recycle
SMCS Code: 1401-561 Always recycle a battery. Never discard a battery. Always return used batteries to one of the following locations:

A battery supplier An authorized battery collection facility

Illustration 88
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Recycling facility
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Battery - Clean
SMCS Code: 1401-070

Battery Hold-Down - Tighten

SMCS Code: 7257-527

Illustration 89

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Illustration 91

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Open the battery compartment of the left side of the cab platform.

Open the battery compartment on the left side of the cab platform.

Illustration 90

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Illustration 92

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

98 Maintenance Section Battery or Battery Cable - Inspect/Replace

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Over time, the vibration of an operating machine can cause the battery hold-downs to loosen. To help to prevent loose batteries and the possibility of loose cable connections, tighten the locknuts to a torque of 14 2 Nm (10 1.5 lb ft).
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Alternator Belt

Battery or Battery Cable Inspect/Replace

SMCS Code: 1401-040; 1401-510; 1402-040; 1402-510 1. Turn the engine start switch key to the OFF position. Turn all of the switches to the OFF position. 2. Turn the battery disconnect switch to the OFF position. Remove the key. 3. Disconnect the positive battery cable at the battery disconnect switch. The battery disconnect switch is connected to the machine frame. Note: Do not allow the disconnected battery cable to contact the disconnect switch. 4. Disconnect the negative battery cable at the battery that is connected to the battery disconnect switch. If the machine has four 12 volt batteries, disconnect the negative battery cables of two of the batteries. 5. Make any necessary repairs or replace the battery. 6. Reconnect the negative battery cable at the battery that is connected to the battery disconnect switch. 7. Reconnect the positive battery cable at the battery disconnect switch. 8. Install the key and turn the battery disconnect switch to the ON position.
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Illustration 93

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1. Open the lower rear access doors on both sides of the machine. 2. Inspect the condition of the alternator belts. 3. Check the tension of the alternator belts. The tension of a used alternator belt with more than 30 minutes of operation at rated speed should be 489 44 N (110 10 lb). The tension of a new alternator belt with 30 minutes of operation or less at rated speed should be 800 22 N (180 5 lb). If the alternator belts require adjustment or replacement, proceed to Step 4.

Illustration 94

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Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510 Note: Always stop the engine before you inspect the belts and before you service the belts.

4. Loosen mounting bolts (1) and adjusting locknut (2). 5. Turn adjusting nut (3) until the correct belt tension is reached. 6. Tighten adjusting locknut (3) to a torque of 110 10 Nm (81.1 7.4 lb ft). 7. Tighten mounting bolts (1).

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99 Maintenance Section Brake Accumulator - Check

8. Recheck the belt tension. If the tension is incorrect, repeat the adjustment procedure. 9. Close the lower rear access doors on both sides of the machine.

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Brake Accumulator - Check

SMCS Code: 4263-535

Air Conditioner Belt

Illustration 97
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Illustration 95

1. Open the upper forward access door on the left side of the machine. 2. Inspect the condition of the air conditioner belt. Inspect the belt for wear and for cracking.

1. Move the engine start switch to the ON position. The alert indicator for the brake oil pressure should come on if the brake system is not at the normal operating pressure. 2. Start the engine and run the engine for one minute in order to increase the accumulator pressure. The alert indicator for the brake oil pressure should go off. Stop the engine. 3. Depress the service brake pedal until the alert indicator for the brake oil pressure comes on. This will decrease the accumulator pressure. A minimum of ve applications should be required. 4. If the alert indicator for the brake oil pressure comes on with less than ve applications of the service brake pedal, measure the nitrogen precharge pressure of the accumulator. Note: Your Caterpillar dealer has the appropriate tools for measuring the precharge pressure of the brake accumulator. Only use dry nitrogen for recharging. Reference: Refer to Systems Operation/Testing and Adjusting, RENR6314, 994F Wheel Loader Braking System for additional information.
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Illustration 96

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3. If the belt requires replacement, perform the following steps. 4. Turn the belt tensioner in order to release the tension from the belt. 5. Remove the belt. 6. Install a new belt. 7. Turn the belt tensioner back into the position. 8. Close the upper forward access door on the left side of the machine.

Braking System - Test

SMCS Code: 4251-081; 4267-081 1. Fasten the seat belt. 2. Make sure that the steering frame lock is in the unlocked position.

100 Maintenance Section Bucket Cutting Edges - Inspect/Replace

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3. Park the machine on a hard, dry, level surface. 4. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles. The following tests are used to determine whether the braking system is functional. These tests are not intended to measure the maximum brake holding effort. The required brake holding effort for sustaining a machine at a specic engine rpm varies from one machine to another machine. The variations include differences in the engine setting, the power train efciency, the brake holding ability, etc.

Parking Brake Holding Ability Test

Personal injury can result if the machine moves while testing. If the machine begins to move, reduce the engine speed immediately and apply the service brake pedal. This test is performed when the parking brake is engaged. If the machine begins to move, compare the engine rpm to the engine rpm of a prior test. This will indicate the amount of system deterioration. 1. Start the engine. Raise the work tool slightly. Engage the parking brake.

Service Brake Holding Ability Test

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake. This test is performed when the service brakes are engaged. If the machine begins to move, compare the engine rpm to the engine rpm of a prior test. This will indicate the amount of system deterioration. 1. Start the engine. Raise the work tool slightly. Apply the service brake. Release the parking brake. 2. Move the hydraulic lockout control to the UNLOCKED position. 3. Place the transmission in THIRD SPEED FORWARD while the service brakes are applied. 4. Gradually increase the engine speed to high idle. The machine should not move. 5. Reduce the engine speed to low idle. Place the transmission in neutral. Engage the parking brake. Lower the work tool to the ground. Stop the engine. If the machine moved during the test, consult your Caterpillar dealer for a brake inspection. Make any necessary repairs before the machine is returned to operation.

2. Move the hydraulic lockout control to the UNLOCKED position. 3. Place the transmission in THIRD SPEED FORWARD while only the parking brake is engaged. The parking brake indicator light should come on. Note: If THIRD SPEED FORWARD is locked out, then use SECOND SPEED FORWARD. 4. Gradually increase the engine speed to high idle. The machine should not move. 5. Reduce the engine speed. Place the transmission in neutral. Lower the work tool to the ground. Stop the engine. If the machine moved during the test, consult your Caterpillar dealer for a brake inspection. Make any necessary repairs before the machine is returned to operation.
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Bucket Cutting Edges Inspect/Replace

SMCS Code: 6801-040; 6801-510

Personal injury or death can result, if the bucket is not blocked up. Block the bucket before changing cutting edge.

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101 Maintenance Section Bucket Tips - Inspect/Replace

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Bucket Tips - Inspect/Replace

SMCS Code: 6805-040; 6805-510

Personal injury or death can result from the bucket falling. Block the bucket before changing bucket tips.

Illustration 98

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Bucket Tips

1. Check for bolts that are missing or loose. Replace any missing bolts and tighten any loose bolts. Reference: Refer to Specication, RENR2512, Ground Engaging Tool Torques for the correct torque. 2. Inspect the cutting edges. If wear or damage is evident, use the following procedure to replace the components. a. Raise the bucket and place blocking under the bucket. Lower the bucket to the blocking. Note: Do not block up the bucket too high. Block up the bucket enough for removing the cutting edges. b. Remove bolts (1). Remove cutting edge (2). c. Clean the contact surfaces. Inspect the cutting edge and install the cutting edge. If the opposite side of the cutting edge is not worn, use that side. If both sides of the cutting edge are worn, install a new cutting edge. d. Install bolts (1). Tighten the bolts to the specied torque. e. Raise the bucket and remove the blocking. Lower the bucket to the ground. f. After a few hours of operation, check the bolts for proper torque.
Illustration 99 (1) Usable (2) Replace the tip. (3) Replace the tip.
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Check the bucket tips for wear. If the bucket tip has a hole, replace the bucket tip. 1. Remove the pin from the bucket tip. The pin can be removed by one of the following methods.

Use a hammer and a punch from the retainer

side of the bucket to drive out the pin. 1.c for the procedure.

Use a Pin-Master. Follow Step 1.a through Step

102 Maintenance Section Bucket Tips - Inspect/Replace

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Illustration 100 (4) Back of Pin-Master (5) Extractor

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Illustration 102

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4. Install the new bucket tip onto the adapter. Note: The bucket tip can be rotated by 180 degrees in order 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:

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.

From the other side of the retainer, drive the

pin through the bucket tip, the adapter, and the retainer. 5.e for the procedure.

Use a Pin-Master. Follow Step 5.a through Step

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

Illustration 101 (6) Retainer (7) Retaining washer (8) Adapter

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2. Clean the adapter and the pin. 3. Fit retainer (6) into retaining washer (7). Install this assembly into the groove that is in the side of adapter (8).
Illustration 103 (4) Back of Pin-Master (9) Pin setter (10) Pin holder
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a. Insert the pin through the bucket tooth. b. Place the Pin-Master over the bucket tooth and locate the pin in the hole of holder (10).

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103 Maintenance Section Bucket Wear Plates - Inspect/Replace

c. Strike the tool with a hammer at the back of the tool (4) in order to start the pin. d. Slide pin holder (10) away from the pin and rotate the tool slightly in order to align pin setter (9) with the pin. e. Strike the end of the tool until the pin is fully inserted. 6. After you drive the pin, make sure that the retainer ts snugly into the pin groove.

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 a slight clockwise rotation.

K-Series Tip
Removal

Illustration 106

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3. Install the retainer. Make sure that the retainer's latch catches under the tip pocket. 4. Make sure that the latch is properly seated by trying to remove the bucket tip.
Illustration 104
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Note: Retainers are often damaged during the removal process. Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced.

Bucket Wear Plates Inspect/Replace

SMCS Code: 6120-040; 6120-510

Personal injury or death can result from falling bucket. When working under or around the bucket or linkage, with the bucket raised, proper support must be provided for the bucket and/or the linkage.

Illustration 105

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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 a slight counterclockwise rotation.

104 Maintenance Section Cab Air Filter - Clean/Replace

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Illustration 107

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Illustration 109

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Before damage to the bottom of the bucket occurs, repair damaged bucket wear plates or replace damaged 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 the specied torque. Reference: For more information, refer to Specications, SENR3130, Torque Specications.
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2. Remove retainer (1) from the cover. Slide pin (2) out of the retainer. Remove fresh air lter (3).

Cab Air Filter - Clean/Replace

SMCS Code: 7342-070; 7342-510 Note: The lters must be cleaned more often if the machine is being operated in dusty conditions.

Illustration 110

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3. Remove the lter cover behind the seat. Remove the recirculation lter. 4. Clean the lter elements with pressure air or wash the lter elements in warm water with a nonsudsing household detergent. 5. If water was used to wash the lter elements, rinse the lter element in clean water and allow the lter element to air dry thoroughly. 6. Install the recirculation lter and the lter cover behind the seat. 7. Install fresh air lter (3) and retainer (1). Close the cover on the outside rear of the cab.

Illustration 108

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1. Lift the cover on the outside rear of the cab.

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105 Maintenance Section Circuit Breakers - Reset

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Circuit Breakers - Reset

SMCS Code: 1420-529 Circuit Breaker Push the button inward in order to reset the circuit breakers. If the system is functioning properly, the button will remain depressed. If the button does not remain depressed, check the appropriate electrical circuit.

Engine Start Switch (1) 10 amp

Engine Control Module (2) 15 amp

Main Circuit (3) 105 amp

Alternator (4) 80 amp

Alternator (5) 80 amp

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Collet Pin Bolt Torque - Check

Illustration 111
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SMCS Code: 6107-535-BC Note: After you operate a new machine for the initial 50 service hours, perform the following maintenance procedure. After you operate a machine with a newly installed bucket for the initial 50 service hours, perform the following maintenance procedure. If neither of these conditions exist, disregard the following maintenance procedure.

