277C,287C,297C

SEBU8020-01 105Maintenance Section

Maintenance Interval Schedule

i02686602

Maintenance Interval Schedule

SMCS Code: 7000

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

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

Use mileage, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

When Required

Aftercooler Core - Inspect/Clean ........................ 107Aftercooler Intake Screen - Clean ....................... 108Air Conditioner Condenser - Clean ..................... 108Battery - Recycle ................................................. 112Battery or Battery Cable - Inspect/Replace ......... 112Blade Frame - Adjust ........................................... 114Bucket Cutting Edges - Inspect/Replace ............ 120Bucket Tips - Inspect/Replace ............................ 121Cab Air Filter - Clean/Replace ............................ 121Cab Interior - Clean ............................................ 122Engine Air Filter Primary Element - Clean/Replace ............................................................. 128

Engine Air Filter Secondary Element - Replace .. 131Engine Compartment - Clean ............................. 132Fuel System Priming Pump - Operate ................ 138Fuel Tank Cap - Clean ........................................ 139Fuel Tank Water and Sediment - Drain ............... 139Fuses - Replace .................................................. 140Lower Machine Frame - Clean ........................... 147Oil Filter - Inspect ................................................ 148Radiator Core - Clean ......................................... 149Track (Rubber) - Remove/Replace ..................... 155Window Washer Reservoir - Fill .......................... 157Window Wiper - Inspect/Replace ........................ 157Windows - Clean ................................................. 157

Every 10 Service Hours or Daily

Axle Bearings - Lubricate ..................................... 110Backup Alarm - Test ............................................. 111Bogie and Idler - Inspect/Replace ........................ 115

Cooling System Level - Check ............................ 125Engine Oil Level - Check .................................... 132Equipment Lowering Control Valve - Check ....... 135Fuel System Primary Filter (Water Separator) -Drain ................................................................. 137

Hydraulic System Oil Level - Check ................... 145Lift Arm and Cylinder Linkage - Lubricate ........... 146Quick Coupler - Clean/Inspect ............................ 148Seat Belt - Inspect .............................................. 151Sprocket Sleeve - Inspect ................................... 153Tilt Cylinder Bearings and Bucket Linkage Bearings -Lubricate ........................................................... 153

Track (Rubber) - Inspect/Adjust .......................... 154Vacuator Valve - Clean/Inspect ........................... 156Work Tool - Lubricate .......................................... 158Work Tool Mounting Bracket - Inspect ................ 160

Initial 250 Service Hours

Final Drive Oil - Change ..................................... 136

Every 250 Service Hours

Engine Oil Sample - Obtain ................................ 133Final Drive Oil Level - Check .............................. 136

Every 250 Service Hours or Monthly

Belts - Inspect/Adjust/Replace ............................. 112


Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 126

Final Drive Oil - Change ..................................... 136Hydraulic Oil Sample - Obtain ............................ 142

Every 500 Service Hours or 6 Months

Fuel System Primary Filter (Water Separator)Element - Replace ............................................ 138

Hydraulic System Oil Filter - Replace ................. 144

Every 500 Service Hours or 1 Year

Engine Oil and Filter - Change ........................... 133Hydraulic Tank Breather - Replace ..................... 146


Engine Valve Lash - Check ................................. 135

Every 1000 Service Hours or 6 Months

Rollover Protective Structure (ROPS) and FallingObject Protective Structure (FOPS) - Inspect ... 150


Sprocket - Inspect ............................................... 151

106 SEBU8020-01Maintenance SectionMaintenance Interval Schedule


Refrigerant Dryer - Replace ................................ 150


Fuel Injection Timing - Check ............................. 137Hydraulic System Oil - Change ........................... 143

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 127

Every 3000 Service Hours or 2 Years

Cooling System Water Temperature Regulator -Replace ............................................................. 128

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

Seat Belt - Replace ............................................. 151

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 124

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 123


Aftercooler Core - Inspect/Clean

i02555053

Aftercooler Core -Inspect/Clean

SMCS Code: 1064-571; 1064-571-Z3

S/N: GCP1-Up

Inspect

Note: Adjust the frequency of inspection according tothe effects of the operating environment. Clean theaftercooler core when you clean the radiator core.

The aftercooler is located behind the cab and in frontof the engine.

g01279112Illustration 104

1. Stop the engine.

2. Clean the grill before you access the aftercoolercore.

3. Remove the pin (2) that holds the grill (1) and liftthe grill.

Note: If parts of the aftercooler system may appearto be damaged or if parts of the aftercooler systemare repaired, a leak test is highly recommended.Consult your Caterpillar dealer for the most currentinformation about the aftercooler.

Inspect the �ns and tubes of the aftercooler fordamage. Some �ns and tubes may be worn fromabrasive material that has passed through theaftercooler cores. Bent �ns may be opened with a�comb�.

Inspect these items for good condition: welds,mounting brackets, air lines, connections, clamps,and seals. Make repairs, if necessary.

Clean

For air-to-air aftercoolers, use the same methods thatare used for cleaning radiators.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

NOTICEWhen you are using compressed air or high pressurewater to clean the radiator �ns, ensure that the air orwater is directed parallel to the �ns. If the compressedair or high pressure water is not directed parallel to theradiator �ns, the radiator �ns could be bent or dam-aged.

Pressurized air is the preferred method for removingloose debris. Hold the nozzle approximately 6 mm(0.25 inch) away from the �ns. Slowly move the airnozzle in a direction that is parallel with the tubes.The air nozzle should point in the opposite directionof the �ow of the fan. This will remove debris that isbetween the tubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud.

Use a degreaser and steam for removal of oil andgrease. Wash the core with detergent and hot water.Thoroughly rinse the core with clean water.

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, ifnecessary.

Note: Adjust the frequency of cleaning according tothe effects of the operating environment. If there is anextreme amount of debris, you may need to removethe air conditioning condenser or the cover plate fromthe fan housing for the aftercooler.

Close the grill and replace the retaining pin.

108 SEBU8020-01Maintenance SectionAftercooler Intake Screen - Clean

i02559029

Aftercooler Intake Screen -Clean

SMCS Code: 1063-070-Z3

S/N: GCP1-Up


Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.


Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

Note: Pressurized air is the preferred method forremoving loose debris. Pressurized water may alsobe used for cleaning. Use pressurized water in orderto soften mud. Clean the screen from both sides. Themaximum water pressure for cleaning purposes mustbe less than 275 kPa (40 psi).

1. Turn off the engine.


(1) Cylinder for the lift arm(2) Air inlet screen

(3) Hydraulic tank(4) Electrical connectors

2. Access the screen from the right side of themachine. Hold the nozzle approximately 6 mm(0.25 inch) away from the screen. Ensure that thespray nozzle is past the electrical connections.


(5) Air inlet screen

3. Access the screen from the left side of themachine. Hold the nozzle approximately 6 mm(0.25 inch) away from the screen.

4. If water is used to clean the screen, ensure thatthe screen is dry before the engine is started. Ifnecessary, use compressed air to dry the screen.

i02555064

Air Conditioner Condenser -Clean(If Equipped)

SMCS Code: 1805-070


Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.



Air Conditioner Condenser - Clean

246C, 256C, 262C, 277C, and 287C

The air conditioner condenser is located behind theengine on the frame.

Open the engine access door.

Inspect the air conditioner condenser for the followingconditions:

� Damaged �ns

� Buildup of debris

� Plugged areas

Remove any debris. Clean the condenser with lowpressure air or low pressure water. The maximumwater pressure for cleaning purposes must be lessthan 275 kPa (40 psi).

272C and 297C

The air conditioner condenser is attached to the sideof the fan housing for the aftercooler.

1. Remove the 3 bolts that retain the condenser tothe fan housing for the aftercooler.

2. Lift the core and remove the core from theretaining lip.

3. Clean the condenser core in the opposite directionof the air �ow.

4. Reinstall the core in reverse order.

110 SEBU8020-01Maintenance SectionAxle Bearings - Lubricate

i02418750

Axle Bearings - Lubricate

SMCS Code: 3282-086-BD


Single Level Suspension (SLS) undercarriage

(1) Front pivot (2) Rear pivot


(3) Front grease zerks (4) Rear grease zerks

SEBU8020-01 111Maintenance SectionBackup Alarm - Test


Dual Level Suspension (DLS) undercarriage

(5) Front pivot (6) Rear pivot


(7) Front grease zerks (8) Rear grease zerks

Apply lubricant to all grease �ttings.

Repeat the process for the opposite side of themachine.

i02580453

Backup Alarm - Test

SMCS Code: 7406-081

To prevent injury, make sure that no people areworking on the machine or near the machine. Toprevent injury, keep the machine under control at alltimes.

1. Get into the operator�s seat. Fasten the seat beltand pull the armrests downward.

112 SEBU8020-01Maintenance SectionBattery - Recycle

2. Start the engine.

3. Disengage the parking brake.

4. Move the joystick control to the REVERSEposition.

The backup alarm should sound immediately.The backup alarm should continue to sound untilthe joystick control is returned to the NEUTRALposition or to the FORWARD position.

i00993589

Battery - Recycle

SMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

� A battery supplier

� An authorized battery collection facility

� Recycling facility

i02520153

Battery or Battery Cable -Inspect/Replace

SMCS Code: 1401-040; 1401-510; 1401-561;1402-040; 1402-510

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

2. The battery is located on the left side of themachine under the cab. Raise the cab. Refer toOperation and Maintenance Manual, �Cab Tilting�for information on raising the cab.

3. Disconnect the negative battery cable at thebattery.

Note: Do not allow the disconnected battery cable tocontact the negative battery post.

4. Disconnect the negative battery cable from theframe in order to inspect the cable.

5. Disconnect the positive battery cable at thebattery.

6. Perform the necessary repairs. Replace thecables or the battery, as needed.

7. Connect the positive battery cable at the battery.

8. Connect the negative battery cable to the frame ofthe machine.

9. Connect the negative battery cable at the battery.

10. Lower the cab. Refer to Operation andMaintenance Manual, �Cab Tilting� for informationon lowering the cab.

i02417482

Belts - Inspect/Adjust/Replace

SMCS Code: 1357-025; 1357-040; 1357-510

If a new belt is installed, check the belt adjustmentafter 30 minutes of operation. A belt is considered tobe used after 30 minutes of operation.

Belts

1. Stop the engine in order to inspect the belt.

2. Open the engine access door. Refer to Operationand Maintenance Manual, �Access Doors andCovers�.


3. Remove the �ve bolts (1) on the top of the guard.Loosen the two bolts (2) on the bottom of theguard.

4. Slide the guard upward from bottom bolts.Remove the guard for the V-belt.


Belts - Inspect/Adjust/Replace


5. Inspect the condition of the belt (3) and theadjustment of the belt. The belt should de�ect10 mm (0.39 inch) under a straight pull of 44 N(10 lb). This measurement should be takenbetween the alternator pulley and the crankshaftpulley.

Note: A 144-0235 Borroughs Belt TensionGauge may be used to measure belt tension.This measurement should be taken between thealternator pulley and the crankshaft pulley. Refer tothe following table for belt tension.

Table 19

Belt TensionInitial

Belt TensionUsed

534 ± 22 N (120 ± 5 lb) 400 ± 44 N (90 ± 10 lb)

6. Loosen the mounting bolt (4). Loosen the adjustinglocknut (5).

7. Move the alternator until the correct tension isreached.

8. Tighten the adjusting locknut. Tighten themounting bolt.

9. Recheck the belt de�ection. If the amount ofde�ection is incorrect, repeat step 5 to step 8.

Air Conditioner (if equipped)

Note: If your machine is equipped with an airconditioner, use the same procedure and the samemeasurements for the belt tension.

1. Inspect the condition of the belt and theadjustment of the belt. The belt should de�ect10 mm (0.39 inch) under a straight pull of 44 N(10 lb). This measurement should be takenbetween the air conditioner compressor pulleyand the crankshaft pulley.


2. Loosen the mounting bolt (6) for the air conditionercompressor. Loosen the adjusting locknut (7) forthe air conditioner compressor.

3. Move the air conditioner compressor until thecorrect tension is reached.

Note: A hole (8) in the bracket has been provided inorder to aid with the adjustment of the tension.

4. Tighten the adjusting locknut. Tighten themounting bolt.

5. Recheck the belt de�ection. If the amount ofde�ection is incorrect, repeat step 2 to step 4.

114 SEBU8020-01Maintenance SectionBlade Frame - Adjust

Finish


1. Install the guard for the V-belt. Tighten all of thebolts (1 and 2) to 6 ± 1 N·m (4 ± 0.7 lb ft).

2. Close the engine access door.

i02549571

Blade Frame - Adjust

SMCS Code: 6060-025-BG

Height Adjustment


(1) Height Adjustment for the Frame

(2) Adjusting Bolts

(3) Frame

The height of the frame may be adjusted in order tocompensate for the wear on the cutting edge. Thefront portion of the frame needs to be lowered as thecutting edge wears. Remove the bolts (2) and lowerthe frame (3). Install the bolts. This will keep theblade level with the ground and this will prevent theblade from digging into the ground.

Note: In order to properly adjust the blade, the worktool coupler needs to be vertical. The position ofthe pivot point of the blade is perpendicular to theground. Follow this procedure in order to ensure thatthe cutting edge will remain �at on the ground duringoperation.


Bogie and Idler - Inspect/Replace

Trunnion Joint

Note: The trunnion is a dry joint. Adding grease tothe trunnion simply attracts abrasive particles. Thetightness of the joint should be monitored. Shimsshould be removed when the joint becomes tooloose. This may be indicated by excessive movementin the blade.


(A) Trunnion Joint

(B) Bolts

(C) Shims

� Remove the four retaining bolts (B) and the cap.

� Remove the necessary shims.

� Replace the cap and bolts.

� The tightening sequence is shown in illustration116.

� Torque the bolts to 530 ± 70 N·m (391 ± 52 lb ft).

Note: Some noise is typical and the noise does notindicate a problem.

i02418754

Bogie and Idler -Inspect/Replace

SMCS Code: 4159-040; 4159-510; 4192-040;4192-510

Inspect

Clean the undercarriage before inspecting the bogiesand the idlers.

Inspect the bogies and idlers for damage and wear.

Note: Minor damage to the rubber on the bogiesand idlers is acceptable. Minor damage includesnicks, cuts, small pieces that are missing, andsmall grooves. This minor damage is normal andacceptable. Minor damage will not adversely affectmachine performance.

The bogies and the idlers should be replaced whenthe damage to the rubber wheels adversely affectsmachine performance. Replace the bogies and theidlers when the rubber is worn beyond the minimumspeci�cations that are listed below.

Note: The hubs for the bogies and the hubs for theidlers on the 277C, 287C and 297C contain oil. Thehubs are sealed for life. Periodically, inspect the hubsfor leaks or for excessive end play. Contact yourCaterpillar dealer if either leaks or excessive endplay is found.

116 SEBU8020-01Maintenance SectionBogie and Idler - Inspect/Replace

Table 20

Bogie Wheels and Idler WheelsWear Limits

Minimum Width Minimum Thickness

254 mm (10 inch) 15 mm (0.59 inch) 1 mm (0.04 inch)

381 mm (15 inch) 15 mm (0.59 inch) 1 mm (0.04 inch)

Loosen the Track


Use an appropriate �oor jack in order to lift themachine off the ground. Use appropriate jack stands(1) in order to block up the machine. Raise themachine until tracks are approximately 50 mm(2.0 inches) (A) off the ground.

Loosen the track in order to work on the bogies andidlers. Refer to Operation and Maintenance Manual,�Track - Inspect/Adjust� for the procedure.

Note: The track may be removed in the illustrationsfor clarity.



Single Level Suspension


(1) Idler wheels (2) Bogie wheels

Idler wheels


(5) Outer idler wheel(6) Bolts and washers for the wheels

(7) Inner idler wheel

1. Remove the bolts (6) and the washers for theouter idler wheel.

2. Remove the outer idler wheel.

118 SEBU8020-01Maintenance SectionBogie and Idler - Inspect/Replace


(3) Front scraper plate

(4) Rear scraper plate

3. If the inner idler wheel needs to be removed, youwill need to remove the scraper plate. Remove thebolts that hold each scraper plate.

4. If necessary, remove the bolts and the washers forthe inner idler wheel and remove the wheel.

5. Install the wheels in reverse order. Tighten thebolts to a torque of 120 ± 20 N·m (89 ± 15 lb ft).

6. If necessary, install the scraper plates.

Note: The torque for the bolts for the scraper plate onthe rear idler is 120 ± 20 N·m (89 ± 15 lb ft). All othertorque values for the bolts for the scraper plates arestandard torque values.

Bogie wheels


(10) Scraper plate

(11) Bolts and washers for the wheels(12) Outer bogie wheel

(13) Inner bogie wheel

1. Remove the bolts (11) and the washers for theouter bogie wheel.

2. Remove the outer bogie wheel.


(8) Front scraper plate(9) Rear scraper plate

3. If the inner bogie wheels need to be removed, youwill need to remove the scraper plate. Remove thebolts that hold each scraper plate.

4. If necessary, remove the bolts and the washers forthe inner bogie wheel and remove the wheel.

5. Install the wheels in reverse order. Tighten thebolts to a torque of 50 ± 10 N·m (37 ± 7 lb ft).



6. If necessary, install the scraper plates.

Note: All torque values for the bolts for the scraperplates are standard torque values.

Dual Level Suspension


(1) Idler wheels (2) Bogie wheels

Idler wheels

The idler wheels are removed and installed with thesame procedure as the Single Level Suspension.

120 SEBU8020-01Maintenance SectionBucket Cutting Edges - Inspect/Replace

Bogie wheels


(14) Bogie wheel assembly

(15) Rubber inserts(16) Cover plate

(17) Bolts and washers for cover plate(18) Outer wheel bolts and washers

(19) Outer wheel(20) Bolts for the bogie assembly

(21) Inner wheel(22) Inner wheel bolts and washers

1. Remove the bolts (18) and the washers for theouter bogie wheel (19).

2. Remove the outer bogie wheel.

3. Install the new wheel. Tighten the bolts to a torqueof 50 ± 10 N·m (37 ± 7 lb ft).

4. In order to remove the inner bogie wheels, youmust remove the bogie suspension group fromthe frame. Remove the 2 bolts and 2 washers (17)that hold the cover plate.

5. Remove the bolts (20), washers, and nuts for thesuspension group.

Note: There are 4 rubber inserts between thetwo suspension groups. Retain these inserts forinstallation later.

6. Remove the suspension group and the rubberinserts from the frame.

7. Remove the bolts (22) and the washers for theinner bogie wheel (21).

8. Install the new wheel. Tighten the bolts to a torqueof 50 ± 10 N·m (37 ± 7 lb ft).

9. Loosely install the bolts (20), washers, and nutson the suspension group.

10. Slide the suspension group onto the frame.

11. Lubricate the rubber inserts and slide the rubberinserts into the suspension group.

12. Tighten the bolts (20) to a torque of 120 ± 20 N·m(89 ± 15 lb ft).

13. Install the cover plate (16), 2 bolts, and 2 washers(17). Tighten the bolts to a torque of 50 ± 10 N·m(37 ± 7 lb ft).