The circuit breakers are located under an access door on the left side of the cab platform.

Illustration 112

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Illustration 114

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Torque the bolts again on the collet pins for pin joints (A), (C), (E), (D), (F), and (Y). 1. Torque the bolts to 1800 200 Nm (1330 150 lb ft).

Illustration 113

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106 Maintenance Section Cooling System Coolant (ELC) - Change

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NOTICE When striking the collet with a large hammer, protect the bolt head with a spacer to prevent bolt damage. 2. Strike the collet until the bolt torque decreases to 950 Nm (750 lb ft) or less. 3. Torque the bolts to 1800 200 Nm (1330 150 lb ft). 4. Strike the collet until the bolt torque decreases to 1600 Nm (1200 lb ft) or less. 5. Torque the bolts to 1800 200 Nm (1330 150 lb ft).
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NOTICE Mixing Cat Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and shortens coolant life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specications for premixed or concentrate coolants. Use only Cat Extender with Cat ELC. Failure to follow these recommendations could result in damage to the cooling systems components. If ELC cooling system contamination occurs, refer to Operation and Maintenance, Extended Life Coolant (ELC) under the topic ELC Cooling System Contamination. This machine was factory lled with Cat Extended Life Coolant. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Reference: If the coolant in the machine is changed to Extended Life Coolant from another type of coolant, refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations. If the coolant is dirty or if you observe any foaming in the cooling system, change the coolant before the recommended interval. It is important to replace the water temperature regulator in order to avoid any unexpected failure of the water temperature regulator. This is a good preventive maintenance practice that reduces the chances of unscheduled downtime. Failure to replace the water temperature regulator on a regularly scheduled basis could cause severe engine damage. Note: If you are only replacing the water temperature regulator, drain the coolant from the cooling system so that the level of the coolant is below the housing for the water temperature regulator. Always operate Caterpillar engines with a water temperature regulator because these engines have a shunt design cooling system.

Cooling System Coolant (ELC) - Change

SMCS Code: 1350-044-NL

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. NOTICE Do not change the coolant until you read and understand the material in the Cooling System Specications section.

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107 Maintenance Section Cooling System Coolant (ELC) - Change

Note: Water temperature regulators can be reused if the water temperature regulators meet certain test specications. The tested water temperature regulators must not be damaged and the tested water temperature regulators must not have an excessive buildup of deposits. 1. Stop the engine. Allow the radiator to cool sufciently.

Illustration 118

g01139178

3. Open both drain valves under the rear of the machine. Allow the coolant to drain into a suitable container. Dispose of the used coolant properly. 4. Flush the cooling system with clean water until the draining water is clean. Close the drain valves. Dispose of the drained water properly.
Illustration 115
g01139172

5. Replace the water temperature regulator. Reference: Refer to Disassembly and Assembly, SENR1126, 3500B Engines Built for Caterpillar Machines for the correct procedure. 6. Add the coolant solution. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the capacity of the cooling system. 7. Start the engine. Run the engine without cooling system pressure caps (2) until the thermostat opens and the coolant level stabilizes. 8. Start the engine. Run the engine without installing cooling system pressure caps (2) until the water temperature regulator opens and the coolant level stabilizes. 9. Check the coolant level. Maintain the coolant within the red range of sight gauges (1). 10. Install cooling system pressure caps (2).

Illustration 116

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2. Open the access doors on the top of the cab platform at the rear of the machine. Slowly remove cooling system pressure caps (2) in order to relieve system pressure.

Illustration 117

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108 Maintenance Section Cooling System Coolant Extender (ELC) - Add

SEBU7885-12

i02274534

Cooling System Coolant Extender (ELC) - Add

SMCS Code: 1352-544-NL

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. When a Caterpillar Extended Life Coolant (ELC) is used, an extender must be added to the cooling system. Reference: Refer toOperation and Maintenance Manual, Maintenance Interval Schedule for the proper service interval. The amount of extender is determined by the cooling system capacity. 1. Stop the engine. Allow the radiator to cool sufciently.
Illustration 121
g01139177

Illustration 119

g01139172

Illustration 120

g01139174

2. Open the access doors on the top of the cab platform at the rear of the machine. Then, slowly remove cooling system pressure caps (2) in order to relieve system pressure.

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109 Maintenance Section Cooling System Coolant Level - Check

The coolant level gauges are located under access doors on the top of the cab platform at the rear of the machine.

Illustration 122

g01139178

3. If necessary, drain enough coolant from the radiator in order to allow the addition of the Extender. The coolant drain valves are located at the rear of the machine under the engine compartment. Dispose of the used coolant properly. 4. Add 9 L (9.5 qt) of Extender to the cooling system. 5. Check the coolant level. Maintain the coolant level within the red range of the sight gauges (1). 6. Check the condition of cooling system pressure caps (2)and the seal. If there is damage or a residue buildup on the caps, replace cooling system pressure caps (2). 7. Install cooling system pressure caps (2).
i02274527

Illustration 124

g01139174

Maintain the coolant level within the red range of sight gauges (1). If necessary, stop the engine and allow the radiator to cool sufciently. Then, slowly remove cooling system pressure caps (2) and add coolant. If it is necessary to add coolant daily, check for leaks.
i02231902

Cooling System Coolant Sample (Level 1) - Obtain

SMCS Code: 1350-008; 1395-008; 7542 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Note: Level 1 results may indicate a need for Level 2 Analysis. Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of SOS analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:

Cooling System Coolant Level - Check

SMCS Code: 1350-535-FLV

Illustration 123

g01139172

110 Maintenance Section Cooling System Coolant Sample (Level 2) - Obtain

SEBU7885-12

Complete the information on the label for the

sampling bottle before you begin to take the samples. bags.

Open the access doors on the right and the left of the machine. Remove the caps from the sample valves. Attach a hose to a couple. Install the threaded end of the coupling into the sample valve in order to unseat the internal drain valve. Take a sample from each of the sample valves. Put the caps on the valves. Close the access doors. Submit the samples for Level 1 analysis. Reference: For additional information about coolant analysis, refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
i02126353

Keep the unused sampling bottles stored in plastic Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples from any other location. are ready to collect the sample.

Keep the lids on empty sampling bottles until you Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid contamination.

Never collect samples from expansion bottles. Never collect samples from the drain for a system.
The cooling system is equipped with two sampling valves.

Cooling System Coolant Sample (Level 2) - Obtain

SMCS Code: 1350-008; 1395-008; 7542 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Obtain the sample of the coolant as close as possible to the recommended sampling interval. Supplies for collecting samples can be obtained from your Caterpillar dealer. Reference: Refer to Operation and Maintenance Manual, Cooling System Coolant Sample (Level 1) - Obtain for the guidelines for proper sampling of the coolant. Submit the sample for Level 2 analysis. Reference: For additional information about coolant analysis, refer toSpecial Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.

Illustration 125

g01125907

The sampling valve is located on the left side of the machine behind the bottom rear access door.

Illustration 126

g01125909

The sampling valve is located on the right side of the machine behind the bottom rear access door.

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111 Maintenance Section Cooling System Pressure Cap - Clean/Replace

i02339536

Cooling System Pressure Cap - Clean/Replace

SMCS Code: 1382-070; 1382-510

1. Remove the pressure caps slowly in order to relieve the pressure. 2. Inspect the pressure caps for damage, for foreign material, and for deposits. 3. Clean the pressure caps with a clean cloth or replace the pressure caps, if necessary. 4. Install the pressure caps.
i02100387

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

Cooling System Water Temperature Regulator Replace

SMCS Code: 1355-510; 1393-010 NOTICE Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a thermostat installed. If the thermostat is installed wrong, it will cause the engine to overheat. Inspect gaskets before assembly and replace if worn or damaged. Replace the water temperature regulator and the regulator housing gasket while the cooling system is being cleaned. If you only need to replace the water temperature regulator, drain the cooling system coolant to a level that is below the regulator housing. Reference: Refer to Disassembly and Assembly, SENR1126, 3500B Engines Built for Caterpillar Machines for the correct procedure for replacing the water temperature regulator.

Illustration 127

g01167408

Illustration 128

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112 Maintenance Section Crankshaft Vibration Damper - Inspect

SEBU7885-12

i02274683

i02236207

Crankshaft Vibration Damper - Inspect

SMCS Code: 1205-040

Differential and Final Drive Oil - Change

SMCS Code: 3278-044; 4050-044 NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products.

Illustration 129

g01139244

Dispose of all uids according to local regulations and mandates.

The crankcase vibration damper is located at the rear end of the engine compartment. Damage to the vibration damper or failure of the vibration damper will increase torsional vibrations. These vibrations will result in damage to the crankshaft and to the other engine components. A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range. Caterpillar recommends replacing the vibration damper for any of the following reasons:

The engine has had a failure because of a broken

crankshaft.
Illustration 130
g01127753

The SOS oil analysis detected a worn crankshaft

front bearing.

1. Position the wheels so that the nal drive drain plugs are facing downward. 2. Remove the nal drive drain plugs and allow the oil to drain into a suitable container. Dispose of the used oil properly. 3. Clean the drain plugs and install the drain plugs.

The SOS oil analysis detected a large amount of

gear train wear that is not caused by a lack of oil. The vibration damper can be used again if none of the above conditions are found and the vibration damper is not damaged. Note: Some wobble on the outer ring of the vibration damper is normal. Reference: Refer to Disassembly and Assembly, SENR1126, 3500B Engines Built for Caterpillar Machines for more information about replacing the vibration damper.

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113 Maintenance Section Differential and Final Drive Oil - Change

Illustration 131 Front Differential

g01127754

Illustration 133

g01127757

8. Position each wheel so that the ller plugs for the nal drives are ush with the centerline of each wheel. Remove the ller plugs. 9. Fill the nal drives to the bottom of the ller plug openings. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities and Rell Capacities for the correct type of oil and for the correct amount of oil. 10. Clean the ller plugs and install the ller plugs.

Illustration 132 Rear Differential

g01127756

11. If the specied amount of oil will not t in the nal drives, install the nal drive ller plugs. Operate the machine on level ground for a few minutes in order to equalize the oil level in the axles. 12. Remove the nal drive ller plugs and add the remaining oil. 13. Operate the machine for a few minutes and recheck the oil level. The oil level should reach the bottom of the ller plug opening. Note: If the oil level is higher than the ller plug opening, do not allow the oil to drain to the proper level. Install the ller plug.

4. Remove differential drain plugs (1) and allow the oil to drain into a suitable container. Dispose of the used oil properly. 5. Clean the drain plugs and install the drain plugs. 6. Remove differential ller plugs (2). Fill the differentials to the bottom of the ller plug openings. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities and Rell Capacities for the correct type of oil and for the correct amount of oil. 7. Clean the ller plugs and install the ller plugs.

114 Maintenance Section Differential and Final Drive Oil Level - Check

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i02236806

Differential and Final Drive Oil Level - Check

SMCS Code: 3278-535-FLV; 4050-535-FLV

Illustration 136 Rear Differential

g01128101

3. Remove the differential ller plugs. The oil level should be at the bottom of the ller plug openings. Add oil, if necessary.
Illustration 134
g01127757

1. Position the wheels so that the ller plugs for the nal drives are ush with the centerline of the wheels. 2. Remove the oil ller plugs. The oil level should be at the bottom of the ller plug openings. Add oil, if necessary. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities and Rell Capacities for the correct type of oil and for the correct amount of oil. Note: If the oil level is higher than the ller plug openings, do not allow the oil to drain to the proper level. Install the ller plugs.

Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities and Rell Capacities for the correct type of oil and for the correct amount of oil. Note: If the oil level is higher than the ller plug openings, do not allow the oil to drain to the proper level. Install the ller plug.
i02237079

Differential and Final Drive Oil Sample - Obtain

SMCS Code: 3278-008; 4050-008; 4070-008; 7542

Illustration 137 Illustration 135 Front Differential

g01128098

g01128098

Front Axle

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115 Maintenance Section Drive Shaft Spline (Center) - Lubricate

Illustration 138 Rear Axle

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Illustration 140

g01139253

Wipe off the tting before you apply any lubricant. Apply lubricant through the tting on the drive shaft spline until the relief overruns.
i01298803

The axles are not equipped with sampling valves. Obtaining a sample of the differential and nal drive oil will require a vacuum pump or an equivalent. Withdraw the oil through the ller opening of each axle.
i02274698

Drive Shaft Spline (Center) Lubricate

SMCS Code: 3253-086-SN NOTICE To prevent damage to the seal, articulate the machine full right or left, before lubricating the splines.

Drive Shaft Support Bearing Lubricate

SMCS Code: 3267-086-BD

Illustration 141

g00733137

Illustration 139

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Illustration 142

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116 Maintenance Section Engine Air Filter Primary Element - Clean/Replace

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Wipe off the tting before any lubricant is applied. Apply lubricant through the tting on the right side of the articulation joint.
i02331730

Engine Air Filter Primary Element - Clean/Replace

SMCS Code: 1054-070-PY; 1054-510-PY NOTICE Service the air lter only with the engine stopped. Engine damage could result. There is a total of four engine air lters on the top of the cab platform. Perform this procedure for each primary element.

Illustration 145

g00039201

3. Clean the inside of the air lter housing. 4. Install a clean primary air lter element. For more information, refer to Cleaning the Primary Air Filter Element. 5. Install the cover on the air lter housing. 6. Repeat this procedure for the air cleaner on the other side of the machine.

Cleaning the Primary Air Filter Element

NOTICE Caterpillar recommends certied air lter cleaning services available at participating Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufcient lter life. Observe the following guidelines if you attempt to clean the lter element: Do not tap or strike the lter element in order to remove dust. Do not wash the lter element. Use low pressure compressed air in order to remove the dust from the lter element. Air pressure must not exceed 207 kPa (30 psi). Direct the air ow up the pleats and down the pleats from the inside of the lter element. Take extreme care in order to avoid damage to the pleats.
Illustration 144
g01163939

Illustration 143

g01128393

1. Remove the cover on the air lter housing.

2. Remove the primary element from the air lter housing.

Do not use air lters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to engine components.

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117 Maintenance Section Engine Air Filter Primary Element - Clean/Replace

The primary air lter element can be used up to six times after the element is properly cleaned and inspected. When the primary air lter element is cleaned, check for rips or tears in the lter material. The primary air lter element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings. NOTICE Do not clean the air lter elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets, or seals. Damaged elements will allow dirt to pass through. Engine damage could result. Visually inspect the primary air lter element before cleaning. Inspect the air lter element for damage to the seal, the gaskets, and the outer cover. Discard any damaged air lter elements. There are two common methods that are used to clean the primary air lter element:

Vacuum Cleaning
Vacuum cleaning is another method for cleaning a primary air lter element which requires daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil.

Inspecting the Primary Air Filter Elements

Pressurized air Vacuum cleaning Pressurized Air

Pressurized air can be used to clean a primary air lter element that has not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil. Use ltered, dry air with a maximum pressure of 207 kPa (30 psi).
Illustration 147
g00281693

Inspect the clean, dry primary air lter element. Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air lter element. Rotate the primary air lter element. Inspect the primary air lter element for tears and/or holes. Inspect the primary air lter element for light that may show through the lter material. If it is necessary in order to conrm the result, compare the primary air lter element to a new primary air lter element that has the same part number. Do not use a primary air lter element that has any tears and/or holes in the lter material. Do not use a primary air lter element with damaged pleats, gaskets or seals. Discard damaged primary air lter elements.

Storing Primary Air Filter Elements

If a primary air lter element that passes inspection will not be used, the primary air lter element can be stored for future use.

Illustration 146

g00281692

Note: When the primary air lter element is cleaned, always begin with the inside of the lter in order to force dirt particles toward the outside. Aim the hose so that the air ows inside the element along the length of the lter in order to help prevent damage to the paper pleats. Do not aim the stream of air directly at the primary air lter element. Dirt could be forced further into the pleats.

118 Maintenance Section Engine Air Filter Secondary Element - Replace

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There is a total of four engine air lters on the top of the cab platform. Perform this procedure for each secondary element.

Illustration 148

g00281694

Do not use paint, a waterproof cover, or plastic as a protective covering for storage. An airow restriction may result. To protect against dirt and damage, wrap the primary air lter elements in Volatile Corrosion Inhibited (VCI) paper. Place the primary air lter element into a box for storage. For identication, mark the outside of the box and mark the primary air lter element. Include the following information:

Illustration 149

g01128393

1. Remove the cover on the air lter housing.

Date of cleaning Number of cleanings

Store the box in a dry location.
i02331799

Engine Air Filter Secondary Element - Replace

SMCS Code: 1054-510-SE NOTICE Service the air lter only with the engine stopped. Engine damage could result. NOTICE Always replace the secondary element. Do not attempt to reuse it by cleaning. Engine damage could result. Note: Replace the secondary element when you service the primary element for the third time. If a clean primary element has been installed and a warning for the air lter still occurs, replace the secondary element. Also, replace the secondary element if the exhaust smoke remains black after installation of a clean primary element.

Illustration 150

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2. Remove the primary element. Reference: Refer to Operation and Maintenance Manual, Engine Air Filter Primary Element Clean/Replace for the correct procedure for servicing the primary element.

Illustration 151

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119 Maintenance Section Engine Air Precleaner - Clean

3. Remove the secondary element From the air cleaner housing. 4. Cover the air inlet opening. Clean the inside of the air lter housing. 5. Uncover the air inlet opening. Install a new secondary element. 6. Install a clean primary element, a clean primary lter, and the cover.
i02237503

i02119046

Engine Components Clean/Inspect, Rebuild/Install Reman, Install New

SMCS Code: 1000-012-IC; 1000-022-MC; 1000-571-IC Caterpillar recommends additional maintenance for the following components on 3516B-HD Engines. Consult your Caterpillar dealer for further information.

Engine Air Precleaner - Clean

SMCS Code: 1055-070 NOTICE Service the air cleaner only with the engine stopped. Engine damage could result.

Clean Components and Inspect Components for Reusability

Aftercooler Core Camshaft Lifters Connecting Rods Crankshaft Cylinder Block Cylinder Liners Damper Gear Train

Illustration 152

g01128355

Pistons Piston Pins Spacer Plates Engine Control Module (ECM)

1. Stop the engine. 2. Remove the precleaner. 3. Inspect the air inlet screen for dirt and debris. Remove the screen. Clean the screen if the screen is dirty. 4. Inspect the precleaner tube openings. Remove any dirt and debris. 5. Clean the precleaner with compressed air or wash the precleaner in warm water. Dry all of the parts. 6. Install the precleaner screen. 7. Repeat the procedure for each precleaner. There is a total of four precleaners.

Rebuild Components and/or Install Remanufactured Components

Cylinder Heads Fuel Transfer Pump Injectors Oil Coolers Oil Pump Scavenge Oil Pump

120 Maintenance Section Engine Components - Replace/Install Reman

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Install New Components

All Seals, Gaskets and O-rings Camshaft Bearings Fuel Pressure Regulating Valve Fuel Priming Pump Bushings for Gear Train and Bearings for Gear
Train

i02274850

Engine Crankcase Breather Clean

SMCS Code: 1317-070 There are a total of four engine crankcase breathers (two breathers on each side of the engine). Perform this procedure for each breather.

Main Bearings, Rod Bearings and Crankshaft

Thrust Bearings

Piston Rings Engine Mounts Engine Wiring Harness New Software Crankshaft Seals
Illustration 153
i02119051 g01139353

Engine Components Replace/Install Reman

SMCS Code: 1000-022-MC Caterpillar recommends this additional maintenance for the following components on 3516B-HD Engines. Consult your Caterpillar dealer for further information.

1. Open the upper front access door on the right side of the machine.

Air Starter or Electric Starter Alternator Fuel Transfer Pump Injectors Turbochargers Refrigerant Compressor Air Compressor
Illustration 154
g01128608

2. Loosen breather outlet hose clamp (1). Remove the hose from the breather cover. 3. Loosen breather inlet hose clamp (2) and remove breather (3). 4. Remove the cover from the breather. 5. Check the condition of the cover seal. If the seal is damaged, replace the seal. 6. Wash the breather element and the cover in clean, nonammable solvent. Shake the element dry or use air pressure.

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121 Maintenance Section Engine Mounts - Inspect

7. Inspect the hose for damage. If necessary, replace the hose. 8. Install the breather element in the cover. 9. Install breather (3). Tighten breather inlet hose clamp (2). 10. Install the outlet hose and tighten breather outlet hose clamp (1). 11. Close the upper front engine access door on the right side of the machine. 12. Repeat steps 12 to 11 for the left side of the machine.
i01947006

Illustration 156

g01129267

Engine Mounts - Inspect

SMCS Code: 1152-040 Caterpillar recommends checking the engine mounts for deterioration and for proper bolt torque. This will help to prevent excessive engine vibration that is caused by improper mounting. Reference: Refer to Specications, SENR3130, Torque Specications for the proper bolt torques for the engine mounts.
i02274838

2. Remove the engine oil level gauge and clean the gauge with a clean cloth. Reinsert the gauge completely and remove the gauge again. This will give a more accurate measurement of the oil level. 3. When the engine is running at low idle, check the LOW IDLE side of the engine oil level gauge. Maintain the oil level between the ADD mark and the FULL mark. When the engine is stopped, check the ENGINE STOPPED side of the engine oil level gauge. Maintain the oil level between the ADD mark and the FULL mark. 4. If necessary, remove the ller cap and add oil.

Engine Oil Level - Check

SMCS Code: 1000-535-FLV

5. Make sure that the engine oil level gauge and the ller cap are installed securely. 6. Close the lower rear access door.
i02239897

Engine Oil Sample - Obtain

SMCS Code: 1348-008; 7542

Illustration 155

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1. Open the lower rear access door on the right side of the machine.

Illustration 157

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122 Maintenance Section Engine Oil and Filter - Change

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The sampling valve for the engine oil is located on the engine oil lter base on the right side of the engine compartment. Reference: Refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations, SOS Oil Analysis for information that pertains to obtaining a sample of the engine oil. Refer to Special Publication, PEHP6001, How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil.
i02857316

Engine Oil and Filter - Change

SMCS Code: 1318-510 Note: Some commercial oils that meet API specications may require shorter oil change intervals. The oil change intervals are determined by close monitoring of the oil condition and engine wear metals. Caterpillar prefers the scheduled oil sampling as the proper method of checking engine wear metals. Consult your Caterpillar dealer for the latest oil recommendations.

Illustration 159

g01423870

2. Open the door of the fast ll service center and locate the correct tting. Connect an oil pump to the tting. 3. Turn on the oil pump and withdraw the engine oil from the engine crankcase. Dispose of the used oil properly. 4. Open both lower access doors on the right side of the machine.

Fast Fill Service Center

NOTICE Do not under ll or overll engine crankcase with oil. Either condition can cause engine damage. Your machine is equipped with a fast ll service center for changing the engine oil. The fast ll service center allows the engine oil to be changed faster than the conventional method.

Illustration 160

g01131149

5. Use a strap type wrench in order to remove the four used lter elements.
Illustration 158 (1) Fast Fill Service Center (2) Access Doors
g01423856

6. Clean the lter mounting bases with a clean cloth. Ensure that the used gaskets are completely removed.

1. Park the machine on a level surface. Lower the bucket to the ground and engage the parking brake.

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123 Maintenance Section Engine Oil and Filter - Change

Reference: Refer to Operation and Maintenance Manual, Engine Oil Level - Check for the correct procedure. 13. Close the lower access doors on the right side of the machine.

Conventional Method

Hot oil and components can cause personal injury.