14. Tighten the track to the proper tension. Referto Operation and Maintenance Manual, �Track -Inspect/Adjust� for the procedure.

i01743875

Bucket Cutting Edges -Inspect/Replace

SMCS Code: 6801-040; 6801-510

Personal injury or death can result from bucketfalling.

Block the bucket before changing bucket cuttingedges.

1. Lower the lift arms fully. Tilt back the bucket sothat the bucket cutting edge is accessible.

2. Place blocks under the raised edge of the bucket.

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

4. Clean the contact surfaces.

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

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

7. Install the bolts.

8. Remove the blocks that are under the bucket.

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


Bucket Tips - Inspect/Replace

i01764331

Bucket Tips - Inspect/Replace

SMCS Code: 6805-040; 6805-510

Personal injury or death can result from bucketfalling.

Block the bucket before changing bucket cuttingedges.

1. Lower the lift arms fully. Tilt back the bucket sothat the bucket tips are accessible.

2. Place blocks under the raised edge of the bucket.

3. Remove the mounting bolts. Remove the buckettips.

4. Clean the mounting surface.

5. Replace the bucket tips.

6. Install the bolts.

7. Remove the blocks that are under the bucket.

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

i02417532

Cab Air Filter - Clean/Replace(If Equipped)

SMCS Code: 7342-070; 7342-510

Fresh Air Filter

Note: The cover for the cab air �lter is located on theleft hand side of the machine behind the cab.


1. Turn the thumb screw until the thumb screw is freefrom the duct. Lift up on the cover and removethe cover.

2. Remove the air �lter element from the duct andclean the �lter element with low pressure air(maximum 207 kPa (30 psi)). Direct the air �owup the pleats and down the pleats from the sideof the �lter opposite of the air �ow. Replacethe element if the element is damaged or if theelement seal is damaged. Replace the element ifthe air conditioner performance is low.

Note: Do not use water for cleaning the �lter.

3. Install the element. Replace the cover and tightenthe thumb screw.

122 SEBU8020-01Maintenance SectionCab Interior - Clean

Recirculation Filter


1. Turn the thumb screws until the thumb screws arefree from the duct. Remove the cover.

2. Remove the air �lter element from the duct andclean the �lter element with low pressure air(maximum 207 kPa (30 psi)). Direct the air �owup the pleats and down the pleats from the sideof the �lter opposite of the air �ow. Replacethe element if the element is damaged or if theelement seal is damaged. Replace the element ifthe air conditioner performance is low.

Note: Do not use water for cleaning the �lter.

3. Install the element. Replace the cover and tightenthe thumb screws.

i02616708

Cab Interior - Clean

SMCS Code: 7301-070

The �oor mat is removable. The �oor mat has sidesin order to help retain the material.


Floor mat in the cab

The �oor mat does not protect the foot pedal andthe pedal linkage. Debris may accumulate aroundthe foot pedal. The foot pedal must be kept clear ofexcessive dirt and debris in order to ensure properactivation of the pedal. Debris must be cleaned fromthe area around the pedal. This can be done afteryou remove the �oor mat.


The drain on the left side of the machine

You can wash the �oor of the cab with water. There isa drain in the front, left corner of the �oor of the cab.


Cooling System Coolant (ELC) - Change

i02417605

Cooling System Coolant (ELC)- Change

SMCS Code: 1395-044-NL

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

NOTICEMixing ELC with other products will reduce the effec-tiveness of the coolant.

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

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

Note: The machine was shipped from the factory withExtended Life Coolant (ELC) in the cooling system.

For information about the addition of Extender to yourcooling system, see the Operation and MaintenanceManual, �Cooling System Coolant (ELC) Extender -Add� or consult your Caterpillar dealer.

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

The radiator cap is located under the radiator guardon the top of the engine compartment.

Allow the machine to cool before you change thecoolant.


2. Raise the radiator guard. Refer to Operation andMaintenance Manual, �Radiator Tilting�.

Note: The radiator cap is located on the right sideof the radiator.


(1) Sight gauge(2) Radiator cap

3. Slowly loosen the radiator cap (2) in order torelieve system pressure. Remove the radiator cap.


Coolant drain

4. Locate the drain hose for the coolant system. Thedrain hose is attached to the drain valve that isshown in illustration 130.

124 SEBU8020-01Maintenance SectionCooling System Coolant Extender (ELC) - Add


5. Remove the access panel under the rear of themachine. Pull the drain hose through the accesshole.

6. Open the drain and allow the coolant to drain intoa suitable container.

7. Close the drain.

8. Push the hose back into the engine compartment.Replace the access panel.

9. Replace the thermostat. See Operation andMaintenance Manual, �Cooling System WaterTemperature Regulator - Replace� for the processfor replacing the thermostat.

10. Add the coolant solution directly to the radiator.Do not use the coolant over�ow reservoir asa �ller for the coolant. Refer to Operation andMaintenance Manual, �Capacities - (Re�ll)�. Referto Special Publication, SEBU6250, �CaterpillarMachine Fluids Recommendations�.

Note: Premix the coolant solution before �llingthe cooling system. The coolant solution shouldcontain 50 percent coolant and 50 percentdistilled water.

Note: Add the coolant solution at a maximum rateof �ve liters per minute. This will reduce the chanceof trapping air inside the engine block. A large amountof trapped air can cause localized heating to occurupon start-up. Localized heating may result in enginedamage, which may lead to failure of the engine.

11. Start the engine. Run the engine without theradiator cap for 30 seconds. Stop the engine.Allow the engine to sit for 1 minute. Check thecoolant level. If necessary, add coolant.

Note: The sight gauge for the coolant level is locatedon the left side of the radiator.

12. Check the coolant level in the sight gauge on theradiator. Maintain the coolant level to the top ofthe sight gauge with the radiator in the LOWEREDposition.

13. Stop the engine. Inspect the radiator cap and thegasket. Replace the cap if the cap or the gasket isdamaged. Install the radiator cap.

14. Pull the radiator guard downward.


i02417747

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352-544-NL


When a Caterpillar Extended Life Coolant is used,an extender must be added to the cooling systemperiodically.


2. Tilt the radiator guard upward. Refer to Operationand Maintenance Manual, �Radiator Tilting�.


Cooling System Level - Check



Note: The radiator cap is located on the right sideof the radiator.

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


Coolant drain

4. If necessary, drain enough coolant from theradiator in order to allow the addition of the coolantadditive.

5. Add 0.17 L (0.18 qt) of cooling system additive.

6. Inspect the radiator cap and the gasket. If the capor the gasket is damaged, replace the cap. Installthe radiator cap.

Note: The sight gauge for the coolant is located onthe left side of the radiator on machines that areequipped with the 3044 engine.

7. Check the coolant level in the sight gauge on theradiator. Maintain the coolant level to the top ofthe sight gauge with the radiator in the LOWEREDposition.

8. Add the extender directly to the radiator. Do notuse the coolant over�ow reservoir as a �ller forthe extender.

9. Tilt the radiator guard downward.


For additional information on the addition of extender,see Special Publication, SEBU6250, �CaterpillarMachine Fluids Recommendations�.

i02417701

Cooling System Level - Check

SMCS Code: 1350-040-HX; 1350-535-FLV;1382-070; 1382-510



2. Tilt the radiator guard upward.

126 SEBU8020-01Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain



3. Check the coolant level in the sight gauge (1)on the radiator. Maintain the coolant level to thetop of the sight gauge with the radiator in theLOWERED position. If you need to add coolant,add the coolant directly to the radiator. Removethe radiator cap (2) slowly in order to relievesystem pressure.

Note: The radiator cap is located on the right sideof the radiator. Inspect the cooling system hoses forany leaks, cracks, or signs of deterioration. Replaceany damaged hoses.

4. Inspect the radiator cap and the gasket. Replacethe cap if the cap or the gasket is damaged. Installthe radiator cap.



6. The coolant over�ow reservoir is located on therear door. Maintain the coolant level in the coolantover�ow reservoir between the �MIN� and �MAX�lines.


i02664591

Cooling System CoolantSample (Level 1) - Obtain

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

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

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


Refer to the Operation and Maintenance Manual,�Access Doors and Covers� for the location of theservice points.



Cooling System Coolant Sample (Level 2) - Obtain

Obtain the sample of the coolant from the radiator.When the system is cool, slowly remove the radiatorcap (2).

Note: Do not take the sample from the CoolantOver�ow Reservoir.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

� Keep the unused sampling bottles stored in plasticbags.

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

� Complete the information on the label for thesampling bottle before you begin to take thesamples.

� Use a designated pump to collect the sample inorder to avoid contamination.

� Obtain coolant samples directly from the coolanttank. You should not obtain the samples from anyother location.

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

� Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

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

i02664598

Cooling System CoolantSample (Level 2) - Obtain

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

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


Refer to the Operation and Maintenance Manual,�Access Doors and Covers� for the location of theservice points.


Obtain the sample of the coolant from the radiator.When the system is cool, slowly remove the radiatorcap (2).

Note: Do not take the sample from the CoolantOver�ow Reservoir.

128 SEBU8020-01Maintenance SectionCooling System Water Temperature Regulator - Replace

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

Refer to Operation and Maintenance Manual,�Cooling System Coolant Sample (Level 1) - Obtain�for the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.

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

i02417821

Cooling System WaterTemperature Regulator -Replace

SMCS Code: 1355-510; 1393-010

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

The thermostat should be replaced after the coolingsystem has been cleaned. Replace the thermostatwhile the cooling system is completely drained orwhile the cooling system coolant is drained to a levelthat is below the thermostat housing.

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


2. Drain the coolant from the machine. See Operationand Maintenance Manual, �Cooling SystemCoolant (ELC) - Change� for the procedure todrain the cooling system.


3. Loosen the hose clamp (1) and remove the hosefrom the thermostat housing assembly (2).

4. Remove the two bolts (3) from the thermostathousing assembly. Remove the thermostathousing assembly.

5. Remove the seal and the thermostat from thethermostat housing assembly.

6. Install a new thermostat and a new seal. Installthe thermostat housing assembly on the enginecylinder head.

7. Install the hose. Tighten the hose clamp.

8. Re�ll the cooling system. Refer to Operation andMaintenance Manual, �Capacities - (Re�ll)�. Referto Operation and Maintenance Manual, �CoolingSystem (ELC) - Change� for information aboutre�lling the cooling system. Refer to SpecialPublication, SEBU6250, �Caterpillar MachineFluid Recommendations� for coolant information.


i02417909

Engine Air Filter PrimaryElement - Clean/Replace

SMCS Code: 1054-070-PY; 1054-510-PY

NOTICENever service the air cleaner when the engine is run-ning, to avoid engine damage.


Engine Air Filter Primary Element - Clean/Replace

NOTICECaterpillar recommends certi�ed air �lter cleaning ser-vices that are available at Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and suf�cient �lter life.

Observe the following guidelines if you attempt toclean the �lter element:

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

Do not wash the �lter element.

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

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

Service the air �lter elements when the alert indicatorfor air �lter restriction lights. Refer to Operationand Maintenance Manual, �Alert Indicators� forinformation about the indicator.

Clean

The primary �lter element can be used up tothree times if the element is properly cleaned andif the element is properly inspected. When theprimary �lter element is cleaned, check for rips ortears in the �lter material. The primary �lter elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

1. Open the engine access door.

2. The air �lter housing is located on the right side ofthe engine compartment.


3. Unlatch the air cleaner housing cover (1). Rotatethe cover counterclockwise and remove the cover.

4. Remove the primary �lter element (2).

5. If it is appropriate, clean the primary �lter element.Use air pressure to clean the primary �lterelements. Pressurized air will not remove depositsof carbon and oil. Use �ltered, dry air with amaximum pressure of 207 kPa (30 psi).

Note: When the primary �lter elements are cleaned,always begin with the inside in order to force dirtparticles toward the outside. Aim the hose so that theair �ows inside the element along the length of the�lter in order to help prevent damage to the paperpleats. Do not aim the stream of air directly at theprimary �lter element.

6. Inspect the cleaned, dry primary air �lter element.Use a 60 watt blue light in a dark room or in asimilar facility. Place the blue light in the primaryair �lter element. Rotate the primary air �lterelement. Inspect the primary air �lter element fortears and/or holes. Inspect the primary air �lterelement for light that may show through the �ltermaterial. If it is necessary in order to con�rm theresult, compare the primary air �lter element to anew primary air �lter element that has the samepart number.

Note: Do not use a primary air �lter element that hasany tears and/or holes in the �lter material. Do notuse a primary air �lter element with damaged pleats,gaskets or seals. Discard damaged primary air �lterelements.

7. Clean the inside of the air cleaner housing with adamp cloth. Do not use compressed air to cleanthe housing.

8. Install the primary �lter element into the �lterhousing.

9. Install the cover for the �lter housing.

130 SEBU8020-01Maintenance SectionEngine Air Filter Primary Element - Clean/Replace


10. Rotate the cover clockwise and latch the cover.

Note: Make sure that the cover is properly positioned.The arrows on the air �lter cover should point upwardwhen the cover is in the locked position.


12. Start the engine. The alert indicator for air �lterrestriction should turn off. If the alert indicatorcontinues to light, replace the secondary air �lter.Refer to Operation and Maintenance Manual,�Engine Air Filter Secondary Element - Replace�.

Replace

The primary �lter element should be replaced at leastone time per year. You can clean the primary �lterup to three times.







6. Install a new primary �lter element into the �lterhousing.



8. Rotate the cover clockwise and latch the cover.




Engine Air Filter Secondary Element - Replace

10. Start the engine. The alert indicator for air �lterrestriction should turn off. If the alert indicatorcontinues to light, replace the secondary air �lter.Refer to Operation and Maintenance Manual,�Engine Air Filter Secondary Element - Replace�.

i02417939

Engine Air Filter SecondaryElement - Replace

SMCS Code: 1054-510-SE

NOTICEAlways replace the secondary �lter element. Nev-er attempt to reuse the secondary �lter element bycleaning the element.

When the primary �lter element is cleaned for the thirdtime, the secondary �lter element should be replaced.

The secondary �lter element should also be replacedif the restricted Air Filter indicator comes on after theinstallation of a clean primary �lter element or if theexhaust smoke is still black.








6. Remove the secondary �lter element.

7. Cover the air inlet opening.

8. Clean the inside of the air cleaner housing with adamp cloth, if necessary. Do not use compressedair to clean the housing.

9. Uncover the air inlet opening.

10. Install a new secondary element.

11. Install the primary element.



13.Rotate the cover clockwise and latch the cover.

132 SEBU8020-01Maintenance SectionEngine Compartment - Clean



i02520141

Engine Compartment - Clean

SMCS Code: 1000-070

Inspect the engine compartment for dirt buildup ordebris. Remove any dirt or debris from the enginecompartment.



2. Remove any debris or dirt from the enginecompartment. If necessary, remove theaccess panel in order to clean out the enginecompartment.

Note: Use care when you clean the enginecompartment. Damage to the machine may occur.

3. Install the access panel. Close the engine accessdoor.

i02417992

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

NOTICEDo not over�ll the crankcase. Engine damage can re-sult.

1. Stop the engine and allow the oil to drain backinto the oil pan.


(1) Oil Filler Cap(2) Dipstick



(1) Oil level add mark

(2) Full mark

3. Maintain the oil level between the �ADD� (1) markand the �FULL� (2) mark on the dipstick.


Engine Oil Sample - Obtain

4. If oil is necessary, tilt the radiator upward. Referto Operation and Maintenance Manual, �RadiatorTilting�.

5. Remove the oil �ller cap (1) and add oil.

6. Clean the oil �ller cap and install the oil �ller cap.

7. Tilt the radiator downward.


i02418014

Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM; 7542-008


The sampling port (1) for the engine oil is located onthe right side of the engine block next to the oil �lterbase (2).

i02418097

Engine Oil and Filter - Change

SMCS Code: 1308-510; 1348-044

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

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

Dispose of all �uids according to local regulations andmandates.

The normal oil change interval for the machine isEvery 500 Service Hours or every year when thefollowing conditions are met:

� Use an engine oil in the Operation and MaintenanceManual, �Lubricant Viscosities�.

� Caterpillar �lters are used.

� The altitude does not exceed 2300 m (7545 ft).

� Sulfur content in the fuel is between 0.05% and0.50%.

An oil change interval of Every 250 Service Hoursor every six months is required when the followingconditions occur:

� Use an engine oil in the Operation and MaintenanceManual, �Lubricant Viscosities�.

� The altitude exceeds 2300 m (7545 ft).

� Sulfur content in the fuel is between 0.50% and1.00%.

An oil change interval of Every 125 Service Hours isrequired when the following condition occurs:

� Sulfur content in the fuel is above 1.00%.

Refer to the results of the S·O·S oil analysis inorder to determine if the oil change interval shouldbe decreased. Consult your Caterpillar Dealer fordetailed information regarding the optimum oilchange interval.

134 SEBU8020-01Maintenance SectionEngine Oil and Filter - Change


2. Tilt the radiator upward. Refer to Operation andMaintenance Manual, �Radiator Tilting�.

Note: The crankcase drain is located on the rightside of the oil pan.


3. Remove the access panel that is located belowthe drain plug. Remove the drain plug and allowthe oil to drain into a suitable container. Install thedrain plug and install the access panel.


4. Remove the �lter element with a 187-2718 FilterWrench. Refer to Operation and MaintenanceManual, �Oil Filter - Inspect� in order to inspectthe used �lter for debris.

5. Apply a thin �lm of clean engine oil to the sealingsurface of the new �lter element.

6. Install the new �lter element by hand. When thegasket contacts the �lter base, tighten the �lterfor an additional 3/4 turn.


(1) Oil Filler Cap(2) Dipstick

7. Remove the oil �ller cap (1). Fill the crankcasewith new oil. Refer to Operation and MaintenanceManual, �Lubricant Viscosities� and Operationand Maintenance Manual, �Re�ll Capacities� forinformation about the oil. Clean the oil �ller plugand install the oil �ller plug.

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


Engine Valve Lash - Check


(1) Oil level add mark(2) Full mark

9. Stop the engine and allow the oil to drain back intothe oil pan. Fill the crankcase to the �FULL� mark(2) on the dipstick. Do not exceed the �FULL�mark on the dipstick. Add oil or drain oil if it isnecessary.

10. Tilt the radiator downward.

11.Close the engine access door.

i01020861

Engine Valve Lash - Check

SMCS Code: 1105-025

Refer to the Service Manual for the completeadjustment procedure for the engine valve lash.