Illustration 161
g00101318

7. Apply a thin coat of clean engine oil to the seal on the new lter. Install a new engine oil lter hand tight until the seal of the engine oil lter contacts the base. Note the position of the index marks on the lter in relation to a xed point on the lter base. Note: There are rotation index marks on the engine oil lter that are spaced 90 degrees or 1/4 or a turn away from each other. When you tighten the engine oil lter, use the rotation index marks as a guide. 8. Tighten the lter according to the instructions that are printed on the lter. Use the index marks as a guide. For non-Caterpillar lters, use the instructions that are provided with the lter. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the lter to the amount that is required for nal installation. Make sure that the installation tool does not damage the lter. Note: Improper installation of the engine oil lters can result in the loosening of the lter due to vibration, which can cause substantial engine damage. 9. Clean the end of the male coupler at the fast ll service center. Connect an oil pump to the male coupler. Fill the crankcase with new oil. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscositites and Rell Capacities for the type of lubricant and for the rell capacity. 10. Clean the end of the male coupler. Close the door to the fast ll service center. 11. Start the engine and allow the oil to warm. Check the machine for oil leaks. 12. Check the engine oil level.

Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. NOTICE Do not under ll or overll engine crankcase with oil. Either condition can cause engine damage. Note: Some commercial oils that meet API specications may require shorter oil change intervals. The oil change intervals are determined by close monitoring of the oil condition and engine wear metals. Caterpillar prefers the scheduled oil sampling as the proper method of checking engine wear metals. Consult your Caterpillar dealer for the latest oil recommendations. 1. Run the engine for a few minutes in order to warm up the oil. 2. Park the machine on a level surface. Lower the bucket to the ground and engage the parking brake.

124 Maintenance Section Engine Oil and Filter - Change

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Note: Oil will be trapped in the lter housing bases. To avoid possible burns, remove the lters when the lters are cool enough to touch with your bare hand. 6. Use a strap type wrench to remove four used lter elements (1). Dispose of the used lter elements properly. 7. Clean the lter housing bases. Make sure that all of the used gaskets are removed.

Illustration 162 (1) Fast Fill Service Center (2) Access Doors

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3. Open both lower access doors on the right side of the machine.

Illustration 165

g00101318

8. Apply a thin coat of clean engine oil to the seal on the new lter. Install a new engine oil lter hand tight until the seal of the engine oil lter contacts the base. Note the position of the index marks on the lter in relation to a xed point on the lter base. Note: There are rotation index marks on the engine oil lter that are spaced 90 degrees or 1/4 or a turn away from each other. When you tighten the engine oil lter, use the rotation index marks as a guide. 9. Tighten the lter according to the instructions that are printed on the lter. Use the index marks as a guide. For non-Caterpillar lters, use the instructions that are provided with the lter. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the lter to the amount that is required for nal installation. Make sure that the installation tool does not damage the lter. Note: Improper installation of the engine oil lters can result in the loosening of the lter due to vibration, which can cause substantial engine damage. 10. Remove ller cap (2) and ll the crankcase with oil.
Illustration 164
g01131397

Illustration 163

g01131145

4. Open the drain valve on the bottom of the oil pan. Allow the oil to drain into a suitable container. Dispose of the used oil properly. 5. Close the drain valve on the bottom of the oil pan.

Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities and Rell Capacities for the correct type of oil and for the correct amount of oil.

SEBU7885-12

125 Maintenance Section Engine Valve Lash and Bridge - Check

11. Start the engine and operate the engine at low idle for ve minutes. Inspect the engine oil lters for oil leaks. Make any necessary repairs.

Caterpillar recommends replacing valve rotators that are operating improperly. An improperly operating valve rotator will shorten valve life because of accelerated wear on the valves. Also, metal particles from a damaged valve rotator could fall into the cylinder and damage to the piston head and to the cylinder head may result.

Illustration 166

g01129267

12. Check the oil level on the LOW IDLE side of the engine oil level gauge. Maintain the oil level between the ADD mark and the FULL mark. Add oil, if necessary. 13. Close both lower access doors on the right side of the machine.
i01947678

Illustration 167

g00882731

Start the engine and run the engine at low idle. Watch the top surface of each valve rotator. Whenever an inlet valve closes or an exhaust valve closes, each valve rotator should turn. If a valve rotator fails to turn, consult your Cat dealer for service.
i02099172

Engine Valve Lash and Bridge - Check

SMCS Code: 1102-535; 1121-535 Perform the rst valve lash adjustment for new engines and for rebuilt engines at the rst oil change. The initial wear of the valve train components and the initial seating of the valve train components makes this valve lash adjustment necessary. Reference: To check the engine valve lash and the bridge, refer to Testing And Adjusting, RENR2211, 3500B Engines For Caterpillar Built Machines. Consult your Caterpillar dealer for any additional information.
i03952000

Engine Water Pump - Inspect

SMCS Code: 1361-040 Failure of the engine water pump may cause severe engine overheating problems such as cracks in the cylinder head or piston seizure. Visually inspect the water pump for leaks. If you nd leaks, all of the seals on the water pump must be replaced. Reference: Refer to Disassembly and Assembly, SENR1126, 3500B Engines for Caterpillar Built Machines for additional information about the water pump.

Engine Valve Rotators - Inspect

SMCS Code: 1109-040

When inspecting the valve rotators, protective glasses or face shield and protective clothing must be worn, to prevent being burned by hot oil or spray.

126 Maintenance Section Ether Starting Aid Cylinder - Replace

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i02274883

Ether Starting Aid Cylinder Replace

SMCS Code: 1456-510-CD

Ether is poisonous and ammable. Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Use ether only in well ventilated areas. Do not smoke while changing ether cylinders. Use ether with care to avoid res. Do not store replacement ether cylinders in living areas or in the operator's compartment. Do not store ether cylinders in direct sunlight or at temperatures above 49 C (120 F). Discard cylinders in a safe place. Do not puncture or burn cylinders. Keep ether cylinders out of the reach of unauthorized personnel. To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.
Illustration 170
g00102460

Illustration 169

g00102459

Note: There are two ether cylinders. 2. Loosen the cylinder retaining clamp. Unscrew the empty ether cylinder and remove the empty ether cylinder.

3. Remove the used gasket. Install the new gasket that is provided with the new ether cylinder. 4. Install the new ether cylinder. Tighten the ether cylinder by hand. Tighten the cylinder retaining clamp securely. 5. Close the engine access door.

Illustration 168

g01139353

1. Open the upper front access door on the right side of the machine.

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127 Maintenance Section Frame - Inspect

i02857319

Frame - Inspect
SMCS Code: 7051-040; 7054-040

Illustration 173 Non-Engine End Frame The side covers are removed for clarity. Illustration 171 Engine End Frame
g01082021

g01082025

Illustration 174

g01458379

Illustration 172 Engine End Frame

g01082024

Inspect the frames. Clean the indicated areas with a wire brush. Consult your Caterpillar dealer for repairs if cracks or any damage is found on the frames.

128 Maintenance Section Fuel System - Prime

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i02233097

i02234284

Fuel System - Prime

SMCS Code: 1250-548

Fuel System Primary Filter Clean/Inspect/Replace

SMCS Code: 1260-040; 1260-070; 1260-510

Illustration 175

g01139353

1. Make sure that the ignition key is in the OFF position. 2. Open the lower rear access door on the right side of the machine.

Illustration 177

g01139046

1. Open the lower rear access door on the left side of the machine.

Illustration 178 Illustration 176

g01126322

g01126600

2. Loosen retaining bolt (1). 3. Remove lter housing (2) and the lter element. 4. Wash the lter element, the lter housing, and the lter housing base with a clean, nonammable solvent. 5. Use pressure air to dry the lter element. 6. Inspect the lter housing seal. Replace the seal if the seal is damaged. 7. Inspect the lter element. If the lter element is damaged, replace the lter element.

3. Pull the toggle out and up. This will start the pump. The pump will shutoff when the lter elements are full of fuel. 4. Start the engine. Look for leaks around the lter elements. If the engine will not start or the engine misres, more priming is necessary.

SEBU7885-12

129 Maintenance Section Fuel System Secondary Filter - Replace

NOTICE Do not ll fuel lters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts. 8. Install the lter element and lter housing (2) onto the lter housing base. 9. Tighten the retaining bolt. 10. Close the lower rear access door.
i02233286

4. Lubricate the gaskets of the new fuel lters with clean diesel fuel. NOTICE Do not ll fuel lters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts. 5. Install the new fuel lters by hand. After the gaskets contact the lter mounting base, tighten the fuel lters by an additional 3/4 turn. Note: There are rotation index marks on each lter at 90 degree intervals. Use these marks as a guide for proper tightening. 6. Prime the fuel system. Reference: Refer to Operation and Maintenance Manual, Fuel System - Prime for the correct procedure. 7. Close the lower rear access door.
i02857320

Fuel System Secondary Filter Replace

SMCS Code: 1261-510-SE

Fuel Tank Cap and Strainer Clean

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

Illustration 179

g01139353

1. Open the lower rear access door on the right side of the machine.

Illustration 181

g01458390

The fuel tank caps are located on the rear of the machine.

Illustration 180

g01126442

2. Use a strap type wrench to remove the fuel lters. Dispose of the used lters properly. 3. Clean the lter mounting base. Make sure that all of the used gaskets are removed.

130 Maintenance Section Fuel Tank Water and Sediment - Drain

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Illustration 182

g01386240

Illustration 184

g01130140

1. Lift lever (1) and turn lever (1) counterclockwise until the cap stops. Lift the cap straight up in order to remove the cap. 2. Inspect seal (2) for damage. If necessary, replace the seal. 3. Wash the cap in clean, nonammable solvent. 4. Remove the strainer from the ller opening. 5. Wash the strainer in a clean nonammable solvent. 6. Install the strainer into the ller opening. 7. Install the fuel tank cap.
i02857324

1. Open the drain valve. Allow the water and the sediment to drain into a suitable container. 2. Close the drain valve.
i02235078

Fuses - Replace
SMCS Code: 1417-510 NOTICE Replace the fuses with the same type and size only. Otherwise, electrical damage can result. If it is necessary to replace fuses frequently, an electrical problem may exist. Contact your Caterpillar dealer Fuses Fuses protect the electrical system from damage that is caused by overloaded circuits. Replace the fuse if the element separates. If the element of a new fuse separates, check the circuit. Repair the circuit, if necessary.

Fuel Tank Water and Sediment - Drain

SMCS Code: 1273-543-M&S

Illustration 183

g01458481

Illustration 185

g01138824

The drain valves are located under each fuel tank at the rear of the machine.

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131 Maintenance Section Fuses - Replace

(7) ROPS HID 15 amp

(8) Front Wipers and Rear Wipers 15 amp

(9) Front ROPS Floodlight 15 amp

Illustration 186
g01126989

The fuse panel is located under an access door on the left side of the cab platform.

(10) Front Fender Floodlight 10 amp

(11) Rear Radiator Floodlights 10 amp

(12) ROPS HID 15 amp

(13) Platform Floodlights 10 amp

Illustration 187

g01126992

(1) Spare 15 amp

(14)Converter and Bucket Floodlights 10 amp

(2) Spare 15 amp (15) Side Wipers 10 amp (3) Spare 10 amp (16) Beacon 10 amp (4) Spare 10 (17) Implement ECM 10 amp (5) Spare 10 (18) Horn 10 amp (6) Spare 10

132 Maintenance Section High Intensity Discharge Lamp (HID) - Replace

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(19) Engine Compartment Lamps 10 amp

(32) Rear ROPS Floodlight 10 amp

(20) Prelube Primer and Stair Lamps 10 amp

i02245859

High Intensity Discharge Lamp (HID) - Replace (If Equipped)

SMCS Code: 1434-510

(21) Product Link 15 amp

(22) Spare 10

HID lamps operate at very high voltages. To avoid electrical shock and personal injury, disconnect power before servicing HID lamps.