A quali�ed mechanic should adjust the engine valvelash and the fuel injector timing because special toolsand training are required.

i02659078

Equipment Lowering ControlValve - Check

SMCS Code: 5147-MA

Personal injury or death can result from a worktool falling.

Keep personnel away from the front of the ma-chine when lowering the work tool.

Before lowering any equipment, clear the areaaround the equipment of all personnel.

1. Lower arms to the fully lowered position. Turn thekeyswitch to the OFF position.

2. Slide the seat forward. Slide the left hand armrestforward.


3. Pull up on the red handle in order to fully actuatethe valve.

4. Push the red handle to the original position.Ensure that the handle is fully seated.

136 SEBU8020-01Maintenance SectionFinal Drive Oil - Change

i02578244

Final Drive Oil - Change

SMCS Code: 4050-044-OC


(1) Oil drain plug

(2) Oil �ller plug

1. Position one �nal drive so that the oil drain plug(1) is at the bottom.

Note: Refer to Operation and Maintenance Manual,�General Hazard Information� for information oncontaining �uid spillage.

2. Use an 8 mm (5/16 inch) allen wrench. Removethe oil drain plug (1) and the oil �ller plug (2). Allowthe oil to drain into a suitable container.

3. Check the drained oil for metal chips or forparticles. If there are any chips or particles, consultyour Caterpillar dealer.

Note: Dispose of drained �uids according to localregulations.

4. Clean the plugs and inspect the plugs. Replace aworn plug or a damaged plug.

5. Install the oil drain plug (1). Tighten the oil drainplug to a torque of 27 ± 1 N·m (20 ± 0.7 lb ft).

6. Add oil through the opening of the oil �ller plug (2).

7. Fill the �nal drive to the bottom of the openingfor the oil �ller plug (2). Refer to Operation andMaintenance Manual, �Lubricant Viscosities� andOperation and Maintenance Manual, �Capacities(Re�ll)�.

8. Install the oil �ller plug (2). Tighten the oil �ller plugto a torque of 27 ± 1 N·m (20 ± 0.7 lb ft).

9. Perform Step 1 to Step 8 on the other �nal drive.

10.Completely remove any oil that has spilled.

11.Start the engine and allow the �nal drives tooperate through several cycles.

12.Stop the engine.

13.Check the oil level.

14.Maintain the oil level to the bottom of the openingfor the �ller plug (2).

i02578245

Final Drive Oil Level - Check



(1) Oil drain plug(2) Oil �ller plug

1. Position one �nal drive so that oil drain plug (1) isat the bottom.

Note: Refer to Operation and Maintenance Manual,�General Hazard Information� for information onContaining Fluid Spillage.

2. Use an 8 mm (5/16 inch) allen wrench. Removeoil �ller plug (2).

3. Check the oil level. The oil should be near thebottom of the opening of �ller plug (2).


Fuel Injection Timing - Check

4. Add oil through the opening of �ller plug (2), ifnecessary.

Note: Over�lling the �nal drive will cause the seals onthe travel motor to allow hydraulic oil or water to enterthe �nal drive. This may contaminate the �nal drive.

5. Clean oil �ller plug (2).

6. Install oil �ller plug (2). Tighten the oil �ller plug toa torque of 27 ± 1 N·m (20 ± 0.7 lb ft).

7. Repeat the procedure for the other �nal drive.

i00916186

Fuel Injection Timing - Check

SMCS Code: 1251-531

Note: The correct fuel timing speci�cation isfound on the Engine Information Plate. Fueltiming speci�cations may vary for different engineapplications and/or for different power ratings.

A quali�ed mechanic should adjust the fuel injectiontiming because special tools and training arerequired.

Refer to the Service Manual for the completeadjustment procedure for the fuel injection timing.Refer to your Caterpillar dealer for the completeadjustment procedure for the fuel injection timing.

i02520136

Fuel System Primary Filter(Water Separator) - Drain

SMCS Code: 1263-543




The fuel system water separator is located in the leftside of the engine compartment.



The Fuel Filter/Water Separator is located on the left side of theengine compartment.

2. Insert the drain hose (3) into a suitable container.Loosen the drain valve on the bottom of the waterseparator.

3. Tighten the drain valve by hand. Do not tightenthe drain valve with a tool. Damage to the valve orto the seals may occur.


5. Dispose of the water and sediment according tolocal regulations.

138 SEBU8020-01Maintenance SectionFuel System Primary Filter (Water Separator) Element - Replace

i02520124

Fuel System Primary Filter(Water Separator) Element -Replace

SMCS Code: 1260-510-FQ; 1263-510-FQ




Note: This unit has a dual purpose. The elementserves as a water separator and a fuel �lter.



The Fuel Filter/Water Separator is located on the left side of the

engine compartment.

2. Open the drain on the fuel �lter/water separator(3). Allow the water and fuel to drain into a suitablecontainer.

3. Close the drain valve by hand. Do not tighten thedrain valve with a tool. Damage to the valve orto the seals may occur.

4. Support the fuel �lter/water separator and rotatethe locking ring (1) counterclockwise. Remove thefuel �lter/water separator.

5. Rotate the locking ring (2) counterclockwise.Remove the bowl assembly.

6. Clean the mounting base for the fuel �lter/waterseparator.

7. Clean the bowl assembly for the fuel/waterseparator.

8. Install the bowl assembly onto the new fuel/waterseparator and rotate the locking ring clockwise.

9. Install the new fuel �lter/water separator onto themounting base. Rotate the locking ring clockwisein order to fasten the fuel �lter/water separator tothe mounting base.

10.Prime the fuel system in order to �ll the fuel�lter/water separator with fuel. Refer to Operationand Maintenance Manual, �Fuel System PrimingPump - Operate�.

11.Close the engine access door.

i02418180

Fuel System Priming Pump -Operate

SMCS Code: 1258-548

This machine is equipped with a fuel transfer pumpthat is electric. Two examples that may cause the fuelsystem to lose prime are listed here:

� The machine runs completely out of fuel.

� The Fuel System Filter/Water Separator Elementis replaced.

Follow the steps below in order to prime the fuelsystem.

1. Ensure that the engine start switch is in the OFFposition. Turn the engine start switch to the ONposition.

Note: Do not start the engine. This operation onlystarts the fuel pump.

2. Locate the Primary Fuel Filter. This is located inthe left side of the engine compartment.


Fuel Tank Cap - Clean

3. Examine the clear bowl. The bowl must becompletely full of fuel. If the bowl is not full of fuel,repeat Steps 1 and 2.

4. Attempt to start the engine. If the engine startsand the engine runs rough or the engine mis�res,operate the engine at low idle until the engineruns smoothly.

Note: If the engine fails to start or if the enginecontinues to mis�re or smoke, stop the engine andrepeat the procedure. If the problem persists afterrepeating the procedure, consult your Caterpillardealer.

i01819309

Fuel Tank Cap - Clean

SMCS Code: 1273-070-Z2

1. Remove the fuel cap.


2. Inspect the cap. Replace the cap if the cap isdamaged.

3. Wash the fuel cap in a clean, non�ammablesolvent and dry the fuel cap.

4. Put a light coating of fuel on the cap gasket.

5. Install the fuel cap.

i02418544

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S




Note: Drain the water and the sediment from the fueltank when the tank is almost empty.

1. Slowly remove the fuel tank cap in order to allowthe tank to vent while you drain the tank.


2. The fuel tank drain plug is located on the bottomof the fuel tank in the engine compartment on theright side of the machine. Remove the plug.

3. Allow the water and the sediment to drain into asuitable container.

4. Install the fuel tank drain plug.

140 SEBU8020-01Maintenance SectionFuses - Replace

Note: Apply 5P-3413 Pipe Sealant to the threads onthe drain plug.

5. Install the fuel tank cap.

i02417559

Fuses - Replace

SMCS Code: 1417-510; 1417; 7528

Fuses

Fuses � Fuses protect the electrical system fromdamage that is caused by overloaded circuits.Replace the fuse if the element separates. If theelement of a new fuse separates, check the circuit.Repair the circuit, if necessary.

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

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


The fuse panel is located behind the seat on the rightside.


Remove the cover in order to access the fuse panel.


The following is a list of the fuses in the panel:

1 � Spare

2 � Wiper

3 � Front Work Lights and Beacon


Fuses - Replace

4 � Right Joystick

5 � 12 volt power socket

6 � Radio

7 � Solenoid for the Compressor

8 � Air Conditioner

9 � Left Joystick

10 � Cold Start

11 � Rear Work Lights

12 � Backup Alarm and Brake Lights

13 � HVAC Blower Fan

14 � Spare

15 � Headlights

16 � Hydraulic Solenoid

17 � Fuel Shutoff and Secondary EngineShutoff

18 � Hydraulic Quick Coupler

19 � Hydraulic Solenoid

20 � Spare

Solenoids

21 � Auxiliary Electrical Control �AUX6(C1)�

22 � Auxiliary Electrical Control �AUX5(C2)�

23 � Secondary Auxiliary Electrical Control�(C+)�

24 � Secondary Auxiliary Electrical Control�(C )�

25 � Auxiliary Electrical Control �AUX7�

26 � Stop Lamp

27 � Backup Alarm

28 � Fuel Shutoff

29 � Self-Level and Ride Control

30 � Glow Plugs

142 SEBU8020-01Maintenance SectionHydraulic Oil Sample - Obtain

Main Fuse


(21) Battery(22) Main fuse

The main fuse (22) is located behind the battery (21)on the left side of the machine under the cab. This isa 105 amp fuse. You must disconnect the negativebattery cable before you replace this fuse.

Fuse panel behind cab

There is an additional fuse panel behind the cab onthe right side of the machine.


(23) First Pair

(24) Second Pair(25) Third Pair

This panel has 6 fuses. In order to change thesefuses, push up on the locking tab on the fuse cover.Pull the cover away from the back of the cab.


26 � Ignition switch

27 � ECM

28 � Horn

29 � Main power relay 1

30 � Miscellaneous cab accessories

31 � Main power relay 2

i02520143

Hydraulic Oil Sample - Obtain

SMCS Code: 5050-008; 7542-008

Open the rear access door. Refer to Operation andMaintenance Manual, �Access Doors and Covers� forinformation about the rear door.

Raise the radiator. Refer to Operation andMaintenance Manual, �Radiator Tilting� forinformation about the radiator.


Hydraulic System Oil - Change


The sampling port for the hydraulic oil is located onthe fan motor.

i02576511

Hydraulic System Oil - Change

SMCS Code: 5095-044





Note: This �lm is located near the hydraulic �llercap on machines that are �lled with arctic oil.

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

Personal injury or death can result without releas-ing all of the hydraulic pressure.

Release all the pressure from the hydraulic sys-tem before any lines are disconnected.

The machine should be on level ground. Lower thebucket to the ground and apply slight downwardpressure. Engage the parking brake and stop theengine. Keep the armrest lowered. Turn the enginestart switch key to the ON position. Push the parkingbrake switch. Move all of the joystick controls whileyou press several times on each side of the auxiliaryhydraulic control (if equipped) in order to relievehydraulic pressure. Move the engine start switch keyto the OFF position.


(1) Hydraulic Tank Filler Cap

(2) Sight Gauge

1. Remove the hydraulic tank �ller cap (1).

144 SEBU8020-01Maintenance SectionHydraulic System Oil Filter - Replace


(1) Access panel(2) Retaining bolts

2. Remove the access panel in the belly guardunderneath the machine.

3. The hose is located on the right side. Pull the drainhose through the access hole in the belly guard.Remove the plug from the end of the drain hose.Drain the oil into a suitable container.

4. Install the drain plug into the drain hose. Tightento 22 ± 3 N·m (16 ± 2 lb ft). Pull the drain hoseback into the machine.

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

6. Fill the hydraulic system oil tank. Refer toOperation and Maintenance Manual, �LubricantViscosities� and Operation and MaintenanceManual, �Capacities (Re�ll)�.

7. Maintain the hydraulic oil level approximately inthe middle of the sight gauge (2).

Check the oil level with the loader arms in the fullylowered position.

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

8. Install the hydraulic tank �ller cap.

i02418554

Hydraulic System Oil Filter -Replace

SMCS Code: 5068-510




The hydraulic oil �lter is located in the enginecompartment.


2. Remove the hydraulic tank �ller cap.


The hydraulic �lter is located on the rear door.

3. Remove the �lter with a strap type wrench.


Hydraulic System Oil Level - Check

Note: Place a suitable nonconductive containerunder the hydraulic oil �lter. Use this container inorder to catch any oil that may spill from the �lter orthe �lter element mounting base.

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

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

6. Install the new �lter element by hand. When thegasket contacts the �lter element mounting base,tighten the �lter element for an additional threequarters of a turn.

7. Maintain the hydraulic oil level to the middle of thesight gauge. Refer to Operation and MaintenanceManual, �Hydraulic System Oil Level - Check�. Donot over�ll the hydraulic tank.

8. Inspect the gasket on the hydraulic tank �ller capfor damage. Replace the hydraulic tank �ller cap,if necessary. Install the hydraulic tank �ller cap.


i02418557

Hydraulic System Oil Level -Check



Filler for adding hydraulic oil


(2) Sight gauge on right side of tank

1. Park the machine on level ground.

2. Lower the work tool to the ground. Turn off theengine.

3. Wait for about �ve minutes before checking thelevel of the hydraulic oil.

4. Use the hydraulic oil �ller on the radiator in orderto top off the hydraulic oil.

5. Maintain the oil level to the middle of the two lineson the sight gauge. Do not over�ll the hydraulictank.

146 SEBU8020-01Maintenance SectionHydraulic Tank Breather - Replace

i02557991

Hydraulic Tank Breather -Replace

SMCS Code: 5050-510-BRE; 5056-510-BRE


The breather for the hydraulic tank is located on thetop of the hydraulic tank.

1. Raise the cab. Refer to Operation andMaintenance Manual, �Cab Tilting� for theprocedure to raise the cab.

2. Remove the breather.

3. Install the new breather and tighten to 20 ± 3 N·m(15 ± 2 lb ft).

i02418559

Lift Arm and Cylinder Linkage- Lubricate

SMCS Code: 5102-086-BD; 6107-086-BD


Radial Lift

(1) Lift Arm Pivot

(2) Lift Cylinder Rod End(3) Head End Fitting


Vertical Lift

(1) Lift Arm Pivot(2) Lift Cylinder Rod End

(3) Head End Fitting(4) Link Arm


Lower Machine Frame - Clean


The Link Arm is located behind the loader arm.

(5) Mounting for Link Pin

(6) Rear of Link Arm

Apply lubricant to all the grease �ttings on one side.

Repeat the process for the opposite side of themachine.

i02576463

Lower Machine Frame - Clean

SMCS Code: 7050-070

1. Tilt the cab upward. Refer to Operation andMaintenance Manual, �Cab Tilting�.


This �lm is located in the air duct.

NOTICEDo not spray water or cleaning �uids into the venti-lation ducts. Cover the opening in order to preventforeign material or �uid from entering the ventilationducts.

2. Seal the opening of the ventilation ducts withplastic.


(1) Access panel(2) Retaining bolts

3. The access panel (1) is located in the frameunderneath the machine.

4. Remove the four retaining bolts (2).

5. Slide the panel forward or slide the panel rearward.Pull the panel downward and remove the accesspanel from the machine.

148 SEBU8020-01Maintenance SectionOil Filter - Inspect

6. Remove any debris or dirt from the inside of theframe.

7. Reinstall the access panel.

8. Remove the cover from the ventilation ducts.

9. Tilt the cab downward.

i02106227

Oil Filter - Inspect

SMCS Code: 1308-507; 3067-507; 5068-507

Inspect a Used Filter for Debris


The element is shown with debris.

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

If metals are found in the �lter element, a magnet canbe used to differentiate between ferrous metals andnonferrous metals.

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

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

Small amounts of debris may be found in the �lterelement. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer in orderto arrange for further analysis if an excessive amountof debris is found.

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

i02634143

Quick Coupler - Clean/Inspect

SMCS Code: 6129-040; 6129-070

Personal injury or death can result from improp-erly checking for a leak.

Always use a board or cardboard when checkingfor a leak. Escaping air or �uid under pressure,even a pin-hole size leak, can penetrate body tis-sue causing serious injury, and possible death.

If �uid is injected into your skin, it must be treatedimmediately by a doctor familiar with this type ofinjury.

Note: Do not weld on the quick coupler withoutconsulting your Caterpillar dealer.

1. Clean the quick coupler prior to inspection in orderto properly inspect the quick coupler.


This is the back side of the quick coupler. The lift arm and the tilt

cylinder are removed for clarity.

2. Tilt the quick coupler all the way forward in orderto clean the debris away from the pins.

3. Move the quick coupler levers. Ensure that thelevers are not bent or broken.

4. Make sure that the coupler pins extend throughthe bottom of the quick coupler assembly. Checkthe pins for wear and check the pins for damage.


Radiator Core - Clean

5. Check the top edges of the quick coupler assemblyfor wear or for damage. Check the face of thequick coupler assembly for wear or for damage.

6. Inspect the components inside the quick couplerfor the following problems:loose bolts, oilleaks, broken parts, missing parts, and crackedcomponents

7. Inspect the hydraulic lines and the hydraulic�ttings for damage or for wear. Repair any worncomponents or replace any worn components.Repair any leaking components.

8. Inspect the steel material of the quick coupler forcracks.

Note: Perform all repairs before placing the quickcoupler back into operation.

i02575087

Radiator Core - Clean

SMCS Code: 1353-070-KO

The radiator is located at the rear of the machineabove the engine compartment.

Note: Adjust the frequency of cleaning according tothe effects of the operating environment. On models272C and 297C, clean the aftercooler core when youclean the radiator core.

1. Stop the engine. Open the engine access door.Refer to Operation and Maintenance Manual,�Access Doors and Covers�.

2. Tilt the radiator guard upward. Refer to Operationand Maintenance Manual, �Radiator Tilting�.


Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.


NOTICEWhen you are using compressed air or high pressurewater to clean the radiator �ns, ensure that the air orwater is directed parallel to the �ns. If the compressedair or high pressure water is not directed parallel to theradiator �ns, the radiator �ns could be bent or dam-aged.

Note: Pressurized air is the preferred method forremoving loose debris. Hold the nozzle approximately6 mm (0.25 inch) away from the �ns. Slowly move theair nozzle in a direction that is parallel with the tubes.The air nozzle should point in the opposite directionof the �ow of the fan. This will remove debris thatis between the tubes. Pressurized water may alsobe used for cleaning. The maximum water pressurefor cleaning purposes must be less than 275 kPa(40 psi). Use pressurized water in order to softenmud. Use a degreaser and steam for removal of oiland grease. Wash the core with detergent and hotwater. Thoroughly rinse the core with clean water.

3. Clean the radiator core from the top toward thefan.

Note: If parts of the cooling system appear tobe damaged or if parts of the cooling systemare repaired, a leak test is highly recommended.Consult your Caterpillar dealer for the most currentinformation about the cooling system.