(23) Spare 10 HID bulbs become very hot during operation. Before servicing, remove power from lamp for at least ve minutes to ensure lamp is cool. NOTICE Although HID bulb materials may change over time, HID bulbs produced at the time of the printing of this manual contain mercury. When disposing of this component, or any waste that contains mercury, please use caution and comply with any applicable laws. 1. Remove the electrical power from the high intensity discharge lamp (HID). The electrical power must be removed from the HID lamp for at least ve minutes, in order to ensure that the bulb is cool. 2. Disassemble the housing for the HID lamp in order to have access to the bulb. Note: On some HID lamps, the bulb is an integral part of the lens assembly. The bulb is not removed separately from the lens assembly. Replace the entire lens assembly on these HID lamps. 3. Remove the bulb from the HID lamp. 4. Install the replacement bulb in the HID lamp. If the bulb is an integral part of the lens assembly, install the replacement lens assembly in the HID lamp.

(24) Precleaner 10 amp

(25) Spare 10

(26) Lighter 10 amp

(27) Seat Air Compressor 10 amp

(28) Fan 15 amp

(29) Power Train Control 10 amp

(30) Vital Information Management System 10 amp

(31) Air Dryer 10 amp

SEBU7885-12

133 Maintenance Section High Pressure Screens - Clean/Replace

Note: In order to avoid failure to the bulb that is premature, avoid touching the bulb's surface with your bare hands. Clean any ngerprints from the bulb with alcohol prior to operation. 5. Reassemble the housing for the HID lamp. Ensure that any printing on the lens is oriented correctly with respect to the HID lamp's mounting position on 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 additional information on HID lamps.
i02252336

Illustration 190

g01133992

High Pressure Screens Clean/Replace

SMCS Code: 5068-070-Z3; 5068-510-Z3

The high pressure screens for the implement pumps are located on the front frame. Screen (1) is for the rear implement pump. Screen (2) is for the front implement pump. Screen (3) is for the left implement pump. Clean the screens whenever an implement pump fails. Screen (4) is for the right implement pump.

Illustration 188

g01139408

Illustration 191

g01138824

The screens are located behind the front axle from the bottom.

Illustration 192 Illustration 189 The screens are located at the articulated joint.
g01133991

g01133993

The high pressure screens for the steering pumps are located behind the cab on the platform. Open the access door behind the cab in order to access the screens. Screen (5) is for the left steering pump. Screen (6) is for the right steering pump.

134 Maintenance Section Hydraulic System Oil (Brake Cooling) - Change

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Clean the screens whenever a steering pump fails. 1. Remove the plug at the bottom of the lter housing. Allow the oil to drain from the lter housing into a suitable container. 2. Use a strap type wrench to remove the lter housing. 3. Clean the screen, the lter housing, and the lter mounting base in a clean, nonammable solvent. 4. Check the condition of the screen. Replace any screen that is damaged. 5. Check the condition of the lter housing seal. Replace any seal that is damaged. 6. Install the clean screen in the lter housing. Install the lter housing on the lter mounting base. 7. Start the engine and run the engine at low idle. Inspect the screens for leaks.
i02857341

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

Fast Fill Service Center

Your machine is equipped with a fast ll service center for changing the hydraulic oil. The fast ll service center allows the hydraulic oil to be changed faster than the conventional method. 1. Operate the machine in order to warm the oil. 2. Park the machine on a level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.

Hydraulic System Oil (Brake Cooling) - Change

SMCS Code: 5056-044-BRK

Personal injury can result from hot oil. At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the ll plug only when the engine is stopped, and the ll plug is cool enough to touch with your bare hand. Do not allow hot oil or components to contact skin.
Illustration 193
g01139416

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135 Maintenance Section Hydraulic System Oil (Brake Cooling) - Change

Illustration 195

g01135709

9. Stop the engine and top off the hydraulic tank so that the oil level is above the halfway mark on sight gauge (2).
Illustration 194
g01458485

3. Open the door to the fast ll service center that is on the right side of the machine near the articulation joint. Locate the correct male coupler and connect an oil pump to the tting. 4. Turn on the oil pump and withdraw the hydraulic oil from the hydraulic tank for the steering and the brakes. Dispose of the used oil properly. 5. Turn off the oil pump. Clean the end of the male coupler. 6. Connect the oil pump to the male coupler. Fill the hydraulic tank with new oil. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscositites for the type of lubricant. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the rell capacity. 7. Clean the end of the male coupler and close the door to the fast ll service center. 8. Start the engine and run the engine at low idle. Operate the steering and the brakes in order to circulate the oil.

Note: The oil must be free of air bubbles. If air bubbles are present in the hydraulic oil, air is entering the hydraulic system. Inspect the hydraulic suction line and the hose clamps. 10. If necessary, tighten any loose clamps or any loose connections. Replace any damaged hoses.

Conventional Method
1. Operate the machine in order to warm the oil. 2. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.

Illustration 196

g01139419

136 Maintenance Section Hydraulic System Oil (Implement) - Change

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13. Start the engine and run the engine for at least ten seconds. Then, stop the engine and add hydraulic oil to the tank until the oil level is above the halfway mark on sight gauge (2). 14. Start the engine and run the engine at low idle. Operate the steering and the brakes in order to circulate the oil. 15. Stop the engine and top off the hydraulic tank so that the oil level is above the halfway mark on sight gauge (2). Note: The oil must be free of air bubbles. If air bubbles are present in the hydraulic oil, air is entering the hydraulic system. Inspect the hydraulic suction line and the hose clamps. 16. If necessary, tighten any loose clamps or any loose connections. Replace any damaged hoses. 17. Inspect the gasket on ller cap (1) for damage. Replace the gasket, if necessary. Install ller cap (1).
i02958014

Illustration 197

g01135709

3. Open the access door in the platform behind the cab. Slowly loosen ller cap (1) in order to relieve any tank pressure. 4. Remove the ller cap 1 and the ller strainer. Wash the ller cap and the ller strainer in a clean, nonammable solvent. 5. Remove the drain plug from the bottom of the hydraulic tank. 6. Attach a hose to a pipe nipple that is long. 7. Install the pipe nipple into the drain plug opening in order to open the internal drain valve. Allow the oil to drain into a suitable container. Dispose of the used oil properly. 8. Remove the pipe nipple in order to close the internal drain valve. 9. Clean the drain plug and install the drain plug. 10. Clean the cooling screen. Reference: Refer to Operation and Maintenance Manual, Hydraulic System Oil Filter (Steering Cooler Screen) (Brake Cooler Screen) - Clean for the correct procedure. 11. Install the ller strainer. 12. Fill the hydraulic oil tank with clean oil. Ensure that the oil level is above the halfway mark on sight gauge (2). Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities for the correct type of hydraulic oil. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the correct amount of hydraulic oil.

Hydraulic System Oil (Implement) - Change

SMCS Code: 5056-044

Personal injury can result from hot oil. At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the ll plug only when the engine is stopped, and the ll plug is cool enough to touch with your bare hand. Do not allow hot oil or components to contact skin.

SEBU7885-12

137 Maintenance Section Hydraulic System Oil (Implement) - Change

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

2. The valve is located on the right side of the machine on the front frame. Locate the correct male coupler and connect an oil pump to the tting. 3. Turn on the oil pump and withdraw the hydraulic oil from the hydraulic tank. Dispose of the used oil properly. 4. Turn off the oil pump. Clean the end of the male coupler. 5. Replace the oil lter. Reference: Refer to Operation and Maintenance Manual, Hydraulic System Oil Filter (Implement Pump Case Drain) - Replace for the correct procedure. 6. Connect the oil pump to the male coupler. Fill the hydraulic tank with new oil. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscositites for the type of lubricant. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the rell capacity. 7. Clean the end of the male coupler.

Quick Fill/Drain Valve

Your machine is equipped with a quick ll/drain valve for changing the hydraulic oil for the implements. The quick ll/drain valve allows the hydraulic oil to be changed faster than the conventional method. 1. Park the machine on a level surface. Lower the bucket to the ground and engage the parking brake.

Illustration 198

g01167682 g01134388

Illustration 200

8. Ensure that the oil level is visible in the top section of the sight gauge. 9. Start the engine. Run the engine for a few minutes. 10. Maintain the oil level within the top section of the sight gauge. Add hydraulic oil, if necessary. Note: The oil must be free of bubbles. If bubbles are present in the oil, air is entering the hydraulic system. Inspect the hydraulic suction line and the hose clamps. 11. Stop the engine.

Illustration 199

g01134389

138 Maintenance Section Hydraulic System Oil (Implement) - Change

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12. If necessary, tighten any hose clamps and any hydraulic connections. Replace any damaged hoses.

Conventional Method
Your machine is equipped with a fast ll service center for changing the hydraulic oil. The fast ll service center allows the hydraulic oil to be changed faster than the conventional method. 1. Operate the machine in order to warm the oil. 2. Park the machine on a level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.
g01134389

Illustration 203

4. The valve is located on the right side of the machine on the front frame. Locate the correct male coupler and connect an oil pump to the tting. 5. Turn on the oil pump and withdraw the hydraulic oil from the hydraulic tank. Dispose of the used oil properly. 6. Turn off the oil pump. Clean the end of the male coupler. 7. Replace the oil lter. Reference: Refer to Operation and Maintenance Manual, Hydraulic System Oil Filter (Implement Pump Case Drain) - Replace for the correct procedure.

Illustration 201

g01138023

Illustration 202

g01134785

3. Press the breaker relief valve in order to relieve any pressure.

Illustration 204

g01167711

8. Remove the ller cap. Fill the hydraulic tank with new oil. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscositites for the type of lubricant. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the rell capacity.

SEBU7885-12

139 Maintenance Section Hydraulic System Oil (Steering, Brake) - Change

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products.
Illustration 205
g01134388

Dispose of all uids according to local regulations and mandates.

9. Ensure that the oil level is visible in the top section of the sight gauge. Install the ller cap. 10. Start the engine. Run the engine for a few minutes. 11. Maintain the oil level within the top section of the sight gauge. Add hydraulic oil, if necessary. Note: The oil must be free of bubbles. If bubbles are present in the oil, air is entering the hydraulic system. Inspect the hydraulic suction line and the hose clamps. 12. Stop the engine. 13. If necessary, tighten any hose clamps and any hydraulic connections. Replace any damaged hoses.
i02857347

Fast Fill Service Center

Your machine is equipped with a fast ll service center for changing the hydraulic oil. The fast ll service center allows the hydraulic oil to be changed faster than the conventional method. 1. Operate the machine in order to warm the oil. 2. Park the machine on a level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.

Hydraulic System Oil (Steering, Brake) - Change

SMCS Code: 5056-044-US

Illustration 206

g01139416

Personal injury can result from hot oil. At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the ll plug only when the engine is stopped, and the ll plug is cool enough to touch with your bare hand. Do not allow hot oil or components to contact skin.

140 Maintenance Section Hydraulic System Oil (Steering, Brake) - Change

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Illustration 207

g01458585

3. Open the door to the fast ll service center that is on the right side of the machine near the articulation joint. Locate the correct male coupler and connect an oil pump to the tting. 4. Turn on the oil pump and withdraw the hydraulic oil from the hydraulic tank for the steering and the brakes. Dispose of the used oil properly. 5. Turn off the oil pump. Clean the end of the male coupler. 6. Replace the oil lter. Reference: Refer to Operation and Maintenance Manual, Hydraulic System Oil Filter (Steering and Braking) - Replace for the correct procedure. 7. Connect the oil pump to the male coupler. Fill the hydraulic tank with new oil. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscositites for the type of lubricant. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the rell capacity. 8. Clean the end of the male coupler and close the door to the fast ll service center. 9. Start the engine and run the engine at low idle. Operate the steering and the brakes in order to circulate the oil.
Illustration 208
g01458748

10. Stop the engine and top off the hydraulic tank so that the oil level is above the ADD mark on the sight gauge. Note: The oil must be free of air bubbles. If air bubbles are present in the hydraulic oil, air is entering the hydraulic system. Inspect the hydraulic suction line and the hose clamps. 11. If necessary, tighten any loose clamps or any loose connections. Replace any damaged hoses.