4. After cleaning, start the engine and acceleratethe engine to high idle rpm. This will help in theremoval of debris and drying of the core. Stop theengine. Use a light bulb behind the core in orderto inspect the core for cleanliness. Repeat thecleaning, if necessary.

5. Inspect the �ns and tubes of the radiator corefor damage. Some �ns and tubes may be wornfrom abrasive material that has passed throughthe radiator core . Bent �ns may be opened with a�comb�.

NOTICEDo not clean a rotating fan with high pressure water.Fan blade failure can result.

6. Remove any dirt or debris from the fan, the fanhub, the oil cooler, the radiator guard and the fanguard.

Note: Dirt or debris on the cooling fan can cause animbalance.



150 SEBU8020-01Maintenance SectionRefrigerant Dryer - Replace

i01968724

Refrigerant Dryer - Replace(If Equipped)

SMCS Code: 7322-510

Personal injury can result from contact with refrig-erant.

Contact with refrigerant can cause frost bite. Keepface and hands away to help prevent injury.

Protective goggles must always be worn when re-frigerant lines are opened, even if the gauges in-dicate the system is empty of refrigerant.

Always use precaution when a �tting is removed.Slowly loosen the �tting. If the system is still un-der pressure, release it slowly in a well ventilatedarea.

Personal injury or death can result from inhalingrefrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through alit cigarette or other smoking method or inhalingfumes released from a �ame contacting air con-ditioner refrigerant gas, can cause bodily harm ordeath.

Do not smoke when servicing air conditioners orwherever refrigerant gas may be present.

Use a certi�ed recovery and recycling cart to prop-erly remove the refrigerant from the air condition-ing system.

NOTICEIf the refrigerant system has been open to the outsideair (without being plugged) for more than 30 minutes,the receiver-dryer must be replaced. Moisture will en-ter an open refrigerant system and cause corrosionwhich will lead to component failure.

Refer to Service Manual, SENR5664, �AirConditioning and Heating R-134a For All CaterpillarMachines� for the proper procedure to change thereceiver-dryer assembly and for the procedure toreclaim the refrigerant gas.

Note: The receiver-dryer must also be replaced whenthe air conditioning system is evacuated.

i02418592

Rollover Protective Structure(ROPS) and Falling ObjectProtective Structure (FOPS) -Inspect

SMCS Code: 7323-040; 7325-040


1. Inspect the ROPS for loose bolts. Tighten thebolts (1) to the following torque 125 ± 20 N·m(92 ± 15 lb ft). Check the hinge on the cab (2).Check the ROPS and the FOPS for damagedbolts or missing bolts. Replace any damaged boltsor missing bolts with original equipment parts only.

2. Operate the machine on a rough surface. Replacethe ROPS mounting supports if the ROPSemits a noise. Replace the ROPS mountingsupports if the ROPS rattles. Refer to Operationand Maintenance Manual, �Cab Tilting� for adescription of the mounting support.

Do not straighten the ROPS or the FOPS. Donot repair the ROPS or the FOPS by weldingreinforcement plates to the ROPS or the FOPS.

Consult your Caterpillar dealer for repair of anycracks in the ROPS or the FOPS.

Inspect the Flying Object Guard (if equipped) fordamage.

Consult your Caterpillar dealer for repair of anycracks in the Flying Object Guard.


Seat Belt - Inspect

i02429589

Seat Belt - Inspect

SMCS Code: 7327-040

Always check the condition of the seat belt and thecondition of the seat belt mounting hardware beforeyou operate the machine. Replace any parts that aredamaged or worn before you operate the machine.


Typical example

Check the seat belt mounting hardware (1) for wearor for damage. Replace any mounting hardware thatis worn or damaged. Make sure that the mountingbolts are tight.

Check buckle (2) for wear or for damage. If the buckleis worn or damaged, replace the seat belt.

Inspect the seat belt (3) for webbing that is worn orfrayed. Replace the seat belt if the seat belt is wornor frayed.

Consult your Caterpillar dealer for the replacement ofthe seat belt and the mounting hardware.

Note: Within three years of the date of installation orwithin �ve years of the date of manufacture, replacethe seat belt. Replace the seat belt at the date whichoccurs �rst. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

If your machine is equipped with a seat beltextension, also perform this inspection procedure forthe seat belt extension.

i01970036

Seat Belt - Replace

SMCS Code: 7327-510

Within three years of the date of installation (2) orwithin �ve years of the date of manufacture (1),replace the seat belt. Replace the seat belt at thedate which occurs �rst. A date label for determiningthe age of the seat belt is attached to each seat belt.


(1) Date of Manufacture

(2) Date of Installation

Contact your Caterpillar dealer for the replacementof the seat belt.

i02418756

Sprocket - Inspect

SMCS Code: 4164-040

Note: Operating the machine in conditions that aremuddy or sandy will cause accelerated wear on thesprocket and other undercarriage components. It isimportant to clean the undercarriage of the machinedaily in order to maximize component life. Sleevesthat do not meet the minimum thickness or sleevesthat do not turn freely may cause unnecessary wearon the drive lugs on the rubber track.

152 SEBU8020-01Maintenance SectionSprocket - Inspect

Remove the Sprocket


(1) Drive motor (2) Bolts and washers (3) Sprocket assembly

Note: In order to service the sprocket, the tracks mustbe loosened. Refer to Operation and MaintenanceManual, �Track - Inspect/Adjust� for the procedure.

1. Remove the 12 bolts (2) and the 12 washers thathold the sprocket assembly (3) to the drive motor(1).

2. Slide the sprocket assembly off the drive motor.

Sleeves and Rings


(4) Outer ring(5) Washers and Locknuts

(6) Outer sleeve(7) Inner sleeve

(8) Sprocket mounting ring(9) Middle ring

(10) Inner ring

The sprocket is equipped with two types of sleeves.

� Inner Sleeves (7)

� Outer sleeves (6)


Sprocket Sleeve - Inspect

The outer sleeves (6) are free to rotate on the innersleeves (7). The sleeves are held in position by theouter ring (4), the sprocket mounting ring (8), themiddle ring (9), and inner ring (10).

Note: There are many parts in the sprocket assembly.Remove the sprocket completely from the machinein order to work on the sprocket. Use a clean, �atsurface in order to disassemble the sprocket andassemble the sprocket.

1. Remove the 12 locknuts and washers that holdthe outer ring (4) in place.

2. Remove the ring.

3. Remove the outer sleeves and the inner sleeves.

4. Measure thickness (A) for the outer sleeves. If thethickness of the outer sleeves measures less than3 mm (0.12 inch), replace the sleeves. Sleevesthat do not meet the minimum thickness or sleevesthat do not turn freely may cause unnecessarywear on the drive lugs on the rubber track.

5. When you replace the outer sleeves, rotate theinner sleeves for 180°. If the inner sleeves havealready been rotated, replace the inner sleeves.

6. Repeat steps 2 through 5 for each set of sleeves.

7. Install the sleeves and the rings.

8. Install the new locknuts. Do not reuse thelocknuts. Tighten the locknuts to a torque of55 ± 5 N·m (40.6 ± 3.7 lb ft) in a star pattern. Turnthe locknuts an additional 180° ± 5° in the samestar pattern.

9. Install the sprocket on the drive motor. Tighten thebolts to a torque of 270 ± 40 N·m (199 ± 30 lb ft).

Rings

The inner ring (10), the middle ring (9), the outerring (4), and the sprocket mounting ring (8) will wearfrom the rotation of the outer sleeves. Measure thethickness of the inner ring, the middle ring, and outerring. If the thickness of the rings measures less than4.75 mm (0.19 inch), replace the ring. If the thicknessof the sprocket mounting ring measures less than8 mm (0.32 inch), replace the sprocket mounting ring.

Track

Tighten the track to the proper tension. Referto Operation and Maintenance Manual, �Track -Inspect/Adjust� for the procedure.

i02565868

Sprocket Sleeve - Inspect

SMCS Code: 4164-040-ZV

Note: Operating the machine in conditions that aremuddy or sandy will cause accelerated wear on thesprocket and other undercarriage components. It isimportant to clean the undercarriage of the machinedaily in order to maximize component life. Sleevesthat do not meet the minimum thickness or sleevesthat do not turn freely may cause unnecessary wearon the drive lugs on the rubber track.


3 rows of outer sleeves

Check the 3 rows of outer sleeves in order to ensurethat the sleeves rotate freely. If the sleeves do notrotate freely, refer to Operation and MaintenanceManual, �Sprocket - Inspect� for information aboutthe inspection of the sprocket assembly.

i01878236

Tilt Cylinder Bearings andBucket Linkage Bearings -Lubricate

SMCS Code: 5104-086-BD; 6107-086-BD

Wipe all of the grease �ttings before you applylubricant.

154 SEBU8020-01Maintenance SectionTrack (Rubber) - Inspect/Adjust


Note: Lubricate the �ttings with the loader lift arms inthe fully lowered position.

Apply lubricant to the grease �ttings (1) for the upperbearings for the tilt cylinders.

Apply lubricant to the grease �ttings (2) for the lowerbearings for the tilt cylinders.

Apply lubricant to the grease �ttings (3) for thecoupler engagement pins.

Apply lubricant to the grease �tting (4) for the pivotpin of the quick coupler assembly.