Conventional Method
1. Operate the machine in order to warm the oil. 2. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.

SEBU7885-12

141 Maintenance Section Hydraulic System Oil (Steering, Brake) - Change

6. Attach a hose to a pipe nipple that is long. 7. Install the pipe nipple into the drain plug opening in order to open the internal drain valve. Allow the oil to drain into a suitable container. Dispose of the used oil properly. 8. Remove the pipe nipple in order to close the internal drain valve. 9. Clean the drain plug and install the drain plug. 10. Replace the oil lter.
Illustration 209
g01139419

Reference: Refer to Operation and Maintenance Manual, Hydraulic System Oil Filter (Steering and Braking) - Replace for the correct procedure. 11. Install the ller strainer. 12. Fill the hydraulic oil tank with clean oil. Ensure that the oil level is above the ADD COLD mark on sight gauge (2). Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities for the correct type of hydraulic oil. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the correct amount of hydraulic oil. 13. Start the engine and run the engine for at least ten seconds. Then, stop the engine and add hydraulic oil to the tank until the oil level is above the ADD mark on the sight gauge. 14. Start the engine and run the engine at low idle. Operate the steering and the brakes in order to circulate the oil.

Illustration 210 (1) Breaker Relief Valve (2) Filler Cap

g01458779

3. Open the access door in the platform behind the cab. Press the button on the breaker relief valve in order to relieve any tank pressure. 4. Remove the ller cap and the ller strainer. Wash the ller cap and the ller strainer in a clean, nonammable solvent.

Illustration 211

g00454166

5. Remove the drain plug from the bottom of the hydraulic tank.

142 Maintenance Section Hydraulic System Oil Filter (Hydraulic Cooler Screen) - Clean

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i02857349

Hydraulic System Oil Filter (Hydraulic Cooler Screen) Clean

SMCS Code: 5068-070-Z3

Personal injury can result from hot oil. At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the ll plug only when the engine is stopped, and the ll plug is cool enough to touch with your bare hand. Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 1. Operate the machine in order to warm the oil. 2. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.

Illustration 212

g01458748

15. Stop the engine and top off the hydraulic tank so that the oil level is above the ADD mark on the sight gauge. Note: The oil must be free of air bubbles. If air bubbles are present in the hydraulic oil, air is entering the hydraulic system. Inspect the hydraulic suction line and the hose clamps. 16. If necessary, tighten any loose clamps or any loose connections. Replace any damaged hoses. 17. Inspect the gasket on ller cap for damage. Replace the gasket, if necessary. Install ller cap.

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143 Maintenance Section Hydraulic System Oil Filter (Implement Pump Case Drain) - Replace

Illustration 213

g01138023

Illustration 216

g01458764

3. The breaker relief valve is located on the platform on the front frame.

6. Unscrew the nut and remove the cover from the lter housing. 7. Clean the screen in a nonammable solvent. 8. Check the condition of the lter housing seal. Replace any seal that is damaged. 9. Install the clean screen in the lter housing. Place the cover on the lter housing and screw the nut on the lter housing. 10. Start the engine and run the engine at low idle. Operate the implements in order to circulate the oil.

Illustration 214

g01134785

11. Inspect the screens for leaks. 12. Close the access door in the platform in front of the engine air cleaners.
i02341095

4. Press the breaker relief valve in order to release the pressure in the hydraulic system.

Hydraulic System Oil Filter (Implement Pump Case Drain) - Replace

SMCS Code: 5068-510; 5091-510-II 1. Operate the machine in order to warm the oil. 2. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.

Illustration 215

g01139419

5. Open the access door in the platform in front of the engine air cleaners.

144 Maintenance Section Hydraulic System Oil Filter (Pilot) - Replace

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7. Install the new lter element into the lter housing. Inspect the lter housing seal. Replace the seal if the seal is damaged. 8. Install the lter housing into the lter mounting base. 9. Repeat steps 5 to 8 for each of the lter elements. 10. Close the access door. 11. Start the engine. Run the engine at low idle and check for leaks in the hydraulic system.
Illustration 217
g01138023

12. Check the hydraulic oil level. Reference: Refer to Operation and Maintenance Manual, Hydraulic System Oil (Implement) Check for the correct procedure. 13. Stop the engine.
i02349138

Hydraulic System Oil Filter (Pilot) - Replace

SMCS Code: 5092-510
Illustration 218
g01134785

3. Press the breaker relief valve in order to relieve any tank pressure. 4. Open the access door in front of the cab on the platform.

Illustration 220

g01138023

The oil lter is located on the left side of the machine. 1. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.
Illustration 219
g01167645

5. Remove the lter housing from the housing base. Dispose of the used lter element properly. 6. Clean the lter housing and clean the lter mounting base with a clean, nonammable solvent.

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145 Maintenance Section Hydraulic System Oil Filter (Steering Cooler Screen) (Brake Cooler Screen) - Clean

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products.
Illustration 221
g01134916

Dispose of all uids according to local regulations and mandates. 1. Operate the machine in order to warm the oil. 2. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.

2. Remove the lter housing from the housing base. Dispose of the used lter element properly. 3. Clean the lter housing and clean the lter mounting base with a clean, nonammable solvent. 4. Install the new lter element into the lter housing. Inspect the lter housing seal. Replace the seal if the seal is damaged. 5. Install the lter housing into the lter mounting base. 6. Start the engine and run the engine at low idle. 7. Inspect the pilot system for leaks. Stop the engine and make any necessary repairs.
i02857350

Hydraulic System Oil Filter (Steering Cooler Screen) (Brake Cooler Screen) - Clean
SMCS Code: 4295-070; 431F-070-Z3

Illustration 222

g01139419

3. Open the access door in the platform in front of the engine air cleaners.

Personal injury can result from hot oil. At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the ll plug only when the engine is stopped, and the ll plug is cool enough to touch with your bare hand. Do not allow hot oil or components to contact skin.
Illustration 223
g01458769

4. Slowly loosen ller cap (2) in order to relieve any tank pressure.

146 Maintenance Section Hydraulic System Oil Filter (Steering Pump Case Drain) - Replace

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5. Unscrew the nut and remove the cover from lter housing (1). 6. Clean the screen in a nonammable solvent. 7. Check the condition of the lter housing seal. Replace any seal that is damaged. 8. Install the clean screen in the lter housing. Place the cover on the lter housing and screw the nut on the lter housing. 9. Start the engine and run the engine at low idle. Operate the steering and the brakes in order to circulate the oil. 10. Inspect the screens for leaks. 11. Close the access door in the platform in front of the engine air cleaners.
i02857351

Illustration 224

g01139419

2. Open the access door in the platform in front of the engine air cleaners.

Hydraulic System Oil Filter (Steering Pump Case Drain) Replace

SMCS Code: 5068-510-US; 5091-510-ZH

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 1. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.

Illustration 225

g01458592

3. Slowly remove the ller cap in order to relieve any tank pressure. 4. Open the access door in the platform behind the cab.

Illustration 226

g01135360

5. Use a strap type wrench to remove the lters. Dispose of the used lters properly.

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147 Maintenance Section Hydraulic System Oil Level (Brake Cooling) - Check

6. Clean the lter mounting bases. Make sure that all of the used gaskets are removed from the lter mounting bases. 7. Lubricate the gaskets of the new lters with clean hydraulic oil. 8. Install the new lters by hand. When the gasket contacts the lter base, tighten the lter by an additional 3/4 turn. 9. Install the ller cap. 10. Close the access doors.
i02857353

Hydraulic System Oil Level (Brake Cooling) - Check

SMCS Code: 5056-535-BRK; 5056-535-FLV
Illustration 229
g01458773

The hydraulic tank can also be lled from the fast ll service center.
i02857356

Hydraulic System Oil Level (Implement) - Check

SMCS Code: 5056-535-FLV

Illustration 227

g01139419

The access doors for the hydraulic tank (steering and braking cooling system) are located on the platform in front of the engine air cleaners.

Illustration 230

g01167682

Illustration 228

g01135709

Maintain the oil level above the halfway mark of sight gauge (2). If necessary, remove ller cap (1) and add hydraulic oil.

148 Maintenance Section Hydraulic System Oil Level (Implement) - Check

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Illustration 231

g01134388

The sight gauge for the hydraulic oil level is located in the articulation joint on the right side of the front frame. Maintain the oil level in the center section of the sight gauge.
Illustration 233
g01458776

The hydraulic tank can also be lled from the fast ll service center.

Illustration 232

g01134342

If necessary, press the button on breaker relief valve (2) in order to relieve any tank pressure. Remove ller cap (1) and add hydraulic oil.

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149 Maintenance Section Hydraulic System Oil Level (Steering, Brake) - Check

i02857357

Hydraulic System Oil Level (Steering, Brake) - Check

SMCS Code: 5056-535-US; 5056-535-FLV

Illustration 236

g01458585

The hydraulic tank can also be lled from the fast ll service center that is located on the right side of the machine.
i02857378

Hydraulic System Oil Sample (Implement) - Obtain

Illustration 234
g01458748

SMCS Code: 5050-008; 5056-008; 7542

The access doors for the hydraulic tank (steering system and braking system) are located on the platform in front of the engine air cleaners. The sight gauge for the hydraulic oil is located on the left side of the machine on the side of the platform.

Illustration 237

g01166670

The sampling valve is located at the front of the cab platform. Take off the front access panel in order to access the sampling valve.
g01458592

Illustration 235

Maintain the oil level between the top of sight gauge and the ADD COLD mark. If necessary, remove ller cap (1) and add hydraulic oil.

150 Maintenance Section Hydraulic System Oil Sample (Steering, Brake) - Obtain

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i04025996

Failure of the Steering Cleaning of the Hydraulic Tank PCR (Engine Overhaul)
1. Park the machine on a level surface. Lower the work tool to the ground. Engage the parking brake. 2. Turn the engine start switch key to ON. 3. Move the hydraulic control levers through all of the positions in order to release pressure. 4. Turn the engine start switch key to OFF.

Hydraulic System Oil Sample (Steering, Brake) - Obtain

SMCS Code: 5050-008; 5056-008; 7542

At operating temperature, the hydraulic tank is hot and under pressure.

Illustration 238
g01139419

1. Open the access door in the platform in front of the engine air cleaners.

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Before removing the ller cap, press the valve relief button on the hydraulic tank in order to relieve the tank pressure. Remove the ller cap only when the engine is stopped and the ller cap is cool enough to touch with your bare hand. Remove the ller cap slowly in order to relieve any remaining pressure.

Illustration 239

g02208994

2. Remove ller cap (1). 3. Obtain an oil sample. 4. Replace the cap. Close the access door.
i02857360

Illustration 240

g01139419

Hydraulic System Return Screen - Replace

SMCS Code: 5068-510-Z3 The screen should be cleaned especially when one of the following situations have occurred:

Failure of the Implement Pump Failure of the Brake Pump

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151 Maintenance Section Hydraulic Tank Breaker Relief Valve - Clean

Illustration 241 (1) Breaker Relief Valve (2) Filler Cap

g01458779

Illustration 243

g01173183

5. Press the button on the breaker relief valve in order to relieve any tank pressure. 6. Drain the hydraulic oil tank. Reference: For the correct procedure, refer to Operation and Maintenance Manual, Hydraulic System Oil (Steering, Brake) - Change. 7. Disconnect the drain lines. 8. Remove the hydraulic tank. 9. Remove all of the bolts around the tank. Separate the tank.