There are a total of 8 grease �ttings.

i02418763

Track (Rubber) - Inspect/Adjust

SMCS Code: 4197; 4198-025; 4198-040

Periodic adjustment of the track tension is necessaryin order to avoid damage to the tracks. Maintainingthe tracks at the proper tension will maximize theservice life of the undercarriage components. Theundercarriage components include the sleeves of thedrive sprocket, the rings of the drive sprocket, thewheels, and the track.

NOTICEDo not overtighten the tracks. Tracks that are too tightcan cause premature failure of the tracks. Tracks thatare too tight can cause power loss and bearing fail-ures.

Tracks that are too loose increase the possibility ofthe track derailing or the drive lugs mis-feeding on thedrive sprocket. In aggressive operating conditions, oc-casional mis-feeding is normal. If consistent mis-feed-ing is observed, ensure that the track tension is set tothe recommended speci�cation. If the track tension isset to the recommended speci�cation and mis-feed-ing is still observed, then your application may requirea tighter track tension. Increase the track tension untilconsistent mis-feeding is no longer observed.

The intervals for track tension vary depending on thefollowing conditions: the machine application, the op-erator, the soil conditions, the climate, and the condi-tion of the undercarriage components. Operators areresponsible for basic visual inspections of the tracktension on a daily basis.

Inspect


(1) Weight(2) Straight edge

(3) Adjuster(4) Jam nut

Place approximately 45 kg (100 lb) (1) betweenthe drive sprocket and the front idler wheel. Placea straight edge (2) across the drive sprocket andidlers. Measure the track sag between the bottom ofthe straight edge and the top of the track. The tracksag should be set at 12 mm (0.5 inch). If the trackneeds adjustment proceed with the following steps.

Track Adjustment

1. Loosen the jam nut (4). A 48 mm (1.875 inch)wrench is recommended.


Track (Rubber) - Remove/Replace

2. Turn the adjuster (3) in order to raise or lower thedrive sprocket. A 44 mm (1.75 inch) wrench isrecommended.

3. Tighten the jam nut to the following torque270 ± 40 N·m (199 ± 30 lb ft).

4. Recheck the track tension.

Detension the track


Clean the area under the sprocket.

Note: Many operations for maintenance of theundercarriage require the track to be loosened.

1. Remove any debris from the area under thesprocket before you loosen the track. Trappedmaterial in this area may prevent the drivesprocket from lowering fully.

2. Loosen the jam nut (4). A 48 mm (1.875 inch)wrench is recommended.

3. Turn the adjuster (3) in order to lower thedrive sprocket. A 44 mm (1.75 inch) wrench isrecommended.

4. Lower the drive sprocket completely in order toprovide the necessary clearance for maintenanceor for removal of the track.

i02418767

Track (Rubber) -Remove/Replace

SMCS Code: 4197; 4198-011; 4198-510

Removing the Track

1. Position the machine on �rm, level ground.

2. Remove any work tool that is attached to the quickcoupler.

3. Raise the loader arms and install the bracefor the loader lift arm. Refer to Operation andMaintenance Manual, �Loader Lift Arm BraceOperation�.


4. Use an appropriate �oor jack in order to lift themachine off the ground. Use appropriate jackstands (1) in order to block up the machine. Raisethe machine until tracks are approximately 50 mm(2.0 inch) (A) off the ground.

5. Detension the track. Refer to Operationand Maintenance Manual, �Track (Rubber) -Inspect/Adjust�.

156 SEBU8020-01Maintenance SectionVacuator Valve - Clean/Inspect


(2) Front idler wheel

6. Remove the front outboard idler wheel and thefront inboard idler wheel. Remove the mud scraperplate. Refer to Operation and MaintenanceManual, �Bogie and Idler - Inspect/Replace� forthe procedure to remove the idler wheels and themud scraper plate.

7. Lubricate the remaining front idler wheels and theinside of the track in order to ease the removalof the track.

8. Grasp the track on top of the front idlers. Pull thetrack forward and pull the track away from theframe. Slide the drive lugs past the inside frontidler wheels.

9. Lift the track off the drive sprocket and pull thetrack away from the rear idler wheels.

Installing the Track

1. Slide the track onto the drive sprocket.

2. Position the rear of the track so that the drive lugsare aligned between the rear idler wheels.

3. Pull all of the slack forward and make sure thatthe drive lugs are properly meshed with the drivesprocket. This will provide the maximum amount ofslack to aid with installation across the front idlers.

4. Lubricate the idler wheels and the inside of thetrack in order to ease the installation of the track.

5. Pull the track over the front idler wheels.

6. Install the front inboard idler wheel and the frontoutboard idler wheel. Install the mud scraperplate. Refer to Operation and MaintenanceManual, �Bogie and Idler - Inspect/Replace� forthe procedure to install the idler wheels and themud scraper plate.

7. Tension the track. Refer to Operation andMaintenance Manual, �Track (Rubber) -Inspect/Adjust�.

i02558847

Vacuator Valve - Clean/Inspect

SMCS Code: 1051-571-VL

Service the air �lter elements when the alert indicatorfor air �lter restriction lights. Refer to Operationand Maintenance Manual, �Alert Indicators� forinformation about the indicator.




3. Check the vacuator valve after every ten servicehours or at the end of each day. Actuate the valveby squeezing the lips of the valve in order toremove any accumulated debris.


Window Washer Reservoir - Fill

i02418610

Window Washer Reservoir -Fill(If Equipped)

SMCS Code: 7306-544-KE

NOTICEWhen operating in freezing temperatures, useCaterpillar nonfreezing window washer solvent orequivalent. System damage can result from freezing.


The reservoir for the window washer solvent islocated inside the cab by the left footrest.

Fill the reservoir with window washer solvent.Window washer solvent with isopropyl alcohol isrecommended.

i01085034

Window Wiper -Inspect/Replace(If Equipped)

SMCS Code: 7305-040; 7305-510

Inspect the condition of the windshield wiper blade.Replace the windshield wiper blade if the windshieldwiper blade is worn or damaged. If the window wiperblade streaks the window, replace the window wiperblade.

i02418633

Windows - Clean

SMCS Code: 7310-070

Rear Window and Glass Front Door

Use commercially available window cleaningsolutions in order to clean the windows.

Apply the cleaning solution liberally. Wipe the surface.

Dry the surface in order to prevent spots.

Side Windows

Use commercially available window cleaningsolutions in order to clean the windows.

The side windows of the cab can be removed forcleaning. Refer to the following procedure in order toremove the side windows.


1. Release the latch. Slide the front window rearwardbetween the circular marks (1) in the top of thewindow frame. Push the window upward in thetrack. Pull outward on the bottom of the window inorder to remove the window.

2. Release the latch. Slide the rear window forwardbetween the circular marks (1) in the top of thewindow frame. Push the window upward in thetrack. Pull outward on the bottom of the window inorder to remove the window.

3. Pull straight up on the bottom window in order toremove the window from the track. Pull inward inorder to remove the window.

158 SEBU8020-01Maintenance SectionWork Tool - Lubricate

4. Reverse the process in order to install thewindows. Install the lower window �rst. Theninstall the rear window in the outer track. Installthe front window in the inner track next.

Polycarbonate Front Door andPolycarbonate Top Window

Note: Do not wipe the window dry. Do not usepaper towels. This may scratch the �nish of thepolycarbonate windows over time.

For cleaning your polycarbonate top window orpolycarbonate front door, use a soft cloth, a sponge,or a chamois. Use any of the following cleaners:

� soap and water

� isopropyl alcohol

� kerosene

� denatured alcohol

� commercially available window cleaning solutions

Apply the cleaning solution liberally. Wipe the surface.

i02557791

Work Tool - Lubricate

SMCS Code: 6700-086

Multipurpose Bucket


Apply lubricant to the grease �tting (1) for the pivotpin of the apron.

Apply lubricant to the grease �tting (2) for the rod endof the multipurpose bucket cylinder.

Apply lubricant to the grease �tting (3) for the headend of the multipurpose bucket cylinder.

Repeat for the other side of the bucket.

There are six grease �ttings.

Utility Grapple Bucket and UtilityGrapple Fork


Apply lubricant to the four grease �ttings for thegrapples.


Apply lubricant to the two �ttings for the grapplecylinder.


SEBU8020-01 159Maintenance SectionWork Tool - Lubricate

Industrial Grapple Bucket and

Industrial Grapple Fork


Apply lubricant to the four grease �ttings for the forkcylinders.


Apply lubricant to the four grease �ttings for the twoforks.

There are eight grease �ttings.

Angle Blade


Apply lubricant to the grease �tting on the rod end ofthe angle cylinder.


Apply lubricant to the grease �tting on the horizontalpivot point of the blade.


Apply lubricant to the grease �tting on the verticalpivot point of the blade. Repeat for opposite side ofthe blade.


This is a bottom view of the angle blade.

Apply lubricant to the grease �tting on the pivot pointof the cylinder.

160 SEBU8020-01Maintenance SectionWork Tool Mounting Bracket - Inspect

There are �ve grease �ttings.

Dozer Blade


Apply lubricant to the grease �tting on both ends ofthe right hand angle cylinder (1). Repeat for oppositeside of the blade.

Apply lubricant to the grease �tting on the pivot pointson each end of the tilt cylinder (2).


i01809997

Work Tool Mounting Bracket -Inspect

SMCS Code: 6700-040-BK


Inspect upper angled plate (1) and ensure that theplate is not bent or otherwise damaged. Inspect holes(2) for wear and for damage. Inspect lower angledplate (3) and ensure that the plate is not bent orotherwise damaged. If any wear is suspected or anydamage is suspected, consult your Caterpillar dealerbefore you use the work tool.

277C,287C,297C

Documents

Transcript of 277C,287C,297C