10. Remove the screens. Clean the screens with a clean, nonammable solvent. If the screens cannot be cleaned then replace the screens. 11. Inspect all of the O-ring seals. If a seal is damaged, replace the seal. 12. Replace return screens. 13. Bolt the hydraulic tank together. 14. Install the hydraulic tank. 15. Assemble the drain lines. 16. Fill the hydraulic tank. Reference: For the correct procedure, refer to Operation and Maintenance Manual, Hydraulic System Oil (Steering, Brake) - Change.
i02265629

Hydraulic Tank Breaker Relief Valve - Clean

SMCS Code: 5118-070

Illustration 242

g01173181

Illustration 244

g01138023

152 Maintenance Section Oil Filter - Inspect

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Use a lter cutter to cut the lter element open. Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the lter element can indicate a possible failure. If metals are found in the lter element, a magnet can be used to differentiate between ferrous metals and nonferrous metals. Ferrous metals can indicate wear on steel parts and on cast iron parts. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings, rod bearings, or turbocharger bearings. Small amounts of debris may be found in the lter element. This could be caused by friction and by normal wear. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. Using an oil lter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings, to the crankshaft, and to other parts. This can result in larger particles in unltered oil. The particles could enter the lubricating system and the particles could cause damage.
i02067046

Illustration 245

g01138044

The breaker relief valve is located on the platform on the front frame. 1. Press the breaker relief valve in order to release the pressure in the hydraulic system. 2. Remove the breaker relief valve. 3. Clean the breaker relief valve in a clean, nonammable solvent. Shake the breaker relief valve dry or use compressed air. 4. Install the breaker relief valve.
i02106227

Oil Filter - Inspect

SMCS Code: 1308-507; 3067-507; 4295-507; 431F-507; 5068-507

Oil Renewal System Oil Level Check (If Equipped)

SMCS Code: 1348-535-FLV 1. Park the machine on level ground. Lower the work tool to the ground. Engage the parking brake and stop the engine. 2. Check the oil level of the makeup oil tank. Reference: If the oil level of the makeup oil tank does not decrease daily, refer to Systems Operation, RENR8160, Troubleshooting or contact your Caterpillar dealer. Note: Keeping a daily maintenance log of all the additions of oil is necessary for determining whether the ORS is working properly.

Inspect a Used Filter for Debris

Illustration 246 The element is shown with debris.

g00100013

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153 Maintenance Section Power Train Oil Filter (Transmission, Torque Converter) - Replace

i02335628

Power Train Oil Filter (Transmission, Torque Converter) - Replace

SMCS Code: 3004-510; 3067-510

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 1. Operate the machine in order to warm the oil. 2. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake. Stop the engine.
Illustration 248
g01131970

4. Remove the drain plugs from the lter housings. Allow the oil to drain into a suitable container. Dispose of the used oil properly. Note: The majority of the oil will not drain until the seal around the lid has been broken. 5. Unscrew the bolts on the lids. 6. Remove the lids. The lters are attached to the lids. Unscrew the nuts and slide off the lters. Dispose of the used lter elements properly. 7. Clean the lter housings, the drain plugs, and the lter mounting bases with a clean, nonammable solvent. 8. Inspect the lter housing seals. Replace the seals if the seals are damaged. 9. Place new lters on the rods that are attached to the lids. Screw on the nuts. Tighten the nut for the high pressure lter to a torque of 15 Nm (11.1 lb ft). Tighten the nut for the low pressure lter to a torque of 30 Nm (22.1 lb ft). Replace the lids on the lter housing. Screw the bolts onto the lids. 10. Install the drain plugs in the lter housings. 11. Start the engine. Apply the service brake. Only use the right brake pedal. 12. Slowly operate the STIC transmission direction control switch in order to circulate the oil. 13. Move the STIC transmission direction control switch to the NEUTRAL position. Engage the parking brake. Inspect the entire transmission system for leaks. 14. Check the transmission oil level.

Illustration 247

g00732990

3. Open the access panel that is located behind the cab.

154 Maintenance Section Pump Drive (Front) Oil - Change

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Reference: Refer to Operation and Maintenance Manual, Transmission Oil Level - Check for the correct procedure. 15. Close the access panel that is located behind the cab.
i02946576

1. Park the machine on a level surface. Lower the bucket to the ground and engage the parking brake.

Pump Drive (Front) Oil Change

SMCS Code: 3108-044

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

Illustration 249

g01460733

Illustration 250

g01201282

2. The valve is located on the right side of the machine on the front frame. Locate the correct male coupler and connect an oil pump to the tting. 3. Turn on the oil pump and withdraw the oil from the tank. Dispose of the used oil properly.

Crushing Hazard. Connect the steering frame lock between front and rear frames before servicing the machine in the articulation area. Disconnect the steering frame lock and secure it in the stored position before resuming operation. Failure to do so could result in serious injury or death. Note: Refer to Operation and Maintenance Manual, Steering frame Lock for the correct procedure.

4. Completely drain the front pump drive. 5. Turn off the oil pump. Clean the end of the male coupler.

Quick Drain Valve

Your machine is equipped with a quick drain valve for draining the pump drive oil. The quick drain valve allows the pump drive oil to be drained faster than the conventional method.

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155 Maintenance Section Pump Drive (Front) Oil - Change

Conventional Drain

Procedure for Rell

Reference: Please refer to Technical Information Bulletin, TIBU5143 for more information about the Front Pump Drive. Refer to Operation and Maintenance Manual, Capacities (Rell) for the correct amount of oil. Refer to Operation and Maintenance Manual, Lubricant Viscosities for the correct type of oil.

Illustration 251

g01165669

The pump drive is located inside the front frame near the articulation joint. 1. Park the machine on level ground. Lower the bucket to the ground. Engage the parking brake and stop the engine.

Illustration 253

g01460742

1. Open the access panel on the platform in front of the cab. Remove the dipstick (1) from the pump drive housing. 2. Fill the pump drive with half of the correct amount of oil. 3. Purge any air from the drain line. Collect any oil that is removed from the system. 4. Run the machine for 3 to 5 minutes.
Illustration 252 (1) Dipstick (2) Drain Plug
g01460741

5. Add any oil that was collected back into the system and continue to ll the system to the correct amount of oil according to the table.

2. Remove drain plug (2) from the pump drive housing. Allow the oil to drain into a suitable container. Dispose of the used oil properly. 3. Completely drain the front pump drive. 4. Clean the drain plug and install the drain plug.

156 Maintenance Section Pump Drive (Front) Oil Filter - Change

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Illustration 254

g01100724

Illustration 255

g01138023

6. While the engine is stopped, make sure that the oil level is between the ADD and FULL marks on the ENGINE STOPPED side of the dipstick (1). 7. Clean the dipstick and install the dipstick.
i02249398

The lter for the front pump drive is located at the front of the cab platform. Take off the front access panel in order to access the lter.

Pump Drive (Front) Oil Filter Change

SMCS Code: 3108-510-FI

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

Illustration 256

g01132280

1. Use a strap type wrench to remove the lter. Dispose of the used lter properly. 2. Clean the lter mounting base. Make sure that all of the used gasket is removed from the lter mounting base. 3. Lubricate the gasket of the new lter element with clean hydraulic oil. 4. Install the new lter by hand. After the gasket contacts the lter mounting base, tighten the lter by an additional 3/4 turn. 5. Start the engine and run the engine at low idle. Inspect the system for leaks. 6. Stop the engine. Make any necessary repairs.

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157 Maintenance Section Pump Drive (Front) Oil Level - Check

i02778946

Pump Drive (Front) Oil Level Check

SMCS Code: 3108-535-FLV

Illustration 259

g01100724

While the engine is stopped, make sure that the oil level is between the ADD and FULL marks on the ENGINE STOPPED side of the dipstick (1).
Illustration 257
g01165669

1. Remove the dipstick (1) and add oil through the ller tube. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities for the correct type of oil. 2. Install the dipstick (1).
i02857380

The front pump drive is located inside the front frame near the articulation joint.

Pump Drive Oil Sample Obtain

SMCS Code: 3108-008; 7542

Illustration 258

g01388336

Illustration 260

g01132306

The sampling valve for the pump drive is located at the front of the cab platform. Take off the front access panel in order to access the sampling valve. Reference: Refer to Special Publication, PEHP6001, How To Take A Good Oil Sample for more information about obtaining a sample of the pump drive oil.

158 Maintenance Section Pump Drive Shaft (Front) - Lubricate

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i02857361

i02857363

Pump Drive Shaft (Front) Lubricate

SMCS Code: 3108-086-D6

Pump Drive Shaft Support Bearing (Rear) - Lubricate

SMCS Code: 3108-086-D6; 3267-086-BD

Illustration 261

g01165669

Illustration 263

g01458938

Illustration 262

g01458814

1. Wipe off the tting before any lubricant is applied. 2. Apply lubricant through tting for the slip joint on the pump drive shaft.
Illustration 264
g01458935

1. Wipe off the tting before any lubricant is applied. 2. Apply lubricant through one tting on the right side of the articulation joint.

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159 Maintenance Section Radiator Core - Clean

i02857366

i02723802

Radiator Core - Clean

SMCS Code: 1353-070-KO

Receiver Dryer (Refrigerant) Replace

SMCS Code: 7322-510

Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.
Illustration 265
g01458815

Always use precaution when a tting is removed. Slowly loosen the tting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a ame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certied recovery and recycling cart to properly remove the refrigerant from the air conditioning system. NOTICE If the refrigerant system has been open to the outside air (without being plugged) for more than 30 minutes, the receiver-dryer must be replaced. Moisture will enter an open refrigerant system and cause corrosion which will lead to component failure. Refer to Service Manual, SENR5664, Air Conditioning and Heating System with R-134a Refrigerant for All Caterpillar Machines for the proper procedure to change the receiver-dryer assembly and for the procedure to reclaim the refrigerant gas.

Illustration 266

g00100062

Compressed air, high pressure water, or steam can be used to remove dust and other debris from the radiator core. However, the use of compressed air is preferred. Reference: Refer to Special Publication, SEBD0518, Know Your Cooling System for the complete procedure for cleaning the radiator core.

160 Maintenance Section Rollover Protective Structure (ROPS) - Inspect

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i02337495

3. Install the access covers.

i02429589

Rollover Protective Structure (ROPS) - Inspect

SMCS Code: 7325-040 NOTICE Do not attempt to straighten the ROPS structure. Do not repair the ROPS by welding reinforcement plates to the structure. If there are any cracks in the welds, in the castings, or in any metal section of the ROPS, consult your Caterpillar dealer for repairs.

Seat Belt - Inspect

SMCS Code: 7327-040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine. Replace any parts that are damaged or worn before you operate the machine.

Illustration 269 Typical example Illustration 267

g01166758

g00932801

Check the seat belt mounting hardware (1) for wear or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting bolts are tight. Check buckle (2) for wear or for damage. If the buckle is worn or damaged, replace the seat belt. Inspect the seat belt (3) for webbing that is worn or frayed. Replace the seat belt if the seat belt is worn or frayed. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware.

Illustration 268

g01129835

1. Remove the access covers from both sides of the Rollover Protective Structure (ROPS). 2. Inspect the ROPS for bolts that are damaged, loose, or missing. Use only original equipment parts for bolts that are damaged or missing. Tighten the bolts to a torque of 1600 200 Nm (1200 150 lb ft). Note: Apply oil to the bolt threads before you install the bolt. Failure to apply oil can result in improper bolt torque.

Note: Within three years of the date of installation or within ve years of the date of manufacture, replace the seat belt. Replace the seat belt at the date which occurs rst. A date label for determining the age of the seat belt is attached to the seat belt, the seat belt buckle, and the seat belt retractor. If your machine is equipped with a seat belt extension, also perform this inspection procedure for the seat belt extension.

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161 Maintenance Section Seat Belt - Replace

i02429594

Seat Belt - Replace

SMCS Code: 7327-510 Within three years of the date of installation or within ve years of the date of manufacture, replace the seat belt . Replace the seat belt at the date which occurs rst. A date label for determining the age of the seat belt is attached to the seat belt, the seat belt buckle, and the seat belt retractor.

Caterpillar recommends adjusting the side rails after the initial 500 hours of machine operation. After the initial 500 service hours, perform this procedure when it is necessary. Reference: Refer to Service Manual, SENR6615, Contour Series Seat for the adjustment procedure.
i03694709

Secondary Steering - Test

SMCS Code: 4300-081-SE; 4300-081-SST; 4324-081; 4324

The service brake must be checked in order to ensure proper operation before you test the supplemental steering system. Personal injury, death, or property damage could occur if the supplemental steering system is tested and the service brake is not operational.
Illustration 270 (1) Date (2) Date (3) Date (4) Date of installation (retractor) of installation (buckle) of manufacture (tag) (fully extended web) of manufacture (underside) (buckle)
g01152685

Test the service brake before you test the supplemental steering system. Perform the following procedure if your machine is equipped with a ground driven supplemental steering and if the procedure is required by local regulations. Ensure that there are no hazards in the test area. The test area must be unobstructed and level. Operate the machine in second gear. Ensure that all air tanks and accumulators are properly charged. Ensure that there is no load in the work tool. Position the machine with the bucket or the work tool in the carry position with the machine in neutral. Release the parking brake. Apply the service brakes and put the engine at low idle. Ensure that The area around the machine is clear of personnel. Shift the transmission to second gear forward and slowly release the service brakes. Moderately increase the engine speed to high idle. Shift the transmission to neutral. Turn the ignition to the OFF position. Allow the machine to coast. While the machine is in motion, turn the machine to the left and to the right. If the machine responds to the steering input, the supplemental steering system is operating. Stop the machine with the service brakes. Apply the parking brake. The machine can then be returned to normal operation.

Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. If your machine is equipped with a seat belt extension, also perform this replacement procedure for the seat belt extension.
i01547608

Seat Side Rails - Adjust

SMCS Code: 7312-025

Illustration 271

g00804394

162 Maintenance Section Starting Motor - Inspect

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If there is no response to the steering input, the supplemental steering system is not operating. Stop the machine immediately. Repair the supplemental steering system before returning the machine to service.
i02119057

2. Apply lubricant through the tting for the rod end of each steering cylinder. Apply lubricant through the tting for the head end of each steering cylinder.
i02246969

Steering Stop - Check

SMCS Code: 4330-535-SQ

Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040 Caterpillar recommends a scheduled inspection of the starting system. Check the starting motor and the battery charger for proper operation. Check for loose electrical connections Reference: Refer to Systems Operation/Testing and Adjusting, SENR1123, 3500B and 3500B High Displacement Engines For Caterpillar Built Machines, Electric Starting System for information about testing the starting system.
i02857368

Illustration 273

g01131473

Steering Cylinder Bearings Lubricate

SMCS Code: 4303-086-BD The steering cylinder bearings are lubricated by the automatic lubrication system. If any of the lubrication lines are damaged, install a tting at the bearing and lubricate the bearing. The damaged line must be replaced.

Check for contact between the steering stops. If the steering stops have been contacting each other, the steering neutralizer valve needs to be adjusted. Adjusting the steering system should be done by a qualied Caterpiller product support representative. Reference: Refer to Testing and Adjusting, RENR6325, 994F Steering System, Steering Neutralizer Valve - Adjust for the correct procedure.
i02243191

Tire Ination - Check

SMCS Code: 4203-535-AI

Illustration 272

g01173772

1. Wipe off all ttings before any lubricant is applied. Note: There are a total of four ttings.
Illustration 274
g01130702

Measure the tire pressure on each tire. Inate the tires, if necessary.

SEBU7885-12

163 Maintenance Section Transmission Magnetic Screen - Clean

Reference: Refer to Operation and Maintenance Manual, Tire Ination Information for more information or consult your Caterpillar dealer.
i02337526

1. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine. 2. Remove cover assemblies (1) and seals (2). 3. Remove screen tube assemblies (3) and suction screens (4). 4. Wash the screen tube assemblies and the suction screens in a clean, nonammable solvent. Allow the components to air dry. 5. Install screen tube assemblies (3) and suction screens (4). 6. Inspect seals (2). Replace the seals, if necessary. 7. Install seals (2) and cover assemblies (1).
i02857369

Transmission Magnetic Screen - Clean

SMCS Code: 3030-070-MGS; 3159-070-MGS Clean the transmission magnetic screens if the transmission oil pump fails or the transmission is disassembled. Drain the transmission oil before you remove the transmission magnetic screen. Reference: Refer to Operation and Maintenance Manual, Transmission Oil - Change for the procedure to drain the transmission oil.

Transmission Oil - Change

SMCS Code: 3030-044

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

Illustration 275

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The two transmission magnetic screens are located in the transmission case at the center of the machine.

Fast Fill Service Center

Your machine is equipped with a fast ll service center for changing the transmission oil. The fast ll service center allows the transmission oil to be changed faster than the conventional method.
Illustration 276
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164 Maintenance Section Transmission Oil - Change

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1. Park the machine on a level surface. Lower the bucket to the ground and engage the parking brake.

Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the rell capacity. 6. Clean the end of the male coupler and close the door to the fast ll service center. 7. Start the engine. Cycle the transmission control in order to warm the oil. Check the transmission for oil leaks. 8. Check the transmission oil level in sight gauge (1). Reference: Refer to Operation and Maintenance Manual, Transmission Oil Level - Check for the correct procedure.

Conventional Method
Illustration 277
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1. Operate the machine in order to warm the oil. 2. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake. Stop the engine.

Illustration 278

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Illustration 279

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2. Open the door to the fast ll service center that is on the right side of the machine near the articulation joint. Locate the correct male coupler and connect an oil pump to the tting. 3. Turn on the oil pump and withdraw the transmission oil from the transfer gear case. Dispose of the used oil properly. 4. Turn off the oil pump. Clean the end of the male coupler. 5. Connect the oil pump to the male coupler. Fill the transfer gear case with new oil. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscositites for the type of lubricant.

3. The drain valve for the transmission oil tank is located on the bottom of the transmission case near the center of the machine. Open the drain valve and allow the oil to drain into a suitable container. Dispose of the used oil properly. 4. Change the lter element. Reference: Refer to Operation and Maintenance Manual, Power Train Oil Filter (Transmission and Torque Converter) - Replace for the correct procedure. 5. Clean the transmission magnetic screen. Reference: Refer to Operation and Maintenance Manual, Transmission Magnetic Screen - Clean for the correct procedure. 6. Close the drain valve for the transmission oil tank.

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165 Maintenance Section Transmission Oil Level - Check

Illustration 280

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Illustration 282

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13. Check the transmission oil level in the sight gauge on the right side of the articulation joint. Maintain the oil level between the marks on the oil level sight gauge. If necessary, remove the transmission oil ller cap and add oil.
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Transmission Oil Level - Check

SMCS Code: 3030-535-FLV

Illustration 281

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7. The transmission oil ller tube is located behind the cab. Remove ller cap (1) and ll the transmission with oil. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities for the correct type of oil. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the correct amount of oil. 8. Clean the ller cap and install the ller cap. 9. Remove transmission breather (2). Wash the breather in a clean, nonammable solvent. Allow the breather to dry or use air pressure to dry the breather. Install the transmission breather. 10. Start and run the engine at low idle. Inspect the transmission for leaks. 11. Slowly operate the STIC transmission direction control switch in order to circulate the oil. 12. Move the STIC transmission direction control switch to the NEUTRAL position. Engage the parking brake. Inspect the entire transmission system for leaks.

Illustration 283

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The transmission sight gauge is located on the right side of the machine in the articulation joint. While the engine is running at low idle, maintain the oil level between the marks on the sight gauge.

166 Maintenance Section Transmission Oil Sample - Obtain

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Obtain the sample for the torque converter from port (1). Obtain the sample for the transmission from port (2). Close the access panel once the samples have been obtained. Reference: Refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations, SOS Oil Analysis for information that pertains to obtaining a sample of the transmission oil. Reference: Refer to Special Publication, PEHP6001, How To Take A Good Oil Sample for more information about obtaining a sample of the pump drive oil.
Illustration 284
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If necessary, remove transmission oil ller cap (1) and add oil.
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Turbocharger - Inspect
SMCS Code: 1052-040 If the turbocharger fails during engine operation, severe damage to the turbocharger compressor wheel and to the entire engine can result. Turbocharger bearing failures can cause large quantities of oil to enter the intake system and the exhaust system. Loss of engine oil can result in serious engine damage. Do not continue to operate the engine when a turbocharger bearing failure is accompanied by a signicant loss of engine performance. Engine smoke and speeding up of the engine with no load are characteristics of a loss of engine performance. Reference: For additional information about inspecting the turbocharger, refer to System Operation, SENR1123, 3500B and 3500B High Displacement Engines For Caterpillar Built Machines , Air and Inlet Exhaust System.

Transmission Oil Sample Obtain

SMCS Code: 3080-008; 7542

Illustration 285

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The sampling valve is located behind the cab. Lift the access panel in order to obtain the samples.

VIMS Module Battery - Replace

SMCS Code: 7601-510-B11 A lithium battery is contained inside the main module of the VIMS. The internal battery prevents the loss of stored information. An example of the stored information is the payload data. The internal battery also retains the time and the date.

Illustration 286

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167 Maintenance Section Window Washer Reservoir - Fill

If power is removed from the main module of the VIMS, the internal battery will begin to retain the stored data. Power is removed from the main module of the VIMS when the battery disconnect switch is in the OFF position. The internal battery retains the time and the date when the engine start switch is in the OFF position. This will occur regardless of the position of the battery disconnect switch. Note: To prevent the loss of stored information, replace the internal battery at the service interval. If the ambient temperature is continuously in the range of 0 to 40C (32 to 40F), cut the service interval in half. Note: If the Vital Information Management System (VIMS) detects a failed battery, a fault code will indicate that the battery needs a replacement. If power is removed from the main module of the VIMS during this fault code, loss of the stored data can occur within several hours. The lithium battery fails quickly. When the fault code is present, immediately download the stored data. Then replace the internal battery without turning off the engine start switch or the battery disconnect switch. Note: If ECM BKUP BATT ERR is displayed in the message area of the VIMS, do NOT turn the engine start switch to the OFF position. Go to Step 3. 1. Stop the machine and turn off the engine. Leave the battery disconnect switch in the ON position. 2. Turn the engine start switch to the ON position or turn the keyswitch for the VIMS to the ON position. 3. Use the service tool for the VIMS to download all of the stored information. The service tool for the VIMS is not part of the machine. Failure to perform this step may result in the loss of stored data. 4. Leave the engine start switch in the ON position or leave the keyswitch for the VIMS in the ON position. Leave the battery disconnect switch in the ON position. Note: If these switches remain in the ON position during replacement, the date and the time of day are less likely to require programming. 5. Remove the battery from the back of the VIMS module. Note: Do not allow dirt or water into the opening. Keep the area clean. 6. Install a new internal battery. Be careful to align the pins of the new battery with the sockets. 7. Check the O-ring seal. Tighten securely against the housing.

8. The real time clock format in the main module is powered by this battery. A dead battery will cause the date to be lost and a dead battery will cause the time to be lost. After the battery has been replaced, the date will default to 01/01/00. Also, the time will default to 00:00:00. If necessary, use the service tool for the VIMS to set the time and the date. Refer to Service Manual, SENR6059, Vital Information Management System (VIMS) for additional information.
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Window Washer Reservoir Fill

SMCS Code: 7306-544 NOTICE When operating in freezing temperatures, use Caterpillar nonfreezing window washer solvent or equivalent. System damage can result from freezing. The window washer reservoir is located behind the cab on the right side. Remove the cap and ll the reservoir with window washer solvent.
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Window Wiper Inspect/Replace

SMCS Code: 7305-040; 7305-510 Inspect the condition of the wiper blades. Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs.
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Windows - Clean
SMCS Code: 7310-070 Use commercially available window cleaning solutions in order to clean the windows. Use a clean cloth or a squeegee to clean the windows from the cab platform.